ACCE Bulletin highlights innovative bridge design award

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Vol. No. 10
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No. 1
QUARTERLY
January-March 2011
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BULLETIN
of Association of Consulting Civil Engineers (India)
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Winner of the ACCE- SIMPLEX AWARD 2010 for Innovative Design of Structures other than Industrial Structure
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# 2, U. V. C. E. Alumni Association Building, K. R. Circle, Bangalore - 560 001 Phone : 91-80-22247466 E-mail : admin@accehq.net Tel/Fax : 91-80-22219012 Website : www.accehq.net
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ACCE
Vol. 10 ABOUT COVER PAGE
ACCE - SIMPLEX AWARD 2010 FOR INNOVATIVE DESIGN OF STRUCTURES OTHER THAN INDUSTRIAL STRUCTURE AWARDED TO TANDON CONSULTANTS PVT LTD., NEW DELHI A Grade Separator at Mukarba Chowk, Delhi, proposed in 2005 at this important nerve centre was experiencing chaotic traffic jams. The challenges around the project site included a Heritage structure, Graveyard, Sanitary land fill, major Electrical sub-stations, Nallahs, Live water mains, Optic fibre/ other cables and Gas pipelines. The task on hand was to tackle these challenges and design an aesthetically pleasing structure. The main flyover along the outer ring road is designed using steelconcrete composite tub girder. Slip roads, Loops, Bridge over drain and open stilted portion are constructed using RCC integral Voided Slab. The integral bridge concept offers merits like superior performance for sharp radius of plan curvature, elimination of expansion joints and bearings. The uplift that is likely to occur in a curved bridge is absorbed by integral piers. The end piers where there is practice of providing bearing even in the integral bridge, also become very critical for design if the curvature is extended in this zone. This complexity was eliminated by replacing large diameter single pier into small diameter twin piers. The small diameter twin pier in longitudinal direction offer flexibility for temperature and shrinkage forces and improves torsion rigidity in transverse direction which is required for sharp curvature bridges. A unique solution of providing two independent piers for the separated voided slab at expansion joint locations was proposed. At intermediate locations, large diameter pier is provided. The work commenced in December 2005, was completed during October, 2008. Tandon Consultants Pvt Ltd. (TCPL) was established in 1986 to undertake specialist consultancy services in the filed of structural engineering. TCPL specialise in design of large and complex structures and consists of carefully trained professionals geared to produce high
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BULLETIN
No. 1 CONTENTS
Presidents Message ............................................ 4 From the Editorial Desk ........................................ 4 From Secretary Generals Desk ............................ 5 ACCE AWARDS 2011 - Call for Nominations ......... 6 Eugne Freyssinet his incredible journey to invent and evolutionize prestressed concrete construction ..................................... 7 The Alternative Building Materials and Technologies for Individual Housing in Coastal Karnataka .................................... 13 Estimating the Strength of Concrete Maturity Method ........................................... 19 Whitetopping A case study ............................... 33 An Experimental Study on Carbonation of Concrete 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 .............................................. 50 Bulletin Committee
Chairman : RAVINDRANATH B. V. Advisory Committee Dr. MANAMOHAN R KALGAL, Dr. R.JAGADISH, Mr. SHINGAREY AMOL M Mr. RANGANATH D, Mr. UMESH B RAO, Mr. RATNAVEL S, Mr. S. PICHAIYA Editorial Committee Dr. M N HEGDE, Dr V RAMACHANDRA, Dr. R N PRANESH, Dr. R V RANGANATH Mr. M. SANJAY KUMAR JAIN, Mr. K G K MOORTHY Secretaries of all Centres (Ex Office Members)
January - March 2011
ACCE (I) Office Bearers

Avinash D. Shirode Hemant Hari Dhatrak T. Senthil Nayagam Dr. M. U. Aswath Badarinaath Singri Umesh B. Rao Ravindranath B. V. Raghunath B. N. President Vice-President (West) Vice President (South) Secretary General Treasurer Imm. Past President Imm. Past Secretary General Imm. Past Treasurer
Bulletin of ACCE (I)
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
PRESIDENTS MESSAGE
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. Nirmal Prasad had done extensive work in identifying various buildings for the Head Quarter office and also trying to get land from the local authorities. It is in the process and hopefully in near future HQ will have its own premises. As everyone knows that the cost of land or building 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 various committees constituted and each committee had done excellent work within a short span of two years. The most important had been the celebration of Silver Jubilee of ACCE(I) and it was a grand show under the dynamic leadership of Shri Ajit Sabnis. The major achievement is the revision of Bye-Laws of ACCE(I) in tune with the global scenario and other organisations in the profession. The major laudable achievement is introduction of Student membership category which 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 programme from AGM and giving sufficient time to award winners which was made memorable by the Hyderabad Centre under Shri P. Suryaprakash and Shri S. P. Anchuri. There is only one addition of new centre of Karim Nagar but there is considerable increase of membership. There had been excellent work done by Dr. M. U. Aswath, Secretary General, Shri Badarinath Singri, Treasurer and very dynamic Manager Shri S. D. Annegowda. My role as President was negligible with hardly any contribution. The whole 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 and contribution of all the members. I wish them all the success. With very warm personal regards, Avinash D. Shirode
From the Editorial Desk

Dear Fellow Members, Greetings to all from HQ. We have recently concluded the elections for new office bearers. The results will be announced by Secretary General in the next AGM. It's welcoming to note that many members participated to vote in a democratic way to elect the new office bearers. I would have appreciated if more members come forward to cast the votes and participate in the election process. New team will pave way for new thought process and new vision to achieve 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 your town, topics of interest that can shared with others, professional tips etc., which makes the bulletin livelier to read. Best wishes Ravindranath BV Bulletin of ACCE (I) 4 January - March 2011
From Secretary Generals Desk

Dear Members, Some time back, I had written in the bulletin that all our engineers should involve themselves in social activities for the betterment of the society. One of the ways we can contribute is to extend technical support and knowledge sharing with the general public. The awareness of the public in critical issues of building construction will enable them to demand for better quality from the builders. 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 aspects of buildings. The questions will be answered by professionals connected to the Association of Consulting Civil Engineers (I). The readers can send the queries to ranju@thehindu.co.in 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 also provided. 1. Safety first, always: Stability of high-rise buildings depends on factors such as height, width and configuration of the structure, March 12, 2011, http://www.hindu.com/pp/2011/03/12/stories/2011031250280200.htm Know the significance of sunshades: In our enthusiasm to achieve newer styles in the design of buildings, we should not overlook certain time-tested basic rules, advises, Mar 19, 2011, http://www.hindu.com/pp/2011/03/19/ stories/2011031950290300.htm Ideal designs need collaborative efforts: Beams that are visible inside homes are not commentaries on buildings being unsafe. They form part of the structural get-up of a design, march 26, 2011 http://www.hindu.com/pp/2011/03/26/stories/2011032650440200.htm 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 strange sense of freedom, April 9, 2011 http://www.hindu.com/pp/2011/04/09/stories/2011040950410300.htm For the right plumbing techniques: Improper plumbing designs cause leakages in pipes and damage the building, April 16, 2011 http://www.hindu.com/pp/2011/04/16/stories/2011041650320200.htm Passing on a new look, making a style statement: The building envelope design must include structural integrity, moisture/temperature/noise control and regulation of air flow. An article related to building cladding, April 23, 2011 http://www.hindu.com/pp/2011/04/23/stories/2011042350300200.htm Bamboo adds to the building strength: with earthquakes occurring frequently, the basic care that should be taken is in the material that we use in construction. An article related to bamboo in building industry, April 30,2011 http://www.hindu.com/pp/2011/04/30/stories/2011043050520300.htm
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I invite the members to involve in this activity and send the willingness to admin@accehq.net so that the queries will be forwarded for comments. The local centers of ACCE (I) can start similar activity in association with the local news papers and other media. With best regards, Dr.Aswath M.U. Bulletin of ACCE (I) 5 January - March 2011
ACCE AWARDS 2011 - CALL FOR NOMINATIONS

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, Chennai 7. ACCE GOURAV AWARD for Significant Contribution to Civil Engineering Consultancy. Instituted by: Gourav Engineers, Bangalore 8. ACCE CDC AWARD for Best Software Package in Civil Engineering. Instituted by: Computer Designs Consultants, Chennai 9. ACCE NAGADI AWARD for Best Publication (Book) in Civil Engineering. Instituted by: Nagadi Consultants Pvt. Ltd., Delhi 10. 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, Computer Software Developers and Authors. The works completed in the above areas during the last 3 years are to be submitted on or before 30th July 2011 in a prescribed Proforma. Proforma can be down loaded from the website: www.accehq.net These awards will be presented during the ACCE ANNUAL Awards Function to be held on third week of October 2011 at Nagpur. for more details please contact: 1.
Chairman, Awards Committee

ASSOCIATION OF CONSULTING CIVIL ENGINEERS (INDIA)
No. 2, UVCE Alumni Association Building, K. R. Circle, Bangalore - 560 001 Tel: 91-080-2224 7466 Tel/Fax: 91-080-2221 9012 E-mail: admin@accehq.net Website: www.accehq.net
EUGNE FREYSSINET HIS INCREDIBLE JOURNEY TO INVENT AND EVOLUTIONIZE PRESTRESSED CONCRETE CONSTRUCTION
Authors : 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 EUGNE FREYSSINET STARTED HIS CAREER IN 1905 in Moulins, France as Ingnieur des Ponts et Chausses (Engineer of Bridges and Roads). He approached problems in a graphic way using free hand drawings and simple calculations in the margins and sometimes used Graphic Vector resolution where required.. He built numerous bridges in the Moulins region. The Praireal-sur-Besbre Bridge built in 1907, a three hinged arch with a span of 26 m was the first bridge in the world to have the arch lifted from the formwork by the use of hydraulic jacks at the crown hinge. This was created by Freyssinet in a very early stage of his career. One of the fortunate events in the life and career of Eugne Freyssinet was his close association with likeminded contractors Franois Mercier, Claude Limousin and Edme Campenon. Freyssinet patented Prestressed Concrete (pre-tensioning) in 1928, the Flat Jack in 1938 and the concrete anchorage (post tensioning) in 1939. We will discuss this later in this lecture. One of the fortunate events in the life and career of Eugne Freyssinet was his close association with likeminded contractors like Franois Mercier, Claude Limousin and Edme 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, brilliant colleagues (they were all geniuses with an IQ of over 160). Yves Guyon, his Associate, gave prestressing its mathematical basis, Pierre Xercavins, who joined in 1950 was involved in large projects with Eugne Freyssinet, he soon followed Yves Guyon to become the Technical Director of Europe Etudes which was the design subsidiary of Socit Technique pour l'utilisation de la Prcontrainte (STUP), which was created in 1944 to spread the knowledge of Freyssinet's inventions relating to Prestressed Concrete across the world they designed many bridges in France and internationally. Pierre Xercavins was awarded the Fdration Internationale de la Prcontrainte (FIP) Medal in 1970 for outstanding work in Prestressed Concrete Structures and the Albert Caquot Prize in 1991 for being the best Civil Engineer in the world. He also designed many other large and complex structures most notably the Montreal Olympic Stadiaii, Ekofisk and Ninian Offshore Platforms, the last two being the first and the tallest Prestressed Concrete oil platforms in the world. Pierre Xercavins had the same approach to conception of structures as Eugne Freyssinet. I was able to observe the works of Eugne Freyssinet and be a disciple of Xercavins for 2 years. Between 1958 and 1963 I shared the enthusiasm of Pierre Xercavins to spread the knowledge of Prestressing with engineers all over the world. In 1963 I was sent to work by Yves Guyon for the newly opened design office of STUP in India: STUP Consultants Pvt. Ltd. STUP Consultants Pvt. Ltd. has now worked in 36 countries, has 1400 Engineers, Architects and Technicians and support staff and still carries on Freyssinet's, Guyon's and Xercavin's mission. I therefore, would like to offer this tribute to these great men by presenting a summary of the Article made by Pierre Xercavins about Eugne Freyssinet "EUGENE FREYSSINET HIS INCREDIBLE JOURNEY TO INVENT AND REVOLUTIONIZE PRESTRESSED CONCRETE CONSTRUCTION" a short time before Mr. Xercavins passed away in 2008. Whenever I was at the limit of my knowledge, from 1958 up to the time he passed away, I was able to get advice from Pierre Xercavins. I also met along with Mr. Xercavins, Mr. Yves Guyon, the First Technical Director of STUP France and Mr. Eugne Freyssinet, whenever the solution of a problem required their advice. I have also to explain the role played by Mr. K.K. Nambiar, the first Indian Chief Engineer of the erstwhile Madras State P.W.D. and Yves Guyon in setting up STUP Consultants Pvt. Ltd. in India, without the technical courage of Mr. K.K. Nambiar and his accepting Prestressed Concrete for the Palar Bridge, the use of this technique by India would have been much delayed - they encouraged the creation of STUP Consultants Pvt. Ltd. by becoming respectively the first Chairman and a Founder Director of this Company. WORLD RECORD SPAN LENGTH BRIDGES The long-term relationship between Freyssinet and the contractor Mercier started with Veurdre Bridge. During their period together Freyssinet designed and built concrete Arch Bridges, which successively broke his own world records for span length. Due to financial constraints and bureaucratic obstacles, money was not available for the Veurdre Bridge and two other bridges across the Allier River: Boutiron Bridge, and Mercier's friend Regnier was interested in the third bridge at Chatel-de-Neuvre. They made a bold proposal undertaking to build all three bridges together for 630,000 Francs, which had been allocated for the Veurdre Bridge alone; Mercier assuming total financial responsibility and Mr. Freyssinet the technical responsibility. The proposal never had to pass an Inspection Committee as Freyssinet had to do the Design for Mr. Mercier and supervision of the same for the Government - also Mercier agreed to be paid only after the work was completed.
The main problem during construction was the decentering of the long arches that were subjected to creep and shrinkage. This was achieved by using thrusts created directly, following the procedure first used on Praireal-sur Besbre Bridge. After constructing the Veurdre Bridge, Freyssinet kept on observing the behaviour of the same. It was a very flat arch with a depth to span ratio of 1:15. Fig.4 : Plougastel Bridge (3 spans @ 186 m) For this construction, Eugne Freyssinet took advantage of the tides to bring on floating barges, an enormous wooden truss, which was used for the successive construction of the three arches. The truss was built on the riverbank, launched at high tide with the aid of two barges, and installed for the construction of the first arch. After completion of a span, prestressing was used for raising up the arch from the centering, the centering truss was then lowered and floated 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 by prestressing. It took twenty five years of laboratory tests and profound thought to discover the difficulties involved and the ways to over come them.
Fig. 2: Veurdre Bridge (72.5 m span) (1911-1912) He observed deformations due to creep and shrinkage first slowly and then rapidly till collapse seemed inevitable and he and his loyal workers replaced the Decentering Jacks in the early morning when no one was around and raised all three vaults at once to the correct levels. The bridge regained its shape and behaved perfectly until 1940, when it was destroyed during the IInd World War. This bridge on the Lot River consists of a plain concrete arch with a span of 96 m, a world record at the time.
Fig.5 : Pre-tensioning (Forclum electricity poles) He applied for a patent for a "Fabricating Process for Reinforced Concrete Elements". The process was adapted to precast beams, pipes, sleepers, poles, etc. At the time of the patent, in 1928, the Scientific Community did not believe in prestressing. Thus, Freyssinet decided to go out alone to demonstrate the merits and possibilities of prestressing, risking all his fortune, energy and reputation. He thus started producing electricity poles at the Forclum plant at Montargis in France. He perfected the grinding fineness of cement to increase its strength, improved on his previous invention of mechanical vibration, invented steam curing and perfected the industrial precasting process. The result was a complete technical success but a total commercial failure due to the depression of 1929. In five years, he lost his entire fortune that he had accumulated during his past career. He never regretted it because he had obtained technical results for more important than all of those which he achieved between 1905 and 1928. Flat Jack Patent (1938). Eugne Freyssinet next invented the Flat Jack for compressing the raft of the Portes de Fer Dam in Algeria and immediately after that on a much grander scale for raising the height of the Beni Badhel Dam in Algeria by 7 m to bring it up to 67 m. the patent was applied for in 1938 and validated in 1939.
Fig. 3: Villeneuve-sur-Lot Bridge (96 m span) (1914-1920) Construction was started in 1914 but was soon stopped due to the Ist world war. The bridge was completed after the war in 1920. The most interesting aspect of the bridges from the point of view of construction was the use of Decentering Jacks previously spans collapsed during decentering when the span was greater than 70 m. Freyssinet used them not only for striking the formwork, but also for correcting stresses after construction created by deformation of the arch due to creep and shrinkage. Thus it was possible to carry out this procedure at any time during the lifetime of the bridge. Today, the bridge remains as natural in its urban setting as it did when it was first built. The bridge has reddish exposed brick arcades that hide the spandrels resting on the arch and let the bridge blend well with the buildings in town. The Lot Bridge was followed by Saint-Pierre-du-Vauvray Bridge of 131 m span in 1922-23 which again held the world record at the time. Plougastel Bridge (3 spans at 186 m) (1925 - 1930) The Plougastel Bridge on the Elorn River near the City of Brest, close to its harbour, consists of three reinforced concrete arches each having a span of 186 m (610 ft), a world record at the time. The reinforced concrete trussed double deck accommodates a roadway on the upper deck and a railway on the lower deck (the railway over the bridge was never completed).
The original 5 mm wires were progressively replaced by 7 mm wires, then 8 mm wires and then by seven wire strands. In the case of the concrete anchorage of 1939, the capacity was 20 T which was replaced by a steel anchorage in 1960 with a capacity of 150 T. Individual wedges for each strand came into existence in 1965 and a capacity of 200 mt was achieved. SAVING THE LE HAVRE MARITIME STATION FROM COLLAPSE.3 The Maritime Station in Le Havre completed in 1933 for the ocean liner Normandie, was sinking 25 mm (1 in) per month into 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, was adopted without argument as it constituted the only possible hope of avoiding disaster".
Fig.6 : Flat jack (schematic) The Flat Jack is made of two stamped steel sheets connected by welding. By hydraulically introducing a fluid under pressure, the flat jack is inflated and can develop considerable 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 to vary the compressive forces applied with time to allow for adjustments of structures after their construction. The flat jack has been used on a great many projects around the world, including the Montreal Velodrome described in this paper. CONCRETE ANCHORAGE PATENT (1939) (Post Tensioning). Eugne Freyssinet applied for a patent for "Tensioned Cable Anchorage System for Prestressed Concrete Construction". The patent was issued in 1947 (because of the war). The system consists of 12 Nos. 5 mm diameter parallel steel wires locked or anchored in a concrete anchorage cone by a tensioning jack. The steel wires which were threaded through the anchorage consisting of a reinforced concrete cylinder having a central conical hole (female cone) and a central fluted conical block (male cone). The steel wires were tensioned simultaneously with the aid of a jack and locked-off by the male cone inside the female cone while under tension. The wires transmitted their tension to the structure via the anchorage. This invention allowed tensioning to be achieved by resting on the concrete directly. The prestressing cable could be long or short, rectilinear or curvilinear, and positioned inside or outside the structure (external prestressing as well as internal prestressing). The force in the prestressing cable could be adjusted during construction. This system gave the engineer a wide liberty in the position and intensity of prestress that he/she wished to develop, and has been used in the construction of most of the large structures since that date.
Fig.8: Le Havre Maritime Station The strengthening of this building in 1934 is considered to be the first use of devices for prestressing. In the first stage, Freyssinet strengthened the foundations to make them monolithic by use of external prestressing by Cables and Jacks at their extremities and then increased the bearing capacity of foundations by adding piles that were driven in segments until they reached layers of soil which could carry the 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 a monolithic prestressed horizontal element. The unit was prestressed with parallel wires turned around two reinforced concrete end anchorages One anchorage was displaced by hydraulic jacks having a force of up to 1000 mt (1100 tons). The link between the old and new concrete was assured by the general compression of the whole. The moveable anchorage was fixed by concreting the free space and the jacks were removed. The wires forming the cables were covered by concrete to protect them from corrosion. The A units supported columns above while the B units had sockets in them to drive piles through.
Fig.7 : Post-tensioning (concrete anchorage cone and tensioning jack)
Fig.10 : Le Havre horizontal prestressing of footings
Fig.11 : Le Havre anchorage for horizontal prestressing of footings
protection, and implementation of the techniques of which M. Freyssinet is the inventor". In 1961 STUP created a design company, Europe Etudes, so as not to restrict the development of prestressing technique to the sole use of its original inventor and developer. STUP also wanted to spread this technology all over the world. With this aim, in 1963, STUP started its design bureau in Mumbai - STUP Consultants Pvt. Ltd. Today, STUP Consultants Pvt. Ltd. employs over 1400 Engineers, Architects, Technicians and supporting staff and has designed and implemented projects 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 - including the associated Mechanical and Electrical Engineering. In 1976, STUP France changed its name to Freyssinet International instead of STUP, which soon after became known as Freyssinet International. The group, at that time, included a prestressing supplier, which was a disseminator of technical information around the world (Freyssinet Company), a contractor (Campenon Bernard), and a designer (Europe Etudes). In 1982 STUP Consultants Pvt. Ltd. separated from the Freyssinet Group as it wished to become an independent consultant. INVENTION OF PRECAST SEGMENTAL CONSTRUCTION: The Luzancy Bridge over the Marne River (started in 1941 and completed in 1946 after the war), was the first of a new generation of precast segmental bridges designed and constructed by Eugne Freyssinet. It has a span of 55 m (180 ft), a world record at the time, and was built to replace an old suspension bridge. It is very light in appearance and has a remarkable span to depth ratio of 1: 45.
Fig. 12 : Le Havre existing columns above and the sockets for new piles below the combined footing The second part of the Freyssinet solution was to install 700 piles, 25 to 30 m (82 to 98 ft) long that extended to sound layers of soil. The piles were cast inside the building in 2 m (6.6 ft) sections, and were assembled by prestressing and driven into the ground using special jacks designed by Freyssinet. Vibration, compression, and steam curing of the concrete were all used to improve the rate of casting and quality of concrete. The piles were then prestressed against the footing by means of hydraulic jacks having a vertical prestressing force of 320 mt (352 tons). The settlement immediately ceased as soon as the first piles were installed. The result was both spectacular and convincing, and at once earned Freyssinet a worldwide reputation. This created the opportunity for a meeting between Eugne Freyssinet and Edme Campenon, and started the collaboration between the two in 1934 on the entire range of construction projects of the Campenon Bernard group, a collaboration that finally was destined to ensure the development of prestressing. PROLIFERATION OF FREYSSINET TECHNOLOGY AROUND THE WORLD. With success at Le Havre, the contractor Edme Campenon offered Eugne Freyssinet "the chance to experiment, apply, and develop his invention of prestressing and his ideas on concrete construction, on the entire range of sites of the Campenon Bernard group". Later in 1943, Edme Campenon created a special division called STUP (Societe Technique pour l'Utilisation de la Prcontrainte) [Technical Company for the Use of Prestressing] for the "development,
Fig.13 : Luzancy Bridge (55 m span) (1941-1946) (first precast segmental bridge) The Luzancy Bridge was visited sixty years after completion in October 2007 by me along with other members of the Freyssinet Association. It is in pristine condition and the concrete 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 of three box girders that were precast in segments and assembled on site in sections. The bridge was prestressed longitudinally and transversely with 12 - 5 mm diameter
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tendons, and vertically with 5 mm pre-tensioning wires that were stressed prior to concreting. It was erected by launching equipment consisting of masts and stay cables (one of the most imaginative systems ever used for the assembly of prefabricated bridge elements). The middle box girder being erected is 39 m long and weighs 90 T. All three of Freyssinet's inventions for prestressing (pre-tensioning, flat jacks, and post-tensioning were used here).
for the next segment, in order to obtain perfect contact between adjacent segments and to get directly the final profile of the deck). This bridge has three continuous spans of 37.5m - 55m-37.5m (123ft-180ft-123ft), with a total width of 28.4m (93 ft) that was divided into two parallel single cell box girder bridges. A total of 148 precast segments were fabricated using the long-line casting method. Typical segments weighed 20mt (22 tons). The bridge was erected in balanced cantilever using a floating crane.
Fig. 18 : Choisy-le-Roi Bridge (1962-1964) (first precast segmental "match-cast" bridge) Bear River Bridge (1971-1972) The Bear River Bridge near Digby, Nova Scotia in Canada was the first precast segmental box girder bridge built in North America using the match-cast method with epoxycoated joints. This curved bridge is 609 m (1998 ft) long with six interior spans of 80.8 m (265 ft) and two exterior spans 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 the bridge site using two short-line casting cells each producing one segment per day. The segments weighed a maximum of 82 mt (90 tons), and were placed by a 180 mt (200 ton) mobile crane on land or on a barge over water. The bridge was designed by A.D. Margison and constructed by Beaver Marine Ltd., with construction engineering assistance provided to the Contractor by Europe Etudes under the leadership of Pierre Xercavins and Daniel Demarthe.
Fig.15 : Luzancy Bridge during construction The Underground Basilica at Lourdes takes its inspiration from the Esbly Bridge of the Luzancy lineage. The structure was conceived by Eugne Freyssinet in only fifteen minutes, designed by Jean Chaudesaigues, and constructed by Campenon Barnard from 1956 to 1958. It consists of only 29 portal frames and can accommodate 20,000 people.
Fig.16 : Underground Basilica at Lourdes (capacity: 20,000 people) Fig.17 : Pierre Xercavins speaking at the 50th anniversary of the Basilica of St. Pius X at Lourdes on March 14, 2008 (photo courtesy : Association Eugne Freyssinet).
Fig.19: Bear River Bridge (1971-1972) (first precast segmental "match-cast" bridge in North America Montreal Velodrome (1973-1976)
Choisy-le-Roi Bridge (1962-1964) Jean Muller also a genius like Xercavins worked as a close collaborator and eminent disciple of Eugne Freyssinet in Campenon Bernard and Company, pioneered match-cast technology in the early sixties with the Choisy-le-Roi Bridge over the Seine River in France. On this bridge, he used for the first time, precast segmental box girder technology with match-cast epoxy-coated joints. I visited the site with Jean Muller, while outsiders were not allowed to visit unless the bridge was completed and put into service. (In the precasting yard the previously cast segment was used as the end form
The Montreal Velodrome for the 1976 Olympic Games pays tribute to Eugne Freyssinet because it incorporates so many of his prestressing and construction techniques. This very flat airy vault of prestressed concrete and is supported at four abutments only, and is inscribed in a rectangle of 172 m by 130 m. The covered area without intermediate supports is 16, 000m2 .
Completed Structure
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One of the most interesting phases of construction was the decentering (the transfer of loads from the false work to the permanent supports at the abutments).
63 double Y-shaped beams span between the arches. The structure is completed with cast-in-place concrete joining the arches to the abutments. Caracas Viaduct during construction Bridge(1) completed Bridges (2)and (3) completed Caracas Viaduct Completed (1951-1953)
Structure during construction. By placing flat jacks at the four abutments and jacking to an amount equal to the calculated reactions, the roof slowly rose until the entire weight of the structure was taken by the four abutments only. A total of 226 flat jacks each with a capacity of 1000 mt were used for the decentering. Once the loads were transferred, the false work was removed giving a clear span of 172 m. The veledrome was designed by Trudeau, Gascon, and Lalancette with technical assistance provided by Europe Etudes under the leadership of Pierre Xercavins and Daniel Demarthe.
Orly Airport Bridge (1957 - 1959) I visited this bridge under construction when I was a traineeit 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 water flow during floods. This was the first prestressed concrete portal bridge carrying Railway lines.
Flat jack scheme at Abutment The main structural elements are six arches which spread away from the Z abutment, and meet again in pairs on either side of the W, X and Y abutments. Two secondary arches connect the X abutment to the W and Y abutments. The arches are comprised of 142 precast segments that are built using the match-cast method with epoxy-coated joints, and erected on temporary false work. A network of Saint Michel Bridge (1959 - 1962) CONCLUSIONS Freyssinet 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 words of Jean Montagnon "If Eugne Freyssinet had been a musician, he would have been a composer, an instrument maker, an instrumentalist, and a conductor." Freyssinet also stated repeatedly that he had invented an entirely new material which led to "a revolution in the art of building". He continued to design and build until his death. Included in his latter structures are the three arch bridges of the Caracas Viaduct from 1951 to 1953, the Underground Basilica at Lourdes from 1956 to 1958, the Number 10 Bridge at Orly Airport from 1957 to 1959, and the Saint-Michel Bridge at Toulouse from 1959 to 1962. The Saint-Michel Bridge opened in March 1962, three months before Freyssinet's death. Eugne Freyssinet has been proclaimed as one of the most complete engineers of the 20th century and is certainly one of the greatest builders in world history. I present this paper with some emotion as it includes slices of my life.
Structural Layout
Flat jack layout at Abutment
Decentered structure (172 m span) Bulletin of ACCE (I)
Caracas Viaduct (1951-1953) 12
The Alternative Building Materials and Technologies for Individual Housing in Coastal Karnataka
RAJENDRA KALBAVI RAO, Project Director D. K. Nirmithi Kendra, National Institute of Technology Karnataka, Surathkal SUDEEP KUMAR SHETTY, Rachana consultants, , 1st floor, Venkataramana Arcade, Bhavanthi Street, Mangalore JOHN KENET DSOUZA, Consulting Engineer, 1st Floor, Krishna Complex, MG Road, Kodailbail, Mangalore Introduction World hates change, yet, it is the only thing that has brought progress- Charles Kettering. Normal is boring is the common saying. Man needs change in every aspect of life, for which construction is no exception. He needs change, needs different designs, needs variety, needs choices and other options before he decides. The various research Organizations in the country and world wide are in continuous investigation to develop different alternative materials and technologies. These vary from basic materials like stone and sand to finishing materials like paints and coatings. As science and technology advances, it is becoming challenging work to the scientists to give an improvised, fault free and performance oriented products and technologies to suit the general public. List of building materials to choose from has become very exhaustive and expensive results in the urge to develop newer and different materials to suit local condition and to suit the varying human requirements. Costal Karnataka The cities in costal Karnataka are situated attached to Arabian Sea. Mangalore is located at 12-52N latitude and 74-49E longitude. The average rainfall is 3875 mm between Junes to September every year. The ambient temperature varies minimum from 17c to a maximum 37c.The maximum average humidity is 93% in July and average minimum humidity is 56% in January. There are only 2 seasons, namely rainy season and summer season. 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 materials of construction today. Modern day house construction involves in construction of framed structure with lintels and chajjas and RCC for roof slabs. Those who can afford will have air conditioned rooms and others will keep large openings for ventilation and comfort inside the house. Why Alternative building Materials and technologies Selection of materials and technologies for the building construction should satisfy the felt needs of the user as well as the development needs of the society, without causing any adverse impact on environment. The first energy crisis of 1973 was perhaps the trigger, which lead to the concept of Alternative Building Technology. Technologies of the Developed West often could not meet Bulletin of ACCE (I) 13 these requirements and many thinkers argued in favour of a middle path and this approach is the genesis of the Alternative Technology movement. With the development of science and technology alternative materials and technology is available, right from the basic materials like cement to building blocks, from foundations to finishing items. Few of them are explained below. Building Blocks Naturally occurring laterite stone blocks are commonly used in coastal areas. Fig.1. The concrete blocks have spearheaded the construction industry with varying sizes form brick to laterite. The investment is very low and it can be produced throughout the year as compared to the brick industry. Fig.2 Burnt Clay Hollow Blocks:These are burnt high clay blocks made by a process of extrusion. The wall thickness of the hollow block is often as low as 15 to 20 mm. They come in various sizes from laterite block to brick. Stabilized Mud Blocks Soils when compacted using external energy, the density of the soil reaches a maximum value at the optimum moisture content (OMC). The value of OMC and the maximum density depends on the energy input during compaction. The compressive strength of the soil, in the dry state, depends on the density. Thus the process of mechanical compaction can lead to densification and strengthening of the soil. Addition of stabilized additives like Cement, lime or bitumen further improves the densification during saturation. These blocks can be produced locally with manually operated machines with suitable mould sizes. Fig 3 Stone Blocks using recycled wastes The BIS specification IS: 12440 give the details of this technique. It is a very simple technology involving using odd sized stones, which are shaped by a layer of concrete surrounding the stone. Steel moulds resting on level ground can be used to place the odd shaped stone in the centre of the mould. Lean concrete is now poured in the space between the stone and the mould. Block sizes matching to laterite or concrete blocks are commonly used. Compressive strength in the range of 5.0 to 7.0 MPa can be easily achieved. Masonry construction techniques English bond is the most common mode of construction in India. When Concrete blocks are used, the blocks have to be kept in Stretcher bond leading to a wall January - March 2011
thickness of 100,150 or 200mm and a course height of 200mm as shown again in Fig.2. When stabilized mud blocks of size 230x190x100mm are used, either a header bond with wall thickness of 230mm or a stretcher bond of 190mm wall thickness can be used. The concept of rat-trap bond was popularized by Ar.Laurie Baker in Kerala in the seventies. This involves keeping bricks on edge creating a gap in the thickness of the wall. About 25% of the bricks can be saved by this process. The cavity created within the wall offers thermal comfort inside the house. Fig 4&5 Arches, Corbels and Reinforced brick lintels Masonry arches are the age old construction techniques can still today replace concrete lintels. Arches can be circular, segmental or even flat. (Fig 6 & 7) These are also used in the masonry foundations between the corners to save on earthwork excavation and materials. Corbels (Fig 8) and arches give aesthetic look to the structure while carrying the desired load. Reinforced brick lintels are the one used or small openings up to 1.8m with and nominal reinforcement of 3-8 mm in CM 1:3 and bricks laid on edges with the same mortar. Ferro Cement Elements Ferro cement is a special form of reinforced concrete. It is a composite material consisting of cement-sand mortar (matrix) reinforced with layers of small diameter wire meshes. It differs from conventional reinforced concrete primarily by the manner in which the reinforcement is arranged within the brittle matrix. The success of ferro cement in various terrestrial applications can be attributed to ready availability of materials locally, need of low level technology for its production, better utilization of available human resources and architectural flexibility. Ferro cement products are so versatile that they have reached common mans kitchen to drawing room furniture to commercial structures. It is all geared to replace timber in all the areas of construction. (Fig 9)
ii) Partially prefabricated roof iii) Cast in-situ roof Few of the technologies commonly used in coastal Karnataka are explained below. a) Filler Slab Roofs:Filler slab roofs are basically solid reinforced concrete slabs with partial replacement of the concrete in the tension zone by a filler material. The filler material could be cheaper and lighter. A number of filler materials can be 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 filler material are governed by the factors like slab thickness, code guidelines on spacing of reinforcement bars, desired ceiling finish etc and has to be carefully selected. This is a cast in situ system and is widely accepted and is most suitable for tropical Climate and for buildings in coastal region. The laying of this roof is in line with conventional technique. The form work is done at desired height and shape, the filler material is placed and the reinforcement is tied and the concrete is laid. This method also satisfies all the requirements of the code and the needs of the common man. Layout of filler material (Hollow clay block roofing block) along with the reinforcements before the pouring of the concrete and the ceiling (with regular Mangalore tile) after completion are shown in figure. (Fig 10, 11 & 12) b) The Concept of Composite Beam and Panel Roofs: This system is similar to the traditional wooden rafters and wooden planks used as attic in the olden days. Now we are using concrete beams and planks made of materials like brick, ferro cement, stabilized mud blocks etc are used. The roofing system consists of panels and beams cast separately and assembled such that the system behaves like a T-beam. The beams can be fully pre cast or partially pre cast beams. These types of roofing systems can be broadly grouped into two categories viz: Flat panel roof and curved panel or jackarch roof, based on the shape/geometry of the panel. Since the panels and beams are cast separately and then assembled, there should be proper shear connection between them to achieve composite action for the system to behave as an integral structural unit. The flexibility of composite beam and panel roofs arises out of the fact that the materials for the beams and the panels could be of two different materials and the composite action between them could be achieved by proper shear connectors. Both the beams and the panels can be precast and then assembled into a roofing system. In case of precast beams, the beams are partially cast and hence they require some props while assembling the roofing system. These roofs can be laid flat or with gentle slope. Fig 13. 14 January - March 2011
Alternative Roofing Systems:Due to invent of extensive research done by various institutions various technological options are available for implementation. The research for an alternative roof must be based on a simultaneous satisfaction of several objectives. 1. 2. 3. 4. 5. 6. Withstand imposed dead and live loads. Prevent leakage during rainy season Provide a secure enclosure To be cost effective Provide a durable comfort in the interior Give aesthetics to the structure
Roofs can be i) Pre fabricated roof
c) Masonry Domes and Vaults: Romans rediscovered the use of the arch, and the vault. However, they often used semicircular barrel vaults built out of concrete. The vaulted constructions spread to Europe and one can see vaults in Roman architecture of England. The vault construction was no longer confined to mosques in this region. The superiority of the brick masonry vault over the conventional construction using timber palaces, granaries, ammunition stores were some of the important structures where the vaulted construction was readily accepted. A thin layer of nominally reinforced concrete over and above the unreinforced masonry can vastly enhance the performance of masonry roofs. Fig 14. Use of modern materials like glass fiber reinforced plastic as externally attached reinforcement can also provide additional flexibility and strength. d) Mangalore tiles over ferro cement rafters and reapers. Mangalore tiles over wooden supporting structure are accepted and adopted technology since centuries. It is most suitable roof for the coastal region in the tropical county like India. Timber of good quality is not available as per requirement and above that it is expensive material. Concrete and ferrocement can be a suitable substitute alternative replacement for implementing Mangalore tile roofing system. The size and the shape can match the timber and the member can be designed as per requirement on IS codes. The wall plate, the rafters and the reepers are manufactured to design in a factory and shifted and erected at site. These structures are unlike wood are fire resistant, termite resistance, anti fungal, low maintenance and it has a long life then compared to timber structures. It is a look-a-like structure and one cannot make out the difference between the conventional and alternative method once erected. Fig 15. Energy efficient and eco friendly: Considerable amount of energy is spent in the manufacturing processes and transportation of various building materials. Conservation of energy becomes important in the context of limiting of green house gases emission into the atmosphere and reducing costs of materials. A comparison of energy in different types of masonry has been studied. Energy in different types of alternative roofing systems has been discussed and compared with the energy of conventional reinforced concrete (RC) slab roof. It is found that total embodied energy of load bearing masonry buildings can be reduced by 50% when energy efficient/alternative building materials are used. Table1. Conclusion Opening up of the Indian market has given the common man to look for the latest and the best suited material and technique for his suited budget and needs. Table 2 Bulletin of ACCE (I) 15
shows the cost benefit in using these technologies. With internet available at nook and corner of the state, every man is well informed and has access to knowledge super highway. Recently lot of materials and techniques are coming to the market and the common man is confused to use, adopt, judge and implement the right technology. We Engineers with all the technical back ground and experience should have the updated knowledge to use the appropriate technology at right place at correct time with proper technical design, supervision and implementation. Thus the efforts of the scientists and researchers will have a value addition and a dream come true for the common man. Fig1. The only shortfall is the information which reaches the common man gradually and all the building materials and technologies are time tested over the years, it takes its own time to prove its credibility and durability requirements. References: [1] A.J.Joseph Increasing the service life of low-cost buildings, Building Materials for Low-Income Housing, Oxord & IBH Publishing Co.Pvt.Ltd. New Delhi. P 335-340. [2] Harrison S. W, Sinhat B. F, A study of alternative building materials and technologies for housing in Bangalore, India Construction and Building Materials Vol. 9, No. 4, January 1995, pp. 21 l-211. [3] Jagadish K. S, venkatarama Reddy K. S, Nanjunda Rao, Alternative Building Materials and Technologies.2008.New Age International Publishers. New Delhi. [4] Jamal M. Khatib, Sustainability of construction materials. Woodhead publishing Limited.New Delhi. P 85,86 & 116. [5] Venkatarama Reddy B. V, Sustainable building technologies, Current Science, Vol. 87, NO. 7, 10 OCTOBER 2004, pp 899-907. [6] Venkatarama Reddy B. V, and Jagadish K.S., Embodied energy of common and alternative building materials and technologies, Energy and Buildings 35 (2003) 129137. [7] Venkatarama Reddy B.V., Jagadish K.S. / Energy and Buildings 35 (2003) 129137, Energy and Buildings 35 (2003) 129137, Embodied energy of common and alternative buildingi materials and technologies . [8] Ross Spiegel, Dru Meadows, Green Building Materials, John wiley & sons, Inc. Professional/Trade Division,605 Third Avenue, New Yark,N.Y.101580012.P 9,27-30. [9] S.Q.Jamal and A.S.Sheikh, The use and Performance of soil stabilized blocks in flood affected rural areas, Building Materials for Low-Income.
Table 1. Energy in different roofs/floor systems Number Type of roof/floor Energy/m2 of plan area (MJ) 73.0 59.0 56.0 57.5 41.8 22.7 15.8 49.1 Equivalent of RC solid slab energy (%) 100 80.8 76.7 78.8 57.3 31.1 21.6 67.3
1 2 3 4 5 6 7 8
RC slab SMB filler slab roof Composite brick panel roof Burnt clay brick masonry vault roof SMB masonry vault roof Mangalore tile roof Ferro concrete roof RC ribbed slab roof
Table 2. Cost savings of Innovative technologies over conventional options S.No 1 3 4 5 6 7 8 9 10 11 12 13 14 15 Innovative Technologies 230mm thick wall Rat trap bond walls Hollow blocks walls Tiles over RCC rafters Brick panel with joists Ferro cement shell roofing Filler slab roofing Jack arch brick roofing Precast blocks over inverted T-beams Corbelling for lintels Brick arch for lintels Hollow clay block Hollow roofing block Precast ferro cement shelves Conventional Options 330mm brick walls English/Flemish bond Hollow blocks walls Tiles over timber rafters RCC RCC RCC RCC RCC RCC lintels RCC lintels walls & corners RCC slabs Timber/concrete % of saving 5 25 20 25 20-25 40 22 15 25 40 30 20 15-25 35-45
Fig 4 Layout for rat-trap bond construction Fig 1. The residence of Mr. Kenet Dsouza( Co author) constructed using Laterite stone blocks and alternative building technologies Bulletin of ACCE (I) 16 January - March 2011
Fig 2. Hollow concrete block laid with stretcher bond for wall construction
Fig 5. Brick wall constructed with rat-trap bond technique.
Fig 3 Stabilized Mud block under production.
Fig 6. Brick arches in place of lintels and beams
Fig 7. Flat arch with brick masonry to avoid lintels.
Fig 10 Hollow clay block Filler slab before pouring of concrete 17 January - March 2011
Fig 8. Large corbels can replace lintels, arches and beams.
Fig 11 Filler slab ceiling after completion
Fig 9 Cross section of a Ferro cement member
Fig 12 Filler slab ceiling using Mangalore tiles after completion.
Fig 13. Ceiling view of a brick panel roof.
Fig 14 View of a circular brick vault
Fig 15. Mangalore tiles supported on Ferro cement rafters and reepers. 18 January - March 2011
Estimating the Strength of Concrete - Maturity Method

Bharathi 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 Introduction Many operations like when to strip forms, when to posttension, when to remove shores, and when to terminate cold-weather protection are based on reaching a minimum level of concrete strength development. Waiting too long is very expensive but acting prematurely with out confirmation of strength measurement may cause the structure to crack or collapse. Few cases of failures of structures (Fig. 1) under construction due to form stripping and shore removal at improper time have been witnessed. More timely knowledge of compressive strength evolution at required time interval during concrete hardening process is needed, in order to achieve savings in many ways during construction and also to improve safety. Although there are several procedures predicting concrete compressive strength, reliable methodologies involve either extensive testing or voluminous databases. Hence a simple and fast methodology is required to consequently predict compressive strength evolution. A simple 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 mechanical properties of concrete and particularly the evolution of compressive strength.
Fig.2 Effect of Curing Temperature on the Rate of Strength Gain At early age, the mechanical properties of cement-based materials are time-dependent and involve hydration of cement. The hydration process is a thermally-activated chemical reaction, directly related to the development of strength which depends on rate of reaction. The integral over time of the rate of reaction gives the degree of reaction. 19 January - March 2011
Fig. 1 Failures of Structures due to form stripping and shore removal at improper time Bulletin of ACCE (I)
Measurement and Predictions of mechanical properties of concrete are possible by a method based on the empirical 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 to predict the compressive strength evolution of concrete, based on the determination of maturity indexes. These indexes lead to the prediction of the evolution of compressive strength of concrete at a required period after pouring it or from the instant of adding water to the mix. The effect of the temperature after similar elapsed times of hydration, changes with the Thermal Expansion Coefficient (TEC), and this coefficient depends on curing temperature (fig.2) and the degree of hydration. To perform predictions of compressive strength evolutions, knowledge of maturity indexes is required. Maturity indexes need to be determined experimentally for each concrete type. Originally, hardening time was intended to be an equivalent of setting time. Studies of the mechanism of force transmission between sensors and concrete-matrix indicate that hardening time depends on the degree of concrete hydration. The methodology presented here assumes that the hardening time is an indicator of the degree of reaction. The relationship between the hardening time and the degree of reaction is an important issue for the extension of the methodology to the general field of hardening materials. Values of hardening time depend on the following factors degree of reaction which in tern depends on factors like type of materials and machineries used in making concrete, temperature of hydration, time etc. features of sensors such as thermal expansion properties and stiffness.
Fig.3 shows curing conditions Why Maturity Method Proper method of quality control is essential in every construction because test samples do not reflect the influence of temperature extremes, weather conditions, Cylindrical Specimen critical curing conditions, concrete thickness and any number of other actual job site conditions. Fig. 3 shows curing conditions of deck cured by Heating & Covered with full jacketing. And also the cylindrical specimen cured at the same site. Principle Maturity Method is based on the principle that the extent of hydration of a concrete mixture and, therefore, the strength at any age is based on the thermal history of the concrete. Using the thermal history of a concrete mixture and a maturity function, a maturity index that quantifies the combined effects of time and temperature can be calculated and plotted against the strength of the concrete by means of a strength-maturity relationship (fig.4).
The basis of this methodology The basis of this methodology involves passing from mechanical properties of concrete (hardening time) to thermodynamic chemical properties (activation energy and rate constant) and back again to mechanical properties (compressive strength). What is Maturity Method The maturity method is a nondestructive technique that is used to estimate the in-place strength of concrete by accounting for the effects of temperature and time on strength development. ASTM standard practice for estimating concrete strength by maturity method is ASTM 1074.
Fig.4. Maturity Strength Relationship Maturity Index The relationship between the temperature history of a concrete and its strength can be empirically determined, and is called its maturity index. Concrete of a given mix at the same maturity has approx. the same strength, regardless of the temperature and time history that made up that maturity. Maturity Function There are two alternate functions for computing the maturity value from the measured temperature history 20 January - March 2011
of the concrete, the Nurse-Saul equation and the Arrhenius 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 age t, 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 usually obtained from field cured cylinders, pullout tests, or penetration testing. Some codified methods use similar concepts by inserting the final setting time into maturitystrength equations and Maturity methods are yet to become popular used in practice. Scope Maturity method is a modification of ASTM C 1074 covering the procedures for estimating concrete strength by means of the maturity method. A relationship must be established between the maturity values and the concrete strength, as measured by cylinder testing. The development of the maturity-strength curve shall be performed using project materials and the proposed concrete mix design. The contractor shall be responsible for the development of the maturity curve. The Mix Design Expert shall monitor the curve development. The temperature monitoring process of the concrete construction is the responsibility of the contractor and shall be monitored by the Engineer. Acceptance of the concrete shall be based upon the 28day cylinder strength. Instrument - Sensors The maturity method involves the measurement of three key parameters time, concrete temperature and concrete strength. Using one of two widely-used expressions, a temperature-time factor with units of Degree Hour is calculated by multiplying concrete temperature, with respect to a datum, by the elapsed time (in hours) after the concrete was batched. The temperature of fresh concrete is measured using Temperature Sensors (Fig.5) Concrete maturity can also be measured in the laboratory or field using strength test specimens. Working of Sensors Insert two temperature sensors at the required place of measurement appropriately depending on the type of construction. After concrete hardens, both sensors measure only the deformation of the concrete matrix and the difference between the deformations measured by the two sensors remains constant. The hardening time Bulletin of ACCE (I) 21
is defined as the time when the derivative of the difference between the deformations measured by these sensors by setting initial reading in standard sensors. In ASTM C 1074, Standard Practice for Estimating Concrete 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 concrete strength, for a given mixture, can be determined by graphing each actual strength data and the corresponding degree-hours.
Fig. 5 Temperature Sensors & Field Measurements
Procedure for Field Measurements

1. Establishing Maturity Strength Relationship for a particular site / mix used at site. Prepare at least 15 cylindrical specimens (fig.6) according to Kentucky Method 64-305. The mixture proportions and constituents of the concrete shall be the same as the concrete whose strength will January - March 2011
be estimated using this practice. The concrete shall be produced using the same equipment as that which will produce concrete for the project. The cylinders may be cast at the concrete plant or the job site. Since there is a direct relationship between the w/c (water/cement) ratio and strength, the concrete used to develop the maturity-strength relationship shall be at the maximum w/c ratio expected during production.
Acceptance Criteria The R2 value can be found on the maturity curve chart. The computed R2 value of maturity curve obtained from regression analysis of the maturity strength relationship (fig.7) shall be 0.95 or higher. When R2 value is below 0.95 the curve is unacceptable and a new curve will be required.
Fig.6. Maturity Strength Relationship Moist cure the specimens in a water bath or in a moist room meeting the requirements of KM 64-305. Perform compression tests at five different ages. Test three specimens at each age and compute the average strength. If a low test result is due to an obviously defective specimen, discard the low test result. The tests shall be spaced such that they are performed at somewhat consistent intervals of time and span a range in strength that includes the opening strength desired. The table.1 gives suggested test times. Test 3 is the target test. This is only a guide and may need to be modified depending on specific mixtures and conditions. At each test age, record the average maturity value for the instrumented specimens. Use the spreadsheet available to determine the maturity-strength relationship. This spreadsheet can be found on the Materials Web Page at The TTF number corresponding to the desired compressive strength. This curve is used to determine when the concrete has reached desired strength. Table 1. Approximate Test Times
Mix Test 1 Class X Class X/24 Class X /48 Class X /72 2 days Strength in MPa Test 2 3 days Test 3 4 days Test 4 5 days Test 5 6 days
Fig.7. Maturity Strength Relationship fox a Particular mix at Field Precautions While evaluating concrete maturity using small test specimens, it is extremely important to insulate them from heat loss to minimize the time needed to develop the strength-maturity relationship. If small test specimens are not insulated during curing, strength development will 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 the edge of the concrete. They should be placed in the plastic concrete as soon as possible. Avoid placing the sensors near reinforcing steel. A threaded rod with a wing nut may be used to insert the sensors in the pavements and immediately removed. Consolidate the concrete around the sensor as needed. The rod can be marked for various insertion depths. This device will allow the placement of the sensors with minimal disturbance to the concrete. Sensors should be placed in the concrete where the temperatures are expected to be the coolest. For a normal day production, randomly place two sensors to determine the maturity. They shall be located in the last 100 feet of pavement placed. Embed temperature sensors in the centers of at least two cylinders. Connect the sensors to One or more maturity meters (fig.8). Use the average of the readings to develop the maturity strength curve. Connect the sensors to maturity instruments (Fig. 9) and activate the recording devices as soon as is practicable.
6 hours 10 hours 12 hours 14 hours 24 hours 24 hours 36 hours 48 hours 60 hours 72 hours 48 hours 60 hours 72 hours 84 hours 96 hours
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E Earthwork Import data from CSV, Excel or CAD for Quantity Estimates / Quantity Takeoffs Earthwork for fixed formation level or between two surfaces Generate quantity calculation reports using multiple methods Generate interim Earthwork reports during progress of projects for payments Generate Earthwork calculations for Stepped or Sloping surface
play with sections
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digital terrain modeling made affordable
Quantity calculation made simple
e earth work
E Sections
Import section and alignment data from Excel, Field Book / CAD for generation of C/S and L/S Generates Section for multiple profiles / multiple layers Provision for customized profiles or shapes for various requirement like irrigation, roads, railways etc Generates Area / Volume Reports in Excel and CAD with interpolation facility Modify Sections graphically Import data from Total Station,Traverse correction, Interpolation
E Contours Import data from CSV, Excel or CAD for Contour generation Generate Contours directly within your CAD software Draw Section for any alignment fixed on the Contour map Generate Grid Elevations or Block Levels from existing Contours map Generate Contour Area / Volume and estimate capacity
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BANGALORE : Industry House, 5th Floor, Fair Field Layout 45, Race Course Road, Bangalore - 560 001 Tel : 080-22250748, 22250749 Fax : 080-22204839 CHENNAI : 23, Anna Salai, Little Mount (Above Swaraj Mazda Show Room) Saidapet, Chennai - 600 015 Tel : 044-42328003, 42328018 Fax : 044-42328017 DELHI : 12th Floor, Ambadeep Building K.G. Marg, Cannaught Place New Delhi - 110 001 Tel : 011-23315007-10 Fax : 011-23315000 KOLKATA : Constantia, 7th Floor, 11, Dr. U.N. Brahmachari Street Kolkata - 700 017 Tel : 033-30214100, 30214400 Fax : 033-30214490, 30214590 MUMBAI : A Wing, Ahura Centre, 1st Floor Mahakali Caves Road, Near M.I.D.C. Office Andheri (East), MUMBAI - 400 093 Tel : 022 - 66917800, 66928400, 66917274 Fax : 022-66928401, 66917250
When the strength at the location of a sensor is to be estimated, read the maturity value (Fig.10) from the instrument. The strength of the concrete can be determined from the spreadsheet or calculated from the curve equation.
Fig. 8. Maturity Meter
specimens or the maturity method to determine the in-place concrete strength. With the maturity method, a change in cement performance during a project (due to different loads or lots of material) could produce variability in results. Test specimens on the other hand may contain flaws or lose heat during curing and not be representative of in-place concrete performance. Until sufficient experience has been obtained with a given mix, the most reliable way to determine concrete strength is to use both strength and maturity measurements to determine concrete strength. Changes in material sources, proportions, admixtures, and mixing equipment all affect the maturity value of a given concrete mixture. Therefore, development of a new maturity curve is required for any change to a concrete mix.
Fig. 9 Measurement on Fresh Concrete
Correction for results Direct reading maturity devices are preset with initial temperature reading for an assumed temperature below which cement hydration ceases. The displayed values may have to be corrected if this assumed temperature differs from the true temperature below which hydration ceases. ASTM standard practice tells how to make the corrections. Benefit from Maturity Testing Pulling cables and stripping forms as soon as possible leads to project acceleration. Curing times are usually cut dramatically, especially in the winter. Improve site safety by not stripping forms or stressing cables too soon. Improve concrete quality by learning the temperature history of the concrete. Compensate for changes in field conditions on-the-fly. Save money by assessing cold weather protection to ensure sufficient temparatures for curing without wasted heating. Allows in-place strength determination of critical areas of a structure. Non-destructive, inexpensive and cost-effective. Application of method In practice, the maturity-based test method can be used to 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 degreehours and actual strength, a contractor or transportation agency can use the maturity method 31 January - March 2011
Fig. 10 Reading Maturity Meter Advantages of the test Maturity-based testing can reduce project costs by eliminating the need to cast and test compressive or flexural strength specimens.
Once a strength-maturity relationship is established for a particular concrete, temperature histories can be used to predict the strengths of samples of the same concrete subjected to different temperature conditions. 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 established for a given concrete mix before a specific project begins. Limitations of test There are, however, limitations to using either test Bulletin of ACCE (I)
to open a newly-repaired concrete pavement to traffic without testing a specimen for strength. Maturity testing can provide an alternative to strength testing in determining when a newly built concrete pavement can be opened to traffic. The information obtained from field cured concrete test specimen is used to make the important decisions on To decide when to strip forms, when to post-tension, when to remove shores, and when to terminate cold-weather protection are based on reaching 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-Early Pavement Patches / Main-Line Paving / Saw-Cut Times / Airport /Runways/Taxiways / Driveways / Pre-Cast/ Prestressed / Tilt-Up / Mass Concrete(fig. 11 & fig.12 )/ Cold Weather Concreting / Hot Weather Concreting. Improve concrete quality by learning the temperature history of the concrete. Compensate for changes in field conditions on-the-fly. Reduce Costs and improve performance of concrete by 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.
Compressive strengths of several widely used concrete mixtures have been successfully predicted using a procedure that involves early age deformation monitoring. This methodology allows a fast and accurate prediction of compressive strength on site. Seventy-two hours are sufficient to gather the necessary data and provide accuracy of less than 8% error. It is also an attractive procedure for the determination of the activation energy and the rate constant. More timely knowledge of compressive strength evolution will lead to savings during construction and improve safety.
Fig.11 Monitoring Temps allows earliest cessation of external heating operations
Recognized, recommended and referenced test Methods: 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 & Conclusions Expressing necessity of Maturity test in another way Any time-sensitive placement where knowing the in-place strength would be beneficial for quality, engineering or economic reasons. Bulletin of ACCE (I) 32
Continued on page 48 January - March 2011
WHITETOPPING A CASE STUDY

Dr. 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 construction with the use of innovative materials viz., use of Pozzolana cement from the village Pozzouli near Italy, horse hairs as fibres in concrete, admixtures in their primitive form (like animal fat, milk & blood). These roads, scientifically designed and constructed had a long life and thus lead to the adage all (concrete) roads lead to Rome. Portland Cement Concrete (PCC) overlay on an existing bituminous pavement is commonly known as White topping. The principal purpose of an overlay is either to restore 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 existing pavements which have suffered rutting and deformations, in addition to rectifying other defects such as loss of texture. In our country, bituminous overlays have been popularly constructed in the past mainly due to abundant supply of bitumen, its amenability to stage construction and manageable traffic conditions, in terms of volume and axle loads in addition to the comfort levels of construction methods among engineers. It was also making economic sense to make bituminous pavements as it was relatively cheaper. In recent times all these advantages are reversed viz., petroleum industry is using refined processing technology leading to reduction in the production of bitumen leading to increased imports, favourable cost economics of cement concrete and rapidly changing traffic scenario (in terms of volume as well as axle loads). In addition, rapid developments in concrete material technology and mechanization (both in concrete production & its laying) are favouring concrete overlays as a sustainable option. In recent times PPP (Public-Private Partnership) models are becoming popular in road construction shifting the focus on selection of overlays based on life-cycle costs rather than initial costs. India is currently producing about 240 million tonnes of cement and cement industry is quite matured and equipped to meet the challenges in terms of various grades of cements as well as high quality blended cements suitable for making Pavement Quality Concrete (PQC). Concrete overlays have been used to rehabilitate bituminous pavements since 1918 in USA. There has been a renewed interest in whitetopping, particularly on Thin White Topping (TWT) and Ultra-Thin White Topping (UTWT) over Conventional White Topping. Based on the types of interface provided and the thickness of overlay, classification is as follows: Bulletin of ACCE (I) 33
i)
Conventional White topping which consists of PCC overlay of thickness 200 mm or more, which is designed & constructed without consideration of any bond between existing overlay & underlying bituminous layer (without assuming any composite action). Thin White topping (TWT) which has PCC overlay between 100 200 mm. It is designed either considering bond between overlay & underlying bituminous layer or without consideration of bond. High strength concrete (M 40 or higher) is normally used to take care of flexure requirement. Joints are at shorter spacing of 0.6 to 1.25 m. Ultra-Thin White topping (UTWT) which has PCC overlay of less than 100 mm. Bonding between overlay & underlying bituminous layer is mandatory. To ensure this, the existing layer of bitumen is either milled (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.
ii)
iii)
1.1 Advantages of White topping: i) ii) Reduced thickness due to thickness of overlay remaining constant for over 2 decades. Fast-Track construction making use of innovations in concrete technology & batch mixing, concretes can be designed to have 3 days compressive (& flexural) strength, so as to open the road for traffic within 5 days of construction. Reduced maintenance as the concrete overlays live for over 2 decades, with least maintenance. Cost-effective compared to asphalt overlays when Life Cycle Cost is taken into consideration. Improved service life with better riding quality, improved fuel efficiency of vehicles. Little pre-overlay repairs
iii) iv) v) vi)
vii) Improvement in safety in view of the increased reflection of light particularly on city roads, it would save 24 % less electricity compared to flexible pavements. viii) Reduction in operational costs and lower absorption of solar energy ix) Improving the environmental benefits as concrete roads are much greener and less polluting. In this paper, the case history of a Thin White topping Technology Demonstration Project carried out on a stretch of road was carried out recently is presented. January - March 2011
1. Details of the Project The trial stretch is located on Hosur Road in Bangalore. The details of the existing bituminous road and the other data are as follows: 1 2 3 4 5 6 7 8 9 CBR Commercial vehicles per day Temp differential at Bangalore Thickness of bituminous layer Base (40 mm metal) thickness Road width Length of road Concrete grade Axle load 8 to 10 1000 17.3 deg C 4 to 7 inches 4 to 9 inches 100 feet 350 m M 45 16 T
Milling the existing bituminous surface to obtain a uniform surface. Milling can be used to remove surface distortion like cracks in the top portion and adjust cross slopes. Thickness of milling usually is in the range of 25 to 50 mm. Surface scrapping is carried out on bituminous surfaces which are quite hard. This can be for a depth of 10 mm and carried out with tools which have vertical impact control, so that the sub-grade is not damaged. Chiselling of the surface at regular intervals, if the 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 of filling existing potholes, ruts and wide cracks and also to ensure a level surface for resting the pavement. Profile correction and correction of camber can be carried out together with a thin bituminous leveling course or with dry lean concrete (DLC). a. If the existing road surface is good & only a few localized potholes / cracks e xist, they can be repaired with a bituminous mix before concreting is done. If potholes/ cracks are wider than 3 mm, they have to be treated with bituminous emulsion, slurry seal after trimming them to shape and cleaning out loose fragments with compressed air. Milling of the existing surface also addresses this problem.
2.1 Design of Pavement and Concrete Mix Design of the overlay was carried out using Westergaards Equation and warping stress as per IRC:58 -2002 and IRC: SP: 76 2008. Total stress (including temperature stress) was obtained as 30.83 Kg/cm2 and corresponding flexural strength requirement was 4.7 MPa. Design was done by M/s L.R. Kadiyali & Associates, New Delhi. Thickness of white topping was 150 mm. Concrete mix design was arrived at by evaluating trial mixes and the design mix was arrived at with a cement content of 430 kgs, fly ash 30 kgs, with a w/c ratio of 0.283, achieving a slump of 40 60 mm at site. 2.2 Details of Construction In order to achieve the desired advantages of concrete roads, three essential conditions need to be satisfied. i) ii) iii) Production of concrete in a RMC plant or in a dedicated batching plant. Using either fixed form or slip form mechanical pavers Strict quality control at site including testing of fresh, hardened and extracted specimens of concrete and tests on pavement quality. iii)
b.
In this project design and production of concrete was carried out by UltraTech RMC; Fixed form paver provided by M/s Allen Buildwell Pvt Ltd., was used. Quality control at site and testing were jointly done by the Technical Services team of UltraTech and M/s Civil Aid Technoclinic (P) Ltd., Bangalore. 2.3 Salient features of construction i) Surface preparation: In case of TWT, bond between PCC overlay & existing bituminous pavement is atleast partly desirable; in case of UTWT, effective bond is essential. To ensure this any of the following method can be adopted. iv)
Laying of PQC is quite similar to the construction of new concrete pavement. As mentioned earlier, concrete should be made either in an RMC or in a weigh batching plant. Use of either fixed form pavers or slip form paver machines is an essential ingredient for getting a good quality pavement. In the current project, a fixe form paver was used with a fixed side formwork (steel channel box section) with 16mm diameter steel rods of 1 m length as tie rods @ 500mm c/c) and the paver had gang mounted vibrators equally spaced with variable rpm and three integral steel tubes with 8 Tonnes vibratory rollers for screeding, levelling, compaction and finishing. Finishing of the surface is mostly achieved by the paver itself. But to achieve uniform finish, a simple hand operated bull float is used when concrete is still in its fresh state. After the bull float operation, uniform surface texture is provided by using steel wire brush. January - March 2011
34
v)
To avoid evaporation of surface water from concrete surface (which leads to plastic shrinkage cracks), wax based curing compound is sprayed. As an additional measure, plastic sheets are spread over the pavement surface till normal curing process starts. Contraction joints are provided by cutting groves (for a depth of one-third of the depth of white topping, 150 mm in this case) at a spacing of 1.2 m in longitudinal as well as transverse directions. The joints are cut using electrical grove machines within about 8 to 10 hours of pouring concrete. These joints are sealed with high quality sealant (either bitumen or poly sulphides) to prevent moisture and incompressible infiltration into the overlay system.
vi)
Bull float operation to smoothen surface
vii) To ensure effective load transfer across the longitudinal segments as well as transverse construction joints, tie bars and dowel bars are provided.
Surface texturing with wire brush
Surface preparation and alignment of rails for paver
Groove cutting
Paver machine in operation Bulletin of ACCE (I) 35
Low slump of PQC January - March 2011
1. Evaluation of quality Strict quality control not only during mix design and production of concrete, but also testing for quality at regular intervals (for every 50 cum of concrete) was carried out. These tests included: Tests conducted on fresh concrete (slump test at site) Tests on hardened state (compressive strength of cube & cylinder specimens for 1, 3, 7 & 28 days), split tensile strength, flexural strength of concrete beams Fatigue and abrasion tests on pavement quality (results awaited). Test on extracted specimens of concrete (core tests) would be conducted to assess the long term performance of concrete. All the above tests are conducted by Civil Aid Technoclinic (P) Ltd., Bangalore and the results obtained so far are tabulated. The road was opened for traffic after 5 days of curing.
Compressive Strength of Concrete Cubes (Total no. of samples 936) Sample size One-day strength (MPa) Max: 24.1 Min: 21.1 Avg: 22.05 3-day strength (MPa) Max: 48.2 Min: 38.4 Avg: 43.2 7-day strength (MPa) Max: 55.2 Min: 48.4 Avg: 51.02 28 day strength (MPa) Max: 67.2 Min: 57.4 Avg: 61.8
The test results clearly show that the compressive & more importantly the flexural strength of concrete is much beyond the design requirement. In case of normal concrete structures, cube/beam test results are higher than the structural strength as compaction and curing are carried out as per the codal requirement. In this case, since mechanical pavers were used with high degree of vibro-compaction followed by use of self curing compounds and plastic sheet covering, the structural strength of pavement is higher than the cube/ beam test results. 1. Conclusions: Due to advances in the area of mechanization and fast track construction, concrete roads and white topping provide a sustainable as well as cost effective option for pavement construction. This technology demonstration project in Bangalore has evoked positive response from people across the spectrum viz., technical consultants, construction industry, academic & research institutions. The Government of Karnataka, BBMP and other civic agencies have come forward to adopt this technology. On behalf of the cement industry, CMA (Cement Manufacturers Association) has come forward to assist all those involved in the construction on concrete roads/ white topping by way of several useful publications, userfriendly software for analysis, design and estimation of quantities (and comparative cost), conducting training programs for engineers and providing the necessary technical assistance. References: 1. Cement Manufacturers Association, Concrete Overlays White topping of roads, 2010 2. Cement Manufacturers Association, Handbook on Cement Concrete Roads, 2010 3. IRC: SP: 76 2008, Tentative guidelines for conventional, thin and Ultra-thin white topping, The Indian Roads Congress, New Delhi, 2008 4. Michael E. Ayers & Dale Harrington, Selection and use of concrete overlays, The Indian Concrete Journal, May 2010 5. National Concrete Pavement Technology Centre, USA, Guide to Concrete Overlays Sustainable solutions for resurfacing and rehabilitating existing pavements, Sept. 2008.
60 cubes per test
Compressive Strength of Concrete Cylinders (Total no. of samples 60) No. Sample size 60 per test 28 day strength (MPa) Max: 61.4 Min: 43.7 Avg: 52.45
Flexural Strength of Concrete Cylinders (Total no. of samples 60) No. Sample size 60 per test 28 day strength (MPa) Max: 7.35 Min: 6.2 Avg: 6.3
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36 January - March 2011
Split Tensile Strength of Concrete Cylinders (Total no. of samples 60) No. Sample size 60 per test 28 day strength (MPa) Max: 4.01 Min: 2.92 Avg: 3.36
An Experimental study on Carbonation of Concrete under accelerated carbonation

T. Chandrasekaraiah, K.V. Manjunatha, Dr. M. N. Hegde and Dr. K. Shantharaju
Faculty of Civil Engineering, Dr. Ambedkar Institute of Technology, Bangalore-560 056
Introduction: Deterioration of RC Structures is directly related to deterioration of materials i.e. concrete and steel in its members. Degradation of concrete is related to its durability aspect and that of reinforcing steel to its corrosion. For the condition assessment of RC structure, one has to have a thorough knowledge of the various causes of deterioration and their effects on materials. It is necessary to separate the causes of degradation of concrete and steel though they are occurring simultaneously in structural members. The Durability is a major concern for concrete structures exposed to aggressive environments. Carbonation is one of the major factors to cause structure deterioration. Carbonation is the reaction of the hydration products dissolved in the pore water with the carbon dioxide in the air which reduces the pH of concrete pore solution. Carbonation reduces pH value and destroys the passive film around the steel, but it seems to densify concrete surface and reduce chloride ion permeability, reduce surface porosity and hence sorptivity in concrete (Leber and Blakey, 1956, Dias, 2000). Carbonation could have both positive and negative effects on concrete durability. Glass et al, (1991) pointed out that the presence of even a small amount of chloride in carbonated concrete enhances the corrosion rate resulted from carbonation of concrete. The study of the durability of concrete structures needs a multidisciplinary approach based on the physics and chemistry of the materials. In particular the durability depends both on the ability of concrete to resist the penetration of aggressive substances from the environment, and on its ability to protect embedded steel reinforcement. The transport of aggressive species may follow different mechanisms, depending on the pore structure of the concrete, the exposure conditions and characteristics of the diffusing substances. The penetration of carbon dioxide or oxygen, as well as of many other gaseous substances, may occur only if the pores of concrete are almost dry, while the diffusion of chloride or sulphate ions takes place only in water. Therefore all these mechanisms should be studied together with evolution of moisture content inside the concrete. One of the processes which takes place in the pores of concrete and which may limit the service life of reinforced concrete structures is the carbonation of material, i.e., the chemical process denoting the reaction of calcium hydroxide with carbon dioxide resulting in the formation of calcium carbonate and water. The main consequence of carbonation is the drop of the Bulletin of ACCE (I) 37
pH value of the pore solution of concrete from the standard values between 12.5 and 13.5, to a value of about 8.3 in the fully carbonated zones, so that the passive layer that usually covers and protects the reinforcing steel against corrosion becomes no longer stable, Anna et al, (1993). The basic factor influencing carbonation is the diffusivity of the hardened cement paste. Carbonation rate is controlled by the ingress of CO2 into concrete pore system by diffusion with a concentration gradient of CO2 acting as the driving force. Factors affecting diffusion rate include the type and amount of cement, porosity of the material, time of curing, type and quantity of pozzolanic additions. Moreover, several mechanical properties of concrete such as compressive strength, surface hardness, and resistance to aggressive agents may change due to carbonation. Corrosion of steel bars embedded in concrete is a worldwide problem that affects numerous Reinforced Concrete (RC) structures. Theoretical models have also been developed and calibrated with experimental results to predict the behaviour of concrete structures with corroding steel bars as well as their service lives. The majority of works reported on corrosion of structures in the absence of a sustained load, which is not true. In reality corrosion process occurs under sustained load.
The mechanism of corrosion, effects of corrosion on concrete structures, measure to control corrosion, and effectiveness of repair and strengthening of corroded structures Solev and Richardson, (2008). Theoretical models have also been developed and calibrated with experimental results to predict the behaviour of concrete structures with corroding steel bars as well as their service lives (Vidal et al, 2004, Li et al, 2006). Tarek Mohammed et al (1999) studied the orientation of steel bars (main steel and stirrups) in concrete during corrosion process. Orientation of steel bars has significant influence on macrocell and microcell corrosion of steel bars in concrete. It was observed that deformed bars corroded more than the plain bar. Formation of gaps under horizontal steels causes significant corrosion. Water cement ratio has a significant influence on corrosion of steel in concrete. Goitseone Malumbela et al (2009) reviewed previous studies carried out to investigate the effects of simultaneous load and steel corrosion, on the rates of corrosion and behaviour of RC structures. Corrosion under load was found to significantly increase deflection of specimens. There was no gain in stiffness during corrosion process under service load, which is often observed at early carrion stages on structures corroded in the absence of a sustained load (Solev and Richardson, (2008), Li et al, (2006)). Newlands et al, (2002), formulated a probabilistic analysis using a selection of published deterministic models pertaining to long term carbonation of concrete. The outcome of the probabilistic analysis determined the minimum concrete requirements to resist the progress of carbonation and subsequent carbonation inducedcorrosion for a minimum period of 50 years. Ali et al, (2000), introduced both deterministic and stochastic modelling of concrete carbonation front depth such as Monte Carlo Simulation method. In the present study, concrete cube specimens are exposed to carbon dioxide in the carbonation chamber. The effect of carbonation of concrete on compressive strength, CO2 concentration, curing periods, and duration of carbonation have been studied and reported. Carbonation process Carbonation is a neutralizing procedure in which gases such as carbon dioxide (CO2) in the atmosphere react with calcium hydroxide, Ca (OH)2 dissolved in the concrete pore water, producing calcium carbonate, CaCO3 and water, H2O. In addition, hydrated calcium silicate (CSH), unhydrated tri-calcium silicate (C3S) and bicalcium silicate (C3S) consume carbon dioxide as well. Carbonation changes the chemical composition and the microstructure of the concrete, thereby obviously affecting its chemical and mechanical properties. Carbonation is a very complex physical-chemical procedure where Bulletin of ACCE (I) 38
carbon dioxide penetrates, diffuses and reacts from surface to inside the concrete. The primary reactions are:
Partial destructive testing systems Partial destructive testing system (PDTS) serves as a good support for any field investigation. These methods are well established and enable visual inspection of the interior regions of a member to be coupled with strength estimation. Other physical properties that can be measured include density, water absorption and indirect tensile testing. The tested material and specimen samples are frequently used as a sample for chemical analysis. Following are the general partial destructive testing system (PDTS) usually preferred Core sampling and testing Penetration resistance test Pull-off resistance test Using the above methods, the extent of deterioration and the strength potential of concrete in the existing RC structures, cement content and water cement ratio can be evaluated. The voids and relative density, variation of compressive strength of concrete in the structure with respect to ultrasonic pulse velocity (UPV) values is given in Table 1. Experimental programme The different grades of concrete cubes with different water cement ratios were cast. The test specimens were pond cured for 7, 14 and 28 days. The concrete cubes, RC beams and slabs were exposed to carbon dioxide of three intensities (25%, 50% and 75%) in the carbonation chamber. The intensity of carbon dioxide in the carbonation chamber is monitored at regular interval of 1 hour. Testing of cube specimens for compressive strength was carried out on a compression-testing machine (CTM1000KN). The least count of the compression-testing machine is 100N. The compressive strength of each curing period (7, 14 and 28 days) for all the mix proportions was an average of three cubes. The strength of concrete cubes and porosity of concrete are evaluated for three grades of concrete M15, M20 and M25 with varying water-cement ratios 0.40, 0.50, and 0.60. The depth of carbonation of concrete is established using core samples removed from carbonated concrete cubes. Non-destructive testing such as ultrasonic pulse velocity and rebound hammer tests have been carried out for finding the quality and strength of January - March 2011
concrete. The effect on compressive strength of concrete, cement content, and curing period on carbonation and cover thickness and intensity of carbon dioxide on corrosion of reinforcement embedded in concrete have been studied. Porosity of concrete: The concrete porosity is one of the major factors affecting the durability of concrete. The porosity depends on the proportions of the ingredients and the construction practices. The porosity of concrete is established by knowing the dry weight of concrete cubes and wet weight of concrete cube i.e. the cubes immersed in water for twenty-four hours. The difference in dry weight and wet weight gives the weight of water penetrated into the concrete and the pores available in the concrete. Carbonation of concrete: The concrete cube specimens were exposed to carbon dioxide in the carbonation chamber for different durations with varying intensity of carbon dioxide. The intensity of carbon dioxide in the carbonation chamber is monitored using gas analyzer at regular interval. The carbonation chamber with suitable housing arrangements for concrete cubes is shown in Fig 2. The carbon dioxide is supplied to the carbonation chamber by burning rice husk ash and other waste materials. Concrete cubes are exposed to carbon dioxide for known duration in the carbonation chamber. Figures 2 & 3 depict the carbonation chamber and staging for housing specimens. The depth of carbonation is established by removing the cores from the carbonated concrete cubes at the center of the specimen and phenaphalene solution is applied on the core samples, the carbonated part of the concrete is found to be colourless. On the other hand the uncarbonated concrete shows the pink colours of the phenaphalene. The depth of carbonation is measured from the surface of the core sample. Bulletin of ACCE (I) 39
Testing: The portable ultrasonic nondestructive instrument for testing (PUNDIT) is used for establishing the quality and compressive strength of concrete cubes. Then these specimens of same batch were also subjected to destruction under compression for compressive strength of concrete. Gas analyzer is used for establishing the intensity of carbon dioxide in the carbonation chamber. The availability of oxygen in the carbonation chamber is also measured. The intensity of carbon dioxide is regulated to simulate the condition created by air pollution due to industrial gases, exhaust of locomotives and induction of carbon dioxide into atmosphere. Probability of corrosion of rebars embedded in concrete due to carbonation is established using CORMAP. The potential difference developed between the anode and cathode in the rebars embedded in concrete indicates the probability of corrosion. When the potential difference is 330mV and more the probability of corrosion is positive. The variation of carbonation with respect to different parameter is discussed here. The depth of carbonation is established by the application of phenolphthalein January - March 2011
solution on the core samples removed from the carbonated specimens. The carbonated surface becomes colourless after the application of phenolphthalein and uncarbonated surface is pink in colour. The temperature largely affects diffusion of gases and water; in the present investigation laboratory temperature of 27C is considered and kept 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 of concrete are studied. Discussion on Experimental results Effect of water / cement ratio on carbonation of concrete Water / cement ratio is one of the important factors affecting the carbonation process in concrete. The w/c ratio generally determines the gel/space ratio, the capillary porosity and hence the permeability of concrete. As the water /cement ratio is more water is trapped inside the concrete and with the process of hydration of cement water evaporates leaving small pockets in concrete. If these pores are interconnected they cause a big problem, it is through these pores carbon dioxide can diffuse and destroy the passive layer of the steel. It is observed that the depth of carbonation increases 9.5mm to 12mm and 13.75 as the water cement ratio increases from 0.4 to 0.6 with 150 hours of carbonation for M15 concrete. Figures 4 to 6 show the effect of water content in concrete on depth of carbonation of concrete. It is observed that the depth of carbonation increase nonlinearly with increase in water content in concrete. It is observed that the depth of carbonation increase non-linearly with increase in water content in concrete.
Effect of curing period on carbonation of concrete As the hydration reaction takes place in concrete, and it is an exothermic reaction, energy is evolved in the form of heat, due to this cracking occurs which makes pores in concrete thereby decreasing the strength of the concrete to counter act his process curing of concrete is required. Concrete specimens are pond cured for 7, 14 and 28 days. It is observed form Figures 7 to 9 that the strength of concrete increases with curing periods. The permeability of concrete reduces as the curing period increases. Figures 7 to 9 show the variation of carbonation with curing period for M15 concrete, M20 concrete and M25 concrete. As the curing period decreases form
40
28 to 14 and 7 days the depth of carbonation increases from 9.50mm to 12mm and 13.5mm respectively for 150 hours of carbonation. The same trends are observed with M20 and M25 concrete with different curing periods irrespective of the intensity of carbon dioxide.
Effect of compressive strength of concrete on carbonation Durability factors mainly depend on the strength of concrete and the strength of concrete depends on the mix proportions, water cement ratio, cement content in the concrete and degree of compaction and curing type and period. The porosity of concrete gets reduced with increase in compressive strength of concrete and the depth of carbonation decreases as the strength of concrete increases. Depth of carbonation is reduced from 9.5mm to 8.75mm and 7.00mm with concretes of grade M15, M20 and M25 respectively with water cement ratio 0.4 for 28 days cured specimens. Depth of carbonation is reduced from 12mm to 8.75mm and 7.50mm with concretes of grade M15, M20 and M25 respectively with water cement ratio 0.5 for 28 days cured specimens. Depth of carbonation is reduced from 13.mm to 9.75mm and 9.25mm with concretes of grade M15, M20 and M25 respectively with water cement ratio 0.6 for 28 days cured specimens. The reduction in depth of carbonation is observed with increase in compressive strength of concrete for all the intensities of carbon dioxide in the carbonation chamber. Figures 10 and 11 represent the variation of depth of carbonation with strength of concrete. The reduction in carbonation of concrete is non linear.
41
Effect of porosity of concrete on carbonation The porosity of concrete increases the ingress of aggressive gases and solution into the concrete. It is the turtocity of concrete, which depends on the porosity of concrete. It is observed that the average porosity of concrete in the present study varied form 0.75 to 2.75 based on the water absorption test. The total porosity of concrete is the sum of weight gained in absorption test and moisture in capillary pores. Figs. 12 to 14 represent the porosity of M15, M20 and M25 concrete with different curing period and water cement ratio. It is observed that the porosity of concrete increases with increase water content and with reduced curing periods. For all the mix proportions, M15, M20 and M25, the porosity of concrete is more for 7 days of curing period compare to other curing periods. It is clear from Figures 12 to 14 depth of carbonation is more for 7 days cured specimens; this is due to presence of more pores and interlinking of pores in the concrete.
Effect of CO2 concentration on carbonation of concrete The amount of CO2 present in the atmosphere is of the order 0.03%. The level of CO2 in the industrial areas and urban area are higher due to release of carbon dioxide from the industries and the exhaust gases from the locomotives. The carbon dioxide into the carbonation chamber of size 6x 6 x 6 is supplied by burning rice husk ash and other waste materials. The intensity of carbon dioxide in the carbonation chamber by volume is measured with the gas analyzer. The intensity of carbon dioxide 25%, 50% and 75% is used in the present investigation. The depth of carbonation increases with increase in CO2 content, the depth of carbonation increased from 12.00mm to 18.00mm and 19.75mm respectively with 25%, 50% and 75% of CO2 content for M15 concrete with water cement ratio 0.5. The depth of carbonation increased from 9.75mm to 19.00mm and 23.25mm respectively with 25%, 50% and 75% of CO2 content for M20 concrete with water cement ratio 0.6. The depth of carbonation increased from 7.75mm to 11.00mm and 13.25mm respectively with 25%, 50% and 75% of CO2 content for M25 concrete with water cement ratio 0.4. Figures 15 to 17 respectively represent the variation of carbonation of concrete with intensities of carbon dioxide 25%, 50% and 75% for M15 concrete with varying water cement ratio exposure time 150hrs. Figures 15 to 17 depict the variation of carbonation with carbon dioxide intensities for concrete of mix proportions M15, M20 and M25. It is observed that the depth of carbonation increases nonlinearly with increase in carbon dioxide content in the carbonation chamber. The depth of carbonation increases 2 to 3 times, to that of depth of carbonation with 25% of CO2 as the intensity of CO2 increases respectively to 50% and 75%. The rate of carbonation increases with increase in CO2 content.
42
Effect of duration of carbonation The concrete specimens are carbonated in the carbonation chamber and durations of carbonation 90hours, 120hours and 150hours are adopted in the present investigation. The depth of carbonation increases asymptotically as the duration of carbonation increases. It is observed that the depth of carbonation increased from 5.25mm to 7.00mm and 9.50mm, 7.00mm to 9.75mm and 12.00mm and 8.25mm to 10.5mm and 13mm respectively for 28days, 14 days and 7 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 cement ratios and duration of carbonation periods. It is observed from above Figures 18 to 20 that depth of carbonation increases non-linearly with increase in carbonation period. It is also noticed that depth of carbonation increases by 25 Bulletin of ACCE (I) 43 January - March 2011
% to 55% and 90% to 120% when the duration of carbonation is respectively increased from 90 hours to 120 hours and 150 hours. The same trend is observed for all other grades of concrete also, i.e., the depth of carbonation increases with increase in duration of carbonation. Diffusion coefficient of CO2 in hardened concrete It is observed that the diffusion coefficient of CO2 reduces with increase in compressive strength of concrete and increases with increase in water cement ratio. Figure 4.55 shows the increase in diffusion coefficient of CO2 with water cement ratio. The depth of penetration of carbon dioxide increases with increase in diffusion coefficient of CO2. The diffusion coefficient of CO2 increases by 10% to 15% when the water cement ratio is increased from 0.4 to 0.5 and 0.6 respectively to that of diffusion coefficient of CO2 with water cement ratio 0.4. It is also observed that, this small increase in diffusion coefficient of CO2 with increase in water cement ratio results in greater increase in depth of carbonation of concrete for all the mix proportions. The diffusion coefficient of CO2 decreases with increase in curing period. Figures 21 and 22 indicate the reduction in diffusion coefficient of CO2 with curing period for concrete M15, M20 and M25. With availability of moisture content during curing the formation of pores and cracks due to heat of hydration of cement is reduced. It is also observed that the depth of carbonation reduces with curing period for all the mix proportions.
Conclusions: The following conclusions are deduced from the experimental results: (i) The carbonation depth increases with an increase in exposure time and higher CO2 concentration results in higher carbonation depth for all mixtures. (ii) The compressive strength and splitting tensile strength of carbonated concrete at the age of 28 days are slightly higher than those of concrete without carbonation. (iii) The electrical resistivity of concrete increases with an increase in exposure time and the amount of charge passed significantly decreases with an increase in carbonation depth. However, carbonation of concrete enhances the rate of corrosion of reinforcement from the electrochemical corrosion test results. Acknowledgements: All India Council for Technical Education (AICTE), New Delhi (File No. 8021/RID/NPROJ/TAP-71/2002-03) provided financial support to this research. We are grateful for the financial support from AICTE, New Delhi and logistic support from Dr. Ambedkar Institute of Technology, Bangalore-560 056.
VERY IMPORTANT
We are updating our members database. Please furnish your complete contact details including your postal address, phone no., mobile no. and e-mail ID (must) to admin@accehq.net on or before 30th June 2011 - Secretary General
Bulletin of ACCE (I) 44 January - March 2011
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45
News from ACCE(I) Head Quarters

Association of Consulting Civil Engineers (India) Head Quarters organising the technical Evening Lecture on 22nd February 2011 at Century Club, Bangalore in association with Indian Institute of Bridge Engineers (IIBE), Indian Concrete 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 deliver the lecture on Eugene Freyssinet, His incredible Journey to Invent and Revolutionize prestressed Concrete Construction. Dr. C S Viswanatha, Chairman Task Force for quality Assurance in Public Construction Govt. of Karnataka, 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 Construction company Ltd., will be the guests of honour. Mr. Avinash D Shirode, President ACCE (I) preside over the function. In this occasion ACCE (I) felicitated Mr. C R Alimchandani. Dr. M N Hegde, Secretary give the vote of thanks. More than 300 members attended the above programme. This programme was sponsored by Natarajan Construction Company Limited.
News from ACCE(I) Centres

BANGALORE CENTRE
Association of Consulting Civil Engineers (India), Bangalore Center organising the technical Evening Lecture Jointly with Bangalore Institute of Technology (BIT) & UltraTech Cement Limited on Developments in New Construction Materials by Dr. Ramakrishnan & Recent Fiber Reinforced Concrete Constructions by Cliff MacDonald on Saturday, 29th January 2011 at 06.00 PM at Bangalore Institute of Technology (BIT), Seminar Hall, 2nd Floor, K R Road, V V Puram, Bangalore560004. Dr. Manamohan R Kalgal, Senior Vice President (Technical) UltraTech Cement Limited will be the Chief Guest, 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 150 members participated in the above lecture. This programme was sponsored by UltraTech Cements Ltd., 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 concrete Roads. Life Time achiever award to Engineer K. N. Alva. THE TECHNICAL TALK AND PRESENTATION on the topic of Flow guard- Lubrizol is shared by Mr.Sanjay Durani, on 2nd February 2011 at Hotel Ocean Pearl, Mangalore. Large number of our members were present. THE TECHNICAL TALK AND PRESENTATION on the topic of Durability of Concrete for sustainable Development is given by professor M.V.Shetty. on 23rd February 2011 at Hotel Ocean Pearl, Mangalore. It was well attended by our members and also had the lively interaction. THE TECHNICAL TALK on Hindcon Chemicals held on 26-02-2011 by to company experts. THE TECHNICAL TALK AND PRESENTATION on the topic of Green BuildingEnvironment friendly Design.. by Ar. Venkatsh Pai, Architect,was arranged on 8 th March 2011 at Hotel Maya International Mangalore. The concept of Green Building was nicely presented by the chief guest. For the first time in the history of Mangalore centre a week long program Engineers week is arranged from 19/03/2011 to 26/03/2011. Inaugural Function of Engineers week was held at Ocean Pearl and Dr. Sandeep Sanchiti director NITK Surathkal was inaugurator of the function. Er. Balakrishna SE PWD Mangalore circal was the chief guest. Sri. Varadarajan ( Chief fire officer). Gave a talk on fire precautionary measures. 46 January - March 2011
MANGALORE CENTRE
A.C.C.E.(I) MANGALORE - ULTRA TECH MANGALORE- AWARD FUNCTION held on 28th January 2011 at Loyola Hall, St. Aloysius Campus Mangalore. The Award function was well attended by more than 500 delegates. Dr. Shantharam Shetty, Vice chancellor Nitte University was the Chief Guest. Er. Dr. Ashwath Secretary General was the guest of the owner. 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 Vishnu Mayya, Secretary ACCE(I), Mangalore Centre were present. The members of Mangalore Centre attended in large numbers. In the beautiful function with the entertainment and messages from dignitaries the following awards have been given under different categories. Best Residential Villa (Udupi District) - Parampara Residence of Swapna Ganesh, Udupi. Bulletin of ACCE (I)
Association members have arranged a picnic to Pilikula. Members forgetting their profession for a day enjoy the panoramic scenery of Pilikula and participated in the games, fellowship etc. Students Seminar was conducted at PA Engineering College and BI Technology. Students Seminar was conducted at Srinivas Engineering College and Alvas Engineering College. Students Seminar was conducted at Bantwala Polytechnic, Vivekananda College, K.V.G Engineering College, Sahyadri Engineering College and Nitte Engineering College. Site Masons Training and Students Seminar was conducted at Karnataka Polytechnic. Site Supervisors Training, Students Seminar and Engineers Seminar was conducted at Karnataka Polytechnic, N.I.T.K Surathkal and P.W.D Superintending Engineer Office Hall Mangalore. Apart from the above activities, the Managing Committee meetings are held in the 1st week of every month discussing the various aspects including membership growth, future programs etc.
2x300 MW thermal power plant of Reliance Industries at Vidarbha Industries Power Ltd. Butibori. Out of the two chimneys, one was already constructed and other was under construction. The members keen interest in the slip form construction technique and even went upto 70m height where actual concreting was going on. The Project Manager Mr.Nimkar explained in detail the methodology and technicalities of the construction. The members also visited the quality control and testing laboratory. The strict quality control followed by VIPL and their results were greatly appreciated by all the members. Overall it was a marvelous and highly technical visit and well enjoyed by all the members. About 20 members gathered for the visit. Prominent among the visitors were Mr.Dungaji from Stewols India, Mr. Navin Chandak, Mr. Abhay Siralkar, Mr. Matte etc. Mr. Shri. S.V.Slapekar chairman proposed formal vote of thanks to all the staff of VIPL and members. on 05.03.2011, First city is the talk of town since last 3 years not only because of its big township but also because of the technology being used for the construction. There are five towers each of 13 storey are proposed in environment friendly manner. One of the tower reached up to 12 storey height, ACCE thought to grab the opportunity and visit the site along with the members. Befitting to the project scale, we at ACCE received great response for the visit, around 25 members joined for the event. The project is of 1832 flats ranging from 1 BHK to 5 BHK. All the walls of the building are RCC walls, the entire shuttering (including for walls) is of Aluminum. The detachable fixed size mould of the walls is shifted to above heights for further construction called as MIVAN technique. This process not only expedite the construction activity but also makes the structure strong and earthquake resistant (shear wall being all around).Mr Arvind Ladhe, the Project Manager has explained all the minute technical details of the project where as Ms Sonalika Adyalkar explained the marketing policies of the promoters. The promoters claim that there are many things which are being implemented for the first time in central India , which suits the title FIRST CITY, few of them are the above explained Malaysian Shuttering technology , The green concept of Design, the Freshness arising out of comfortable distance between two towers, the Podium , the two level parking etc. The targeted completion date for the project is Dec 2012, and in spite of global recession, the project is running just 3 months behind the schedule said Mr Ladhe. Around 50% of the flats are booked till date. The visit ended with the vote of thanks and commitment to extend the technical support to the project by ACCE members. 47 January - March 2011
NAGPUR CENTRE
A evening lecture on program OPPORTUNITIES IN PRECAST CONCRETE - A South African Experience was organized by ACCE Nagpur on 12.02.11. The Chairman Shri.Satish Salpekar explained to the audience the exhaustive use of precast products he experienced during his South Africa visit. All the medians, compound walls, storm and sewer chambers, tree planters etc. were pre cast in factories and installed ready-to-use stage in the fields. Even readymade toilets and septic tanks were also used excessively in low cost mass housing projects. He gave an exhaustive presentation on their manufacturing process and installation. He also highlighted some of his personal experiments in precast in Nagpur. The program was well attended by ACCE as well as IIA members. There was lot of interaction among the members regarding increasing the use of precast in India. Manufacturer of precast Mr.Ahay Siralkar also added his viewpoint from the commercial aspect of precast structures. More than 50 delegates attended the program. The delegates included Mr.S.S.Doifode, Mr.Madahv Pandit, Ar. Sunil Degwekar, Mr.S.G.Khirwadkar, Mr.Sumant Mundle, Ar.Jiten Shrivastav, Ar.Ranade, Mr.Parag Pandharipande etc. The program ended with formal vote of thanks by Mr. Amol Shingarey past president West ACCE and dinner. A visit was arranged on 29.01.2011 by ACCE Nagpur centre to the construction site of Chimney of the proposed Bulletin of ACCE (I)
ACCE (I) MEMBERSHIP ADDITIONS

ACCE (I) welcomes the following new fellow members, life members, members and associate members. ACCE also congratulates the members who have been upgraded to Life/ Fellow Members and Senior Citizen Fellow Members.
M. No.
2568-OL 2569-OL 2570-F 2571-F 2572-L 2573-M 2574-L 2575-M 2576-L 2577-L 2578-L 2579-L 2580-L 2581-L 2582-L 2583-L 2584-L 2585-L 2586-L 2587-L 2588-L 2589-L 2590-L 2591-L 2592-L 2593-L 2594-L 2595-L 2596-L 2597-L 2598-L 2599-L 2600-L 2601-L 2602-L 2603-L 2604-L 2605-L 2606-L 2607-L 2608-L 2609-M 2610-M 2611-M 2612-A 2613-L 2614-F 2615-F 2616-L 2617-F 2618-F 2619-F 2620-L 2621-L 1401-M 1957-M
Name
Place
ASCENT BUILDERS (INDIA) PVT. LTD. Bangalore INNOTECH ENGINEERING CONSULT PVT LTD Bangalore RAMESH B NANDIGIRI Bangalore AMARNATH R BORAIAH Bangalore MADHAVA RAO N Bangalore BALAJI SINGH B M Bangalore P KRISHNAMOORTHY Chennai Dr. B HEMALATHA Chennai BASAVANTHA N H Davangere SURESH KALLAPPA GOWDA Davangere DEVENDRAPPA E Davangere B MAHADEVAPPA Davangere M S KUMAR Davangere RAJANNA S Davangere GUDRU RAGHU RAM REDDY Hyderabad GEORGE Mangalore MAXIM JEEVAN LOBO Udupi Dist VINOD T DSOUZA Mangalore H C CHINNAGIRI GOWDA Mangalore N VITTOBA Mangalore G P VENKATESHA Mangalore SUDHIR BHANDARKAR BANTWAL Mangalore SURESH B SALIAN Mangalore SHIVANANDA Mangalore SHRIRAMA Mangalore SUJITH S SALIAN Mangalore SURAJ KUMAR A Mangalore MANJUNATHA H B Chickmagaluru PRAVEEN KUMAR Mangalore VASANT G HEGDE Mangalore B PRADEEP RAO Mangalore SADASHIVA K Mangalore P C HASHIR Mangalore P V PRAKASH Surathkal PRAKASH PRABHU B Bantwal PRAKASH ACHAR Mangalore LOKESH Mangalore GANESAN RAMASAMY Mangalore PAVITHRA KUMAR Mangalore NAGARAJ S Mangalore SANDEEP R BOLAR Mangalore PRASHANTH KUMAR M Mangalore EDWIN GONSALVES Mangalore PARAMESHWARA P Bantwal HARIPRASAD Mangalore K PANDIA RAJAN Madurai N SARAVANAKUMAR Mumbai RAHUL VASANT RALEGAONKAR Nagpur ASHISH MORESHWAR CHAPHEKAR Nagpur PRAFULLA VASUDEO ATHALYE Nashik S RAJKUMAR Trichy T THAMIL SELVAN Tirupur DESAI RAMMOHAN Bellary K L N College Of Information Technology Sivagangai Dist. P MUKUND KAMATH VIVEKANDA HEGDE A Mangalore Mangalore
0711-M 0749-M 1302-M 1304-M 1517-M 1714-M 1959-A 2100-M 2102-M 2144-M 2148-M 2216-M 2217-M 2218-M 2220-M 2224-M 2236-M 2237-M 2346-M
UP-GRADATION FROM MEMBER TO LIFE MEMBER M I KHLEEL Mangalore SAMPATH KUMAR SHETTY D Mangalore VINOD SHETTY Mangalore VIMAL KEERTHI JAIN Mangalore DEVENDRA K SHETTY Mangalore LATHISH Mangalore SHIVA PRASAD ACHARYA Mangalore JAGADEESH K ACHARYA Mangalore ATHMA CHARAN J Mangalore K NAVEENCHANDRA SEMITHA Mangalore P SUBRAYA SHARMA Mangalore NAVEEN KUMAR K V Davangere SHIVAKUMAR B E Davangere SHANTHAMURTHY G B Davangere A B RAVI Davangere PRAKASH CHINIWAL Bangalore K S MAHADEV Davangere KOTRESH U R Davangere AUSTIN MIRANDA Mangalore
Continued from page 3
quality work of int4rnational standards. In the last decade, TCPL has spread its operations beyond the Indian borders and taken up assignments in several countries including Germany, Thailand Nepal, Maldives Malaysia, Singapore and Russia, Many of its projects have received national as well as international acclaim for their design and exceptional innovations. The Awards Committee and the Governing Council of ACCE, after stringent verification of the nominees, have decided to confer the ACCE-SIMPLEX AWARD 2010 for Innovative Design of Structures other than industrial structure on 22nd October 2010 at Hyderabad for Innovative Design of Structure for Grade Separator at Mukarba Chowk, Delhi designed by Tandon Consultants Pvt Ltd., New Delhi. Continued from page 32
UP-GRADATION FROM MEMBER TO FELLOW MEMBER
UP-GRADATION FROM LIFE MEMBER TO FELLOW MEMBER 2092-L PREMANAND A Mangalore 1224-L K P MANJUNATH Mangalore
Fig.12 Mass Concrete A Special case involving risk severe damage due to excessive heat buildup 48 January - March 2011
PROFESSIONAL DIRECTORY
DAT ENGINEERS INDIA PVT. LTD.
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Civil, Structural & Geotechnical Engineers, 7/6, II Cross, Palace Cross Road, Bangalore-560 020. Tel: 23366398 (M) 98455 11569 E-mail :macsedes@yahoo.com
B.R. RAMESHA
SEACON - SERVE, Structural, Electrical & Allied Consultancy Services,
18, Ratnavilasa Road, Basavanagudi, Bangalore-4. Tel/fax: 41204459 E-mail : brramesha@rediffmail.com
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Architects, Interior Designers & Structural Engineering Consultants, 40, 1st Floor, New BEL Road, RMV 2nd Stage MSR Nagar, Bangalore - 54. Phone : 91-80-23600909 Fax:91-80-23607255 E-mail : karekar_associates@vsnl.com
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K.N. NARAYANA IYENGAR, Valuers, Arbitration Consultants, Arbitrators,Chartered Engineers 26, Jyothi Mansion, 5th Cross, Malleswaram Circle, Bangalore-560 003. Ph: 41280764/23446027 E-mail: spartanassociates@yahoo.co.in Website : www.valuersbangalore.com, valuers.in
KESHAV & ASSOCIATES

Consultants, Structural Designers Project Managers, Valuers and Quality Managers No. 397, 1st & 3rd Block, 20th Cross, Jayanagar, Bangalore-11 Tel/Fax : 26631725 E-mail: keshav_associates@vsnl.net
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Consulting Engineers West of Chord Road, 633, 2nd Block, 3rd Stage, Basaveswaranagar, Bangalore-560 079. Phone: 23222238/23226576 E-mail: dhwajan@gmail.com / dhwajan@yahoo.com
A. N. PRAKASH CONSTRUCTION PROJECT MANAGEMENT CONSULTANTS PVT. LTD.

Vishwakarma, 491, 2nd Floor, East End Main Road, 9th Block, Jayanagar, Bangalore-560 069 Tel. : 26639780 4 Lines E-mail: prakash@anprakashpmc.com www.anprakashpmc.com
S. RATNAVEL POTENTIAL SERVICE CONSULTANTS (P) LTD.

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M.S. RAMASWAMY
Chartered Engineer, Principal Consultant, M/s M.S.R.Consultants, Heavy Engineering, Design, Architecture in since 1980, Interiors, Project Management & Services Consultants, 15/1, Sir Krishna Rao Road, Basavanagudi, Bangalore- 560 004.. Tel: 91-08-26567675 Fax: :91-80-26569069 E-mail: msrconsultants@rediffmail.com
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49
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.
L BALAJI
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THANKS TO PATRONS
ACCE(I) thanks the following patrons for their generous contributions towards the creation of a Permanent Fund for publishing this Bulletin
ADARSH DEVELOPERS Builders of Aesthetically Designed and Quality, Luxury Apar tments for Modern Living Standard, 10, Vittal Mallya Road, Bangalore-560 001. Tel : 080-41343400 Fax : 080-41343777 Web: www.adarshdevelopers.com E-Mail : adarsh@giasbgol.vsnl.net.in CHAMUNDESHWARI BUILD TECH PVT. LTD. No. 2438, Kumara Krupa, Opp. Bangalore Vihara Kendra, 9th Main, BSK 2nd Stage, Bangalore-560 070. Tel. : 26764974, 26764403/05 Fax : 26762978 E-mail: info@eagletonindia.com EON DESIGNERS Architects, Consulting Engineers & Interior Designers 35-B, Vasavi Colony, Behind Vikrampuri, Secunderabad-15. Tel/Fax : 040-27847847 E-mail : eondes@sify.com HYGRADE STEEL PVT. LTD. Manufacturers, Torkari, A/85, 31st Cross, 7th Main, Jayanagar,Bangalore-560 082. Tel : 26546384 , Fax : 080-26545952 E-mail : nsm456@yahoo.com MADHU INDUSTRIES Manufacturers of Steel Doors & Windows with ISI Mark and UPVC Doors and Windows. No. 30, Pillagaganhalli, Gottigere, Bannerghatta Road, Bangalore - 560 083, Tel : 28429778 / 779, Fax : 28429801 Email : madhuwindows@satyam.net.in 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 : 9845013513 E-mail : nsm456@yahoo.com M/s. NAGARJUNA CONSTRUCTION COMPANY LTD. Nagarjuna Hills, Hyderabad - 500 482 Andhra Pradesh, India. Tel : 22224328, 22226214, Telex : 0425-6914 Grams : Buildwell Nagarjuna-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, 23156076 E-mail : bangalore@nagadi.co.in SBS ASSOCIATES Engineers and Contractors, Class I Contractors in Karnataka PWD 795/E, 3rd Cross, A Main, Vijayanagar, Bangalore - 560 040. Tel. ; (R) 23356839 SHRI B. SUNDARAMURTHY 44/4, 4th Main Road, Malleswaram, Bangalore-560 055. Tel : 23348725 E-mail: moorthy_30@hotmil.com TECHNOART CONSTRUCTIONS PVT. LTD. Mayaventure (P) Ltd. Southend Road, Above Canara Bank, 3 rd Floor, Basavanagudi, Bangalore 560 004. THE DESIGNERS AND BUILDERS H.K. Nanjunda Swamy, Consulting Engineer and Par tner 20/1, II Floor, III Cross, Chikkanna Gardens Road, Shankarapuram. Bangalore - 560 004. Tel : 41127098 Tel/Fax : 26521379 UNITED PRECISION ENGINEERS PVT. LTD. Engineers and Contractors 67, Lavina Cour ts, I Floor, 102, 8th Main, 7th Cross, RMV Extension, , Bangalore - 560 080 Tel/fax : 23612825/23618965 E-mail : cavhydro@yahoo.co.in
S. PARAMESH BABU
CSN Engineers & Contractors, No. 37, 6th Cross Road, Azad Nagar, Bangalore - 560 018. Tel : 26748859, 98868 98746 E-mail : paramesh_csn@rediffmail.com
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ACCE Bulletin highlights innovative bridge design award

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ACCE Bulletin highlights innovative bridge design award

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CMYK

MADRAS CEMENTS LTD.

January - March 2011

ACCE (I) Office Bearers

Bulletin of ACCE (I)

January - March 2011

Wish you a Very HAPPY AKSHAY TRUTIYA 2011.

From the Editorial Desk

From Secretary Generals Desk

ACCE AWARDS 2011 - CALL FOR NOMINATIONS

Chairman, Awards Committee

Bulletin of ACCE (I)

January - March 2011

Bulletin of ACCE (I)

January - March 2011

Bulletin of ACCE (I)

January - March 2011

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

Bulletin of ACCE (I)

January - March 2011

Fig.10 : Le Havre horizontal prestressing of footings

Fig.11 : Le Havre anchorage for horizontal prestressing of footings

Bulletin of ACCE (I)

January - March 2011

Bulletin of ACCE (I)

January - March 2011

Flat jack layout at Abutment

Decentered structure (172 m span) Bulletin of ACCE (I)

Caracas Viaduct (1951-1953) 12

January - March 2011

Roofs can be i) Pre fabricated roof

Bulletin of ACCE (I)

January - March 2011

Fig 5. Brick wall constructed with rat-trap bond technique.

Fig 3 Stabilized Mud block under production.

Fig 6. Brick arches in place of lintels and beams

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

Bulletin of ACCE (I)

Fig 8. Large corbels can replace lintels, arches and beams.

Fig 11 Filler slab ceiling after completion

Fig 9 Cross section of a Ferro cement member

Fig 12 Filler slab ceiling using Mangalore tiles after completion.

Fig 13. Ceiling view of a brick panel roof.

Fig 14 View of a circular brick vault

Bulletin of ACCE (I)

Estimating the Strength of Concrete - Maturity Method

Bulletin of ACCE (I)

Fig. 5 Temperature Sensors & Field Measurements

Procedure for Field Measurements

Bulletin of ACCE (I)

January - March 2011

ACCE (I) Headquarters

3rd Governing Council Meeting held at Bangalore on 7th March 2011

ACCE(I) HQ. counting of ballot papers

play with sections

Quantity calculation made simple

Er. Arshal Azeem Yakhub

CENTRAL MARKETING OFFICE

ZONAL MARKETING OFFICE :

Fig. 8. Maturity Meter

Fig. 9 Measurement on Fresh Concrete

Fig.11 Monitoring Temps allows earliest cessation of external heating operations