construction industry review 11 -2014

March 17-23, 2014 1

Volume 3 l Issue No 11 l March 17-23, 2014 l Price: Rs 100An MMR, Braj Binani Group Publication

State apathy adds pressure to construction, infra sector in Rajasthan

notice calling upon the company to pay a sum of Rs 154.51 crore within 15 days after adjusting Rs 18.51 crore, that is, installments paid up to December 2013.

Clearly, coughing up such huge sum overnight was not possible as the health of the balance sheet of the company does not permit it to do so. One way out was to borrow at a high interest cost which in turn would lead to higher operating cost and pressure on the company’s finances.

“This combined by the fact that the

In the last fortnight, the Rajasthan-based Rs 2,200 crore cement major, Binani Cement Ltd (BCL) has been grappling with the government over issues relating to sales tax.

This issue has escalated beyond the control of the promoters of the company to the extent that the management headed by Braj Binani has been forced to pull down its shutters, and all the units housed at Sirohi have come to a grinding halt.

The real issue began with the imposition of sales tax liability on the

eligible amount. This was mainly due to difference in interpretation by the state government with the company’s understanding towards eligibility of amount of EFCI,” states Joshi pointing to the fact that, “BCL, as a listed entity has to deliver shareholder value, over the last few years, on its part engaged in trying to resolve this issue at various levels.”

What came as a surprise was that in 2008, BCL received a stay from the Rajasthan High Court. Based on the court’s order, BCL continued

company and subsequent freezing of bank accounts by the state government.

“This in a nutshell has crippled the basic working of the company,” explains R S Joshi, President, Corporate Affairs at Binani Cement Ltd, a company which started its activities two decades back in 1993, with a clear vision of providing a platform for the economic upliftment of the people in the Sirohi region. Thus was the beginning of the Binani Group setting up a state-of-the-art, integrated cement plant in Rajasthan.

Interestingly, around that time, the then government of Rajasthan also supported the industry and had announced a host of incentives for industry players to come to train their eyes on the state.

Among the many incentives, the state had announced a sales tax incentive scheme (1989) which allowed businesses to avail certain tax benefits based on their size of investment and their nature.

This was good enough incentive for BCL to come to Rajasthan. A year passed and BCL’s plant continued to operate, produce and sell cement in the country. However of late, there were issues raised under the scheme.

“Under this scheme, the sanctioned amount of eligible f ixed capital investment (EFCI) was incorrectly calculated by the government, which was subsequently enhanced by the company on intervention of Rajasthan Tax Board, Ajmer.

“But still the sanctioned amount was less as compared to the actual

Adverse impact on account of freezing bank accounts

Financial losses: Due to the attachment, the company had lost around Rs 50 crore due to non-selling of cement in the market and other expenses in the current month.

Loss to Govt exchequers: The company is contributing more than Rs 650 crore to the state/Central government exchequers annually. Due to the coercive action taken by the Deptt, it has already resulted in a loss of revenue of Rs 46 crore during Feb’14.

Loss to Railways: The company is paying approximately Rs 300 crore per annum to the Indian Railways for deploying rakes for transportation of cement, clinker, coal, etc. Due to the coercive action, there has been A loss of approx. Rs 25 crore during Feb’14.

Sharp jump in cement prices: Due to total stoppage of cement production, despatch and sale by the company, it resulted in a huge jump in the prices of cement in past few days. The prices of cement have been increased by Rs 60-70 per bag, which has resulted in extra burden of approx Rs 125 crore per month on consumers/the public of Rajasthan. It is expected that the prices may further increase which will be extra burden on consumers/the public of Rajasthan.

Labour & employment problem & remuneration: Due to continuing attachment, there is strong likelihood of loss of skilled persons. It will be very difficult to get skilled manpower, once they will leave the company. To retain the skilled persons, the company had been forced to take help from external sources to pay advances against salary & wages.

It will be panic for the employees/labourers who are totally dependent on the company, as they may feel unsecure and worried about the uncertainty of the job. This may also result in unemployment endangering their livelihood. As the plant is situated in the tribal area, and any unrest of labour may have serious consequences in our plant, which may result in huge losses. It is also against the interest of the public at large.

Loss of Market share: In the state of Rajasthan the company is selling 16% of total consumption in the state, but due to attachment, the company is fast losing its market share. Once the market share is lost, it would be challenging to achieve the same.

Loss of strong dealer network: Due to stoppage for a long period, there is a risk of diversion of established dealers from the company’s network due to their business losses. Once the dealer network is broken, it will be very difficult to get these dealers again and start a new exercise for search of new dealers.

Effect on transportation network: Due to stoppage of despatches, the transportation has been not only adversely affected but there is adverse impact on drivers of around 3,000 trucks associated with the company and also on their families.

Impact of local residents: After installation of the plant, thousands of local people benefitted. But due to coercive action taken by the Deptt, there is adverse impact on the livelihood of more than 5,000 families, indirectly associated with the company.

NPA due to defaults in payments of loan dues: Due to non-receipt of funds for the past few weeks, there has been serious default in respect of some of banks & financial institutions. Due to such defaults, the company will not be able to take further loans from any banks/financial institutions, which will further destroy the financial position of the company.

Defaults in statutory payments: Due to non-availability of funds, the company is not able to pay the statutory taxes and duties, that is, excise duty, service tax, ITDS, VAT, CST and taxes of other states, which have already become due. It will lead to major consequences including invocation of penal provisions.

Defaults in payment of creditors/vendors: Due to continual financial hardships, the company is not able to pay the dues of creditors of more than Rs 150 crore during Feb’14, resulting in reduction of credibility. The company is also not able to make the payment of LCs on due dates.

R S Joshi, President, Corporate Affairs, Binani Cement Ltd

collecting value added tax (VAT) and central sales tax (CST) under the sales tax deferment scheme (introduced in 2006) and withheld the amount as liability in its books till August 2011.

To resolve this issue unilaterally, the company also took a decision to foreclose further availment of the scheme (leaving the balance amount unavailed) and started depositing full VAT to the government from September 2011 onwards.

However, in February 2013, the country’s apex court dismissed the company’s case in favour of the government merely on technical grounds and not on the merits. Equipped with this order, the sales tax department raised demand for payment of Rs 173.02 crore.

“This was the genesis of the cup of woes,” adds Joshi.

In reaction to the demand, BCL made an application as per the RVAT Act, 2003 to the government seeking payment of the amount in 40 equal quarterly interest-free installments. “And in good faith, we started depositing monthly installments of Rs. 1.39 crore to the government from April 2013 onwards. The company had already deposited Rs 18.51 crore till December 2013 and also deposited Rs 1.39 crore in January 2014. The application of the company had remained unresolved till January 2014,” says Joshi.

Subsequent to this, BCL received a notice in January this year for depositing the entire demand amount by February 2, 2014, which was subsequently superseded by another

cement industry had been passing through an extremely difficult financial situation due to poor demand and higher input costs. Due to falling profits, the company was not in a position to pay the entire amount under the de fe rment scheme immediately. The only workable way out is for BCL to keep running and operating the plants, earn and pay in installments,” adds Joshi. The government has not yet given into the company’s request for installment payment, on the other hand it has made matters worse by freezing the bank accounts.

Cement prices rise exorbitantly in North on supply constraints

Cement prices increased across all regions India during February 2014 except the southern region.

While the northern region showed an excessive price increase due to supply constraints, the southern region registered continuance of a huge decline in prices due to high inventory pushing by regional players, according to a research report by ICICIdirect.

While prices in the western, eastern and central regions increased by Rs 10 per bag, Rs 9 per bag and Rs 19 per bag respectively, on month-on-month (MoM) basis, the prices in northern region increased exceptionally by Rs 31 per bag from the last month due to

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Exhibit 2: Cement prices in northern region

Source: Cement dealers, ICICIdirect.com Research

stoppage of supply from Rajasthan plant of Binani Cement, the report said.

Price increase in different cities was anywhere between Rs 20 per bag

and Rs 50 per bag. Price increase at Ludhiana, Gurgaon and Delhi was at Rs 45 per bag, Rs 35 per bag and Rs 20 per bag respectively.

(Contd. on pg 10)

(Contd. on pg 10)

March 17-23, 2014 2

Slip Form Assembly 1. Upper Distribution and

Working Deck

2. Working Deck

3. Hanging Scaffold

4. Radius Screw

5. Screw for adjusting Wall Thickness

6. Screw for adjusting inclination

7. Horizontal Turn Buckles

8. Spider beam

9. Lifting Yoke

10. Slipform Jack – 6 Tonne

11. Jack Road

12. Reinforcement

CONSTRUCTION

This is how Heavy Slipform moves up1. M S Tube Supports 2. M S Sieve Pipe3. Jack Rod4. Jack5. Yokes (Soldiers)6. Yoke Beams

The entire load of slipform is taken by jacks. Jacks climb over the jack rods exactly as a monkey climbs a tree1. Monkey has grip on tree through hands and legs.2. He has left the grip of legs and pushed them up.3. Now he has gripped with legs at higher level.4. Now the hands are loosened and lifted up.5. Now he grips with hands at higher elevation.6. Monkey repeats above steps and climbs up a tree.

Slip Form not only gives us high speed of construction, but also high level of accuracy and ensures complete safety of the structure and people connected

with the project

We rise around 300 mm (one foot) per day in the case of conventional formwork. This way the construction of tall chimneys, silos, cooling towers and other high rise structures will take a very long time and delay the entire project. It will not be safe, too.

Take for instance, in one thermal power station costing Rs 400 crore, the cost of a tall chimney was only Rs 3 crore. We are required to first complete the construction of the chimney and then only other structures near the chimney can be taken up from safety considerations.

Because some stones and other hard materials are likely to fall on workers even after all safety measures are implemented. Therefore we need to complete the work with great speed. That’s where the ‘Slip Form’ technique comes to our rescue.

High accuracy & complete safety

In this technique, a structure rises, say, from two meters a day to nine meters a day, or depending upon the type of structure and other arrangements. Slip Form not only gives us high speed of construction, but also high level of accuracy and ensures complete safety of the structure and people (officers, staff and workers) connected with the project.

The initial investment in Slip Form is no doubt more, but as this can be used again and again, it gives us speed and the cost of labour is less in this system. Also, there are no embedments/tie rods in this system, which is economical in the long run.

The technique is used for concreting of both – high-rise vertical concrete structures like tall chimneys, silos, cooling towers and so on, and also

Slip Form technique for high-rise structures (chimneys)

for horizontal concrete structures like road pavements, canal linings, etc.

It is generally understood as a continuous process of concrete, but in actual practice this is not so. Slip Form slips 20 mm to 30 mm per stroke of the hydraulic pump. The interval of stroke depends upon season and time of the day.

This is best understood as we proceed step by step with the Slip Form assembly. Any construction work requires good planning. Since Slip Form is a continuous process, it requires meticulous planning.

Jack rodsThe jack rods or the climbing rods

(as described in slip form system) must be manufactured from EN-8 steel as they have to be sufficiently sturdy to take the load of the entire slip form assembly. They are like structural members provided in a lift well of a housing complex on which the lift moves up and down.

There are instances where people have used ordinary mild steel rods for jack rods with problems during slipping as discussed later. Again, all jack rods have to be of uniform length of three meters or so. Studs are provided at both ends of the jack rods for the purpose of connecting one rod to the other.

The Seelve Pipe Assembly photo shows the arrangement at the start of concrete by Slip Form from a completed concrete surface. In order to extract jack rods easily at intervals (This is done as jack rods are costly. We mentioned in the introduction that Slip Form system does not have any embedments/tie rods, but the lost jack rods which could not be extracted can be compared to embedments.) from concrete, they are inserted in a one meter long mild steel sleeve pipes which move continuously along with Slip Form assembly, making a blockout all around the jack rod.

At the start of the concrete to ensure block out all around the jack rods (arrangement to ensure concrete does not touch jack rods and cement slurry does not flow in the steel tube) a mild steel tube with a base plate at the bottom with joints sealed with steel grip tapes as shown in the photo is provided.

Slip Form assembly components

The author was project manager on the following two tall chimneys: Multi-flue Wanakbori chimney, constructed between 1983 and 1985, and the first 275 meter tall chimney in India for Trombay Thermal Power Station, Unit-6, constructed between 1986 and 1988. On both the chimneys

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Rod

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d

Sleeve pipe assembly in position.Spacer to reinforcement in position

(wind shields) the interform Slip Form system was used. Refer to the figure of slip form assembly.

Upper Distribution & Working Deck (1) This is a structural steel truss consisting of six N trusses (wing beams as denoted by interform) and total 24 girders (spider beams), 4 girders in-between two N trusses.

The entire Slip Form assembly is hung from this truss. This deck is used to pour concrete and store material – reinforcement, inserts and jack rods.

Working Deck (2) This is for vibrating concrete, operation of hydraulic pump to lift the entire assembly and for operating horizontal turn buckles both inside and outside to change the circumference at different elevations as per the drawing.

In Slip Form there is only one hydraulic pump located at one place which operates all the jacks at a time by the single operator.

We had 6.5 tons jacks, a total of 12 two at every truss location and 24 jacks of 3.5 tons jacks at every spider beam location placed circumferentially. The position of jack rods and the number of jacks are to be provided as per design calculated as per the load.

Hang ing Sca f fo ld (3 ) Th i s is provided to do f in ishing of concrete surface exposed, to pull out reinforcement for any external platforms kept flush with form panels and for curing arrangement.

In Slip Form shutters are plane plates (form panels) which are fixed to form supports and then this assembly is fixed to yokes. In Slip Form we have radius screws (4) for adjusting radius and screws for adjusting inclination (6).

Hoists: Ideally one must provide three hoists -- one for lifting concrete, one for the movement of materials and one exclusively for passengers. In many cases contractors have provided only one hoist for all above jobs. This is extremely an unsafe way of working.

Slipping of Slip Form The reference is made to this topic

in the introduction. Further, the rate of slipping and hence the concreting is so adjusted that the concrete exposed at the trailing end would have attained sufficient strength to support the weight of the concrete hardening above as well as to withstand lateral pressures caused by the wind.

Initial Set: This is an important step in the initial assembly of Slip Form. The entire assembly has to be properly leveled and aligned to the correct position. Inner yokes and outer yokes are positioned according to the dimensions of the structure and given

the required inclination to have the correct dimension and thickness as slip form moves up. This is important to avoid out of round shape and shifting.

Laser Levels: These are must to ensure that the chimney is going absolutely vertical and without any twists. The two chimneys referred above had two working laser levels placed diametrically opposite having a range of 300 meters specially imported.

Many in the construction of high rise structures do not use laser levels and land up with problems. They use heavy plumb bob immersed in a container of oil and land up with problems.

Problems during operationWe experience the fol lowing

problems during slipping operation. The chimney going out of plumb, becoming oval-shaped and twisting. These can be totally avoided by the use of lasers.

Dragging: Concrete sticking to form panels and getting lifted. This must be strictly avoided. Along with science this is a work of art and requires proper mix of concrete and proper judgment of lifting. Both the

chimneys did not have any of the above problems.

Stops: We have to take stops in Slip Form due to bad weather, plant breakdown, power failure or for recovering jack rods. Before stopping, lifting of Slip Form must continue until a stage is reached when concrete will no longer form a bond to the form panels. This stage is normally achieved when 20-25 cm of concrete is still left in the forms.

Advantages Th is i s a sa fe sys tem; no

scaffolding is required. Tall structures are concreted in the shortest possible time. Tall structures can be concreted without any construction joints or with only a few construction joints.

This provides continuous concrete. No cleaning of forms is required. No cover blocks are required to maintain the required cover to the main reinforcement. Manufacturers have provided spacers fixed to form which keep perfect cover.

Reduction up to 47 per cent of the diameter without dismantling any form panels up to 55 per cent without rebuilding the form, which means almost all chimneys can slide in one stage. A wide range for reduction of wall thickness; wall inclination can be continuously changed to fit almost all profiles.

An accurate circular section of the structure at any level during the slip forming is secured automatically. A safe and reliable system for operating is mainly achieved by centrally operated hydraulic pumps.

Precautions to takeSafety: Take up high-rise structures

first in the project. The manufacturer of Slip Form takes all safety precautions. Plant and equipment with total safety consideration. All personnel working in and around the chimney construction premises must wear safety helmets. Persons engaged in work in risky and dangerous zones at different elevations must use safety belts.

(Contd. on pg 10)

March 17-23, 2014 3CONSTRUCTION

Uday Structurals: Technical mastery at its best!

Mumbai-based Uday Structurals & Engineers Pvt Ltd is a well-known scaffolding & formwork manufacturer a n d a s o l u t i o n p r o v i d e r f o r construction projects for more than 20 years. The company manufactures scaffolding systems, formwork systems and special custom- built formworks for special applications or extreme heavy loadings at its state-of-the-art modern manufacturing plant at Tarapur on 1,50,000 sq ft work area.

The sca f fo ld ing sys tems i t manufactures include Cuplock, R ing lock , Wedge lock , Frame, Trestle towers as well as aluminium scaffold towers. The company also manufactures special formwork systems as per project requirements as wel l as modular formworks in steel, aluminium or timber H Beams.

Recently, Uday completed two special projects in Mumbai from design, manufacturing to execution that involved very high level of technical expertise and faultless project execution skills. Both these projects applied technology that was used for the first time in India.

Prop-free staging system for transfer girder slabs at Signia Isle Project, BKC, Mumbai

Due to a i rpor t zone he ight restriction, the high profile project Signia Isle, next to the US Consulate at Bandra Kurla Complex in Mumbai, had to float typical floors of the building on the girder slab of 2.25 m thickness, instead of normal transfer girders that would have been about 5 m deep.

The total area of these girder slabs in the two project buildings -- Signia Isle and Signia Pearl -- is approx. 4,500 sq m. Due to heavy slabs, the conventional staging system would not work as it would have punctured the complete floor below.

Uday designed special prop-free staging system for this project, and executed the same at site with their highly skilled engineers and technicians.

The system involved a totally new techno logy o f anchor ing arrangement as well as bracket system to support the formwork. The flat girder slab had columns placed at nearly 9 m centre, which supported the entire slab and the formwork loads.

This is the first time in the country this technology is used for a slab of such gigantic dimensions. The company has executed several projects of prop-free staging system for the transfer girder slabs, the most notable being the Leela Hotel at Chanakyapuri, New Delhi three years back.

Cantilever scaffolding 60 m high for ATC Tower, Mumbai Airport

Uday undertook a very challenging work of designing and executing scaffolding contract for Mumbai’s newest landmark -- Air Traffic Control Tower (ATC Tower). The scaffold required a canti lever design of 18 m at a height of 60 m, without practically no supports to ensure flawless coating to the structure.

Va r ious op t ions , i nc lud ing motorized gondola, were considered by Larsen & Toubro for the Mumbai Airport project. However, Uday’s proposal was finally considered on

account of fine design, highest safety standards and optimum cost.

L&T had full confidence in the ability of Uday Structurals for this highly challenging task – and Uday delivered 100 per cent results as expected!

Signia Isle Project, BKC, Mumbai

ATC Tower, Mumbai Airport

March 17-23, 2014 4IN PERSON

‘Modern Formwork System has reduced manpower on site’

Bharat Patel , Director, Sales & Marketing, Nav Nirman Formwork Systems Pvt Ltd, tells Dilip Phansalkar about formwork technology and various types of formwork

best Engineered Wood and Project Wood Consultancy to the growing construction industry in India.

Our objective is to expand the original value chain of round timber by way of cut timber and to widen and optimize the application thereof.

With decades of rich experience, Nav Nirman started Project Wood Consultancy, the first in India. We provide consultancy services for the construction industry and other involved in the use of wood products.

Since then, Nav Nirman has moved up the value chain with diverse offerings, challenging projects and acquired impressive clients in both domestic and international market.

Nav Nirman is now the leading manufacturers and exporters of Formwork H-Beams in India.

Nav Nirman has its manufacturing plant located in Hyderabad. We have a ded ica ted R&D team that continuously intergrated the advanced technology changes and

in terms of technology. Today, many challenging projects are carried out in less time with good quality of concrete finish with the advancement of Formwork technology.

There has been sharp decline in the period or amount of time required to cast a slab/column/wall due to the introduction of Climbing Formwork System.

The modern Formwork system has also helped immensely to reduce the manpower on the site which has become challenging to the construction industry after the NREGA scheme.

What are some of the projects you have completed and undertaken?

We have executed many projects across India, some of which being the the Riverside Mall in Chennai, Bengaluru Metro project in Bengaluru, Cyber towers in Hyderabad and many more . Currently we are executing a project of Arogya Soudha in Bengaluru.

What precautions do you take to make Formwork secure, safe and danger-free?

We have started with the Skill Development Programme by which we send our technical team to the site place for two days. They impart training and awareness to the workers on the issues related to handling and maintenance, usage of proper tools, security measures to be taken, etc.

What are the potential dangers when building or removing heavy formwork?

The main aspect of any Formwork involves shuttering and de-shuttering of that Formwork. One must follow the proper and standard procedure for shuttering and de-shuttering of the Formwork. Proper tools and skill manpower should be used to handle this job, otherwise this can result in major accidents and can also destroy construction.

What is formwork in construction and why is it used?

Formwork is the temporary structure used to obtain the permanent structure like slab, column, wall etc. Formwork is used to get concrete pouring done on the structure.

What are the special requirements of scaffolding and formwork when used in projects in hilly regions and vallyes?

Construction in hilly areas always poses a challenge and security threat. Keeping in mind these factors, Climbing Formwork is best s u i t e d for these type of construction as they are handled by machinery, and less manpower is required which reduces the risk of any accidents on the site.

Hyderabad-based Nav Nirman Formwork Systems Pvt Ltd, formerly known as Nav Nirman Beam Technics, was established in 2003 to provide the best engineering wood and Project Wood Consultancy to the growing construction industry.

How you would like to evaluate the track record of your company since its inception?

Nav Nirman was established in 2003 with a vision of providing the

modifications to match international standard.

What technological transformations have come about in the industry in the past five years?

The Formwork industry is still at its nascent stage with the conventional shuttering still holding majority share in the construction industry.

With the entrant of new overseas players in the market, the Formwork has gone into a lot of advancement


A case study of a comprehensive software tool for the design and fabrication of free-form

concrete formwork

High-efficiency concrete formwork technology

The characteristics of concrete make it an ideal material for complex, double-curved structures. However, the state-of-the-art in free-form formwork fabrication still consists of labour- intensive or wasteful technologies.

The research project presented here addresses the increasing use of free-form geometry in architectural design and proposes a completely waste-less fabrication method of formwork for free-form, cast-on-site concrete structures.

The process consists of wax formwork e lements, cast on a robotically controlled adjustable mold, which can be assembled on site on standard scaffolding, ready for concrete casting (for further details please see the first phase competition poster).

Free-form concrete formwork

Since the first phase, the wax formwork technology has been developed further through material research, the development of an adjustable mould and development of a comprehensive software tool for design and fabrication of free-form concrete formwork.

A 3 m high concrete prototype was built in order to test all material properties of the wax formwork (pressure, temperature, toughness, surface quality) as well as assembly p rocedures in a 1 :1 , on s i te situation.

Detailing of the wax elements such as a weight saving structure, fixation details and fusing of joints was also developed to be compatible with existing construction industry working methods.

In order to form the wax elements, a robotically controlled adjustable mould was developed. A specifically developed top surface is formed into a double-curved sur face, interpolating between supports, based on information from a digital model.

This mould allows higher precision, faster processing times and smoother surfaces than the earlier developed sand-forming method. The top surface is interchangeable according to the desired surface finish of the concrete.

Architectural potentialThe developed software tools

embed technical information about the formwork system into the design process, allowing an architect to make construction aware decisions in initial design phases. The software also allows the direct export of fabrication information to the robotic wax mold.

A full scale demonstrator project is planned to be executed later this year, showcasing the architectural potential of using wax formwork for cast-on-site concrete structures.

This research has developed in the scope of the European Union Framework Program 7 ‘Tailorcrete’ Project. EU FP7 Tailorcrete partners: Bekaert, Chalmers, Czech Technical University, Danish Technological Institute, design to production, Dragados, El Caleyo, Gibotech, Grace, Paschal, Superpool, Unicon, University of Southern Denmark.

Wax material has been provided by Paramelt. The support regarding concrete technology has been provided by ETH, the Institute for Physical Chemistry of Bui lding Materials. Certain technical details have been omitted due to a patent application for this technology.

New digital design & planning tools

With concre te const ruc t ion spanning a broad range of expertise, collaboration through an effective digi ta l workf low is v i ta l to the successful execution of free-form concrete structures.

The new wax formwork fabrication process is thus integrated with the development of new design software for concrete structures that span the whole development process from architectural design, through planning to fabrication.

The new software provides the architect, already in preliminary design stages, with design relevant formwork in format ion such as maximum curvature radii and gap patterns. It also enables a file to factory flow of planning data from the architect through the formwork planner to the fabricator.

On-site assembly The wax formwork elements

were designed to be compatible with existing formwork systems and assembly methods. After erecting one side of a back structure, the wax elements are fixed on the back structure.

Rebar and form ties are placed. After fixing a second side of wax elements to a back structure, this is lifted in place and form ties are closed.

Process prototype A custom flexible mould was

developed specifically for the forming of the re-useable wax formwork elements. The mould allows for double curvature, with radii down to 0.5 m.

It provides a fast and efficient way of forming wax formwork. The process cycle is as follows: heated wax is poured into the formed mold. After cooling and hardening the wax elements are placed against a standard back structure and concrete is cast in the cavity. After striking the wax elements are melted and can be reused for further elements.

Concrete pressure prototype

A 3 m high column was cast with very liquid self-compacting concrete, testing a worst case scenario for the wax formwork with high concrete pressure. As a remarkable result of the

test, the wax formwork did not break or deform and was released without traces on the concrete surface.

The primary purpose of this column prototype was the testing and evaluation in 1:1 scale of all technical properties of the wax formwork such as strength, deformation, surface quality and release, but also on site

Edward Schwarz General Manager, Holcim Foundation for Sustainable Construction

assembly and handling methods. The wax elements were cast on a robotically formed sand mold and were assembled in a standard back structure.

Research & development Besides 1:1 scale prototyping,

the wax formwork technology was

developed through research on material properties (temperature, shrinkage, strength, deformation) and testing.

Furthermore, detail ing of the system and handling procedures are designed in such a way to be low-tech and readily compatible with conventional on-site working methods and tools. New, system-specific details have also been developed such as fusing seams of wax elements on site, producing quasi-seamless concrete surfaces.

Final result: two-sided free-form (double curved) concrete cast with corresponding wax formwork

Step 1: adjustable mold actuation Step 2: wax formwork cast on adjustable mold Step 4: wax formwork on site

Step 3: wax formwork ready

Step 5: re-melting broken wax for new elements

Step 6: casting a new wax element on adjustable mold


Ashok Mandal, Director, Maini Group of Companies says that Maini aluminium formwork is economical in the long run due its ability to reduce time of slab construction cycle by nearly half besides eliminating the need of plastering, in an interview with Paresh Parmar. Excerpts:

Armed with a B Tech in Civil from IIT Bombay and a Diploma in Marketing Management - Jamnalal Bajaj Institute of Management Studies, Mandal has over 30 years of vast experience in leading positions in the scaffolding and formwork industry, with various companies like Acrow India Ltd and BSL Scaffolding Ltd.

He also has significant experience in the power and transmission sector where he was involved in the designing of high voltage transmission line towers for Tata Exports Ltd. His last assignment was as a Director for the Delhi-NCR-based city gas distribution company Haryana City Gas Distribution Ltd, Gurgaon.

He is also an active member of the Institution of Engineers, the Indian Road Congress and the Indian Concrete Institute.

Would you describe the products and solutions offered by Maini Aluminium Formwork System and also their applications?

We at Maini Group have a dedicated and elaborate manufacturing unit located at Rudrapur, Uttarakhand , exclusively for aluminium formwork system. Our aluminium formwork system provides ideal solutions for all types of monolithic constructions either for vertical buildings or for mass housing projects spread horizontally.

Could you tell us about some of your most challenging projects undertaken?

One of the recent challenging projects was in Noida, UP, for one of our esteemed customers Mahagun Real Estate Pvt Ltd, where we had to design formwork for curved portion at

‘Maini ideal for monolithic constructions’

have slowed down, too. However, the domestic formwork industry has been evolving continuously and in the long-term, this industry will only grow further since India has a long way to go in meeting its huge housing and infrastructure needs in years to come.

What are the company’s current focus, plans and strategies ahead? Any plans to expand your clientele by catering to other industries?

We a r e c o n s o l i d a t i n g o u r manufacturing facilities with further capacity additions in all our business verticals such as aluminium formwork,

higher floors and design for formwork of changed areas from 21st floor to 26th floor in such a way that the additional formwork requirement was reduced to about 10.5 per cent from projected extra formwork requirement of nearly 41.5 per cent, thus ensuring major savings for the customer.

How do you see the cost analysis & effectiveness of aluminium formwork over the conventional formwork techniques?

Although initially the costs may look at higher side, yet for monolithic repetitive nature of construction , Maini Aluminium Formwork is economical in the long run due its ability to reduce time of slab construction cycle by nearly half, besides eliminating the need of plastering.

How do you see the role of software and s imulat ion in formwork modelling and construction in general?

Modern So f twares and 3D simulations , prior to actual production of aluminium formwork for any job ensures perfect formwork solutions at sites eliminating any chance of error in shape or size of the final constructed structure.

You also specialize in steel access scaffolding and steel formwork. Could you tell us more?

We initiated our business of steel scaffolding and formwork in a sombre way. Diversifying into Aluminium Formwork System nearly six years ago and launching Maini Multilevel Car Parking Systems last year , have been

Maini Formwork Systems was felicitated as ‘Sarvottam Aluminium Formwork Manufacturer’ at the Indian Construction Industry Awards 2014 organized by the apex body for realty developers, the Builders Association of India in their 25th convention held in Dubai during February 2014.

This is the result of dedication and sincere efforts of each member associated with our group, according to the company statement.

“Our group led by Ajay Maini with his technical vision, Parmod Maini for his finance managing capabilities and Ashok Mandal for his expertise, is poised to expand into fresh horizons. We would also like to thank all our customers for their continuous support and belief in us,” it said.

Maini bags BAI award for excellence in formwork

programmes on safety & maintenance of scaffolding as value additions.

We also design and manufacture all types of system formwork , decking system , wall/column and purpose-made formwork which are compatible to various similar internat ional systems.

How about your felicitation at the Indian Construction Industry Awards 2014 by the BAI?

The fel icitation at the Indian Construction Industry Award -2014 held in Dubai during February 2014, at the XXVI convention of the Builders Association Of India, was really a ‘Moment of Pride’ for us. The award of ‘Sarvottam Aluminium Formwork Manufacturer’ is a testimonial to our ability to design and manufacture appropriate formwork solutions besides raising the expectations of our valued customers from us to perform better in the future.

How do you see current demand trends in the domestic formwork industry and its further growth prospects?

Due to slowing down of the Indian economy, construction activities

steel scaffolding systems & services, system formwork and multilevel car parking systems.

We are expanding our marketing efforts to add more regions and customers in India and spread again our business network overseas, too.

We have been focussing on requirements of access scaffolding systems and services for power plant boilers, refineries, cement plants, shipyards, monuments and buildings.

What is your outlook on the domestic construction industry?

Although there is a slowdown in overall construction activities, to meet the growing housing demands and other infrastructure requirements such as highways, power plants, airports, etc, the domestic construction industry has to grow only for many more years to come. We anticipate ‘India Growth Story’ to be next to China’s in years to come.

some of the major milestones during our journey so far.

Tell us some of the major milestones you reached in your journey?

We started our business in steel scaffolding and formwork nearly 27 years ago. We design and manufacture all types of Steel Access Scaffolding Systems such as Maini Cuplok , RingLock , Quickwedge, etc, besides providing Safe Erection & Dismantling Supervision Services and Training

March 17-23, 2014 7


Makeshift exhibition gallery Schaustelle is the

scaffold structure that allows visitors to walk through it, while they catch new glimpses of Munich, set off by

artworks on display from collections

German studio Jurgen Mayer H Architekten has constructed images of a temporary gallery made from scaffolding at a modern art museum in Munich.

The skeletal three-storey structure, named Schaustelle, was designed by Jurgen Mayer H to host exhibitions, film screenings, talks and other events of the Pinakothek der Moderne, which is currently undergoing a seven-month renovation.

Think tank“The Schaustelle is an operational

platform and think tank in one,” said Markus Michalke, Chairman of the Pinakothek der Moderne Foundation. The ground floor contains a large and flexible exhibition space, where artworks from the museum’s four collections are on show.

Staircases run along the edges of the structure, leading visitors to short-term installations and video projections on the upper-level platforms, while swinging seats can be suspended into a double-height space in the centre.

The Pinakothek der Moderne was closed in February 2013 for renovation work and reopened in September 2013. The temporary closure had been seen as an opportunity that gave

rise to a makeshift exhibition building -- the Schaustelle.

Lively platformSet up for the duration of the

renovations, it provided the four collections at the Pinakothek der Moderne with a lively platform to hold exhibitions, workshops, talks, performances, film screenings and video installations and much more besides. The scheme had been init iated by the Pinakothek der Moderne Foundation.

Michalke said, “Set up for the duration of the renovations, it will provide the four collections at the Pinakothek der Moderne with a lively platform to hold exhibitions, workshops, talks, performances, film screenings and video installations and much more. The scheme has been initiated by the Pinakothek der Moderne Foundation.

“The ground floor of the Schaustelle contains a large exhibition space that can be easily adapted to suit the requirements of the various exhibitions of the four collections. The plans foresee the use of the open scaffold structure in the outdoor area as a projection area, making it available as an addition exhibition space.

“The scaffold structure allows visitors to walk through it, while they catch new glimpses of the city beyond, set off by works on display from the collections. Accompanying events, including some at night, multimedia projections in the outdoor area and a viewing platform overlooking the city centre: all these things will cast the Kunstareal in a new and exciting light.”

Michalke further added, “The Pinakothek der Moderne Foundation and the four institut ions in the Pinakothek der Moderne are also using the temporary platform to send a political signal to push for the completion of the second section of the main building. The Schaustelle is an operational platform and think tank in one.”

Open scaffold structureThe ground floor of the Schaustelle

contained a large exhibition space that could be easily adapted to suit the requirements of the various exhibitions of the four collections.

The plans foresaw the use of the open scaffold structure in the outdoor area as a projection area, making it available as an addition exhibition space. The scaffold structure allowed visitors to walk through it, while they caught new glimpses of the city beyond, set off by works on display from the collections.

Accompanying events, including some at night, multimedia projections in the outdoor area and a viewing platform overlooking the city centre:

all the things were cast the Kunstareal in a new and exciting light.

The Pinakothek der Moderne Foundation and the four institutions in the Pinakothek der Moderne were also using the temporary platform to send a political signal to push for the completion of the second section of the main building. The Schaustelle has been an operational platform and think tank in one.

Dilemma becomes opportunity

When Andres Lepik was appointed to become the new director for the architecture museum at the Pinakothek der Moderne in Munich he was confronted with a dilemma.

The entire building needed to be closed for a couple of months for renovation. This problematic situation turned into a fantastic opportunity to have all four departments like art, design, drawings and architecture work very closely on interdisciplinairy events and exhibitions.

“Some years before we designed a similar concept for a temporary museum in Berlin which did not get

realize. For Munich it seemed to be right thing. Andres Lepik knew about our temporary museum design and within the very limited time frame from making the decision to close the museum for some months and the opening of a temporary building during that time, he proposed it to the other directors and it was the beginning of a great success story for the Pinakothek der Moderne,“said Michalke.

A global tendency of opening up art institutions to the public, having more involvement and cross-interaction, and making museums more lively, is the conceptual context in which Schaustelle became a very visible prototype. What is usually impossible to happen in a protected and safe environment of a museum institution was now at hand. Temporarily, open to the public beyond fixed opening hours, with performances, food, involvement of independent cultural players, all offered a very successful momentum of excitement and experimentation.

Scaffolding & prefabSchaustelle is a structure for a

limited time that transforms with any kind of art and performance occupation. Over the period of seven months we saw lectures, exhibitions, installations and parties inside, on and around the building.

The frame was the anchor piece for many appropriations -– to extend it to create infills, to shrink and finally dismantle it. All construction materials are part of scaffolding and prefab elements.

These elements temporarily come together to create Schaustelle and will dissolve into other normal construction site scaffoldings. It is sustainable in its use of materials and even beyond recycling since we used standardized pieces that are part of the buildings business anyway -– for a little while parked as Schaustelle.

Jurgen Mayer H


‘For high-rise buildings cuplock system is best’

What has been the company’s track record since its inception in 2010?

Since our inception in 2010 we have made rapid progress. Initially we started with 10 tons of scaffolding material and at present we have a stock of 2000 tons in a mere span of three years.

Tell us about the latest machinery in use?

Many automation machines came in the market, especially MIG robot type welding machines, which are used for welding cuplock system.

How many projects has the company completed?

Our completed projects are as follows:

In the power sector: ABB New Panvel and Indiabulls Sinnar-Musalgaon, Nashik. In the infrastructure sector: Monorail project first phase with all stations and Wadala depot in Mumbai. Metro rail depot, Versova-Andheri, for both the projects we have worked for L&T. Pune-Solapur road widening, strengthening for SSITPL.

Tell us about the cuplock and prop systems.

In modern times, for high-rise buildings the cuplock system has been implemented in place of prop system. The reason is because prop system has height limitations whereas cuplock system has no limitations. Bamboo scaffolding has been replaced by ‘H’frame and cross bracing for external plaster, painting, and facade works.

What is most important when making scaffolding?

While manufacturing scaffolding, the quality and thickness of the tube is

used while erecting scaffolding. This type of scaffolding is mainly used in petrochemical, power plants, ship yards, etc.

Common scaffolding components include base jacks, u jacks, couplers, top cup, bottom cup, and many more.

What is the chief use of formwork?Formwork is chiefly used for

construction of bridges, high-rise buildings, shopping malls and so on.

“While manufacturing scaffolding, the quality and thickness of the tube is most important,” says H Ganesh, Managing Director, Buildtech Scaffolding & Formworks, in this interview with Dilip Phansalkar. Excerpts:

most important. The welding process is to be followed properly, tolerance of tube and welding should be checked before dispatch.

How is structural stability enhanced?

Structural stability of scaffolding is greatly enhanced due to awareness of contracting companies for more safety.

What parts constitute in erecting scaffolding?

In pipe staging scaffolding straight pipes, base jacks, and couplers are

March 17-23, 2014 10

Editor : Bina VermaEditorial Team: Dilip Phansalkar, Paresh Parmar, Remona Divekar Designer: Rajen Mistry

Business Team: Milind Joglekar (9833357005), Shantanu Baraskar (9820904795), Seema Kohli (9820904931)Email: [email protected], [email protected]

No part of the contents of Construction Industry Review, in abridged or unabridged form, can be reproduced without the written permission of the Editor. CIR does not accept any

responsibility for statements and opinions expressed by the authors.

CONSTRUCTION

Jayakumar Jivraj Shah An expert on waterproofing, repairs, durability of RCC buildings, fixing leakage

(contd. from pg 1)

(contd. from pg 1)

“Demand is still at lower levels only. Going forward, due to subdued demand environment, we believe unrealistic price increase will come down as and when supply resumes,” according to the report.

Average prices settled at Rs 304 per bag in February against Rs 294 per bag in January. Though prices have increased MoM in the past two months, the recovery of the sector depends on its sustainability along with improvement in demand.

“At the start of the month, the Rajasthan government had issued notices to banks having accounts of Binani Cements asking them to not allow the company to withdraw money, as a tax of over Rs 185 crore

State apathy Slip Form

Cement prices rise

Today, this has an adverse effect as 3,000-odd employees and their families have been left with uncertainty hanging over their heads. The fate of these over 3000 employees and their families of Binani Cement now rests with the state government of Rajasthan.

The workers’ union, together with the employees at both plants, are grappling with the challenges of living with mounting daily family expenses. Unable to conduct any banking transactions, the company is not in a position to make payments for basic raw material, rail freight, road

transportation, excise duty, wages, taxes & duties and other levies.

The closure of operations of the company’s plant is resulting in a loss to the tune of Rs 50-60 crore per month which is directly and indirectly affecting employees and stakeholders.

“The company has already lost Rs 50 crore due to non-production and absence in the market place, thereby a drop in market share. In fact, the prices of cement have spiraled from Rs 250 per bag in February 2014 to Rs 310 per bag in March 2014-- a rise of 24 per cent increase, in just one month, impacting the common man and infrastructure project in the state of Rajasthan,” concludes R S Joshi.

is due on the company. This may have created a monetary crunch for the company resulting in supply stoppage,” it said further.

The southern region witnessed oversupply by regional players at lower rates in a bid to increase their market share. This resulted in a price decline in the region by Rs 21 per bag after Rs 19 per bag decline in the previous month resulting in lowest price levels in the last two years in the region.

On the demand front, the western region witnessed robust increase in demand after a long time while central region also registered good demand led by rural demand. In rest of the regions, demand remained subdued. Going forward, continual increase in prices and improved demand environment remains the key.

(contd. from pg 2)

Fire extinguishers should be made available to strategic places to meet any exigencies. Power winch operator must have some basic knowledge about the machine. Power winch operator should be guided with correct signals.

Lift, carrying men/material, should never be overloaded more than its capacity. Telephones must be provided at all strategic points with telephone operators for proper and rapid communication.

Adequate lights must be provided in all places. The entry and exit common gate of the lift must be closed while the lift is in operation. Permanent and ‘flu’ openings at lower elevations must preferably be covered while working at top elevations to prevent fall of any material to avoid accidents. Take proper care of electrical cables/wires to ensure leakage of current or short-circuit.

Proper platforms are to be provided at different elevations adjoining to the lift to facilitate passengers for safe boarding and alighting at their respective destinations to avoid accidents.

While doing electrical welding/gas cutting work at top elevations, proper care should be exercised to prevent fall of cut pieces of iron/steel as well as sparks over wooden planks or electrical cables/wires placed nearby or below levels to avoid fire hazards.

General checking of all running winches daily is a must. Any defect noticed must follow rectification action without postponement. Besides, corrective steps must be taken in respect of anticipated breakdowns. Safe operational worthiness of power winch must be determined before carrying men/material.

Bo th e l ec t romagne t i c and handbrake system must be in good working condition. Brake oil level up to the specified mark must be maintained. Proper brake adjustment must be done for effective brake application. Proper application of lubricant to all working gears and pinions of the winch must be adhered to.

Condition of wire rope must be checked daily once and proper lubricant be applied. If wire rope found damaged at any point the same should be discarded and new rope replaced to ensure safety.

Hoist, guide and deflection pulley bearings must be well greased once

a week and their respective bracket bolts must be checked daily and tightened wherever necessary.

All ‘U’ clamps are required to be fitted in the respective places, more so in the right direction as per guidelines. All electrical contact points, carbon brushes, slip ring, laminations of armature and bearing must be checked periodically and right action taken as the situation warrants to prevent failures in the system.

BIS codeThere is no BIS code on Slip Form

as per my knowledge. If this is taken up in future my suggestions are as follows.

Jack rods: This is the backbone of Slip Form and these should be manufactured under strict quality control. The material for jack rods should be as specified by the Slip Form supplier or EN8 steel (EN8 jack rods were used for 275 meter high Trombay chimney and 150 meter high Wanakbori Multiflue chimneys).

Threading of studs should be absolutely in plumb. The threading should be just little more than half the length of the stud to ensure that it always projects above to receive next jack rod for its proper fitting. (Refer to the sketch of jack rod and stud in the relevant paragraph of the article.)

Lasers: Lasers should be made compulsory beyond a certain height (say 100 m) of the chimneys.

I am of the opinion that laser beams should be made compulsory for Slip Form, irrespective of the height of the chimney. The beams help to achieve verticality.

(Note: The two chimneys referred to in this article were constructed by the Hindustan

Construction Company Ltd, Mumbai.)

Jacks and Jack Rods in position

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Printed & published by Bina Verma on behalf of Asian Industry & Information Services Pvt. Ltd., and printed at Amruta Print Arts, 205, Tantia Industrial Estate, J. R. Boricha Marg, Opp. Kastruba Hospital, Mahalaxmi, Mumbai 400 011 and published at 1st Floor, Feltham House, 10, J. N. Heredia Marg, Ballard Estate, Mumbai 400 001. Tel.: 022-2266 0623. Editor: Bina Verma Annual Subscription : Rs. 5,000/-

Construction Industry Review honoured with ‘Best Newspaper’ at 6th CIDC Vishwakarma 2014 Awards

The Cons t ruc t i on I ndus t r y Development Council (CIDC), the apex body for promoting best practices in the Indian construction sector and set up by India’s Planning Commission, conferred the ‘Best Newspaper for Construction Industry Award’ on Construction Industry Review for its notable coverage on the industry.

The award was presented at the 6th CIDC Vishwakarma Awards 2014 held at India Habitat Centre in New Delhi on March 7.

“Main highlight of this award is the practice of awarding artisans who are the unsung heroes of the construction Industry, who work tirelessly to create the wonderful assets that benefit

the entire nation,” said Dr P S Rana, Chairman, CIDC.

The uniqueness of the CIDC Vishwakarma Awards is reflected in its recognition of contributions by individuals like grass root construction workers, artisans who often belong to marg ina l ized sect ions and economically and socially weaker sections of society.

The CIDC accords highest priority to the development of human resources, and has undertaken several initiatives which are well-acknowledged and received by the Industry. These include training, testing & certification of skill of workers, supervisors and engineers, rehabilitation of project-affected persons.

Apart f rom human resource development initiatives, the CIDC also partners institutions for promotion of institutional arbitration, PMC and independent qual i ty assurance services, conferences & workshops, diploma programmes in civil, electrical & mechanical engineering for working professionals, research & studies and business advisory services.

(L-R): Malay Chatterjee, CMD, KIOCL Ltd; RADM Shekhar Mittal, CMD, Goa Shipyard Ltd; Dr B D Mundhra, CMD, Simplex Infrastructures Ltd; V K Gupta, Director General, CPWD; Dr Chander Verma, ex-Chairman, CIDC and Chairman, Continental Constructions Ltd; Mahendra Raj, Sr Consultant, among others

J S Jadhav, BG Shirke Construction Technology Ltd; A K Verma ADG, CPWD; Dr B D Mundhra, CMD, Simplex Infrastructures Ltd; Sanjay Bhoosreddy, IAS; Dr P S Rana, Chairman, CIDC; Dr SPS Bakshi, CMD, EPI; Dr Chander Verma

Bina Verma, Editor, CIR, and Managing Director, Asian Industry & Information Services Pvt Ltd, receiving the award at the hands of Dr P S Rana, Chairman, CIDC and Dr Chander Verma, ex-Chairman, CIDC and Chairman, Continental Constructions Ltd

Dr P R Swarup, Director General, CIDC addressing the audience

March 20-22, 2014International Elevator & Escalator ExpoBombay Convention & Exhibition Centre, Mumbai The event provides an exclusive platform to get an insight into the market, trends and technologies that drive the elevator and escalator industry. The forum, apart from fostering thought leading insights from the stalwarts of the industry, also dwells extensively on leading edge technological advancements to the most contemporary design trends, safety standards, environment compliance codes and regulations.

Contact: Virgo Communications & Exhibitions Pvt Ltd Virgo House, 250 Amarjyoti Layout, Domlur Extension, Bengaluru Tel: +(91)-(80)-25357028/41493996/41493997 Fax: +(91)-(80)-25357028 Contact person : G. Raghu Mob: +91-9845095803

May 22-24, 2014Metal Buildings & Steel Structures ExpoBombay Convention Centre, MumbaiMBSS Expo is an initiative designed to promote the use of steel and allied metals in construction to showcase the latest products and innovations in the industry. The event also proves to be an ideal platform for exploring new business opportunities and for dissemination of knowledge in the quest to deliver world class technology/services.

Contact: INIS Enterprises Pvt Ltd, 116 Atlanta Estate, VItth Bhatti, Goregaon East, Mumbai

April 19, 201418th One-day Workshop on Jirnoddhara of RCC BuildingsThe Institution of Engineers (India), Mahalaxmi, MumbaiThe workshop contains structural audit, upgrading (housekeeping, regular maintenance, repairs, rehabilitation, fixing leakage, waterproofing of RCC buildings and a new concept to construct durable RCC structures without leakage

Contact: Jayakumar Jivraj Shah Tel: 28483541 Mobile: 9819242649

May15-17, 2014Ecobuild India To be decided soonIt is the largest exhibition of the sector that concentrates on the future of sustainable building design, construction and built environment. It plays an important role in the development and advancement of the sector and helps the exhibitors to showcase their products and services associated with the sector.

Contact: UBM India Pvt Ltd. Times Square, B- Wing, Unit 1 & 2,5th Flr, Marol, Andheri Kurla Road, Andheri East. Mumbai

May 16-18, 2014Roof India 2014 Chennai Trade Centre, Chennai The exhibitors will showcase roofing systems, architectural cladding, facade engineering, roof waterproofing, pre-engineered buildings, space frames and more.

Contact: International Trade & Exhibitions India Pvt Ltd 1106-1107, Kailash Building, Kasturba Gandhi Marg, New Delhi

EVENTS