acce bulletin

C M Y K C M Y K

C M Y K C M Y K

ofAssociation of Consulting Civil Engineers (India)

BULLETINVol. No. 10 No. 1 QUARTERLY January-March 2011

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# 2, U. V. C. E. Alumni Association Building, K. R. Circle, Bangalore - 560 001PhoneTel/Fax

: 91-80-22247466: 91-80-22219012

E-mail : [email protected] : www.accehq.net

Winner of the ACCE- SIMPLEX AWARD 2010 for Innovative Design of Structures other than Industrial Structure

MADRAS CEMENTS LTD.Flat No. 100-100/1, M-Floor, Eden Park, No. 20, Vittal Mallya Road, Bangalore – 560 001.

Tel: 080- 4122 6500/03/07 Fax: 080- 4112 6515

Bulletin of ACCE (I) 3 January - March 2011

ACCE (I) Office BearersChairman : RAVINDRANATH B. V.

Advisory CommitteeDr. MANAMOHAN R KALGAL, Dr. R.JAGADISH, Mr. SHINGAREY AMOL MMr. RANGANATH D, Mr. UMESH B RAO, Mr. RATNAVEL S, Mr. S. PICHAIYA

Editorial CommitteeDr. M N HEGDE, Dr V RAMACHANDRA, Dr. R N PRANESH, Dr. R V RANGANATHMr. M. SANJAY KUMAR JAIN, Mr. K G K MOORTHY

Secretaries of all Centres (Ex Office Members)

Bulletin Committee

ACCE BULLETINVol. 10 January - March 2011 No. 1

Avinash D. Shirode PresidentHemant Hari Dhatrak Vice-President (West)T. Senthil Nayagam Vice President (South)Dr. M. U. Aswath Secretary GeneralBadarinaath Singri Treasurer

Umesh B. Rao Imm. Past PresidentRavindranath B. V. Imm. Past Secretary GeneralRaghunath B. N. Imm. Past Treasurer

Printed and published by RAVINDRANATH B. V. on behalf of the Association of Consulting Civil Engineers (India) and printed at Abhiram Graphics, # 2, Anugraha,4th Cross, 8th Main, Papaiah Garden, BSK 3rd Stage, Bangalore – 560 085 and published at 2, UVCE Alumni Association Building, K R Circle, Bangalore – 560 001.Editor: RAVINDRANATH B. V. MAG(3)/NPP/166/2003-04, CMM/BNG/DELL/PP/156/21-2002

C O N T E N T SABOUT COVER PAGE

ACCE - SIMPLEX AWARD 2010 FOR INNOVATIVE DESIGNOF STRUCTURES OTHER THAN INDUSTRIALSTRUCTURE AWARDED TO TANDON CONSULTANTSPVT LTD., NEW DELHI

A Grade Separator at Mukarba Chowk, Delhi, proposedin 2005 at this important nerve centre was experiencingchaotic traffic jams. The challenges around the projectsite included a Heritage structure, Graveyard, Sanitaryland fill, major Electrical sub-stations, Nallahs, Live watermains, Optic fibre/ other cables and Gas pipelines. Thetask on hand was to tackle these challenges and designan aesthetically pleasing structure. The main flyoveralong the outer ring road is designed using steel-concrete composite tub girder. Slip roads, Loops, Bridgeover drain and open stilted portion are constructed usingRCC integral Voided Slab. The integral bridge conceptoffers merits like superior performance for sharp radiusof plan curvature, elimination of expansion joints andbearings. The uplift that is likely to occur in a curvedbridge is absorbed by integral piers. The end pierswhere there is practice of providing bearing even in theintegral bridge, also become very critical for design ifthe curvature is extended in this zone. This complexitywas eliminated by replacing large diameter single pierinto small diameter twin piers. The small diameter twinpier in longitudinal direction offer flexibility for temperatureand shrinkage forces and improves torsion rigidity intransverse direction which is required for sharp curvaturebridges. A unique solution of providing two independentpiers for the separated voided slab at expansion jointlocations was proposed. At intermediate locations, largediameter pier is provided. The work commenced inDecember 2005, was completed during October, 2008.

Tandon Consultants Pvt Ltd. (TCPL) was established in1986 to undertake specialist consultancy services inthe filed of structural engineering. TCPL specialise indesign of large and complex structures and consists ofcarefully trained professionals geared to produce high

President’s Message ............................................ 4

From the Editorial Desk ........................................ 4

From Secretary General’s Desk ............................ 5

ACCE AWARDS 2011 - Call for Nominations ......... 6

Eugène Freyssinet his incredible journeyto invent and evolutionize prestressedconcrete construction ..................................... 7

The Alternative Building Materials andTechnologies for Individual Housingin Coastal Karnataka .................................... 13

Estimating the Strength of Concrete -Maturity Method ........................................... 19

Whitetopping – A case study ............................... 33

An Experimental Study on Carbonation ofConcrete under accelerated carbonation ....... 37

News From ACCE(I) Head Quarters .................... 46

News from ACCE(I) Centres ................................ 46

ACCE (I) Membership Additions ........................ 48

Professional Directory ......................................... 49

Thanks To Patrons .............................................. 50Continued on page 42


PRESIDENT’S MESSAGE

From the Editorial Desk

Dear Members of the ACCE(I) Family,

Wish you a Very HAPPY AKSHAY TRUTIYA 2011.

Let me inform you that the Building Committee under the leadership of Shri A. NirmalPrasad had done extensive work in identifying various buildings for the Head Quarteroffice and also trying to get land from the local authorities. It is in the process and hopefullyin near future HQ will have its own premises. As everyone knows that the cost of land orbuilding in a metro city like Bangalore is very high and hence it is the duty of all the

members to fulfill this dream by contributing financially to this noble cause.

Our team started in 2009 at Davangere with a vision document planning for various activities. There were variouscommittees constituted and each committee had done excellent work within a short span of two years. The mostimportant had been the celebration of Silver Jubilee of ACCE(I) and it was a grand show under the dynamic leadershipof Shri Ajit Sabnis. The major achievement is the revision of Bye-Laws of ACCE(I) in tune with the global scenario andother organisations in the profession. The major laudable achievement is introduction of Student membership categorywhich is the need of the day. Revision of Bye-Laws was a hurriculan task and was carried out by the team of Shri D.Ranganath. The Awards committee led by Shri Umesh B. Rao had done excellent work by delinking the programmefrom AGM and giving sufficient time to award winners which was made memorable by the Hyderabad Centre underShri P. Suryaprakash and Shri S. P. Anchuri. There is only one addition of new centre of Karim Nagar but there isconsiderable increase of membership.

There had been excellent work done by Dr. M. U. Aswath, Secretary General, Shri Badarinath Singri, Treasurer andvery dynamic Manager Shri S. D. Annegowda. My role as President was negligible with hardly any contribution. Thewhole work was done by the HQ other office bearers and the staff.

ACCE(I) will flourish under the new team of HQ office bearers, Shri B.S.C. Rao, Shri Ajit Sabnis and Shri P. S.Deshpande. They will march ahead with the vision for the all round development of the ACCE(I) with the support andcontribution of all the members. I wish them all the success.

With very warm personal regards,

Avinash D. Shirode

Dear Fellow Members,

Greetings to all from HQ.

We have recently concluded the elections for new office bearers. The results will beannounced by Secretary General in the next AGM. It's welcoming to note that manymembers participated to vote in a democratic way to elect the new office bearers. I wouldhave appreciated if more members come forward to cast the votes and participate in theelection process. New team will pave way for new thought process and new vision toachieve and further the objectives of the Association. I wish the new team every success.

I urge members to contribute to the bulletin in the form of articles, news items around yourtown, topics of interest that can shared with others, professional tips etc., which makes

the bulletin livelier to read.

Best wishes

Ravindranath BV


From Secretary General’s DeskDear Members,

Some time back, I had written in the bulletin that all our engineers should involve themselves insocial activities for the betterment of the society. One of the ways we can contribute is to extendtechnical support and knowledge sharing with the general public. The awareness of the public incritical issues of building construction will enable them to demand for better quality from thebuilders. In this direction ACCE (I) in association with THE HINDU the national news paper is

bringing out a column called BUILD-FORUM on Saturdays in PROPERTY PLUS supplement.

Build – Forum, the public query column by property Plus, invites questions related to technical/structural/civil aspectsof buildings. The questions will be answered by professionals connected to the Association of Consulting Civil Engineers(I). The readers can send the queries to [email protected]

We are quite successful in this initiative and already the column BUILD-FORUM is getting popular among the readers.For the benefit of our members I am giving below the details of the articles in The Hindu, the online links are alsoprovided.

1. Safety first, always: Stability of high-rise buildings depends on factors such as height, width and configurationof the structure, March 12, 2011,http://www.hindu.com/pp/2011/03/12/stories/2011031250280200.htm

2. Know the significance of sunshades: In our enthusiasm to achieve newer styles in the design of buildings, weshould not overlook certain time-tested basic rules, advises, Mar 19, 2011, http://www.hindu.com/pp/2011/03/19/stories/2011031950290300.htm

3. Ideal designs need collaborative efforts: Beams that are visible inside homes are not commentaries onbuildings being unsafe. They form part of the structural get-up of a design, march 26, 2011http://www.hindu.com/pp/2011/03/26/stories/2011032650440200.htm

4. Safe design of staircase: April 2, 2011

http://www.hindu.com/pp/2011/04/02/stories/2011040250470200.htm

5. No ceiling for ceiling heights: A high ceiling is an inspiration, improves productivity and provides a strangesense of freedom, April 9, 2011http://www.hindu.com/pp/2011/04/09/stories/2011040950410300.htm

6. For the right plumbing techniques: Improper plumbing designs cause leakages in pipes and damage thebuilding, April 16, 2011http://www.hindu.com/pp/2011/04/16/stories/2011041650320200.htm

7. Passing on a new look, making a style statement: The building envelope design must include structuralintegrity, moisture/temperature/noise control and regulation of air flow. An article related to building cladding, April23, 2011http://www.hindu.com/pp/2011/04/23/stories/2011042350300200.htm

8. Bamboo adds to the building strength: with earthquakes occurring frequently, the basic care that should betaken is in the material that we use in construction. An article related to bamboo in building industry, April30,2011http://www.hindu.com/pp/2011/04/30/stories/2011043050520300.htm

I invite the members to involve in this activity and send the willingness to [email protected] so that the queries willbe forwarded for comments. The local centers of ACCE (I) can start similar activity in association with the local newspapers and other media.

With best regards,Dr.Aswath M.U.


ACCE AWARDS 2011 - CALL FOR NOMINATIONS1. ACCE-BHAGWATI AWARD for Outstanding Design for Industrial Plant/ Structures. Instituted by: Bhagawathi

Associates Pvt. Ltd., Mumbai.2. ACCE-SIMPLEX AWARD for Innovative Design of Structures other than Industrial. Instituted by: Simplex

Concrete Piles (India) Pvt. Ltd., Calcutta.3. ACCE L & T ENDOWMENT AWARD for Excellence in Construction of Industrial Structure. Instituted by: L

& T, ECC Construction Group, Chennai.4. ACCE BILLIMORIA AWARD for Excellence in Construction of High Rise Building. Instituted by: B E

Billimoria & Co. Pvt. Ltd., Mumbai.5. ACCE SOM DATT AWARD for Excellence in Construction of Transportation Projects. Instituted by: SOM

DOTT Builders, Delhi.6. ACCE SARVAMANGALA AWARD for Excellence in Construction of Civil Engineering projects other than

industrial plant & transportation projects. Instituted by: Sarvamangala Constructions, Chennai7. ACCE GOURAV AWARD for Significant Contribution to Civil Engineering Consultancy. Instituted by: Gourav

Engineers, Bangalore8. ACCE CDC AWARD for Best Software Package in Civil Engineering. Instituted by: Computer Designs

Consultants, Chennai9. ACCE NAGADI AWARD for Best Publication (Book) in Civil Engineering. Instituted by: Nagadi Consultants

Pvt. Ltd., Delhi10. ACCE AWARD: For Creative Applications of Building Materials for Durability. Instituted by: Association of

Consulting Civil Engineers (India)11. ACCE INSWAREB AWARD for Effective Use of Blended Cement in Design and Construction of Civil

Engineering Projects. Instituted by: INSWEREB of Vishakapatnam.12. ACCE FOSROC AWARD for Effective Use of Construction Chemicals in Civil Engineering Projects. Instituted

by: Fosroc Chemicals (India) Ltd., Bangalore.13. ACCE-JMC AWARD for Best Construction by Budding Company of India. Instituted by JMC Projects (India)

Limited, Chennai.14. ACCE-GAMMON AWARD for Effective Use of Construction Materials/Systems In Construction Resulting

In National Savings. Instituted by: Gammon India Limited, Mumbai.15. ACCE- L&T FORMWORK AWARD for Best Use of Formwork In Civil Engineering. Instituted by Larsen &

Toubro Limited, ECC Division) Chennai.16. ACCE ESSEN AWARD for Appropriate Use of Construction Chemicals & Epoxy for Rehabilitation /Retrofitting

of Civil Engineering Structure by Consultants. Instituted by Essen Supplements India Ltd., Secunderabad.17. ACCE- Er. P T Mase Memorial Award for Innovative Structural Design by

upcoming structural Designer Instituted by: P T Mase & Associates, Nagpur.18. ACCE MEGH STEELS AWARD for Excellence in the use of Rectangular/ Square Hollow Sections in Steel

Structures. Instituted by: Megh Steels Private Limited, Bangalore.Nominations are invited from Consulting Engineers, Designers, Planners, Construction Agencies, ComputerSoftware Developers and Authors. The works completed in the above areas during the last 3 years are to besubmitted on or before 30th July 2011 in a prescribed Proforma. Proforma can be down loaded fromthe website: www.accehq.net These awards will be presented during the ACCE ANNUAL Awards Functionto be held on third week of October 2011 at Nagpur.

for more details please contact:Chairman, Awards Committee

ASSOCIATION OF CONSULTING CIVIL ENGINEERS (INDIA)No. 2, UVCE Alumni Association Building, K. R. Circle, Bangalore - 560 001Tel: 91-080-2224 7466 Tel/Fax: 91-080-2221 9012E-mail: [email protected] Website: www.accehq.net


EUGÈNE FREYSSINETHIS INCREDIBLE JOURNEY TO INVENT AND EVOLUTIONIZE

PRESTRESSED CONCRETE CONSTRUCTIONAuthors : Pierre Xercavins, Daniel Demarthe and Ken Shushkewich

Presented at fib-days 2010 at Delhi by C.R. Alimchandani

t has been just over 100 years when EUGÈNE FREYSSINETSTARTED HIS CAREER IN 1905 in Moulins, France asIngénieur des Ponts et Chaussées (Engineer of Bridgesand Roads). He approached problems in a graphic wayusing free hand drawings and simple calculations in themargins and sometimes used Graphic Vector resolutionwhere required.. He built numerous bridges in the Moulinsregion. The Praireal-sur-Besbre Bridge built in 1907, a threehinged arch with a span of 26 m was the first bridge in theworld to have the arch lifted from the formwork by the use ofhydraulic jacks at the crown hinge. This was created byFreyssinet in a very early stage of his career.

One of the fortunate events in thelife and career of EugèneFreyssinet was his closeassociation with likemindedcontractors François Mercier,Claude Limousin and EdmeCampenon.

Freyssinet patented PrestressedConcrete (pre-tensioning) in 1928,the Flat Jack in 1938 and theconcrete anchorage (post

tensioning) in 1939. We will discuss this later in this lecture.

One of the fortunate events in the life and career of EugèneFreyssinet was his close association with likemindedcontractors like François Mercier, Claude Limousin andEdme Campenon.

Freyssinet patented Prestressed Concrete (pre-tensioning)in 1928, the Flat Jack in 1938 and the concrete anchorage(post tensioning) in 1939.

After the first stage of development of prestressing,Freyssinet had a small group of dedicated, brilliantcolleagues (they were all geniuses with an IQ of over 160).Yves Guyon, his Associate, gave prestressing itsmathematical basis, Pierre Xercavins, who joined in 1950was involved in large projects with Eugène Freyssinet, hesoon followed Yves Guyon to become the Technical Directorof Europe Etudes which was the design subsidiary ofSociété Technique pour l'utilisation de la Précontrainte(STUP), which was created in 1944 to spread the knowledgeof Freyssinet's inventions relating to Prestressed Concreteacross the world they designed many bridges in Franceand internationally. Pierre Xercavins was awarded theFédération Internationale de la Précontrainte (FIP) Medal in1970 for outstanding work in Prestressed ConcreteStructures and the Albert Caquot Prize in 1991 for being thebest Civil Engineer in the world. He also designed manyother large and complex structures most notably theMontreal Olympic Stadiaii, Ekofisk and Ninian OffshorePlatforms, the last two being the first and the tallest

Prestressed Concrete oil platforms in the world. PierreXercavins had the same approach to conception ofstructures as Eugène Freyssinet.I was able to observe the works of Eugène Freyssinet andbe a disciple of Xercavins for 2½ years. Between 1958 and1963 I shared the enthusiasm of Pierre Xercavins to spreadthe knowledge of Prestressing with engineers all over theworld. In 1963 I was sent to work by Yves Guyon for thenewly opened design office of STUP in India: STUPConsultants Pvt. Ltd. STUP Consultants Pvt. Ltd. has nowworked in 36 countries, has 1400 Engineers, Architects andTechnicians and support staff and still carries onFreyssinet's, Guyon's and Xercavin's mission. I therefore,would like to offer this tribute to these great men by presentinga summary of the Article made by Pierre Xercavins aboutEugène Freyssinet "EUGENE FREYSSINET HISINCREDIBLE JOURNEY TO INVENT AND REVOLUTIONIZEPRESTRESSED CONCRETE CONSTRUCTION" a shorttime before Mr. Xercavins passed away in 2008. WheneverI was at the limit of my knowledge, from 1958 up to the timehe passed away, I was able to get advice from PierreXercavins. I also met along with Mr. Xercavins, Mr. YvesGuyon, the First Technical Director of STUP France and Mr.Eugène Freyssinet, whenever the solution of a problemrequired their advice. I have also to explain the role playedby Mr. K.K. Nambiar, the first Indian Chief Engineer of theerstwhile Madras State P.W.D. and Yves Guyon in setting upSTUP Consultants Pvt. Ltd. in India, without the technicalcourage of Mr. K.K. Nambiar and his accepting PrestressedConcrete for the Palar Bridge, the use of this technique byIndia would have been much delayed - they encouraged thecreation of STUP Consultants Pvt. Ltd. by becomingrespectively the first Chairman and a Founder Director ofthis Company.

WORLD RECORD SPAN LENGTH BRIDGESThe long-term relationship between Freyssinet and thecontractor Mercier started with Veurdre Bridge. During theirperiod together Freyssinet designed and built concrete ArchBridges, which successively broke his own world recordsfor span length. Due to financial constraints andbureaucratic obstacles, money was not available for theVeurdre Bridge and two other bridges across the Allier River:Boutiron Bridge, and Mercier's friend Regnier was interestedin the third bridge at Chatel-de-Neuvre. They made a boldproposal undertaking to build all three bridges together for630,000 Francs, which had been allocated for the VeurdreBridge alone; Mercier assuming total financial responsibilityand Mr. Freyssinet the technical responsibility. The proposalnever had to pass an Inspection Committee as Freyssinethad to do the Design for Mr. Mercier and supervision of thesame for the Government - also Mercier agreed to be paidonly after the work was completed.


The main problem during construction was the decenteringof the long arches that were subjected to creep andshrinkage. This was achieved by using thrusts createddirectly, following the procedure first used on Praireal-surBesbre Bridge. After constructing the Veurdre Bridge,Freyssinet kept on observing the behaviour of the same. Itwas a very flat arch with a depth to span ratio of 1:15.

Fig. 2: Veurdre Bridge (72.5 m span) (1911-1912)He observed deformations due to creep and shrinkage firstslowly and then rapidly till collapse seemed inevitable andhe and his loyal workers replaced the Decentering Jacks inthe early morning when no one was around and raised allthree vaults at once to the correct levels. The bridge regainedits shape and behaved perfectly until 1940, when it wasdestroyed during the IInd World War.

This bridge on the Lot River consists of a plain concretearch with a span of 96 m, a world record at the time.

Fig. 3: Villeneuve-sur-Lot Bridge (96 m span) (1914-1920)Construction was started in 1914 but was soon stoppeddue to the Ist world war. The bridge was completed after thewar in 1920.The most interesting aspect of the bridges from the point ofview of construction was the use of Decentering Jacks -previously spans collapsed during decentering when thespan was greater than 70 m. Freyssinet used them notonly for striking the formwork, but also for correcting stressesafter construction created by deformation of the arch due tocreep and shrinkage. Thus it was possible to carry out thisprocedure at any time during the lifetime of the bridge.Today, the bridge remains as natural in its urban setting asit did when it was first built. The bridge has reddish exposedbrick arcades that hide the spandrels resting on the archand let the bridge blend well with the buildings in town.The Lot Bridge was followed by Saint-Pierre-du-VauvrayBridge of 131 m span in 1922-23 which again held theworld record at the time.

Plougastel Bridge (3 spans at 186 m) (1925 - 1930)The Plougastel Bridge on the Elorn River near the City ofBrest, close to its harbour, consists of three reinforcedconcrete arches each having a span of 186 m (610 ft), aworld record at the time. The reinforced concrete trusseddouble deck accommodates a roadway on the upper deckand a railway on the lower deck (the railway over the bridgewas never completed).

Fig.4 : Plougastel Bridge (3 spans @ 186 m)

For this construction, Eugène Freyssinet took advantage ofthe tides to bring on floating barges, an enormous woodentruss, which was used for the successive construction ofthe three arches. The truss was built on the riverbank,launched at high tide with the aid of two barges, and installedfor the construction of the first arch. After completion of aspan, prestressing was used for raising up the arch fromthe centering, the centering truss was then lowered andfloated into position for construction of the second arch,and then the third arch.

Prestressed Concrete Patent (1928) (Pre-tensioning).Freyssinet first had the idea of compressing concrete byprestressing. It took twenty five years of laboratory testsand profound thought to discover the difficulties involvedand the ways to over come them.

Fig.5 : Pre-tensioning (Forclum electricity poles)

He applied for a patent for a "Fabricating Process forReinforced Concrete Elements". The process was adaptedto precast beams, pipes, sleepers, poles, etc.

At the time of the patent, in 1928, the Scientific Communitydid not believe in prestressing. Thus, Freyssinet decidedto go out alone to demonstrate the merits and possibilitiesof prestressing, risking all his fortune, energy and reputation.He thus started producing electricity poles at the Forclumplant at Montargis in France.

He perfected the grinding fineness of cement to increaseits strength, improved on his previous invention ofmechanical vibration, invented steam curing and perfectedthe industrial precasting process. The result was acomplete technical success but a total commercial failuredue to the depression of 1929.

In five years, he lost his entire fortune that he hadaccumulated during his past career. He never regretted itbecause he had obtained technical results for moreimportant than all of those which he achieved between 1905and 1928.

Flat Jack Patent (1938).Eugène Freyssinet next invented the Flat Jack forcompressing the raft of the Portes de Fer Dam in Algeriaand immediately after that on a much grander scale forraising the height of the Beni Badhel Dam in Algeria by 7 mto bring it up to 67 m. the patent was applied for in 1938 andvalidated in 1939.


Fig.6 : Flat jack (schematic)

The Flat Jack is made of two stamped steel sheetsconnected by welding. By hydraulically introducing a fluidunder pressure, the flat jack is inflated and can developconsiderable force. It is a remarkable device for its power,lightness, and low cost. The fluid can be oil, resin, grout,cement, or other ingredients. The Flat jack can be used tovary the compressive forces applied with time to allow foradjustments of structures after their construction. The flatjack has been used on a great many projects around theworld, including the Montreal Velodrome described in thispaper.

CONCRETE ANCHORAGE PATENT (1939) (PostTensioning).Eugène Freyssinet applied for a patent for "Tensioned CableAnchorage System for Prestressed Concrete Construction".The patent was issued in 1947 (because of the war).

The system consists of 12 Nos. 5 mm diameter parallelsteel wires locked or anchored in a concrete anchoragecone by a tensioning jack. The steel wires which werethreaded through the anchorage consisting of a reinforcedconcrete cylinder having a central conical hole (female cone)and a central fluted conical block (male cone). The steelwires were tensioned simultaneously with the aid of a jackand locked-off by the male cone inside the female conewhile under tension. The wires transmitted their tension tothe structure via the anchorage.This invention allowed tensioning to be achieved by restingon the concrete directly. The prestressing cable could belong or short, rectilinear or curvilinear, and positioned insideor outside the structure (external prestressing as well asinternal prestressing). The force in the prestressing cablecould be adjusted during construction. This system gavethe engineer a wide liberty in the position and intensity ofprestress that he/she wished to develop, and has beenused in the construction of most of the large structures sincethat date.

The original 5 mm wires were progressively replaced by 7mm wires, then 8 mm wires and then by seven wire strands.In the case of the concrete anchorage of 1939, the capacitywas 20 T which was replaced by a steel anchorage in 1960with a capacity of 150 T. Individual wedges for each strandcame into existence in 1965 and a capacity of 200 mt wasachieved.

SAVING THE LE HAVRE MARITIME STATION FROMCOLLAPSE.3The Maritime Station in Le Havre completed in 1933 for theocean liner Normandie, was sinking 25 mm (1 in) per monthinto a deep layer of clay, and according to Freyssinet"Imminent collapse seemed to be inevitable. He wrote,I proposed a solution which, despite its boldness, wasadopted without argument as it constituted the only possiblehope of avoiding disaster".

Fig.8: Le Havre Maritime Station

The strengthening of this building in 1934 is considered tobe the first use of devices for prestressing. In the first stage,Freyssinet strengthened the foundations to make themmonolithic by use of external prestressing by Cables andJacks at their extremities and then increased the bearingcapacity of foundations by adding piles that were driven insegments until they reached layers of soil which could carrythe loads without abnormal sinking.

Fig.9 : Le Havre Maritime Station elevation

Freyssinet solution consisted of adding new footings (B)between the existing footings (A) to make the entire unit amonolithic prestressed horizontal element. The unit wasprestressed with parallel wires turned around two reinforcedconcrete end anchorages One anchorage was displacedby hydraulic jacks having a force of up to 1000 mt (1100tons). The link between the old and new concrete wasassured by the general compression of the whole. Themoveable anchorage was fixed by concreting the free spaceand the jacks were removed. The wires forming the cableswere covered by concrete to protect them from corrosion.The A units supported columns above while the B units hadsockets in them to drive piles through.

Fig.7 : Post-tensioning (concrete anchorage cone andtensioning jack)


Fig.10 : Le Havre horizontal prestressing of footings

Fig.11 : Le Havre anchorage for horizontal prestressing offootings

Fig. 12 : Le Havre existing columns above and the socketsfor new piles below the combined footingThe second part of the Freyssinet solution was to install700 piles, 25 to 30 m (82 to 98 ft) long that extended tosound layers of soil. The piles were cast inside the buildingin 2 m (6.6 ft) sections, and were assembled by prestressingand driven into the ground using special jacks designed byFreyssinet. Vibration, compression, and steam curing ofthe concrete were all used to improve the rate of castingand quality of concrete. The piles were then prestressedagainst the footing by means of hydraulic jacks having avertical prestressing force of 320 mt (352 tons). Thesettlement immediately ceased as soon as the first pileswere installed.The result was both spectacular and convincing, and at onceearned Freyssinet a worldwide reputation. This created theopportunity for a meeting between Eugène Freyssinet andEdme Campenon, and started the collaboration betweenthe two in 1934 on the entire range of construction projectsof the Campenon Bernard group, a collaboration that finallywas destined to ensure the development of prestressing.

PROLIFERATION OF FREYSSINET TECHNOLOGYAROUND THE WORLD.With success at Le Havre, the contractor Edme Campenonoffered Eugène Freyssinet "the chance to experiment, apply,and develop his invention of prestressing and his ideas onconcrete construction, on the entire range of sites of theCampenon Bernard group". Later in 1943, EdmeCampenon created a special division called STUP (SocieteTechnique pour l'Utilisation de la Précontrainte) [TechnicalCompany for the Use of Prestressing] for the "development,

protection, and implementation of the techniques of whichM. Freyssinet is the inventor". In 1961 STUP created adesign company, Europe Etudes, so as not to restrict thedevelopment of prestressing technique to the sole use ofits original inventor and developer. STUP also wanted tospread this technology all over the world. With this aim, in1963, STUP started its design bureau in Mumbai - STUPConsultants Pvt. Ltd. Today, STUP Consultants Pvt. Ltd.employs over 1400 Engineers, Architects, Technicians andsupporting staff and has designed and implementedprojects in 36 countries. Today, STUP Consultants Pvt. Ltd.is active in all branches of Civil and Structural Engineering,Architecture of Buildings as well as of Airports - includingthe associated Mechanical and Electrical Engineering. In1976, STUP France changed its name to FreyssinetInternational instead of STUP, which soon after becameknown as Freyssinet International. The group, at that time,included a prestressing supplier, which was a disseminatorof technical information around the world (FreyssinetCompany), a contractor (Campenon Bernard), and adesigner (Europe Etudes). In 1982 STUP Consultants Pvt.Ltd. separated from the Freyssinet Group as it wished tobecome an independent consultant.

INVENTION OF PRECAST SEGMENTAL CONSTRUCTION:The Luzancy Bridge over the Marne River (started in 1941and completed in 1946 after the war), was the first of a newgeneration of precast segmental bridges designed andconstructed by Eugène Freyssinet. It has a span of 55 m(180 ft), a world record at the time, and was built to replacean old suspension bridge. It is very light in appearance andhas a remarkable span to depth ratio of 1: 45.

Fig.13 : Luzancy Bridge (55 m span) (1941-1946) (firstprecast segmental bridge)

The Luzancy Bridge was visited sixty years after completionin October 2007 by me along with other members of theFreyssinet Association. It is in pristine condition and theconcrete of the precast segments is of excellent quality.

Fig.14 : Luzancy Bridge in 2007

The bridge is an 8 m (26 ft) wide portal frame comprised ofthree box girders that were precast in segments andassembled on site in sections. The bridge was prestressedlongitudinally and transversely with 12 - 5 mm diameter


tendons, and vertically with 5 mm pre-tensioning wires thatwere stressed prior to concreting. It was erected bylaunching equipment consisting of masts and stay cables(one of the most imaginative systems ever used for theassembly of prefabricated bridge elements).

The middle box girder being erected is 39 m long andweighs 90 T. All three of Freyssinet's inventions forprestressing (pre-tensioning, flat jacks, and post-tensioningwere used here).

Fig.15 : Luzancy Bridge during construction

The Underground Basilica at Lourdes takes its inspirationfrom the Esbly Bridge of the Luzancy lineage. The structurewas conceived by Eugène Freyssinet in only fifteen minutes,designed by Jean Chaudesaigues, and constructed byCampenon Barnard from 1956 to 1958. It consists of only29 portal frames and can accommodate 20,000 people.

Fig.16 : Underground Basilica at Lourdes (capacity: 20,000people)

Fig.17 : Pierre Xercavins speakingat the 50th anniversary of theBasilica of St. Pius X at Lourdes onMarch 14, 2008 (photo courtesy :Association Eugène Freyssinet).

Choisy-le-Roi Bridge (1962-1964)Jean Muller also a genius like Xercavins worked as a closecollaborator and eminent disciple of Eugène Freyssinet inCampenon Bernard and Company, pioneered match-casttechnology in the early sixties with the Choisy-le-Roi Bridgeover the Seine River in France. On this bridge, he used forthe first time, precast segmental box girder technology withmatch-cast epoxy-coated joints. I visited the site with JeanMuller, while outsiders were not allowed to visit unless thebridge was completed and put into service. (In the precastingyard the previously cast segment was used as the end form

for the next segment, in order to obtain perfect contactbetween adjacent segments and to get directly the finalprofile of the deck). This bridge has three continuous spansof 37.5m - 55m-37.5m (123ft-180ft-123ft), with a total widthof 28.4m (93 ft) that was divided into two parallel single cellbox girder bridges. A total of 148 precast segments werefabricated using the long-line casting method. Typicalsegments weighed 20mt (22 tons). The bridge was erectedin balanced cantilever using a floating crane.

Fig. 18 : Choisy-le-Roi Bridge (1962-1964) (first precastsegmental "match-cast" bridge)

Bear River Bridge (1971-1972) The Bear River Bridge near Digby, Nova Scotia in Canadawas the first precast segmental box girder bridge built inNorth America using the match-cast method with epoxy-coated joints. This curved bridge is 609 m (1998 ft) longwith six interior spans of 80.8 m (265 ft) and two exteriorspans of 62.1 m (204 ft). The bridge is 12.0 m (39.5 ft) wide.The 145 segments were cast in a plant located near thebridge site using two short-line casting cells each producingone segment per day. The segments weighed a maximumof 82 mt (90 tons), and were placed by a 180 mt (200 ton)mobile crane on land or on a barge over water. The bridgewas designed by A.D. Margison and constructed by BeaverMarine Ltd., with construction engineering assistanceprovided to the Contractor by Europe Etudes under theleadership of Pierre Xercavins and Daniel Demarthe.

Fig.19: Bear River Bridge (1971-1972) (first precastsegmental "match-cast" bridge in North America MontrealVelodrome (1973-1976)

The Montreal Velodrome for the 1976 Olympic Games paystribute to Eugène Freyssinet because it incorporates somany of his prestressing and construction techniques. Thisvery flat airy vault of prestressed concrete and is supportedat four abutments only, and is inscribed in a rectangle of172 m by 130 m. The covered area without intermediatesupports is 16, 000m2 .

Completed Structure


One of the most interesting phases of construction was thedecentering (the transfer of loads from the false work to thepermanent supports at the abutments).

Structure during construction.

By placing flat jacks at the four abutments and jacking to anamount equal to the calculated reactions, the roof slowlyrose until the entire weight of the structure was taken by thefour abutments only. A total of 226 flat jacks each with acapacity of 1000 mt were used for the decentering. Oncethe loads were transferred, the false work was removedgiving a clear span of 172 m.

The veledrome was designed by Trudeau, Gascon, andLalancette with technical assistance provided by EuropeEtudes under the leadership of Pierre Xercavins and DanielDemarthe.

Flat jack scheme at Abutment

The main structural elements are six arches which spreadaway from the Z abutment, and meet again in pairs oneither side of the W, X and Y abutments. Two secondaryarches connect the X abutment to the W and Y abutments.The arches are comprised of 142 precast segments thatare built using the match-cast method with epoxy-coatedjoints, and erected on temporary false work. A network of

63 double Y-shaped beams span between the arches. Thestructure is completed with cast-in-place concrete joiningthe arches to the abutments.

Caracas Viaduct during construction Bridge(1) completedBridges (2)and (3) completed Caracas Viaduct Completed(1951-1953)

Orly Airport Bridge (1957 - 1959)

I visited this bridge under construction when I was a trainee-it was the first continuous bridge in the world.

Orly Airport Bridge (1957 - 1959)Saint Michel Bridge (1959 - 1962)

It has portals with slim piers in the direction of the waterflow during floods. This was the first prestressed concreteportal bridge carrying Railway lines.

Saint Michel Bridge (1959 - 1962)

CONCLUSIONSFreyssinet repeatedly stated, "I was born a builder". Indeed,he became totally immersed in the building of his structures,"becoming simultaneously engineer, contractor, carpenter,form worker, steel worker, cement specialist". In the wordsof Jean Montagnon "If Eugène Freyssinet had been amusician, he would have been a composer, an instrumentmaker, an instrumentalist, and a conductor." Freyssinet alsostated repeatedly that he had invented an entirely newmaterial which led to "a revolution in the art of building". Hecontinued to design and build until his death. Included inhis latter structures are the three arch bridges of the CaracasViaduct from 1951 to 1953, the Underground Basilica atLourdes from 1956 to 1958, the Number 10 Bridge at OrlyAirport from 1957 to 1959, and the Saint-Michel Bridge atToulouse from 1959 to 1962. The Saint-Michel Bridgeopened in March 1962, three months before Freyssinet'sdeath. Eugène Freyssinet has been proclaimed as one ofthe most complete engineers of the 20th century and iscertainly one of the greatest builders in world history. Ipresent this paper with some emotion as it includes slicesof my life.

Structural Layout Flat jack layout at Abutment

Decentered structure (172 m span) Caracas Viaduct (1951-1953)


The Alternative Building Materials and Technologies for IndividualHousing in Coastal Karnataka

RAJENDRA KALBAVI RAO, Project Director D. K. Nirmithi Kendra, National Institute of Technology Karnataka, SurathkalSUDEEP KUMAR SHETTY, Rachana consultants, , 1st floor, Venkataramana Arcade, Bhavanthi Street, Mangalore

JOHN KENET D’SOUZA, Consulting Engineer, 1st Floor, Krishna Complex, MG Road, Kodailbail, Mangalore

IntroductionWorld hates change, yet, it is the only thingthat has brought progress- Charles Kettering.‘Normal is boring’ is the common saying. Man needschange in every aspect of life, for which construction isno exception. He needs change, needs different designs,needs variety, needs choices and other options beforehe decides. The various research Organizations in thecountry and world wide are in continuous investigationto develop different alternative materials andtechnologies. These vary from basic materials like stoneand sand to finishing materials like paints and coatings.As science and technology advances, it is becomingchallenging work to the scientists to give an improvised,fault free and performance oriented products andtechnologies to suit the general public. List of buildingmaterials to choose from has become very exhaustiveand expensive results in the urge to develop newer anddifferent materials to suit local condition and to suit thevarying human requirements.

Costal KarnatakaThe cities in costal Karnataka are situated attached toArabian Sea. Mangalore is located at 12°-52’N latitudeand 74°-49’E longitude. The average rainfall is 3875 mmbetween Junes to September every year. The ambienttemperature varies minimum from 17°c to a maximum37°c.The maximum average humidity is 93% in July andaverage minimum humidity is 56% in January. There areonly 2 seasons, namely rainy season and summerseason. Generally days are warm through out the year.Sloped roof with Mangalore tiles are commonly used,before invention over concrete. Bricks, cement, steel,aluminium, plastic products, paints, polished stone,ceramic products, etc. are the commonly used materialsof construction today. Modern day house constructioninvolves in construction of framed structure with lintelsand chajjas and RCC for roof slabs. Those who can affordwill have air conditioned rooms and others will keep largeopenings for ventilation and comfort inside the house.

Why Alternative building Materials andtechnologiesSelection of materials and technologies for the buildingconstruction should satisfy the felt needs of the user aswell as the development needs of the society, withoutcausing any adverse impact on environment. The firstenergy crisis of 1973 was perhaps the trigger, which leadto the concept of Alternative Building Technology.Technologies of the Developed West often could not meet

these requirements and many thinkers argued in favourof a middle path and this approach is the genesis of theAlternative Technology movement. With the developmentof science and technology alternative materials andtechnology is available, right from the basic materialslike cement to building blocks, from foundations tofinishing items. Few of them are explained below.

Building BlocksNaturally occurring laterite stone blocks are commonlyused in coastal areas. Fig.1. The concrete blocks havespearheaded the construction industry with varying sizesform brick to laterite. The investment is very low and itcan be produced throughout the year as compared tothe brick industry. Fig.2

Burnt Clay Hollow Blocks:-These are burnt high clay blocks made by a process ofextrusion. The wall thickness of the hollow block is oftenas low as 15 to 20 mm. They come in various sizes fromlaterite block to brick.

Stabilized Mud BlocksSoils when compacted using external energy, the densityof the soil reaches a maximum value at the optimummoisture content (OMC). The value of OMC and themaximum density depends on the energy input duringcompaction. The compressive strength of the soil, in thedry state, depends on the density. Thus the process ofmechanical compaction can lead to densification andstrengthening of the soil. Addition of stabilized additiveslike Cement, lime or bitumen further improves thedensification during saturation. These blocks can beproduced locally with manually operated machines withsuitable mould sizes. Fig 3

Stone Blocks using recycled wastesThe BIS specification IS: 12440 give the details of thistechnique. It is a very simple technology involving usingodd sized stones, which are shaped by a layer ofconcrete surrounding the stone. Steel moulds restingon level ground can be used to place the odd shapedstone in the centre of the mould. Lean concrete is nowpoured in the space between the stone and the mould.Block sizes matching to laterite or concrete blocks arecommonly used. Compressive strength in the range of5.0 to 7.0 MPa can be easily achieved.

Masonry construction techniquesEnglish bond is the most common mode of constructionin India. When Concrete blocks are used, the blockshave to be kept in ‘Stretcher bond’ leading to a wall


thickness of 100,150 or 200mm and a course height of200mm as shown again in Fig.2. When stabilized mudblocks of size 230x190x100mm are used, either a headerbond with wall thickness of 230mm or a stretcher bondof 190mm wall thickness can be used. The concept ofrat-trap bond was popularized by Ar.Laurie Baker in Keralain the seventies. This involves keeping bricks on edgecreating a gap in the thickness of the wall. About 25% ofthe bricks can be saved by this process. The cavitycreated within the wall offers thermal comfort inside thehouse. Fig 4&5

Arches, Corbels and Reinforced brick lintelsMasonry arches are the age old construction techniquescan still today replace concrete lintels. Arches can becircular, segmental or even flat. (Fig 6 & 7) These arealso used in the masonry foundations between thecorners to save on earthwork excavation and materials.Corbels (Fig 8) and arches give aesthetic look to thestructure while carrying the desired load. Reinforced bricklintels are the one used or small openings up to 1.8mwith and nominal reinforcement of 3-8 mm in CM 1:3and bricks laid on edges with the same mortar.

Ferro Cement ElementsFerro cement is a special form of reinforced concrete. Itis a composite material consisting of cement-sand mortar(matrix) reinforced with layers of small diameter wiremeshes. It differs from conventional reinforced concreteprimarily by the manner in which the reinforcement isarranged within the brittle matrix. The success of ferrocement in various terrestrial applications can beattributed to ready availability of materials locally, needof low level technology for its production, better utilizationof available human resources and architectural flexibility.Ferro cement products are so versatile that they havereached common man’s kitchen to drawing room furnitureto commercial structures. It is all geared to replace timberin all the areas of construction. (Fig 9)

Alternative Roofing Systems:-Due to invent of extensive research done by variousinstitutions various technological options are availablefor implementation. The research for an alternative roofmust be based on a simultaneous satisfaction of severalobjectives.

1. Withstand imposed dead and live loads.2. Prevent leakage during rainy season3. Provide a secure enclosure4. To be cost effective5. Provide a durable comfort in the interior6. Give aesthetics to the structure

Roofs can bei) Pre fabricated roof

ii) Partially prefabricated roofiii) Cast in-situ roof

Few of the technologies commonly used in coastalKarnataka are explained below.

a) Filler Slab Roofs:-Filler slab roofs are basically solid reinforced concreteslabs with partial replacement of the concrete in thetension zone by a filler material. The filler material couldbe cheaper and lighter. A number of filler materials canbe thought of a) Brick or brick panel, b) Mangalore tile,c) Stabilized mud block d) Hollow concrete block, e)Hollow clay tile block etc. Size and shape of the fillermaterial are governed by the factors like slab thickness,code guidelines on spacing of reinforcement bars, desiredceiling finish etc and has to be carefully selected. Thisis a cast in situ system and is widely accepted and ismost suitable for tropical Climate and for buildings incoastal region. The laying of this roof is in line withconventional technique. The form work is done at desiredheight and shape, the filler material is placed and thereinforcement is tied and the concrete is laid. This methodalso satisfies all the requirements of the code and theneeds of the common man. Layout of filler material(Hollow clay block roofing block) along with thereinforcements before the pouring of the concrete andthe ceiling (with regular Mangalore tile) after completionare shown in figure. (Fig 10, 11 & 12)

b) The Concept of Composite Beam and PanelRoofs:This system is similar to the traditional wooden raftersand wooden planks used as attic in the olden days. Nowwe are using concrete beams and planks made ofmaterials like brick, ferro cement, stabilized mud blocksetc are used. The roofing system consists of panels andbeams cast separately and assembled such that thesystem behaves like a T-beam. The beams can be fullypre cast or partially pre cast beams. These types ofroofing systems can be broadly grouped into twocategories viz: Flat panel roof and curved panel or jack-arch roof, based on the shape/geometry of the panel.Since the panels and beams are cast separately andthen assembled, there should be proper shear connectionbetween them to achieve composite action for the systemto behave as an integral structural unit. The flexibility ofcomposite beam and panel roofs arises out of the factthat the materials for the beams and the panels couldbe of two different materials and the composite actionbetween them could be achieved by proper shearconnectors. Both the beams and the panels can beprecast and then assembled into a roofing system. Incase of precast beams, the beams are partially castand hence they require some props while assemblingthe roofing system. These roofs can be laid flat or withgentle slope. Fig 13.


c) Masonry Domes and Vaults:Romans rediscovered the use of the arch, and the vault.However, they often used semicircular barrel vaults builtout of concrete. The vaulted constructions spread toEurope and one can see vaults in Roman architecture ofEngland. The vault construction was no longer confinedto mosques in this region. The superiority of the brickmasonry vault over the conventional construction usingtimber palaces, granaries, ammunition stores were someof the important structures where the vaulted constructionwas readily accepted. A thin layer of nominally reinforcedconcrete over and above the unreinforced masonry canvastly enhance the performance of masonry roofs. Fig14. Use of modern materials like glass fiber reinforcedplastic as externally attached reinforcement can alsoprovide additional flexibility and strength.

d) Mangalore tiles over ferro cement rafters andreapers.Mangalore tiles over wooden supporting structure areaccepted and adopted technology since centuries. It ismost suitable roof for the coastal region in the tropicalcounty like India. Timber of good quality is not availableas per requirement and above that it is expensive material.Concrete and ferrocement can be a suitable substitutealternative replacement for implementing Mangalore tileroofing system. The size and the shape can match thetimber and the member can be designed as perrequirement on IS codes.

The wall plate, the rafters and the reepers aremanufactured to design in a factory and shifted anderected at site. These structures are unlike wood arefire resistant, termite resistance, anti fungal, lowmaintenance and it has a long life then compared totimber structures. It is a look-a-like structure and onecannot make out the difference between the conventionaland alternative method once erected. Fig 15.

Energy efficient and eco friendly:Considerable amount of energy is spent in themanufacturing processes and transportation of variousbuilding materials. Conservation of energy becomesimportant in the context of limiting of green house gasesemission into the atmosphere and reducing costs ofmaterials. A comparison of energy in different types ofmasonry has been studied. Energy in different types ofalternative roofing systems has been discussed andcompared with the energy of conventional reinforcedconcrete (RC) slab roof. It is found that total embodiedenergy of load bearing masonry buildings can be reducedby 50% when energy efficient/alternative buildingmaterials are used. Table1.

ConclusionOpening up of the Indian market has given the commonman to look for the latest and the best suited materialand technique for his suited budget and needs. Table 2

shows the cost benefit in using these technologies. Withinternet available at nook and corner of the state, everyman is well informed and has access to knowledge superhighway. Recently lot of materials and techniques arecoming to the market and the common man is confusedto use, adopt, judge and implement the right technology.We Engineers with all the technical back ground andexperience should have the updated knowledge to usethe appropriate technology at right place at correct timewith proper technical design, supervision andimplementation. Thus the efforts of the scientists andresearchers will have a value addition and a dream cometrue for the common man. Fig1. The only shortfall is theinformation which reaches the common man graduallyand all the building materials and technologies are timetested over the years, it takes its own time to prove itscredibility and durability requirements.

References:[1] A.J.Joseph Increasing the service life of low-cost

buildings, Building Materials for Low-IncomeHousing, Oxord & IBH Publishing Co.Pvt.Ltd. NewDelhi. P 335-340.

[2] Harrison S. W, Sinhat B. F, A study of alternativebuilding materials and technologies for housing inBangalore, India Construction and BuildingMaterials Vol. 9, No. 4, January 1995, pp. 21 l-211.

[3] Jagadish K. S, venkatarama Reddy K. S, NanjundaRao, Alternative Building Materials andTechnologies.2008.New Age InternationalPublishers. New Delhi.

[4] Jamal M. Khatib, Sustainability of constructionmaterials. Woodhead publishing Limited.New Delhi.P 85,86 & 116.

[5] Venkatarama Reddy B. V, Sustainable buildingtechnologies, Current Science, Vol. 87, NO. 7, 10OCTOBER 2004, pp 899-907.

[6] Venkatarama Reddy B. V, and Jagadish K.S.,Embodied energy of common and alternative buildingmaterials and technologies, Energy and Buildings35 (2003) 129–137.

[7] Venkatarama Reddy B.V., Jagadish K.S. / Energyand Buildings 35 (2003) 129–137, Energy andBuildings 35 (2003) 129–137, Embodied energy ofcommon and alternative buildingi materials andtechnologies .

[8] Ross Spiegel, Dru Meadows, Green BuildingMaterials, John wiley & sons, Inc. Professional/TradeDivision,605 Third Avenue, New Yark,N.Y.10158-0012.P 9,27-30.

[9] S.Q.Jamal and A.S.Sheikh, The use andPerformance of soil stabilized blocks in flood affectedrural areas, Building Materials for Low-Income.


Table 2. Cost savings of Innovative technologies over conventional options

S.No Innovative Technologies Conventional Options % of saving

1 230mm thick wall 330mm brick walls 53 Rat trap bond walls English/Flemish bond 254 Hollow blocks walls Hollow blocks walls 205 Tiles over RCC rafters Tiles over timber rafters 256 Brick panel with joists RCC 20-257 Ferro cement shell roofing RCC 408 Filler slab roofing RCC 229 Jack arch brick roofing RCC 1510 Precast blocks over inverted T-beams RCC 2511 Corbelling for lintels RCC lintels 4012 Brick arch for lintels RCC lintels 3013 Hollow clay block walls & corners 2014 Hollow roofing block RCC slabs 15-2515 Precast ferro cement shelves Timber/concrete 35-45

Table 1.

Energy in different roofs/floor systems

Number Type of roof/floor Energy/m2 Equivalent of RCof plan area (MJ) solid slab energy (%)

1 RC slab 73.0 1002 SMB filler slab roof 59.0 80.83 Composite brick panel roof 56.0 76.74 Burnt clay brick masonry vault roof 57.5 78.85 SMB masonry vault roof 41.8 57.36 Mangalore tile roof 22.7 31.17 Ferro concrete roof 15.8 21.68 RC ribbed slab roof 49.1 67.3

Fig 1. The residence of Mr. Kenet D’souza( Co author)constructed using Laterite stone blocks and alternativebuilding technologies

Fig 4 Layout for rat-trap bond construction


Fig 2. Hollow concrete block laid with stretcher bondfor wall construction

Fig 3 Stabilized Mud block under production. Fig 6. Brick arches in place of lintels and beams

Fig 5. Brick wall constructed with rat-trapbond technique.

Fig 10 Hollow clay block Filler slab before pouring ofconcrete

Fig 7. Flat arch with brick masonry to avoid lintels.


Fig 11 Filler slab ceiling after completion

Fig 9 Cross section of a Ferro cement member

Fig 8. Large corbels can replace lintels, arches andbeams.

Fig 15. Mangalore tiles supported on Ferro cementrafters and reepers.

Fig 14 View of a circular brick vault

Fig 13. Ceiling view of a brick panel roof.Fig 12 Filler slab ceiling using Mangalore tiles aftercompletion.


Estimating the Strength of Concrete - Maturity MethodBharathi Ganesh, Asst. Prof., Dept. of Civil Engg., Global Academy of Technology, Bangalore

Dr. H. Sharada Bai, Professor, Faculty of Engineering – Civil, UVCE, Bangalore University, Bangalore

IntroductionMany operations like when to strip forms, when to post-tension, when to remove shores, and when to terminatecold-weather protection are based on reaching aminimum level of concrete strength development.Waiting too long is very expensive but acting prematurelywith out confirmation of strength measurement maycause the structure to crack or collapse. Few cases offailures of structures (Fig. 1) under construction due toform stripping and shore removal at improper time havebeen witnessed. More timely knowledge of compressivestrength evolution at required time interval during concretehardening process is needed, in order to achieve savingsin many ways during construction and also to improvesafety.

Fig. 1 Failures ofStructures due to formstripping and shoreremoval at improper time

Although there are several procedures predicting concretecompressive strength, reliable methodologies involveeither extensive testing or voluminous databases. Hencea simple and fast methodology is required toconsequently predict compressive strength evolution. Asimple and efficient method based on the parameters -activation energy and the degree of reaction of cement,can be used for a rapid prediction of the mechanicalproperties of concrete and particularly the evolution ofcompressive strength.

Fig.2 Effect of Curing Temperature on the Rate ofStrength Gain

At early age, the mechanical properties of cement-basedmaterials are time-dependent and involve hydration ofcement. The hydration process is a thermally-activatedchemical reaction, directly related to the developmentof strength which depends on rate of reaction. Theintegral over time of the rate of reaction gives the degreeof reaction.


Measurement and Predictions of mechanical propertiesof concrete are possible by a method based on theempirical relationship between the degree of reaction(hydration) in terms of duration of hydration, &temperature of concrete during hardening process.

Maturity method is one such method, which is used topredict the compressive strength evolution of concrete,based on the determination of maturity indexes. Theseindexes lead to the prediction of the evolution ofcompressive strength of concrete at a required periodafter pouring it or from the instant of adding water to themix.

The effect of the temperature after similar elapsed timesof hydration, changes with the Thermal ExpansionCoefficient (TEC), and this coefficient depends on curingtemperature (fig.2) and the degree of hydration. Toperform predictions of compressive strength evolutions,knowledge of maturity indexes is required. Maturityindexes need to be determined experimentally for eachconcrete type.

Originally, hardening time was intended to be anequivalent of setting time. Studies of the mechanism offorce transmission between sensors and concrete-matrixindicate that hardening time depends on the degree ofconcrete hydration.

The methodology presented here assumes that thehardening time is an indicator of the degree of reaction.The relationship between the hardening time and thedegree of reaction is an important issue for the extensionof the methodology to the general field of hardeningmaterials.

Values of hardening time depend on the following factors

• degree of reaction which in tern depends on factorslike type of materials and machineries used inmaking concrete, temperature of hydration, timeetc.

• features of sensors such as thermal expansionproperties and stiffness.

The basis of this methodologyThe basis of this methodology involves passing frommechanical properties of concrete (hardening time) tothermodynamic chemical properties (activation energyand rate constant) and back again to mechanicalproperties (compressive strength).

What is Maturity MethodThe maturity method is a nondestructive technique thatis used to estimate the in-place strength of concrete byaccounting for the effects of temperature and time onstrength development. ASTM standard practice forestimating concrete strength by maturity method isASTM 1074.

Why Maturity MethodProper method of quality control is essential in everyconstruction because test samples do not reflect theinfluence of temperature extremes, weather conditions,Cylindrical Specimen critical curing conditions, concretethickness and any number of other actual job siteconditions. Fig. 3 shows curing conditions of deck curedby Heating & Covered with full jacketing. And also thecylindrical specimen cured at the same site.

PrincipleMaturity Method is based on the principle that the extentof hydration of a concrete mixture and, therefore, thestrength at any age is based on the thermal history ofthe concrete. Using the thermal history of a concretemixture and a maturity function, a maturity index thatquantifies the combined effects of time and temperaturecan be calculated and plotted against the strength ofthe concrete by means of a strength-maturity relationship(fig.4).

Fig.3 shows curing conditions

Fig.4. Maturity Strength Relationship

Maturity IndexThe relationship between the temperature history of aconcrete and its strength can be empirically determined,and is called its maturity index. Concrete of a given mixat the same maturity has approx. the same strength,regardless of the temperature and time history that madeup that maturity.

Maturity FunctionThere are two alternate functions for computing thematurity value from the measured temperature history


of the concrete, the Nurse-Saul equation and theArrhenius equation.

The maturity function, known as the Nurse-Saul equation,is used to compute the TTF as follows:

M(t) = (Ta -To) * t

where: M(t) = the TTF - Time Temperature Factor at aget, degree-days or degree-hours,

t = a time interval, in days or hours,

Ta = average concrete temperature during time interval -t °C, and

To = datum temperature = -10 °C.

The information used to make these decisions is usuallyobtained from field cured cylinders, pullout tests, orpenetration testing. Some codified methods use similarconcepts by inserting the final setting time into maturity-strength equations and Maturity methods are yet tobecome popular used in practice.

ScopeMaturity method is a modification of ASTM C 1074covering the procedures for estimating concrete strengthby means of the maturity method.

A relationship must be established between the maturityvalues and the concrete strength, as measured bycylinder testing. The development of the maturity-strengthcurve shall be performed using project materials and theproposed concrete mix design. The contractor shall beresponsible for the development of the maturity curve.The Mix Design Expert shall monitor the curvedevelopment. The temperature monitoring process of theconcrete construction is the responsibility of thecontractor and shall be monitored by the Engineer.Acceptance of the concrete shall be based upon the 28-day cylinder strength.

Instrument - SensorsThe maturity method involves the measurement of threekey parameters time, concrete temperature and concretestrength. Using one of two widely-used expressions, atemperature-time factor with units of “Degree Hour” iscalculated by multiplying concrete temperature, withrespect to a datum, by the elapsed time (in hours) afterthe concrete was batched. The temperature of freshconcrete is measured using Temperature Sensors (Fig.5)Concrete maturity can also be measured in the laboratoryor field using strength test specimens.

Working of SensorsInsert two temperature sensors at the required place ofmeasurement appropriately depending on the type ofconstruction. After concrete hardens, both sensorsmeasure only the deformation of the concrete matrix andthe difference between the deformations measured bythe two sensors remains constant. The hardening time

is defined as the time when the derivative of the differencebetween the deformations measured by these sensorsby setting initial reading in standard sensors.

In ASTM C 1074, “Standard Practice for EstimatingConcrete Strength by the Maturity Method, 32 °F (0 °C)is recommended as the datum temperature for concrete(containing Type I cement in US)

A relationship between degree-hours and actual concretestrength, for a given mixture, can be determined bygraphing each actual strength data and the correspondingdegree-hours.

Fig. 5 Temperature Sensors & Field Measurements

Procedure for Field Measurements1. Establishing Maturity Strength Relationship fora particular site / mix used at site.• Prepare at least 15 cylindrical specimens (fig.6)

according to Kentucky Method 64-305. The mixtureproportions and constituents of the concrete shallbe the same as the concrete whose strength will


be estimated using this practice. The concrete shallbe produced using the same equipment as thatwhich will produce concrete for the project. Thecylinders may be cast at the concrete plant or thejob site. Since there is a direct relationship betweenthe w/c (water/cement) ratio and strength, theconcrete used to develop the maturity-strengthrelationship shall be at the maximum w/c ratioexpected during production.

Fig.6. Maturity Strength Relationship

• Moist cure the specimens in a water bath or in amoist room meeting the requirements of KM 64-305.

• Perform compression tests at five different ages. Testthree specimens at each age and compute theaverage strength. If a low test result is due to anobviously defective specimen, discard the low testresult. The tests shall be spaced such that they areperformed at somewhat consistent intervals of timeand span a range in strength that includes theopening strength desired. The table.1 givessuggested test times. Test 3 is the target test. Thisis only a guide and may need to be modifieddepending on specific mixtures and conditions.

• At each test age, record the average maturity valuefor the instrumented specimens.Use the spreadsheet available to determine thematurity-strength relationship. This spreadsheetcan be found on the Materials Web Page at TheTTF number corresponding to the desiredcompressive strength. This curve is used todetermine when the concrete has reached desiredstrength.

Table 1. Approximate Test Times

Mix Strength in MPa

Test 1 Test 2 Test 3 Test 4 Test 5

Class X 2 days 3 days 4 days 5 days 6 days

Class X/24 6 hours 10 hours 12 hours 14 hours 24 hours

Class X /48 24 hours 36 hours 48 hours 60 hours 72 hours

Class X /72 48 hours 60 hours 72 hours 84 hours 96 hours

Acceptance Criteria• The R2 value can be found on the maturity curve

chart. The computed R2 value of maturity curveobtained from regression analysis of the maturitystrength relationship (fig.7) shall be 0.95 or higher.When R2 value is below 0.95 the curve isunacceptable and a new curve will be required.

Fig.7. Maturity Strength Relationship – fox a Particularmix at Field

PrecautionsWhile evaluating concrete maturity using small testspecimens, it is extremely important to insulate themfrom heat loss to minimize the time needed to developthe strength-maturity relationship. If small test specimensare not insulated during curing, strength developmentwill be slowed because the volume of concrete is small.

2. Strength measurement of In-situ concrete• Insert temperature sensors at mid-depth of the

pavement and a minimum of 12 inches from theedge of the concrete. They should be placed in theplastic concrete as soon as possible. Avoid placingthe sensors near reinforcing steel. A threaded rodwith a wing nut may be used to insert the sensorsin the pavements and immediately removed.Consolidate the concrete around the sensor asneeded. The rod can be marked for various insertiondepths. This device will allow the placement of thesensors with minimal disturbance to the concrete.Sensors should be placed in the concrete wherethe temperatures are expected to be the coolest.

• For a normal day production, randomly place twosensors to determine the maturity. They shall belocated in the last 100 feet of pavement placed.

• Embed temperature sensors in the centers of atleast two cylinders. Connect the sensors to

• One or more maturity meters (fig.8). Use the averageof the readings to develop the maturitystrength curve.

• Connect the sensors to maturity instruments (Fig.9) and activate the recording devices as soon as ispracticable.

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• When the strength at the location of a sensor is tobe estimated, read the maturity value (Fig.10) fromthe instrument. The strength of the concrete can bedetermined from the spreadsheet or calculated fromthe curve equation.

Fig. 8. Maturity Meter

Fig. 9 Measurement on Fresh Concrete

Fig. 10 Reading – Maturity MeterAdvantages of the test

• Maturity-based testing can reduce project costs byeliminating the need to cast and test compressiveor flexural strength specimens.

• Once a strength-maturity relationship is establishedfor a particular concrete, temperature histories canbe used to predict the strengths of samples of thesame concrete subjected to different temperatureconditions.

Disadvantages of the test• The strength and degree-hour relationship will vary

for different mix proportions and material selection.Therefore, a fresh relationship must be establishedfor a given concrete mix before a specific projectbegins.

Limitations of test• There are, however, limitations to using either test

specimens or the maturity method to determine thein-place concrete strength. With the maturitymethod, a change in cement performance during aproject (due to different loads or lots of material)could produce variability in results.

• Test specimens on the other hand may containflaws or lose heat during curing and not berepresentative of in-place concrete performance.Until sufficient experience has been obtained witha given mix, the most reliable way to determineconcrete strength is to use both strength andmaturity measurements to determine concretestrength.

• Changes in material sources, proportions,admixtures, and mixing equipment all affect thematurity value of a given concrete mixture. Therefore,development of a new maturity curve is required forany change to a concrete mix.

Correction for resultsDirect reading maturity devices are preset with initialtemperature reading for an assumed temperature belowwhich cement hydration ceases. The displayed valuesmay have to be corrected if this assumed temperaturediffers from the true temperature below which hydrationceases.

ASTM standard practice tells how to make thecorrections.

Benefit from Maturity Testing• Pulling cables and stripping forms as soon as

possible leads to project acceleration. Curingtimes are usually cut dramatically, especially in thewinter.

• Improve site safety by not stripping forms orstressing cables too soon.

• Improve concrete quality by learning thetemperature history of the concrete. Compensatefor changes in field conditions on-the-fly.

• Save money by assessing cold weather protectionto ensure sufficient temparatures for curing withoutwasted heating.

• Allows in-place strength determination of criticalareas of a structure.

• Non-destructive, inexpensive and cost-effective.

Application of methodIn practice, the maturity-based test method can be usedto• To estimate the strength of in-place concrete at a

given point in time.• To estimate concrete strength in full-depth pavement

repairs.• After developing the correlation between degree-

hours and actual strength, a contractor ortransportation agency can use the maturity method


to open a newly-repaired concrete pavement to trafficwithout testing a specimen for strength.

• Maturity testing can provide an alternative to strengthtesting in determining when a newly built concretepavement can be opened to traffic.

· The information obtained from field cured concretetest specimen is used to make the importantdecisions on To decide when to strip forms, whento post-tension, when to remove shores, and whento terminate cold-weather protection are based onreaching a minimum level of concrete strength.

• Early form removal especially in cold weather• Speeds up construction• Requires less form/shoring inventory• Allows other trades early access• Sooner completion date• Increases profits

• Method can be used in Post-Tensioned Structures/ High-Rise Buildings / Tunnel and Jump Forms /Early Forms Removal /Bridges / High-EarlyPavement Patches / Main-Line Paving / Saw-CutTimes / Airport /Runways/Taxiways / Driveways /Pre-Cast/ Prestressed / Tilt-Up / Mass Concrete(fig.11 & fig.12 )/ Cold Weather Concreting / Hot WeatherConcreting.

• Improve concrete quality by learning the temperaturehistory of the concrete. Compensate for changes infield conditions on-the-fly.

• Reduce Costs and improve performance of concreteby optimizing mix designs• Lower cement factors, controlled heat of

hydration, at lower cost• Important in the age of cement shortages /

sustainable construction• Monitor critical areas of a structure.• A Non-destructive, inexpensive and cost-effective

method.

Recognized, recommended and referenced testMethods:• ASTM C1074, “Standard Practice for Estimating

Concrete Strength by the Maturity Method.”• ACI 306 (Chapter 6), 228 and many other references• SHRP C376• AASHTO• OSHA Sec. 1926:171:B(c)

Summary & ConclusionsExpressing necessity of Maturity test in another way -Any time-sensitive placement where knowing the in-placestrength would be beneficial for quality, engineering oreconomic reasons.

Compressive strengths of several widely used concretemixtures have been successfully predicted using aprocedure that involves early age deformation monitoring.This methodology allows a fast and accurate predictionof compressive strength on site. Seventy-two hours aresufficient to gather the necessary data and provideaccuracy of less than 8% error. It is also an attractiveprocedure for the determination of the activation energyand the rate constant. More timely knowledge ofcompressive strength evolution will lead to savings duringconstruction and improve safety.

Fig.11 Monitoring Temps allows earliest cessation ofexternal heating operations

Continued on page 48


WHITETOPPING – A CASE STUDYDr. V. Ramachandra , Asst. Vice President (Tech. Services), UltraTech Cement Ltd., Bangalore

1. Introduction:Concrete Roads were first built by Romans (300 BC –476 AD). They were quite innovative in the constructionwith the use of innovative materials viz., use of‘Pozzolana’ cement from the village Pozzouli near Italy,horse hairs as fibres in concrete, admixtures in theirprimitive form (like animal fat, milk & blood). Theseroads, scientifically designed and constructed had a longlife and thus lead to the adage ‘ all (concrete) roadslead to Rome’.

Portland Cement Concrete (PCC) overlay on an existingbituminous pavement is commonly known as Whitetopping. The principal purpose of an overlay is either torestore or to increase the load carrying capacity or both,of the existing pavement. In achieving this objective,overlays also restore the ride-ability of the existingpavements which have suffered rutting and deformations,in addition to rectifying other defects such as loss oftexture. In our country, bituminous overlays have beenpopularly constructed in the past mainly due to abundantsupply of bitumen, its amenability to stage constructionand manageable traffic conditions, in terms of volumeand axle loads in addition to the comfort levels ofconstruction methods among engineers.

It was also making economic sense to make bituminouspavements as it was relatively cheaper. In recent timesall these advantages are reversed viz., petroleum industryis using refined processing technology leading toreduction in the production of bitumen leading toincreased imports, favourable cost economics of cementconcrete and rapidly changing traffic scenario (in termsof volume as well as axle loads). In addition, rapiddevelopments in concrete material technology andmechanization (both in concrete production & its laying)are favouring concrete overlays as a sustainable option.In recent times PPP (Public-Private Partnership) modelsare becoming popular in road construction shifting thefocus on selection of overlays based on life-cycle costsrather than initial costs. India is currently producingabout 240 million tonnes of cement and cement industryis quite matured and equipped to meet the challengesin terms of various grades of cements as well as highquality blended cements suitable for making PavementQuality Concrete (PQC).

Concrete overlays have been used to rehabilitatebituminous pavements since 1918 in USA. There hasbeen a renewed interest in whitetopping, particularly onThin White Topping (TWT) and Ultra-Thin White Topping(UTWT) over Conventional White Topping. Based onthe types of interface provided and the thickness ofoverlay, classification is as follows:

i) Conventional White topping – which consists of PCCoverlay of thickness 200 mm or more, which isdesigned & constructed without consideration of anybond between existing overlay & underlyingbituminous layer (without assuming any compositeaction).

ii) Thin White topping (TWT) – which has PCC overlaybetween 100 – 200 mm. It is designed eitherconsidering bond between overlay & underlyingbituminous layer or without consideration of bond.High strength concrete (M 40 or higher) is normallyused to take care of flexure requirement. Joints areat shorter spacing of 0.6 to 1.25 m.

iii) Ultra-Thin White topping (UTWT) – which has PCCoverlay of less than 100 mm. Bonding betweenoverlay & underlying bituminous layer is mandatory.To ensure this, the existing layer of bitumen is eithermilled (to a depth of 25 mm) or surface scrapped(with a non-impact scrapper) or gently chiseled.Joints are provided at a spacing of 0.6 to 1.25 m.

1.1 Advantages of White topping:

i) Reduced thickness – due to thickness of overlayremaining constant for over 2 decades.

ii) Fast-Track construction – making use of innovationsin concrete technology & batch mixing, concretescan be designed to have 3 –days’ compressive (&flexural) strength, so as to open the road for trafficwithin 5 days of construction.

iii) Reduced maintenance – as the concrete overlayslive for over 2 decades, with least maintenance.

iv) Cost-effective compared to asphalt overlays – whenLife Cycle Cost is taken into consideration.

v) Improved service life – with better riding quality,improved fuel efficiency of vehicles.

vi) Little pre-overlay repairs

vii) Improvement in safety in view of the increasedreflection of light – particularly on city roads, it wouldsave 24 % less electricity compared to flexiblepavements.

viii) Reduction in operational costs and lower absorptionof solar energy

ix) Improving the environmental benefits – as concreteroads are much greener and less polluting.

In this paper, the case history of a Thin White toppingTechnology Demonstration Project carried out on astretch of road was carried out recently is presented.


1. Details of the ProjectThe trial stretch is located on Hosur Road in Bangalore.The details of the existing bituminous road and the otherdata are as follows:

2.1 Design of Pavement and Concrete MixDesign of the overlay was carried out using Westergaard’sEquation and warping stress as per IRC:58 -2002 andIRC: SP: 76 – 2008. Total stress (including temperaturestress) was obtained as 30.83 Kg/cm2 and correspondingflexural strength requirement was 4.7 MPa. Design wasdone by M/s L.R. Kadiyali & Associates, New Delhi.Thickness of white topping was 150 mm.

Concrete mix design was arrived at by evaluating trialmixes and the design mix was arrived at with a cementcontent of 430 kgs, fly ash – 30 kgs, with a w/c ratio of0.283, achieving a slump of 40 – 60 mm at site.

2.2 Details of ConstructionIn order to achieve the desired advantages of concreteroads, three essential conditions need to be satisfied.

i) Production of concrete in a RMC plant or in adedicated batching plant.

ii) Using either fixed form or slip form mechanical paversiii) Strict quality control at site including testing of fresh,

hardened and extracted specimens of concrete andtests on pavement quality.

In this project design and production of concrete wascarried out by UltraTech RMC; Fixed form paver providedby M/s Allen Buildwell Pvt Ltd., was used. Qualitycontrol at site and testing were jointly done by theTechnical Services team of UltraTech and M/s Civil AidTechnoclinic (P) Ltd., Bangalore.2.3 Salient features of constructioni) Surface preparation: In case of TWT, bond between

PCC overlay & existing bituminous pavement isatleast partly desirable; in case of UTWT, effectivebond is essential. To ensure this any of the followingmethod can be adopted.

- Milling the existing bituminous surface to obtaina uniform surface. Milling can be used toremove surface distortion like cracks in thetop portion and adjust cross slopes. Thicknessof milling usually is in the range of 25 to 50mm.

- Surface scrapping is carried out on bituminoussurfaces which are quite hard. This can be fora depth of 10 mm and carried out with toolswhich have vertical impact control, so that thesub-grade is not damaged.

- Chiselling of the surface at regular intervals, ifthe existing surface is hard.

The minimum thickness of existing bituminous pavement(excluding the milled/scrapped thickness) shall be 75 –100 mm to ensure a reliable & strong base.

ii) Profile correction is carried out with the objective offilling existing potholes, ruts and wide cracks andalso to ensure a level surface for resting thepavement. Profile correction and correction ofcamber can be carried out together with a thinbituminous leveling course or with dry lean concrete(DLC).

a. If the existing road surface is good & only afew localized potholes / cracks e xist, theycan be repaired with a bituminous mix beforeconcreting is done.

b. If potholes/ cracks are wider than 3 mm, theyhave to be treated with bituminous emulsion,slurry seal after trimming them to shape andcleaning out loose fragments with compressedair. Milling of the existing surface alsoaddresses this problem.

iii) Laying of PQC is quite similar to the construction ofnew concrete pavement. As mentioned earlier,concrete should be made either in an RMC or in aweigh batching plant. Use of either fixed form paversor slip form paver machines is an essential ingredientfor getting a good quality pavement. In the currentproject, a fixe form paver was used with a fixed sideformwork (steel channel box section) with 16mmdiameter steel rods of 1 m length as tie rods @500mm c/c) and the paver had gang mountedvibrators equally spaced with variable rpm and threeintegral steel tubes with 8 Tonnes vibratory rollersfor screeding, levelling, compaction and finishing.

iv) Finishing of the surface is mostly achieved by thepaver itself. But to achieve uniform finish, a simplehand operated bull float is used when concrete isstill in its fresh state. After the bull float operation,uniform surface texture is provided by using steelwire brush.

1 CBR 8 to 10

2 Commercial vehicles per day 1000

3 Temp differential at Bangalore 17.3 deg C

4 Thickness of bituminous layer 4 to 7 inches

5 Base (40 mm metal) thickness 4 to 9 inches

6 Road width 100 feet

7 Length of road 350 m

8 Concrete grade M 45

9 Axle load 16 T


v) To avoid evaporation of surface water from concretesurface (which leads to plastic shrinkage cracks),wax based curing compound is sprayed. As anadditional measure, plastic sheets are spread overthe pavement surface till normal curing processstarts.

vi) Contraction joints are provided by cutting groves (fora depth of one-third of the depth of white topping,150 mm in this case) at a spacing of 1.2 m inlongitudinal as well as transverse directions. Thejoints are cut using electrical grove machines withinabout 8 to 10 hours of pouring concrete. Thesejoints are sealed with high quality sealant (eitherbitumen or poly sulphides) to prevent moisture andincompressible infiltration into the overlay system.

vii) To ensure effective load transfer across thelongitudinal segments as well as transverseconstruction joints, tie bars and dowel bars areprovided.

Surface preparation and alignment of rails for paver

Low slump of PQC

Groove cutting

Paver machine in operation

Surface texturing with wire brush

Bull float operation to smoothen surface


1. Evaluation of qualityStrict quality control not only during mix design andproduction of concrete, but also testing for quality atregular intervals (for every 50 cum of concrete) wascarried out. These tests included:

- Tests conducted on fresh concrete (slump test atsite)

- Tests on hardened state (compressive strength ofcube & cylinder specimens for 1, 3, 7 & 28 days),split tensile strength, flexural strength of concretebeams

- Fatigue and abrasion tests on pavement quality(results awaited).

- Test on extracted specimens of concrete (coretests) would be conducted to assess the long termperformance of concrete.

All the above tests are conducted by Civil Aid Technoclinic(P) Ltd., Bangalore and the results obtained so far aretabulated. The road was opened for traffic after 5 days ofcuring.

The test results clearly show that the compressive &more importantly the flexural strength of concrete is muchbeyond the design requirement. In case of normalconcrete structures, cube/beam test results are higherthan the structural strength as compaction and curingare carried out as per the codal requirement. In this case,since mechanical pavers were used with high degree ofvibro-compaction followed by use of self curingcompounds and plastic sheet covering, the structuralstrength of pavement is higher than the cube/ beam testresults.

1. Conclusions:Due to advances in the area of mechanization and fasttrack construction, concrete roads and white toppingprovide a sustainable as well as cost effective option forpavement construction. This technology demonstrationproject in Bangalore has evoked positive response frompeople across the spectrum viz., technical consultants,construction industry, academic & research institutions.The Government of Karnataka, BBMP and other civicagencies have come forward to adopt this technology.On behalf of the cement industry, CMA (CementManufacturers’ Association) has come forward to assistall those involved in the construction on concrete roads/white topping by way of several useful publications, user-friendly software for analysis, design and estimation ofquantities (and comparative cost), conducting trainingprograms for engineers and providing the necessarytechnical assistance.

References:1. Cement Manufacturers Association, Concrete

Overlays – White topping of roads, 20102. Cement Manufacturers Association, Handbook on

Cement Concrete Roads, 20103. IRC: SP: 76 – 2008, Tentative guidelines for

conventional, thin and Ultra-thin white topping, TheIndian Roads Congress, New Delhi, 2008

4. Michael E. Ayers & Dale Harrington, Selection anduse of concrete overlays, The Indian ConcreteJournal, May 2010

5. National Concrete Pavement Technology Centre,USA, Guide to Concrete Overlays – Sustainablesolutions for resurfacing and rehabilitating existingpavements, Sept. 2008.

Compressive Strength of Concrete Cubes(Total no. of samples 936)

Sample size One-day 3-day 7-day 28 – daystrength strength strength strength(MPa) (MPa) (MPa) (MPa)

60 cubes Max: 24.1 Max: 48.2 Max: 55.2 Max: 67.2

per test Min: 21.1 Min: 38.4 Min: 48.4 Min: 57.4

Avg: 22.05 Avg: 43.2 Avg: 51.02 Avg: 61.8

Compressive Strength of Concrete Cylinders(Total no. of samples 60)

No. Sample size 28 – daystrength (MPa)

60 per test Max: 61.4Min: 43.7Avg: 52.45

Flexural Strength of Concrete Cylinders(Total no. of samples 60)



Split Tensile Strength of Concrete Cylinders(Total no. of samples 60)



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An Experimental study on Carbonation of Concrete underaccelerated carbonation

T. Chandrasekaraiah, K.V. Manjunatha, Dr. M. N. Hegde and Dr. K. ShantharajuFaculty of Civil Engineering, Dr. Ambedkar Institute of Technology, Bangalore-560 056

Introduction: Deterioration of RC Structures is directlyrelated to deterioration of materials i.e. concrete andsteel in its members. Degradation of concrete is relatedto its durability aspect and that of reinforcing steel to itscorrosion. For the condition assessment of RC structure,one has to have a thorough knowledge of the variouscauses of deterioration and their effects on materials. Itis necessary to separate the causes of degradation ofconcrete and steel though they are occurringsimultaneously in structural members.

The Durability is a major concern for concrete structuresexposed to aggressive environments. Carbonation is oneof the major factors to cause structure deterioration.Carbonation is the reaction of the hydration productsdissolved in the pore water with the carbon dioxide inthe air which reduces the pH of concrete pore solution.Carbonation reduces pH value and destroys the passivefilm around the steel, but it seems to densify concretesurface and reduce chloride ion permeability, reducesurface porosity and hence sorptivity in concrete (Leberand Blakey, 1956, Dias, 2000). Carbonation could haveboth positive and negative effects on concrete durability.Glass et al, (1991) pointed out that the presence of evena small amount of chloride in carbonated concreteenhances the corrosion rate resulted from carbonationof concrete.

The study of the durability of concrete structures needsa multidisciplinary approach based on the physics andchemistry of the materials. In particular the durabilitydepends both on the ability of concrete to resist thepenetration of aggressive substances from theenvironment, and on its ability to protect embedded steelreinforcement. The transport of aggressive species mayfollow different mechanisms, depending on the porestructure of the concrete, the exposure conditions andcharacteristics of the diffusing substances. Thepenetration of carbon dioxide or oxygen, as well as ofmany other gaseous substances, may occur only if thepores of concrete are almost dry, while the diffusion ofchloride or sulphate ions takes place only in water.Therefore all these mechanisms should be studiedtogether with evolution of moisture content inside theconcrete. One of the processes which takes place inthe pores of concrete and which may limit the servicelife of reinforced concrete structures is the carbonationof material, i.e., the chemical process denoting thereaction of calcium hydroxide with carbon dioxideresulting in the formation of calcium carbonate and water.The main consequence of carbonation is the drop of the

pH value of the pore solution of concrete from the standardvalues between 12.5 and 13.5, to a value of about 8.3 inthe fully carbonated zones, so that the passive layerthat usually covers and protects the reinforcing steelagainst corrosion becomes no longer stable, Anna et al,(1993). The basic factor influencing carbonation is thediffusivity of the hardened cement paste. Carbonationrate is controlled by the ingress of CO2 into concretepore system by diffusion with a concentration gradientof CO2 acting as the driving force. Factors affectingdiffusion rate include the type and amount of cement,porosity of the material, time of curing, type and quantityof pozzolanic additions. Moreover, several mechanicalproperties of concrete such as compressive strength,surface hardness, and resistance to aggressive agentsmay change due to carbonation.

Corrosion of steel bars embedded in concrete is aworldwide problem that affects numerous ReinforcedConcrete (RC) structures. Theoretical models have alsobeen developed and calibrated with experimental resultsto predict the behaviour of concrete structures withcorroding steel bars as well as their service lives. Themajority of works reported on corrosion of structures inthe absence of a sustained load, which is not true. Inreality corrosion process occurs under sustained load.


The mechanism of corrosion, effects of corrosion onconcrete structures, measure to control corrosion, andeffectiveness of repair and strengthening of corrodedstructures Soÿlev and Richardson, (2008). Theoreticalmodels have also been developed and calibrated withexperimental results to predict the behaviour of concretestructures with corroding steel bars as well as theirservice lives (Vidal et al, 2004, Li et al, 2006).

Tarek Mohammed et al (1999) studied the orientation ofsteel bars (main steel and stirrups) in concrete duringcorrosion process. Orientation of steel bars has significantinfluence on macrocell and microcell corrosion of steelbars in concrete. It was observed that deformed barscorroded more than the plain bar. Formation of gaps underhorizontal steels causes significant corrosion. Watercement ratio has a significant influence on corrosion ofsteel in concrete.

Goitseone Malumbela et al (2009) reviewed previousstudies carried out to investigate the effects ofsimultaneous load and steel corrosion, on the rates ofcorrosion and behaviour of RC structures. Corrosion underload was found to significantly increase deflection ofspecimens. There was no gain in stiffness during corrosionprocess under service load, which is often observed atearly carrion stages on structures corroded in the absenceof a sustained load (Soÿlev and Richardson, (2008), Liet al, (2006)).

Newlands et al, (2002), formulated a probabilistic analysisusing a selection of published deterministic modelspertaining to long term carbonation of concrete. Theoutcome of the probabilistic analysis determined theminimum concrete requirements to resist the progressof carbonation and subsequent carbonation induced-corrosion for a minimum period of 50 years. Ali et al,(2000), introduced both deterministic and stochasticmodelling of concrete carbonation front depth such asMonte Carlo Simulation method.

In the present study, concrete cube specimens areexposed to carbon dioxide in the carbonation chamber.The effect of carbonation of concrete on compressivestrength, CO2 concentration, curing periods, and durationof carbonation have been studied and reported.

Carbonation processCarbonation is a neutralizing procedure in which gasessuch as carbon dioxide (CO2) in the atmosphere reactwith calcium hydroxide, Ca (OH)2 dissolved in theconcrete pore water, producing calcium carbonate, CaCO3and water, H2O. In addition, hydrated calcium silicate(CSH), unhydrated tri-calcium silicate (C3S) and bi-calcium silicate (C3S) consume carbon dioxide as well.Carbonation changes the chemical composition and themicrostructure of the concrete, thereby obviously affectingits chemical and mechanical properties. Carbonation isa very complex physical-chemical procedure where

carbon dioxide penetrates, diffuses and reacts fromsurface to inside the concrete. The primary reactionsare:

Partial destructive testing systemsPartial destructive testing system (PDTS) serves as agood support for any field investigation. These methodsare well established and enable visual inspection of theinterior regions of a member to be coupled with strengthestimation. Other physical properties that can bemeasured include density, water absorption and indirecttensile testing. The tested material and specimensamples are frequently used as a sample for chemicalanalysis. Following are the general partial destructivetesting system (PDTS) usually preferred

• Core sampling and testing• Penetration resistance test• Pull-off resistance testUsing the above methods, the extent of deterioration andthe strength potential of concrete in the existing RCstructures, cement content and water cement ratio canbe evaluated. The voids and relative density, variation ofcompressive strength of concrete in the structure withrespect to ultrasonic pulse velocity (UPV) values is givenin Table 1.

Experimental programme

The different grades of concrete cubes with different watercement ratios were cast. The test specimens were pondcured for 7, 14 and 28 days. The concrete cubes, RCbeams and slabs were exposed to carbon dioxide ofthree intensities (25%, 50% and 75%) in the carbonationchamber. The intensity of carbon dioxide in thecarbonation chamber is monitored at regular interval of 1hour.

Testing of cube specimens for compressive strength wascarried out on a compression-testing machine (CTM-1000KN). The least count of the compression-testingmachine is 100N. The compressive strength of eachcuring period (7, 14 and 28 days) for all the mixproportions was an average of three cubes.

The strength of concrete cubes and porosity of concreteare evaluated for three grades of concrete M15, M20and M25 with varying water-cement ratios 0.40, 0.50,and 0.60. The depth of carbonation of concrete isestablished using core samples removed from carbonatedconcrete cubes. Non-destructive testing such asultrasonic pulse velocity and rebound hammer tests havebeen carried out for finding the quality and strength of


concrete. The effect on compressive strength of concrete,cement content, and curing period on carbonation andcover thickness and intensity of carbon dioxide oncorrosion of reinforcement embedded in concrete havebeen studied.

Porosity of concrete: The concrete porosity is one ofthe major factors affecting the durability of concrete. Theporosity depends on the proportions of the ingredientsand the construction practices. The porosity of concreteis established by knowing the dry weight of concretecubes and wet weight of concrete cube i.e. the cubesimmersed in water for twenty-four hours. The differencein dry weight and wet weight gives the weight of waterpenetrated into the concrete and the pores available inthe concrete.

Carbonation of concrete: The concrete cubespecimens were exposed to carbon dioxide in thecarbonation chamber for different durations with varyingintensity of carbon dioxide. The intensity of carbondioxide in the carbonation chamber is monitored usinggas analyzer at regular interval. The carbonation chamberwith suitable housing arrangements for concrete cubesis shown in Fig 2. The carbon dioxide is supplied to thecarbonation chamber by burning rice husk ash and otherwaste materials. Concrete cubes are exposed to carbondioxide for known duration in the carbonation chamber.

Figures 2 & 3 depict the carbonation chamber and stagingfor housing specimens. The depth of carbonation isestablished by removing the cores from the carbonatedconcrete cubes at the center of the specimen andphenaphalene solution is applied on the core samples,the carbonated part of the concrete is found to becolourless. On the other hand the uncarbonated concreteshows the pink colours of the phenaphalene. The depthof carbonation is measured from the surface of the coresample.

Testing:The portable ultrasonic nondestructive instrument fortesting (PUNDIT) is used for establishing the quality andcompressive strength of concrete cubes. Then thesespecimens of same batch were also subjected todestruction under compression for compressive strengthof concrete. Gas analyzer is used for establishing theintensity of carbon dioxide in the carbonation chamber.The availability of oxygen in the carbonation chamber isalso measured. The intensity of carbon dioxide isregulated to simulate the condition created by air pollutiondue to industrial gases, exhaust of locomotives andinduction of carbon dioxide into atmosphere. Probabilityof corrosion of rebars embedded in concrete due tocarbonation is established using CORMAP. The potentialdifference developed between the anode and cathode inthe rebars embedded in concrete indicates the probabilityof corrosion. When the potential difference is –330mVand more the probability of corrosion is positive.

The variation of carbonation with respect to differentparameter is discussed here. The depth of carbonationis established by the application of phenolphthalein


solution on the core samples removed from thecarbonated specimens. The carbonated surfacebecomes colourless after the application ofphenolphthalein and uncarbonated surface is pinkin colour. The temperature largely affects diffusionof gases and water; in the present investigationlaboratory temperature of 27°C is considered andkept constant. The effects of water-cement ratio,curing periods, compressive strength of concrete,porosity of concrete, intensity of Carbon dioxide,and duration of carbonation on carbonation ofconcrete are studied.

Discussion on Experimental resultsEffect of water / cement ratio on carbonation ofconcrete Water / cement ratio is one of theimportant factors affecting the carbonationprocess in concrete. The w/c ratio generallydetermines the gel/space ratio, the capillaryporosity and hence the permeability of concrete.As the water /cement ratio is more water istrapped inside the concrete and with the processof hydration of cement water evaporates leavingsmall pockets in concrete. If these pores areinterconnected they cause a big problem, it isthrough these pores carbon dioxide can diffuseand destroy the passive layer of the steel. It isobserved that the depth of carbonation increases9.5mm to 12mm and 13.75 as the water cementratio increases from 0.4 to 0.6 with 150 hours ofcarbonation for M15 concrete. Figures 4 to 6show the effect of water content in concrete ondepth of carbonation of concrete. It is observedthat the depth of carbonation increase nonlinearlywith increase in water content in concrete. It isobserved that the depth of carbonation increasenon-linearly with increase in water content inconcrete.

Effect of curing period on carbonation ofconcreteAs the hydration reaction takes place in concrete,and it is an exothermic reaction, energy is evolved inthe form of heat, due to this cracking occurs whichmakes pores in concrete thereby decreasing thestrength of the concrete to counter act his processcuring of concrete is required. Concrete specimensare pond cured for 7, 14 and 28 days. It is observedform Figures 7 to 9 that the strength of concreteincreases with curing periods. The permeability ofconcrete reduces as the curing period increases.Figures 7 to 9 show the variation of carbonation withcuring period for M15 concrete, M20 concrete andM25 concrete. As the curing period decreases form


28 to 14 and 7 days the depth of carbonation increasesfrom 9.50mm to 12mm and 13.5mm respectively for 150hours of carbonation. The same trends are observed withM20 and M25 concrete with different curing periodsirrespective of the intensity of carbon dioxide.

Effect of compressive strength of concrete oncarbonationDurability factors mainly depend on the strength ofconcrete and the strength of concrete depends on themix proportions, water cement ratio, cement content inthe concrete and degree of compaction and curing typeand period. The porosity of concrete gets reduced withincrease in compressive strength of concrete and thedepth of carbonation decreases as the strength ofconcrete increases. Depth of carbonation is reduced from9.5mm to 8.75mm and 7.00mm with concretes of gradeM15, M20 and M25 respectively with water cement ratio0.4 for 28 days cured specimens. Depth of carbonationis reduced from 12mm to 8.75mm and 7.50mm withconcretes of grade M15, M20 and M25 respectively withwater cement ratio 0.5 for 28 days cured specimens.Depth of carbonation is reduced from 13.mm to 9.75mmand 9.25mm with concretes of grade M15, M20 and M25respectively with water cement ratio 0.6 for 28 days curedspecimens. The reduction in depth of carbonation isobserved with increase in compressive strength ofconcrete for all the intensities of carbon dioxide in thecarbonation chamber. Figures 10 and 11 represent thevariation of depth of carbonation with strength of concrete.The reduction in carbonation of concrete is non linear.


Effect of porosity of concrete on carbonationThe porosity of concrete increases the ingress ofaggressive gases and solution into the concrete. It isthe turtocity of concrete, which depends on the porosityof concrete. It is observed that the average porosity ofconcrete in the present study varied form 0.75 to 2.75based on the water absorption test. The total porosity ofconcrete is the sum of weight gained in absorption testand moisture in capillary pores. Figs. 12 to 14 representthe porosity of M15, M20 and M25 concrete with differentcuring period and water cement ratio. It is observed thatthe porosity of concrete increases with increase watercontent and with reduced curing periods. For all the mixproportions, M15, M20 and M25, the porosity of concreteis more for 7 days of curing period compare to othercuring periods. It is clear from Figures 12 to 14 depth ofcarbonation is more for 7 days cured specimens; this isdue to presence of more pores and interlinking of poresin the concrete.

Effect of CO2 concentration on carbonation ofconcreteThe amount of CO2 present in the atmosphere is of theorder 0.03%. The level of CO2 in the industrial areas andurban area are higher due to release of carbon dioxidefrom the industries and the exhaust gases from thelocomotives. The carbon dioxide into the carbonationchamber of size 6’x 6’ x 6’ is supplied by burning ricehusk ash and other waste materials. The intensity ofcarbon dioxide in the carbonation chamber by volume ismeasured with the gas analyzer. The intensity of carbondioxide 25%, 50% and 75% is used in the presentinvestigation. The depth of carbonation increases withincrease in CO2 content, the depth of carbonationincreased from 12.00mm to 18.00mm and 19.75mmrespectively with 25%, 50% and 75% of CO2 content forM15 concrete with water cement ratio 0.5. The depth ofcarbonation increased from 9.75mm to 19.00mm and23.25mm respectively with 25%, 50% and 75% of CO2content for M20 concrete with water cement ratio 0.6.The depth of carbonation increased from 7.75mm to11.00mm and 13.25mm respectively with 25%, 50% and75% of CO2 content for M25 concrete with water cementratio 0.4. Figures 15 to 17 respectively represent thevariation of carbonation of concrete with intensities ofcarbon dioxide 25%, 50% and 75% for M15 concretewith varying water cement ratio exposure time 150hrs.Figures 15 to 17 depict the variation of carbonation withcarbon dioxide intensities for concrete of mix proportionsM15, M20 and M25. It is observed that the depth ofcarbonation increases nonlinearly with increase in carbondioxide content in the carbonation chamber. The depthof carbonation increases 2 to 3 times, to that of depth ofcarbonation with 25% of CO2 as the intensity of CO2increases respectively to 50% and 75%. The rate ofcarbonation increases with increase in CO2 content.


Effect of duration of carbonationThe concrete specimens are carbonated in the carbonation chamber and durations of carbonation 90hours, 120hoursand 150hours are adopted in the present investigation. The depth of carbonation increases asymptotically as theduration of carbonation increases. It is observed that the depth of carbonation increased from 5.25mm to 7.00mm and9.50mm, 7.00mm to 9.75mm and 12.00mm and 8.25mm to 10.5mm and 13mm respectively for 28days, 14 days and7 days curing periods with M15 concrete as the duration of concrete is increased from 90hrs, 120hrs and 150hrs.Figures 18 to 20 indicate the variation of carbonation for M15, M20 and M25 concrete with different water cementratios and duration of carbonation periods. It is observed from above Figures 18 to 20 that depth of carbonationincreases non-linearly with increase in carbonation period. It is also noticed that depth of carbonation increases by 25


% to 55% and 90% to 120% when the duration ofcarbonation is respectively increased from 90hours to 120 hours and 150 hours. The same trendis observed for all other grades of concrete also,i.e., the depth of carbonation increases withincrease in duration of carbonation.

Diffusion coefficient of CO2 in hardenedconcreteIt is observed that the diffusion coefficient of CO2reduces with increase in compressive strength ofconcrete and increases with increase in watercement ratio. Figure 4.55 shows the increase indiffusion coefficient of CO2 with water cement ratio.The depth of penetration of carbon dioxideincreases with increase in diffusion coefficient ofCO2. The diffusion coefficient of CO2 increases by10% to 15% when the water cement ratio isincreased from 0.4 to 0.5 and 0.6 respectively tothat of diffusion coefficient of CO2 with watercement ratio 0.4. It is also observed that, this smallincrease in diffusion coefficient of CO2 with increasein water cement ratio results in greater increasein depth of carbonation of concrete for all the mixproportions. The diffusion coefficient of CO2decreases with increase in curing period. Figures21 and 22 indicate the reduction in diffusioncoefficient of CO2 with curing period for concreteM15, M20 and M25. With availability of moisturecontent during curing the formation of pores andcracks due to heat of hydration of cement isreduced. It is also observed that the depth ofcarbonation reduces with curing period for all themix proportions.

Conclusions:The following conclusions are deduced from theexperimental results:

(i) The carbonation depth increases with an increasein exposure time and higher CO2 concentrationresults in higher carbonation depth for all mixtures.

(ii) The compressive strength and splitting tensilestrength of carbonated concrete at the age of 28days are slightly higher than those of concretewithout carbonation.

(iii) The electrical resistivity of concrete increases withan increase in exposure time and the amount ofcharge passed significantly decreases with anincrease in carbonation depth. However, carbonationof concrete enhances the rate of corrosion ofreinforcement from the electrochemical corrosiontest results.

Acknowledgements:All India Council for Technical Education (AICTE), NewDelhi (File No. 8021/RID/NPROJ/TAP-71/2002-03)provided financial support to this research. We are gratefulfor the financial support from AICTE, New Delhi andlogistic support from Dr. Ambedkar Institute ofTechnology, Bangalore-560 056.

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Association of Consulting Civil Engineers (India) Head Quarters organising the technical Evening Lecture on22nd February 2011 at Century Club, Bangalore in association with Indian Institute of Bridge Engineers (IIBE), IndianConcrete Institute (ICI-KBC) & Bangalore Institute of Technology (BIT). Dr. M U Aswath, Secretary General ACCE(I)delivering the welcome address. Mr. C R Alimchandani, Chairman & M D Stup Consultants Pvt. Ltd., Mumbai deliverthe lecture on Eugene Freyssinet, His incredible Journey to Invent and Revolutionize prestressed ConcreteConstruction. Dr. C S Viswanatha, Chairman Task Force for quality Assurance in Public Construction Govt. ofKarnataka, will be Chief Guest. Mr. R Srinivasa, Engineering Member, BDA, Dr. R Jagadish, Past President ACCE(I)& ICI, Mr. S A Reddi, Former Dy. M D, Gammon India Ltd., and Mr. J V Rangarajan, Director, Natarajan Constructioncompany Ltd., will be the guests of honour. Mr. Avinash D Shirode, President ACCE (I) preside over the function. Inthis occasion ACCE (I) felicitated Mr. C R Alimchandani. Dr. M N Hegde, Secretary give the vote of thanks. More than300 members attended the above programme. This programme was sponsored by Natarajan Construction CompanyLimited.

News from ACCE(I) Head Quarters

News from ACCE(I) CentresBANGALORE CENTREAssociation of Consulting Civil Engineers (India),Bangalore Center organising the technical EveningLecture Jointly with Bangalore Institute of Technology(BIT) & UltraTech Cement Limited on Developments inNew Construction Materials by Dr. Ramakrishnan &Recent Fiber Reinforced Concrete Constructions by CliffMacDonald on Saturday, 29th January 2011 at 06.00 PMat Bangalore Institute of Technology (BIT), Seminar Hall,2nd Floor, K R Road, V V Puram, Bangalore–560004. Dr. Manamohan R Kalgal, Senior Vice President(Technical) UltraTech Cement Limited will be the ChiefGuest, Shri. M S SUDARSHAN Chairman ACCE(I)Bangalore Centre will preside over the function and Mr.P Nagesh give the vote of thanks. More than 150members participated in the above lecture. Thisprogramme was sponsored by UltraTech Cements Ltd.,

MANGALORE CENTREA.C.C.E.(I) MANGALORE - ULTRA TECHMANGALORE- AWARD FUNCTION held on 28th

January 2011 at Loyola Hall, St. Aloysius CampusMangalore. The Award function was well attended bymore than 500 delegates. Dr. Shantharam Shetty, Vicechancellor Nitte University was the Chief Guest. Er.Dr. Ashwath Secretary General was the guest of theowner. From Ultra Tech Cement Ltd. Dr. V. Ramachandra(Zonal Head- Tech),and Er. Nagesh Puttaswamy(Regional Head, Technical) and Er. Ashok Kumar.B,Chairman, ACCE(I),Mangalore Centre, Er. Vijaya VishnuMayya, Secretary ACCE(I), Mangalore Centre werepresent. The members of Mangalore Centre attended inlarge numbers. In the beautiful function with theentertainment and messages from dignitaries thefollowing awards have been given under differentcategories.

Best Residential Villa (Udupi District) - ‘Parampara’Residence of Swapna Ganesh, Udupi.

Best Residential Villa (D.K. District) - Chandraloka’Residence of Chandrahas Shetty, Mangalore.

Best Concrete structure for D.K & Udupi District -Hostel Building of NITK Surathkal.

Best infrastructure award for Mangalore concreteRoads.

Life Time achiever award to Engineer K. N. Alva.

THE TECHNICAL TALK AND PRESENTATION on thetopic of Flow guard- Lubrizol is shared by Mr.SanjayDurani, on 2nd February 2011 at Hotel Ocean Pearl,Mangalore. Large number of our members werepresent.

THE TECHNICAL TALK AND PRESENTATION on thetopic of “Durability of Concrete for sustainableDevelopment is given by professor M.V.Shetty. on 23rd

February 2011 at Hotel Ocean Pearl, Mangalore. Itwas well attended by our members and also had thelively interaction.

THE TECHNICAL TALK on Hindcon Chemicals heldon 26-02-2011 by to company experts.

THE TECHNICAL TALK AND PRESENTATION on thetopic of “Green Building…Environment friendlyDesign..” by Ar. Venkatsh Pai, Architect,was arrangedon 8th March 2011 at Hotel Maya InternationalMangalore. The concept of Green Building was nicelypresented by the chief guest.

For the first time in the history of Mangalore centre aweek long program “Engineers week” is arranged from19/03/2011 to 26/03/2011. Inaugural Function ofEngineers week was held at Ocean Pearl andDr. Sandeep Sanchiti director NITK Surathkal wasinaugurator of the function. Er. Balakrishna SE PWDMangalore circal was the chief guest. Sri. Varadarajan( Chief fire officer). Gave a talk on fire precautionarymeasures.


Association members have arranged a picnic toPilikula. Members forgetting their profession for a dayenjoy the panoramic scenery of Pil ikula andparticipated in the games, fellowship etc.

Students Seminar was conducted at PA EngineeringCollege and BI Technology.

Students Seminar was conducted at Srinivas EngineeringCollege and Alva’s Engineering College.

Students Seminar was conducted at BantwalaPolytechnic, Vivekananda College, K.V.G EngineeringCollege, Sahyadri Engineering College and NitteEngineering College.

Site Masons Training and Students Seminar wasconducted at Karnataka Polytechnic.

Site Supervisors Training, Students Seminar andEngineers Seminar was conducted at KarnatakaPolytechnic, N.I.T.K Surathkal and P.W.D SuperintendingEngineer Office Hall Mangalore.

Apart from the above activities, the Managing Committeemeetings are held in the 1st week of every monthdiscussing the various aspects including membershipgrowth, future programs etc.

NAGPUR CENTREA evening lecture on program OPPORTUNITIES INPRECAST CONCRETE - A South African Experiencewas organized by ACCE Nagpur on 12.02.11. TheChairman Shri.Satish Salpekar explained to the audiencethe exhaustive use of precast products he experiencedduring his South Africa visit. All the medians, compoundwalls, storm and sewer chambers, tree planters etc.were pre cast in factories and installed ready-to-use stagein the fields. Even readymade toilets and septic tankswere also used excessively in low cost mass housingprojects. He gave an exhaustive presentation on theirmanufacturing process and installation. He alsohighlighted some of his personal experiments in precastin Nagpur. The program was well attended by ACCE aswell as IIA members. There was lot of interaction amongthe members regarding increasing the use of precast inIndia. Manufacturer of precast Mr.Ahay Siralkar alsoadded his viewpoint from the commercial aspect ofprecast structures. More than 50 delegates attended theprogram. The delegates included Mr.S.S.Doifode,Mr.Madahv Pandit, Ar. Sunil Degwekar,Mr.S.G.Khirwadkar, Mr.Sumant Mundle, Ar.JitenShrivastav, Ar.Ranade, Mr.Parag Pandharipande etc. Theprogram ended with formal vote of thanks by Mr. AmolShingarey past president West ACCE and dinner.

A visit was arranged on 29.01.2011 by ACCE Nagpurcentre to the construction site of Chimney of the proposed

2x300 MW thermal power plant of Reliance Industries atVidarbha Industries Power Ltd. Butibori. Out of the twochimneys, one was already constructed and other wasunder construction. The members keen interest in theslip form construction technique and even went upto 70mheight where actual concreting was going on. The ProjectManager Mr.Nimkar explained in detail the methodologyand technicalities of the construction. The members alsovisited the quality control and testing laboratory. The strictquality control followed by VIPL and their results weregreatly appreciated by all the members. Overall it was amarvelous and highly technical visit and well enjoyed byall the members. About 20 members gathered for thevisit. Prominent among the visitors were Mr.Dungaji fromStewols India, Mr. Navin Chandak, Mr. Abhay Siralkar,Mr. Matte etc. Mr. Shri. S.V.Slapekar chairman proposedformal vote of thanks to all the staff of VIPL and members.

on 05.03.2011, First city is the talk of town since last 3years not only because of its big township but alsobecause of the technology being used for theconstruction. There are five towers each of 13 storey areproposed in environment friendly manner. One of the towerreached up to 12 storey height, ACCE thought to grabthe opportunity and visit the site along with the members.Befitting to the project scale, we at ACCE received greatresponse for the visit, around 25 members joined for theevent. The project is of 1832 flats ranging from 1 BHK to5 BHK. All the walls of the building are RCC walls, theentire shuttering (including for walls) is of Aluminum. Thedetachable fixed size mould of the walls is shifted toabove heights for further construction called as MIVANtechnique. This process not only expedite theconstruction activity but also makes the structure strongand earthquake resistant (shear wall being all around).MrArvind Ladhe, the Project Manager has explained all theminute technical details of the project where as MsSonalika Adyalkar explained the marketing policies ofthe promoters. The promoters claim that there are manythings which are being implemented for the first time incentral India , which suits the title “ FIRST CITY”, fewof them are the above explained Malaysian Shutteringtechnology , The green concept of Design, the Freshnessarising out of comfortable distance between two towers,the Podium , the two level parking etc. The targetedcompletion date for the project is Dec 2012, and in spiteof global recession, the project is running just 3 monthsbehind the schedule said Mr Ladhe. Around 50% of theflats are booked till date. The visit ended with the vote ofthanks and commitment to extend the technical supportto the project by ACCE members.


2568-OL ASCENT BUILDERS (INDIA) PVT. LTD. Bangalore2569-OL INNOTECH ENGINEERING CONSULT PVT LTD Bangalore2570-F RAMESH B NANDIGIRI Bangalore2571-F AMARNATH R BORAIAH Bangalore2572-L MADHAVA RAO N Bangalore2573-M BALAJI SINGH B M Bangalore2574-L P KRISHNAMOORTHY Chennai2575-M Dr. B HEMALATHA Chennai2576-L BASAVANTHA N H Davangere2577-L SURESH KALLAPPA GOWDA Davangere2578-L DEVENDRAPPA E Davangere2579-L B MAHADEVAPPA Davangere2580-L M S KUMAR Davangere2581-L RAJANNA S Davangere2582-L GUDRU RAGHU RAM REDDY Hyderabad2583-L GEORGE Mangalore2584-L MAXIM JEEVAN LOBO Udupi Dist2585-L VINOD T D’SOUZA Mangalore2586-L H C CHINNAGIRI GOWDA Mangalore2587-L N VITTOBA Mangalore2588-L G P VENKATESHA Mangalore2589-L SUDHIR BHANDARKAR BANTWAL Mangalore2590-L SURESH B SALIAN Mangalore2591-L SHIVANANDA Mangalore2592-L SHRIRAMA Mangalore2593-L SUJITH S SALIAN Mangalore2594-L SURAJ KUMAR A Mangalore2595-L MANJUNATHA H B Chickmagaluru2596-L PRAVEEN KUMAR Mangalore2597-L VASANT G HEGDE Mangalore2598-L B PRADEEP RAO Mangalore2599-L SADASHIVA K Mangalore2600-L P C HASHIR Mangalore2601-L P V PRAKASH Surathkal2602-L PRAKASH PRABHU B Bantwal2603-L PRAKASH ACHAR Mangalore2604-L LOKESH Mangalore2605-L GANESAN RAMASAMY Mangalore2606-L PAVITHRA KUMAR Mangalore2607-L NAGARAJ S Mangalore2608-L SANDEEP R BOLAR Mangalore2609-M PRASHANTH KUMAR M Mangalore2610-M EDWIN GONSALVES Mangalore2611-M PARAMESHWARA P Bantwal2612-A HARIPRASAD Mangalore2613-L K PANDIA RAJAN Madurai2614-F N SARAVANAKUMAR Mumbai2615-F RAHUL VASANT RALEGAONKAR Nagpur2616-L ASHISH MORESHWAR CHAPHEKAR Nagpur2617-F PRAFULLA VASUDEO ATHALYE Nashik2618-F S RAJKUMAR Trichy2619-F T THAMIL SELVAN Tirupur2620-L DESAI RAMMOHAN Bellary2621-L K L N College Of Information Technology Sivagangai Dist.

UP-GRADATION FROM MEMBER TO FELLOW MEMBER

1401-M P MUKUND KAMATH Mangalore1957-M VIVEKANDA HEGDE A Mangalore

UP-GRADATION FROM LIFE MEMBER TO FELLOW MEMBER2092-L PREMANAND A Mangalore1224-L K P MANJUNATH Mangalore

M. No. Name Place

ACCE (I) MEMBERSHIP ADDITIONSACCE (I) welcomes the fol lowing new fel low members, l i femembers, members and associate members. ACCE alsocongratulates the members who have been upgraded to Life/Fellow Members and Senior Citizen Fellow Members.

UP-GRADATION FROM MEMBER TO LIFE MEMBER0711-M M I KHLEEL Mangalore0749-M SAMPATH KUMAR SHETTY D Mangalore1302-M VINOD SHETTY Mangalore1304-M VIMAL KEERTHI JAIN Mangalore1517-M DEVENDRA K SHETTY Mangalore1714-M LATHISH Mangalore1959-A SHIVA PRASAD ACHARYA Mangalore2100-M JAGADEESH K ACHARYA Mangalore2102-M ATHMA CHARAN J Mangalore2144-M K NAVEENCHANDRA SEMITHA Mangalore2148-M P SUBRAYA SHARMA Mangalore2216-M NAVEEN KUMAR K V Davangere2217-M SHIVAKUMAR B E Davangere2218-M SHANTHAMURTHY G B Davangere2220-M A B RAVI Davangere2224-M PRAKASH CHINIWAL Bangalore2236-M K S MAHADEV Davangere2237-M KOTRESH U R Davangere2346-M AUSTIN MIRANDA Mangalore

Continued from page 32

quality work of int4rnational standards. In the last decade,TCPL has spread its operations beyond the Indian bordersand taken up assignments in several countries includingGermany, Thailand Nepal, Maldives Malaysia, Singaporeand Russia, Many of its projects have received national aswell as international acclaim for their design and exceptionalinnovations.

The Awards Committee and the Governing Council of ACCE,after stringent verification of the nominees, have decided toconfer the ACCE-SIMPLEX AWARD 2010 for InnovativeDesign of Structures other than industrial structure on22nd October 2010 at Hyderabad for Innovative Design ofStructure for Grade Separator at Mukarba Chowk, Delhidesigned by Tandon Consultants Pvt Ltd., New Delhi.

Fig.12 Mass Concrete – A Special case involving risksevere damage due to excessive heat buildup

Continued from page 3


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S. RATNAVELSCEBA CONSULTANCY SERVICESRoads, Rehabilitation, Restoring Geotechnical,Turnkey Projects, Penthose, Bougainvillae106, P. T. Rajan Road, Madurai - 625 014Tel: 0452-2522555 / 2522455E-mail: [email protected]

UMESH B. RAOM/s UMESH B. RAO & CO.Casa Lavelle - 1, C-4, Lavelle Road, Bangalore - 560 001.Tel : 22213770 / 22240359 Mobile : 9902069351E-mail : [email protected]


L BALAJIB.E., M.I.E., F.I.V., M.I.S.E., M.I.C.A., M.I.C.I., P.G.D.S.V., M.B.A.Professional Engineer (International) & Registered ValuerC-1/433/99, Panel Valuer for Banks, Plot No. 11, SBI First Colony,3rd Street, (Behind Reliance Web World), By-pass Road,Madurai-625010 Tel: 0452-4375336, 2383988, (F) 4373367Mob : 98428 68351 / 98421 68351

S. PARAMESH BABUCSN Engineers & Contractors, No. 37, 6th Cross Road, Azad Nagar,Bangalore - 560 018. Tel : 26748859, 98868 98746 E-mail : [email protected]

SIX STAR ASSOCIATESGovt. Registered Valuers & Chartered EngineersFlat No. HO26, Ushas Apartment, 16th Main, 4th Block, Jayanagar,Bangalore - 560 011. Ph : (080) 26631617 Mob : 9483511617Email : [email protected]

M. A. J. PARTHASARATHY ASSOCIATESGovt. Registered Valuers, Chartered Engineers & ConsultingCivil Engineers - A6/6, Eleventh Cross Street, Besantnagar,Chennai - 600090, Ph : (044) 24917194 Mobile : 9445196994Email : [email protected]

UDYAN AGENCIESPreparation of Minor Irrigation Schemes, Complete Civil Engineering,Consultancy for Coffee Plantations/Tea Plantations/ Rubber Plantations,Consultants on Design & Erection of Tea Processing Factories, CoffeeCuring Works, Natural Rubber Latex Processing Units and Hightech GreenHouses - Flat No. HO26, Ushas Apar tment, 16th Main, 4th Block,Jayanagar, Bangalore - 560 011. Ph : (080) 26631617 Mob : 9483511617 / 94451 96994 Email : [email protected]

ACCE(I) thanks the following patrons for theirgenerous contributions towards the creation of aPermanent Fund for publishing this Bulletin

THANKS TO PATRONS

ADARSH DEVELOPERSBuilders of Aesthetically Designed and Quality, Luxury Apar tmentsfor Modern Living Standard,10, Vittal Mallya Road, Bangalore-560 001. Tel : 080-41343400Fax : 080-41343777 Web: www.adarshdevelopers.comE-Mail : [email protected]

CHAMUNDESHWARI BUILD TECH PVT. LTD.No. 2438, Kumara Krupa, Opp. Bangalore Vihara Kendra, 9th Main,BSK 2nd Stage, Bangalore-560 070. Tel. : 26764974, 26764403/05Fax : 26762978 E-mail: [email protected]

EON DESIGNERSArchitects, Consulting Engineers & Interior Designers35-B, Vasavi Colony, Behind Vikrampuri, Secunderabad-15.Tel/Fax : 040-27847847 E-mail : [email protected]

HYGRADE STEEL PVT. LTD.Manufacturers, Torkar i , A/85, 31st Cross, 7th Main,Jayanagar,Bangalore-560 082. Tel : 26546384 , Fax : 080-26545952E-mail : [email protected]

MADHU INDUSTRIESManufacturers of Steel Doors & Windows with ISI Mark and UPVCDoors and Windows. No. 30, Pillagaganhalli, Gottigere, BannerghattaRoad, Bangalore - 560 083, Tel : 28429778 / 779, Fax : 28429801Email : [email protected]

MEGH STEELS PVT. LTD.Distributors “TATA Structura” and Dealer in Iron & Steel,A/85, 31st Cross, 7th Main,Jayanagar, Bangalore-560 082.Tel : 26546384 , Fax : 080-26545952 Mobile : 9845013513E-mail : [email protected]

M/s. NAGARJUNA CONSTRUCTION COMPANY LTD.Nagarjuna Hills, Hyderabad - 500 482 Andhra Pradesh, India.Tel : 22224328, 22226214, Telex : 0425-6914 Grams : BuildwellNagarjuna-Where Quality is Trac

NAGADI CONSULTANTS PVT. LTD.Committed to Reliable Accurate and Professional Service,Regd. Head Office : 1014, 1st Main, IV Block, Rajajinagar,Bangalore-560010. Tel :23303007, 23156076E-mail : [email protected]

SBS ASSOCIATESEngineers and Contractors, Class I Contractors in Karnataka PWD795/E, 3rd Cross, ‘A’ Main, Vijayanagar, Bangalore - 560 040.Tel. ; (R) 23356839

SHRI B. SUNDARAMURTHY44/4, 4th Main Road, Malleswaram, Bangalore-560 055.Tel : 23348725 E-mail: [email protected]

TECHNOART CONSTRUCTIONS PVT. LTD.Mayaventure (P) Ltd. Southend Road, Above Canara Bank,3rd Floor, Basavanagudi, Bangalore – 560 004.

THE DESIGNERS AND BUILDERSH.K. Nanjunda Swamy, Consulting Engineer and Par tner20/1, II Floor, III Cross, Chikkanna Gardens Road, Shankarapuram.Bangalore - 560 004. Tel : 41127098 Tel/Fax : 26521379

UNITED PRECISION ENGINEERS PVT. LTD.Engineers and Contractors67, ‘Lavina Cour ts’, I Floor, 102, 8th Main, 7th Cross,RMV Extension, , Bangalore - 560 080Tel/fax : 23612825/23618965 E-mail : [email protected]

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RNI No. KARENG/2002/9245 - Registrar of New Papers for India

Printed and published by RAVINDRANATH B. V. on behalf of the Association of Consulting Civil Engineers (India) and printed at Abhiram Graphics,# 2, Anugraha, 4th Cross, 8th Main, Papaiah Garden, BSK 3rd Stage, Bangalore – 560 085 and published at 2, UVCE Alumni Association Building, K R Circle,Bangalore – 560 001 Editor: RAVINDRANATH B. V.

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