CHAPTER 1

INTRODUCTION
Structural steel is a versatile engineering material and is major
construction material used orldide! It o""ers considera#le "le$i#ilit% in design
and ena#les eas% Construction sc&eduling even in congested sites! 'it& t&e
state o" t&e art tec&nolog% used during (roduction (rocess) &ig& strengt& steels
it& im(roved tolerance and neer (ro"iles) &ic& are more e""icient &ave #een
introduced!
In India) t&e iron and steel sector &as develo(ed over t&e %ears and
currentl% India is t&e tent& largest (roducer o" steel in t&e orld! T&e Indian steel
sector it& its s&eer si*e +,- million tonne ca(acit% . investment level
+Rs/01)111 crores.) and em(lo%ment o((ortunit% +-!2 lac direct em(lo%ment and
12 lac indirect em(lo%ment. can contri#ute in a #ig a% in t&e national econom%!
T&oug& (rojected to &ave a #rig&t "uture and strong (otential )t&e Indian steel
sector is currentl% in a grim situation and is "acing tremendous c&allenge "or steel
demand +#ot& in domestic and e$(ort segments. "or its overall grot& and
sustaina#ilit% in t&e (ost3li#erali*ed era!
A"ter t&e recent economic slodon) t&e Indian econom% is e$(eriencing
moderate grot& rates it& 4!5 6 in 1005300) 4!-6 in 1000311 and around 46 in
t&e %ear 7111311! T&e Indian econom% is also ta8ing an interesting turn on t&e
grot& "rontiers since t&e last decade9 it is moving "rom industrial sector #ound
toards service sector #ound) t&oug& t&e contri#ution o" t&e industr% +743 7:6.
and o" construction sector +around 26.. in ;DP &as &oever remained same
during t&e (ast :35 %ears!
Similar to t&e earlier decades) #ot& t&e (roduction and a((arent
consum(tion o" steel &ad almost dou#led +<ig! 1. during t&e last decade +10003
11.! Still t&e steel consum(tion in India is muc& less t&an even one "ourt& o" t&at
in C&ina!
T&e overall (er ca(ita steel consum(tion +e$cluding allo% and stainless
steel. in India is onl% 7: 8g against t&e orld average o" 171 8g! T&is varies over
a large range it& 44 8g = ca(ita in ur#an and just 4 8g=ca(ita in t&e rural areas!
Page 1
T&ese considerations (rovide direction and a great o((ortunit% "or
"ostering steel consum(tion in India it& s(ecial re"erence to t&e large rural #ase
o" t&e countr%!
Page 2
CHAPTER 7
INDIAN CONSTRUCTION SECTOR
T&e Indian construction sector accounts "or 26 o" t&e ;DP! It is groing at
a rate o" a#out116! T&e value o" annual construction activit% in t&e orld
e$ceeds 7!137!, trillion (ounds it& an average annual grot& rate o" 4306!
According to Standard > Poor?s glo#al economic surve% and "orecast in t&e %ear
1000! Indian construction sector it& current construction investment o" 71377
#illion (ounds ill attain considera#le grot& in t&e ne$t 23 11 %ears and ill
com(ete it& some o" t&e most advanced and "ast develo(ing countries in Asia
as s&on #elo in +Ta#le 1.! India also ran8s 4
TH
in t&e glo#al list o" @11 "astest
groing construction mar8ets in ne$t 2 %ears? it& an average annual grot& rate
o" 11!- (ercent!
CONSTRUCTION AARBET PROCECTIONSIN 7111!
Countr% Construction
Investment in
1000
+Dillion Pounds.
Annual ;rot&
In 6
Construction
Investment in
7111
+Dillion Pounds.
Sout& Borea ,: 17!1, 1,,
U!B 0- 1!0 1-1
Ca(an ,54 7!, 2:,
India 71 11!- :1
In India) #uilding materials li8e #ric8) cement) gravel etc (redominate and
c&ea( la#our is a#undantl% availa#le all over India) it& some e$(erience in
concrete construction is recentl% re(orted t&at &ile t&e Euantit% o" steel
consumed in construction &as increased over t&e %ears9 its s&are in t&e total steel
consum(tion &as #een declining) almost remain ing constant during t&e (eriodF
100430: to 1005300 ,3- %ears +Ta#le 7.!
Page 3
STEEG CONSUAPTION IN CONSTRUCTION SECTOR IN INDIA!
Hear Steel Consum(tion in
Construction Sector
+1111 tonns.
Steel Consum(tion in
Construction as 6 o"
total steel consumed!
1004 I 100: 11!1 27!5
100:31005 11!- 27!2
100531000 11!4 27!-
100037111 1,!1 2-!1
T&e steel=cement ratio is more t&an 1!1 in develo(ed countries &ereas it is in
t&e range o" 1!731!,1 "or t&e develo(ing countries including India +Ta#le ,.!
STEEG TO CEAENT RATIO <OR JARIOUS COUNTRIES F
Countr% Steel to cement ratio
U!B 1!2-
;erman% 1!11
U!S!A 1!10
Ca(an 1!1:
C&ina 1!75
India 1!,1
Aala%sia 1!71
It is matter o" concern t&at t&e steel to cement ratio in India continues to slide
t&oug& marginall% as s&on in Ta#le -!
STEEG TO CEAENT RATIO IN INDIA IN GAST <E' HEARS!
Year Cement (MT) Steel (MT) Steel Cement Ratio
1997-1998 76.6 22.634 0.29
1998-1999 81.8 23.46 0.28
1999-2000 93.81 2.738 0.27
Page 4
CHAPTER ,
STEEL INTENSIVE CONSTRUCTION IN DEVELOPED COUNTRIES
Steel is idel% used in "raming) "looring) alling and roo"ing in residential =
commercial #uildings o" single = multi3store% construction! Use o" structural steel
&as #een groing and no it &as #ecome one o" t&e im(ortant in(ut materials in
construction in most o" t&e advanced countries! <or e$am(le in t&e UB to da%!
more t&an 016 o" single store% #uildings are steel "ramed and a#out &al" o" t&ese
are (ortal "rames! In multi3store% #uildings also) s&are o" steel in t&e UB) as
measured #% "loor urea) &as reac&ed a level o" :16 against K,16 a#out 12
%ears ago! As regards commercial #uildings) in 1001307) steelor8 construction
in t&e UB &ad a mar8et s&are o" 206) in Seden o" 216 and in Net&erlands
746! In industrial #uildings) t&e mar8et s&are o" steelor8 construction is
re(orted to #e #eteen :: and 076 in t&e UB) Seden) Net&erlands) S(ain)
Delgium and <rance! Steel is t&e leading material used n construction in Ca(an
contri#uting to nearl% -1 (ercent o" all #uildings! In Nort& America more t&an 416
o" t&e #uildings o" "our or more "loors are constructed using steel as t&e (rimar%
structural material!
In UB toda%) ,26 o" total #ridges #uilt in 12371 m s(an are #ased on steel
concrete com(osite construction! Use o" long3s(an steel #o$ girders) read%
availa#ilit% o" &ig& (er"ormance steel) &eav% 3dut% (rotection s%stem) and "ast3
trac8 construction &ave #een t&e (rime "actors in ma8ing tee t&e (re"erred
material in most o" Euro(e! In Sout& Borea all t&e #ridges and most o" t&e &ouses
are #uilt o" steel to cut t&e construction time and ma8e sure t&at environment is
(reserved and t&e "uture generations could de(end u(on rec%cled steel! Total
iron and steel rec%cled (er %ear in t&e orld is a#out -72 At &ic& eEuals to
resource saving o" :15 At o" iron ore and 744 At o" coal!
T&e develo(ment o" steel mar8et s&are is a sustained and continuous
grot& (rocess and not a one time sudden event! In a "ast develo(ing econom%
li8e ours) s&are o" construction sector in t&e total steel consum(tion ill #e &ig&er
t&an t&e develo(ed countries li8e UB) Seden) USA etc!
Page
CHAPTER -
RECENT TRENDS IN STEEL INTENSIVE CONSTRUCTION
Pre3engineered #uildings) steel3concrete com(osite construction and
s(ace "rames are some o" t&e common cost e""ective steel3 intensive construction
o(tions!
Pre-Engineered Metal Building Systems
Pre3Engineered Duilding +PED. conce(t originated a% #ac8 in 1041?s!
Initiall% onl% o""3t&e3s&el" (roducts ere availa#le in t&ese con"igurations!
Hoever) (resentl% due to tec&nological develo(ments in t&e "ield) tailor made
solutions are also o""ered using t&is tec&nolog% in a ver% s&ort time "rame! In USA
a#out 416 o" t&e non3residential lo rise #uildings are (re3engineered steel
#uildings!
Gig&t steel "raming is a s(ecial "orm o" (re3 engineered #uildings! It o""ers
an alternative a((roac& "or t&e construction o" man% t%(e o" #uildings) "rom
domestic3scale to medium rise! Earlier cold3"ormed (roducts ere mainl% used as
com(onents to com(lete conventional steel 3 or concrete structures! Hoever)
(resentl% t&e% are increasingl% #eing used "or (rimar% structural elements as
columns) #eams) "rames and trusses de(ending u(on t&e load #earing ca(acit%
it& res(ect to loading and s(ans!
In t&e est) lig&t steel "raming e$tends t&e range o" steel "ramed o(tions
into areas traditionall% dominated tim#er and masonr% construction! T&e mar8et
"or lig&t steel "rames in domestic) educational) commercial and industrial
#uildings is ell esta#lis&ed in Nort& America and Australia) and use o" t&is
tec&nolog% is "ast e$(anding in t&e UB and in ot&er Euro(ean countries! Gig&t
steel "raming com#ines t&e #ene"its o" s(eed o" construction it& t&e a#ilit% to
create e$citing structural solutions! Com(letion times are ,13-16 Euic8er t&an
masonr% it&out coordination o" et trades and avoiding dr%ing out (ro#lems!
Gig&t steel "raming is o"ten t&e onl% solution in man% situations) "or e$am(le in
roo"ing) or in adding an e$tra store% to a #uilding &ere additional loading on t&e
e$isting "oundations must #e minimi*ed!
Page 6
<raming elements in cold3 "ormed steel ma% also #e com#ined it& &ot
rolled steel sections in areas &ere longer s(anning ca a#ilities or greater load
ca(acities are reEuired
COMPOSITE CONSTRUCTION :-
A modern cost e""ective steel3concrete com(osite construction conce(t)
initiall% develo(ed in Nort& America and no used e$tensivel% in UB &ere it &as
#een "urt&er develo(ed and re"ined) is ma8ing inroads in India! Com(osite
construction is a com#ination o" rolled or "a#ricated steel sections +de(ending
u(on s(eci"ic reEuirement o" si*e. it& concrete sla# to((ing! T&e com(osite
"loor sla# com(rises a metal dec8) +&ic& is a cold "ormed (ro"iled s&eet)
su""icientl% ro#ust to Su((ort t&e et concrete it&out (ro((ing.)17131,1 mm o"
concrete and lig&t mes& rein"orcement! It is initiall% su((orted #% secondar%
#eams!
T&is "orm o" construction &as several attri#utes t&at contri#ute to its
success! Aetal dec8 +t&e (ro"iled s&eet.) t&e concrete! t&e secondar% and t&e
(rimar% #eams or8 e""icientl% leading to econom%! T&e reduced mass o" #uilding
reduces "oundation costs! It is sim(le straig&t"orard conce(t t&at (ermits "aster
construction S&ear connectors are usuall% elded t&roug& t&e dec8!
<ire resistance o" t&e sla# is ac&ieved it&out (assive "ire (rotection9 a
lig&t rein"orcing mes& is adeEuate "or most a((lications! Costs o" "ire (rotection to
t&e #eam and columns are dramaticall% reduced +don ,16 "rame cost to l73l26
o" "rame cost.
T&is tec&niEue essentiall% consists in (roviding t&e reEuired monolit&ic
action #% use o" s&ear connectors #eteen t&e (re"a#ricated units) suc& as
steel #eams) (ie3cast rein"orced or (re3stressed concrete #eams and cast3in3situ
concrete and t&ere#% increasing structural e""icienc% o" t&e &ole section!
Slim "loor is a s(ecial t%(e o" com(osite construction +<ig! 4#.) &ere a
rolled #eam section elded it& steel (late on its #ottom "lange) su((orts t&e
(ro"ile steel dec8 and concrete to((ing on #ot& sides and de(t& o" #eam is
contained it&in t&e t&ic8ness o" t&e "loor sla#! T&is tec&niEue is #ecoming
(o(u1ar in Euro(ean countries +UB) Nora% etc. due numerous advantages suc&
Page 7
as a#ilit% to cover + large column "ree area "aster construction #etter seismic
resistance) reduction in overall eig&t o" structure and in case o" slim "loor
elimination o" s&uttering and (ro((ing! In addition to t&is) "ire resistance o" sla#
is ac&ieved it&out (assive "ire (rotection9 a lig&t rein"orcing mes& is adeEuate
"or most a((lications!
Sa!e "rame Stru!tures
S(ace "rames are anot&er o(tion "or trac8 construction! It involves t&reeL
dimensional structures) &ic& &ave evolved a alternatives to conventional toL
dimensional + +(lain. roo" truss! S(ace "rames &ave loer de"ormation under
service loads! T&e% demonstrate &ig&est a#ilit% and relia#ilit% in accidental
overloading due to su#stantiall% &ig&er reserve strengt&s! S(ace "rame roo"s
(rovide larger column "ree s(aces and s(ans!
T&e main a((lications includeF "actor% #uildings and are&ouses9 ra(id
de(lo%ment structures9 tem(orar% and (ermanent &angers9 #ridge structure and
over&ead guide a%s9 in door and outdoor stadium9 e$&i#ition &alls and
terminals9 #arrac8s and dining &alls! Tu#ular steel is (resentl% t&e most (o(ular
material used in s(ace "rame construction!
In India) a num#er o" s(ace "rame structures &ave #uilt it& su#stantial savings
in time and cost com(ared to RCC=PSC o(tions!
Page 8
C#$PTER %
POSSIBILITIES O" STEEL INTENSIVE CONSTRUCTION IN INDI$
T&e s(ectrum o" steel intensive construction can cover t&e &ole domain
o" Aodern construction ) #e itF #uildings +residential=commercial and multi3
store%ed =single store%ed.F #ridges and "l%overs +&ig&a%sM raila%s.F car (ar8s
and s&o((ing (la*as) air(orts and sea (orts9 (oer and telecommunication9
s(orts) medical and entertainment "acilities9 and ot&er ur#an and rural
construction areas!
'it& massive ur#ani*ation in e (ast "e %ears) in"rastructure in Indian
metros and tons is no under tremendous (ressureF &ousing) trans(ort)
communication and (oer sectors #eing t&e orst a""ected areas! India &as
em#ar8ed u(on massive time #ound (rogramme o" construction involving several
t&ousand crores o" ru(ees on almost all t&e "ronts o" in"rastructure to meet t&e
urgent and demanding reEuirements to #oost u( econom%! Investments o" suc&
magnitude ill de"initel% reEuire &eav% de(endence on #orroed ca(ital and
(rivate (artici(ation in construction (rojects! T&is ill call "or s(eed% (roject
im(lementation it& Eualit% out(ut! <ast trac8 and sustaina#le construction
a((roac& &as s(ecial relevance in toda%?s scenario!
Gi8e most o" t&e develo(ed countries &aving solid in"rastructure #ase) t&e
steel intensive and "ast trac8 construction can (la% t&e lead role amidst toug&
com(etition "rom t&e ell3develo(ed com(eting sectors +it& a((ro(riate
strategies and (olic% measures.!
Page 9
CHAPTER 4
ST$TUS O" STEEL $PPLIC$TION IN INDI$N CONSTRUCTION SECTOR
DURIN& T#E L$ST "E' DEC$DES
T&e current trend o" t&e Indian construction sector is rein"orced cement
concrete +RCC. #ased construction "or t&e #uildings and ot&er similar structures)
&ile #ot& RCC and (re stressed cement concrete +PSC. #ased construction is
no (o(ular "or #ridges and "l%overs! <or #ridge a((lication) even Indian
Raila%s &ave #een moving aa% "rom steel! U(to ,1 m s(an) t&e% (re"er to use
(re stressed concrete #ridges (rimaril% due to loer direct initial cost) un"ounded
"ear o" corrosion o" steel) longer lead time and non3 availa#ilit% o" e""icient
sections "rom t&e (roducers!
Auc& less steel is consumed and muc& larger time is reEuired in t&ese
construction o(tions! ?Construction time? is &aving little or no im(ortance in most
o" t&e cases) and @direct cost? is generall% t&e sole deciding criteria on t&e (roject
decision "ront! Hoever steel intensive construction is invaria#l% used "or large
s(an #ridges) construction in di""icult conditions and in most o" t&e industrial
structures! Garge amount o" c&ea( la#our "orce it& adeEuate 8noledge in
concrete construction is idel% availa#le! T&e recent times &ave seen
consolidation in t&e cement industr% it& some mergers and acEuisitions and
multinational cement com(anies &ave also come u( "urt&er strengt&ening t&e
alread% strong cement industr%!
T&oug& steel &ad dominated t&e construction scenario during t&e si$ties
and earlier) t&e recent (icture is t&at steel intensive o(tions in most cases do not
even "ind (lace in t&e tender documents o" #ot& ;overnment and (rivate
(rojects! T&e muc& needed in"rastructure su((ort "or concrete construction
alread% e$ists in t&e countr% and a large num#er o" re(uted contractors &ave
acEuired e$(ertise in concrete intensive construction! T&e (racticing structural
engineers and in general) teac&ing "acult% and arc&itects are muc& unaare
a#out t&e recent trends in steel intensive construction and toda%9 steel is getting
lesser (riorit% in t&e s%lla#us o" engineering and arc&itecture curriculum! In most
o" t&e cases concrete intensive o(tions (rovide "avora#le cost o" advantages due
Page 10
to t&e s%nergetic e""orts #% t&e sta8e&olders o" t&e concrete construction industr%!
All t&ese &ave ta8en (lace over t&e last , or - decades! Got o" e""orts are needed
to correct t&e situation and li8e ot&er countries) it ill ta8e Euite a num#er o"
%ears to ac&ieve desired results!
Page 11
CHAPTER :
STEEL M$R(ET DEVELOPMENT :E)PERIENCE O" OT#ER COUNTRIES
$ND STR$TE&IES "OR INDI$*
Almost all t&e countries ac&ieving &ig&er steel consum(tion rate &ad made
enormous e""orts in steel mar8et develo(ment! T&oug& t&e e$(erience o" t&e UB
is most recent and ell documented) t&e strateg% ado(ted #% t&ese countries is
more or less similar) #e it Australia) Canada) UB) USA) Seden) Sout& A"rica or
ot&er countries! T&ese strategies "or steel mar8et develo(ment in t&e
construction sector ado(ted #% success"ul countries during t&e &ard middle %ears
are as under!
Mar+et Orientati,n
One o" t&e 8e% reasons "or t&e success o" mar8et develo(ment (olic%
underta8en #% t&e steel (roducers +e!g!) Dritis& Steel in UB. as #eing @Aar8et
<ocused? rat&er t&an @Production Ged?! In t&e @Production Ged? a((roac&) a
manu"acturer (roduces a range o" goods t&at &e ants to sell and t&en as8s t&e
sales "orce to go and sell t&em +as did t&e Indian steel industr% in t&e (re3re"orms
era.) &ile in t&e @Aar8et <ocused A((roac&?) t&e customers are a((roac&ed "irst
to 8no &at t&e% need) t&en t&ese items are manu"actured and lastl%) t&e
customers are given tec&nical assistance in #u%ing and using t&e same +Source
Flan Co$) Dritis& Steel.! T&oug& some o" t&e steel com(anies &ave made
signi"icant ac&ievement n mar8et orientation) t&is as(ect is to #e ado(ted #% all
#ig and small com(anies!
C,st ,- t.e Basi! Steel Pr,du!ts at t.e Plant Le/el
Dritis& Steel &ad started to invest &eavil% in t&e earl% 1051s) re(lacing old3
"as&ioned eEui(ment #% modern) state3o"3t&e3art (roduction met&ods! De"ore
long) (roduction costs started coming don! T&e (rogramme o" tac8ling cost in
UB resulted in staggering --6 reduction in t&e cost o" structural steelor8
#eteen 1051 and 1002 and made steel once main ver% com(etitive against t&e
ot&er major construction materials! T&e stor% in ot&er countries is just similar!
Page 12
All t&e major steel com(anies in India &ave made similar investments!
Per"ormance (arameters o" t&e steel com(anies are continuousl% im(roving!
Some steel com(anies &ave t&eir cost o" (roduction com(ara#le to t&ose in t&e
estern orld! T&is is #ound to re"lect in t&e domestic steel (rices!
C,st ,- Steel 0,r+ at t.e "a1ri!ati,n Le/el
In (arallel it& t&e a#ove) t&e steelor8 "a#ricators ere "acilitated to
invest in #etter eEui(ment to ma8e t&eir manu"acturing (rocess muc& more
com(etitive) &ic& reduced t&e costs o" "a#ricated steelor8 still "urt&er!
T&is area is o" great concern in Indian conte$t! Earlier under controlled
regime) clue to s&ortage o" steel) construction tec&nolog% moved "rom steel to
concrete! T&is dried u( #usiness o" steel "a#ricators! Due to lac8 o" #usiness)
t&e% did not "eel t&e necessit% and also did not &ave adeEuate "unds "or
moderni*ation o" "a#ricating and Eualit% assurance eEui(ment! I" steel
construction &as to "louris&) moderni*ation o" steel "a#ricating "acilities is ver%
essential!
C,st Redu!ti,n ,- Steel0,r+ t.r,ug. E--i!ient Se!ti,ns and #ig. Strengt.
Materials
E""icient structural sections and &ig&er strengt& steels ere develo(ed and
made readil% availa#le in t&e develo(ed countries at same or onl% marginall%
&ig&er (rice com(ared to mild steel it& loer=normal strengt& level! T&is #roug&t
in signi"icant econom% at t&e design level! ReEuirements o" e""icient sections and
materials in t&e Indian construction mar8et!
'ide "lange=(arallel "lange sections) H #eamsL Section range availa#le
no is onl% ISAD and ISAC range it ma$imum de(t& u( to 411 mm! 'ide
"lange #eam and lig&t #eam universal sections are not availa#le t&oug& listed in
t&e DIS &and#oo8!
Deams it& larger de(t&s and "lange t&ic8nessL Around 1 m de(t& rolled
sections and "lange t&ic8ness u( to 172 mm are availa#le a#road! &ic& "acilitate
design and construction o" long s(an #ridges and #uildings it&out need "or
additional cost o" "a#rication! T&ese are not availa#le in India!
Deams it& &ig&er strengt& an im(roved (ro(ertiesL <or #etter strengt&
and ductilit% +TACP variet%. etc! Aaterial grade -21 APa is common "or #uildings
in t&e UB) &ereas in Ca(an) &ig& (er"ormance steel it& a ide range o" %ield
strengt&s +"rom 111 APa to :51 APa. it& ver% good ductilit% is used!
Page 13
"ire Pr,te!ti,n ,- Stru!tural Steel:-
In t&e advanced countries! (rogrammes o" researc& and testing ere identi"ied to
discover &o steel actuall% #e&aves in "ire! Ne (roducts li8e "ire resistant steel
as ell as "ire (rotection #oards) coatings and (aints ere develo(ed and
#ecame availa#le in t&e mar8et! T&e cost o" ac&ieving "ire resistance &ad &alved
in t&e ten %ears (eriod + 105131001. in t&e UB! Jarious (u#lications on "ire ere
(u#lis&ed ranging "rom tec&nical guides to a director% o" "ire (rotection materials!
T&e control aut&orities &ave also #een a((roac&ed and codes ere modi"ied to
ensure t&at steel as not disadvantaged #% t&e regulations!
C,rr,si,n Pr,te!ti,n ,- Stru!tural Steel :-
Encouraging a((lication o" eat&er resistant steel and #etter detailing and #%
ma8ing availa#le &ig& (er"ormance (aints to t&e users &as &el(ed t&e develo(ed
countries in tac8ling t&e (ro#lem o" corrosion!! Pu#lications ere (re(ared to
aare = assist designers on corrosion (rotection!
Page 14
CHAPTER 5
"UTURE CONSTRUCTION TEC#NOLO&IES RE2UIRED IN CIVIL
EN&INEERIN&
According to recent Euestionnaire surve% to clients and contractors) t&eir
concerns "ocus on t&e tec&nologies "or cost reduction and "or maintenance
and re(airing o" e$isting structures! Concerns "or eart&Eua8e resistance and
t&e environment suc& as generation o" less aste "or reduced im(act on t&e
environment are also groing! T&e "olloing are some o" t&e main "uture
tec&nical trends in civil
Cost cutting +reduced construction term) la#or saving) increased ado(tion o"
(recasting.
7! Aaintenance3"ree +&ig& (er"ormance corrosion3(rotection s(eci"ications)
longer intervals #eteen re(airs.
-! Ne tec&nological develo(ments
3 Aaterials F Hig&strengt&) lig&t eig&t)
,! Ainimi*ation o" li"e c%cle cost
-! Ne tec&nological develo(ments I Aaterials F Hig&strengt&) lig&t eig&t)
maintenance I "ree
L Aet&odF Ra(id construction) increase ado(tion o" (recasting! cost cutting
3 Control s%stemF In"ormation3oriented tec&nolog%) la#our saving 3
2! Gess environmental load +(reservation o" ecological s%stems and t&e
nvironment
4! Per"ormance desion +"ree c&oice o" desiun
Steel a((lication tec&nologies and ne steel materials t&at meet t&ese trends
&ave alread% #een (ut into (ractical use) as introduced a#ove) or are under
develo(ment! Iron is t&e metallic matrerial in greatest a#undance in t&e eart&!
T&e "act t&at steel is destined to rust) in a certain sense) can #e inter(reted as
(roo" o" anot&er as(ect o" steel 3 it is a
rec%cla#le eco material! '&en ta8ing into account t&e "uture tec&nological
trends) steel is t&e material t&at can co(e it& an% o" t&ese tec&nological
Page 1
rcuds) ja(anese steel ma8ers are directing t&eir utmost e""orts so t&at steel
(roducts can #e a((lied more e""ectivel% and so(&isticatedl% in t&e civil
engineering "ield!
Page 16
CHAPTER 0
CASE STUDY 1
INNOV$TIVE DESI&N 3 CONSTRUCTION IN CEMENT PL$NTS
G>T &as (ioneered and ca(itali*ed on t&e grot& o" cement industries #%
ma8ing major strides in develo(ing e$(ertise in turn8e% construction o"
cement (lants rig&t "rom conce(t to commissioning! EDRC +Engineering
Design > Researc& Center. t&e design arm o" ECC &as done tremendous
innovations to save cost and time! A "e o" t&e case studies are given #elo!
Sil,s:-
Silos are structures) &ic& "ill t&e s8%lig&t o" cement (lants! Providing a
roo" "or t&ese structures is ver% tric8% as t&ese are eit&er ver% tall or ver% ide!
As structural steel (ermits large s(an construction) it is used invaria#l% to
cover t&ese silos! Storage silos o" large ca(acities &ere t&e &eig&t to
diameter ratio is less t&an 1!5 reEuire a s(ecial design (rocedure not outlined
in silo codes! Since t&is ne conce(t is ver% cost3 e""icient) it& t&e
assistance o" Pro"! Peter o" ;erman% &o (ioneered t&is t&eor%) ECC as
a#le to design and e$ecute a silo o" 42 m dia and ,1 m &eig&t in G>T?s
;ujarat Cement Plant +Re"! <ig I a > I #.! Roo"ing s%stem "or soil consists o" a
truncated conical3s&a(ed dome made o" structural steel radial trusses!
com(ression and tension ring #eams at t&e to( and #ottom res(ectivel%) it&
corrugated 1!1 s&eet as roo" covering! Roo" dome is su((orted on #earings
alloing "ree radial movement and rotation to avoid additional internal "orces
due to ovalling o" t&e silo s&ell resulting "rom uns%mmetrical (ressure
distri#ution on all!
T&e total eig&t o" roo" structures "or t&e 42 m dia (restressed Clin8er
Storage Silo is a((ro$imatel% 421t! Due to t&e si*e o" t&e silo and t&e
congestion o" structures around t&is silo) t&e crane &ardl% &ad an% access "or
erection "rom outside! Hence) t&e erection o" roo" &ad to #e done "rom inside
t&e silo! T&e elements) &ic& ere to #e (laced inside t&e silo) &ad to #e
reduced in si*e and eig&t "or eas% erection! &ic& is a cum#ersome (rocess
and ta8es lot o" time!
Page 17
ECC resorted to t&e erection o" t&e entire roo"ing s%stem in one li"t "rom
inside t&e silo! T&is ena#led "aster and sa"er or8ing #esides (roving sco(e
"or carr%ing out ;!I) s&eeting and (art o" eEui(ment erection at ground level
itsel"! Construction met&od ado(ted involved t&e "olloing ste(s +Re"!<ig!1.F
Sectional elevation o" Silo + Erection sc&eme at to( .
Telve nos! o" li"ting (oints ere considered +one "or a (air o" adjacent
trusses.! T&e li"ting "rames ere erected on t&e alls o" t&e silo it& t&e
strand jac8s seated on t&e "rame! Deams at to levels ere (rovided) eac&
&aving (lates it& &oles and edges! T&e li"ting as ac&ieved #% introducing
t&e jac8 in #eteen t&ese to #eams!
Page 18
Silo 3 G > T Cement Plant at ;ujarat
'it& eac& stro8e o" t&e jac8! t&e strands ere loc8ed into t&e to( #eam
and made to move "reel% t&roug& t&e #ottom (late it& &oles! During
retraction) t&e strands ee gri((ed at t&e loer level and t&e u((er #eam
moved "reel% t&roug& t&e strands! T&us #% alternate stro8e and retraction t&e
load got li"ted u( #% an amount eEual to t&e stro8e lengt&! 'it& t&e
introduction o" t&e central &ole jac8) it t&is case) t&e edging arrangements "or
loc8ing in t&e strands ere (rovided at t&e to( o" t&e (iston and at t&e #ottom
location o" t&e jac8! T&ere ere mini jac8s in cor(orated) &ic& ere used
solel% "or loc8ing in o" t&e edges and releasing t&e same!
T&us t&e strand jac8 s%stem could #e used "or tac8ling &eav% loads it&out
t&e use o" &eav% mac&iner% and at locations &ere access is restricted! Also a
#igger unit could #e assem#led at ground level and li"ted in one go t&us
avoiding elding and jointing at &ig&er levels! T&e strand jac8 s%stem o" li"ting
is a sim(le cost e""ective!
Page 19
CASE STUDY 2
Elegant Steel Duilding in A&meda#ad
A=s Sera Holdings +P. Gtd) A&meda#ad &as o(ted "or a #eauti"ul steel
#uilding "or t&eir o""ice! T&e o(tion o" steel intensive #uilding as a((roved not
onl% "or aest&etic (ur(ose) #ut also "or visi#le advantages li8e earl% com(letion
resulting in saving in cost o" la#our) eEui(ment etc!) #etter eart&Eua8e resistance)
eas% re(air or maintenance! T&e arc&itect "or t&e #uilding is Ar! Anand Naveri!
Salient "eatures o" t&e #uilding are given #eloF
11! OnerF A=s Sera Holdings +P. Gtd!
17! Arc&itectF Ar! Anand Naveri!
1,! Structural EngineersF Ar! N! B! S&a& and Ar! A! N! S&a&
1-! Structural EngineersF Ar! N!B!S&a& and Ar!A!N!S&a&!
12! Heig&t o" t&e DuildingF ;round O , Stories +1,!2 m.
14! Covered AreaF 14m $ 14m
1:! T%(e o" DuildingF Aild Steel 'elded S(ace <rame su((orted #% Aild Steel
Column
15! S(ace <rameF :7mm $ :7mm SEuare Hollo Sections and -0!2mm $
-0)2mm SEuare Hollo Sections
10! Steel Section usedF 7=ISAC ,11)
11! E$terior 'all F -1=41mm t&ic8 (anel made "rom Pre3coated ;I S&eets it&
PU< Insulation!
Page 20
CASE STUDY 3
& 4 5 Residential Building at Pune
Steel "ramed residential #uilding is no longer a distant dream in India! Ar!
Sures& At&aale) an arc&itect) is going a&ead it& construction o" ;O, store%
steel "ramed #uilding in Pune! His reasons "or o(ting steel are s(eed%
construction resulting in com(letion o" #uilding in &al" t&e time com(ared to
conventional material and assured material Eualit%! T&e a((ro$imate cover area
o" eac& "loor is 1,1! rn One o" t&e nota#le "eatures &as #een t&at 71 steel
columns &ave #een erected in a single da%! Alread% 21 tonnes o" steel &as #een
used! T&e #uilding construction is in t&e last stage! Oner o" t&e #uilding is Ar
Sures& At&aale T&e Sructural Engineer o" t&e (roject is Ar! Prasad Oa8!
Avinas& <a#ricators are t&e "a#ricator and erectors involved in t&e (roject!
'eld3<ree Steel <ramed Duildings designed to resist Eart&Eua8esF3
A"ter t&e Nort&ridge eart&Eua8e in Cali"ornia during 100-) it a((eared t&at steel
"ramed structures &ad esca(ed un&armed! Hoever) a"ter care"ul e$amination o"
man% steel "ramed #uildings) it as discovered t&at t&e joints connecting t&e
#eams to t&e columns &ad lost structural integrit%! T&e elded joints ere
"ractured and &ad large crac8s t&at (ro(agated all t&e a% t&roug& t&e columns!
T&e #uildings &ad little strengt& le"t and anot&er large eart&Eua8e ould &ave
#roug&t t&em don!
In a #id to give steel3"ramed #uildings #etter resistance to eart&Eua8es)
researc&ers at t&e Universit% o" Cali"ornia) San Diego?s +UCSD. Caco#s Sc&ool o"
Engineering &ave a((lied (ost tensioning) a tec&niEue commonl% used in t&e
construction o" concrete #uildings and #ridges) to steel "rames! Initial testing
conducted last %ear on a large3scale assem#l% indicated t&at t&e (ost3 tensioned
steel "rames can a#sor# strong eart&Eua8e motions it& little or no damage!
Andre <iliatrault) a Pro"essor o" Structural Engineering) e$(lains "urt&er! D%
adding tremendous tension to rods t&at run &ori*ontall% t&roug& t&e #eams and
columns) a steel "rame can #e constructed it&out elded joints?) &e sa%s!
Page 21
Doctorate student Constantin C&risto(oulos e$(lains &o t&e s%stem
or8s in (ractice! He states) @Strong (ost3 tensioned rods clam( t&e #eams to t&e
columns) &olding t&em toget&er! T&ese rods (rovide t&e s(ring "orce t&at allos
t&e s%stem to return to its initial (osition a"ter it is de"ormed during an eart&Eua8e!
Dut t&ere is still a need to dissi(ate energ%) so e introduce some uniEue
sacri"icial #ars!?
During an eart&Eua8e) to dissi(ate t&e energ%) a ea8er sacri"icial #ar)
contained in a c%linder to avoid #uc8ling) slides #ac8 and "ort&! Anot&er uniEue
"eature o" t&e s%stem is t&at t&e #e&avior o" t&e structure can #e modi"ied as its
"unction c&anges over time) somet&ing clearl% not (ossi#le it& elded joints!
According to <iliatrault) (ost3tensioning &as #een used on concrete structures "or
man% %ears) #ut never #e"ore on steel "ramed structures!
@T&is conce(t s&ould reall% #ene"it t&e steel industr%! One or to or8ers
can add tension to t&e rods and sEuee*e t&e "rame toget&er ver% Euic8l%! During
#uilding t&is ma% eEuate to cost savings?) &e sa%s) @as ell as saving t&e
#uildings "rom colla(se a"ter an eart&Eua8e!
Page 22
Page 23
C#$PTER NO 67
CONCLUSION
Steel mar8et develo(ment is not outcome o" a single action #ut t&e
co3ordinated e""orts on several "ronts #% t&e industr% sta8e &olders done
simultaneousl% and continuousl% over a (eriod o" time I some o" t&em
directl% #% t&emselves &ile t&e tec&nical issues t&roug& t&e concern
construction institutes li8e INSDA;!
In develo(ing countries li8e India in"rastructural develo(ment
+ &ig&a%s) &ousing) commercial com(le$ ) sc&ools) colleges) &os(itals) air(orts)
#ridges) "l%overs) Stadiums) etc! . &as to continue to #e a major area o"
investment "or t&e ne$t "e decades! In t&is area major t&reat is "rom
concrete #ased construction) &ic& &as alread% esta#lis&ed its "oot&olds
and &as retarded steel consum(tion!
Hoever) steel &as #een a#le to get #ac8 its rig&t"ul (lace in t&ose
countries t&roug& ell t&oug&t out strateg%!
Page 24
C#$PTER 66
BIBLIO&R$P#8
1! INSDA; Steel in construction! Cul% 711,) Jolume -) No 7
7! INSDA; Steel in construction! Cul% 7111) Jolume 7) No 7
,! S! Pal and S! R! Aediratta) PSteel in ur#an in"rastructure develo(mentF
An overvieQ Presented and a((eared in Pre(rint o" in t&e Seminar on Role o"
Civil Engineers in Ur#an Develo(ment) 14
t&
National Convention o" Civil
Engineers organised #% t&e Institute o" Engineers at Calcutta) 72374 August
7111
-! S! Pal and S! R! Aediratta) PCurrent trends in "lat steel (roducts a((lication in
constructionQ Pre(rint Pu#! O" t&e National Seminar and 'or8s&o(F <lat Steel
Products in IndiaLA Ne Era) Calcutta) 1431: <e#!7111!
2! S! Pal and S! R! Aediratta) PSteel intensive constructionF An overvieLRecent
trends in a((lication and strategies "or IndiaQ! Presented at t&e International
Seminar on 'orld Steel Aar8et Toda% and Tomorro at Bol8ata on 73, A(ril
7111 and Pu#lis&ed in Steel Scenario) Can3Aar 7111) (!I 3 11
4! R! Aediratta) PSteel intensive construction and structural steel3concrete
com(osite construction and its relevance in Indian conte$tQ) Delivered at t&e
Re"res&er?s Course on Com(osite Construction organi*ed #% INSDA; and
Civil Engg De(t) Cadav(ur Universit%) Jol I) Gecture 1) 1:
t&
L7lst Canuar%
7111
:! S! Pal) INSDA;?s Jision Pa(er on t&e National Steel Polic% it& Particular
<ocus on Construction Sector! Can 7111
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