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White Topping Technology – Urban Green Solutions

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The concepts of "Sustainability" and "Sustainable development" are of much importance and receiving much attention from all walks of life as the causes of global warming and climate changes are debated world over. Concrete White topping Technology is sustainable because of its long life (over 30 years). Concrete overlay is in thinner section, hence consumes minimal raw materials, easy to construct. It requires minimum maintenance and rehabilitation over its lifetime. G Sreenivasa, General Manager – Business Development, UltraTech Cement, makes his case.What is White Topping and Why?

White topping is the covering of an existing asphalt pavement with a layer of Portland cement concreteUsing concrete overlays (against asphalt overlays) provide desirable life, performance against heavy loading & rain, offers safety, friction and skid resistance properties. In addition, concrete overlay offers cost effective and environmental benefits:

  • Non- rutting, ing surface that doesn’t trap water
  • Excellent surface drainage
  • Better light reflectance
  • Fewer repairs,- Fewer work-zone accidents over life of overlays
  • Comparable initial cost to asphalt
  • Lower ownership cost to asphalt (life cycle cost)
  • Cement is available locally where as bitumen has to be imported
  • Price of cement is consistent and predictable where as bitumen price is highly volatile.
  • Cement is available in plenty where as bitumen is scarce material in future.

The many advantages elaborated LongevityThe longevity of concrete roads & concrete overlays (or white topping) is well demonstrated and documented. In this context, the concrete paved Marine Drive in Mumbai is an outstanding example. The concrete pavement was done as far back as in 1939 and the road even now, 71 years later, is still giving satisfactory performance.Life cycle cost of concrete pavement against asphalt pavement

  • An asphalt road requires maintenance every 2 to 4 years and resurfacing every 8 to 10 years
  • The concrete road requires relatively very little maintenance. Depending upon usage, it may require some minor repairs to joints and surface texture, but won’t need to be resurfaced for 30, 40 or even 50 years.
  • Hence, the maintenance cost of concrete overlays is 1/8th to 1/10th of asphalt overlays results in smooth traffic flow over longer period.

Long life concrete overlays have demonstrated economic advantages in terms of life cycle costs (see picture). In addition, they contribute directly to the system’s sustainability in several important ways.Fuel saving (During its Lifecycle time)Properly designed, constructed, grooved, textured concrete overlays have much lesser pavement deflection, which results in reduced vehicle fuel consumption (see picture below). Fuel Consumption on Asphalt and Concrete Pavement (By CRRI & Dr Kadiyali associates) – After construction;The above table shows how the savings progressively increased as the vehicle weight increases. This is a very significant finding for Indian conditions where overloading is common. Hence concrete overlays are not only more capable of resisting heavy loads but also achieve fuel savings.Emission Reduction due to White topping;Assuming, a 10MT truck/bus travel 24000kms in urban areas per annum and (assume fuel consumption as 2.5kms/ltr) Fuel savings of 9.8 per cent (30.24cc/km) achieved on concrete overlay, Thus, total fuel saved in a year will be 800 litres or Rs 33600 per vehicle(Rs 42/ltr), Approx 2MT of CO2 will be reduced per trip.Energy saving due to White Toppinga) The cost of lighting streets in urban areas2Lighting fixtures are important elements of most urban streets. Enhanced night time visibility is related to improved traffic safety. A report comparing environmental impacts of concrete & asphalt overlays indicates that asphalt overlays require more lights per unit length to achieve the same illumination (Gajda and VanGeem 1997).To overcome the lack of light reflectance, during nights, an asphalt overlay requires either1) More street lights per mile than a concrete overlay, or 2) Higher watt light bulbs at the same light pole spacing as used on Concrete overlay.In either case, more energy is consumed to illuminate the asphalt roads. Where more poles are installed, initial costs are more.Visibility during nights – in cityConcrete’s superior reflectance improves night visibility, saves money on street lighting and reduces power consumption.Surface reflectance readings on concrete overlays are 4-5 times higher than asphalt overlays, which means drivers can see the road, other vehicles and pedestrians clearer and sooner, thus helps in reducing accidentsSafety: How Quickly Can You Stop?From a study, it has been noticed that breaking distance for concrete overlays are less compared to asphalt overlay, hence concrete overlays are safe on both dry and wet surface condition. The breaking distance even increases with rutted asphalt surface. This clearly shows that the concrete overlays are more sustainable in reducing the wear and tear of tyres, brake drum, and reduces the consumption of brake oil.Heat Island Effect – Concrete v/s Asphalt overlayIn Urban areas, the Heat Island Effect can contribute significantly to energy consumption for air conditioning to cool the urban building. This also costs money, in-turn leads to emissions at power generation units. One estimate that the increase in temperature due to Heat island effect accounts for 5-10 per cent of peak urban electric demand for air conditioningLower Energy Footprint

Embodied primary energy is a measure of all energy use associated with the production, delivery and maintenance of a facility over predetermined time period. It includes both feedback energy and primary energy.The study here shows that asphalt surface require 2 to 5 times more energy than equivalent concrete surface. Fig shows illustrates, the embodied primary energy associated with concrete pavement is only about 33 per cent of the embodied primary energy of asphalt pavements.Graph shows comparison of embodied primary energy for asphalt and concrete pavementsRecyclability /reusability and Natural resourcesConcrete pavement is a 100 per cent recyclable material and at its ultimate end of fatigue, concrete pavement can be crushed and reused as granular fill, sub base/ base material for new pavement. This leads to reduced demand on non-renewable natural resources. Based on the analysis, on equivalent pavement designs for asphalt and concrete pavements for an arterial road on a low- strength sub grade, approximately twice as much granular material is needed for an asphalt pavement structure than for concrete pavement.ConclusionsConcrete overlays / pavements are sustainable, economical, long- lasting and truly green roads in more than many ways against asphalt overlays;

  • Technical reasons clearly show that concrete overlays are long lasting (over 30 years), require little or no repair or replacement as is in case of asphalt overlays
  • Concrete overlays cost little maintenance or 1/8th to 1/10th of asphalt overlays and thus no frequent repair of road results in traffic jam and fuel emissions
  • Saving in fuel consumption up to 20 per cent has been noticed. However, in urban areas the saving will be about 10 per cent for (10MT) buses and trucks. This results reduction in CO2, NO2 and SO2 emission over life cycle period of 30 years
  • Use of fly ash, GGBS and silica fume, improves the performance of concrete, saves money, reduces the need for disposal in landfills greatly, reduces energy use and generation of green house gases
  • Concrete overlays are light coloured and lead to improved visibility, reduced lighting requirement and reduce accidents in cities
  • Cool surface of concrete overlay reduces heat island effects in cities
  • Concrete overlay’s overall energy footprint means tremendous savings in energy over the lifecycle of concrete overlay
  • Concrete overlays renewability and 100 per cent recyclability lead to reduced demand on non renewable resources and save the quantity of sub base materials

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Economy & Market

RAHSTA Roundtable Sets Agenda for Smarter, Safer Highways

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Roundtable discussions focus on innovation for safer highways.

Held on 12 March 2026 at Courtyard by Marriott, Mumbai, alongside the Infrastructure Today Airport Conclave, the RAHSTA Roundtable brought together stakeholders from across the highways and infrastructure ecosystem to shape the agenda for the 16th RAHSTA 2026, scheduled for 8–9 July 2026 at the Jio Convention Centre, Mumbai. The session focused on key industry themes including road construction, technology, safety and long-term sustainability.

Opening the discussion, Pratap Padode, Founder, FIRST Construction Council, said the roundtable marked the beginning of a broader consultative process leading up to the July event. The aim, he noted, is to bring together industry stakeholders to refine the agenda for discussions on the future of roads, bridges, tunnels and allied infrastructure.

Padode noted that while central road project awards have slowed in recent years, states are increasingly driving the next phase of infrastructure growth. Maharashtra, with its long-term road development plans and agencies such as MSRDC and MSIDC, is expected to play a significant role in this expansion.

RAHSTA Expo 2026 as a specialised platform dedicated to road infrastructure, covering highways, tunnels, bridges and flyovers along with construction technologies, safety systems and maintenance solutions. He also highlighted the growing importance of rural connectivity and said the organisers are engaging with government bodies to highlight rural road development initiatives.

Tanveer Padode, CIO, ASAPP Info Group, presented insights from IMPACCT, the group’s infrastructure intelligence platform. He pointed to a strong project pipeline despite slower highway awards earlier in the year, noting that states such as Maharashtra, Odisha and Arunachal Pradesh are emerging as key drivers of new projects. The data also revealed that only a small group of contractors participates in large-value infrastructure bids.

Lt Gen Rajeev Chaudhary, former Director General, Border Roads Organisation and Chairman of the RAHSTA Expo Committee, emphasised the need for stronger collaboration across the ecosystem, including policymakers, contractors, technology providers and financiers. He also called for addressing systemic issues within the sector and encouraged greater participation of women in infrastructure leadership.

The discussion also explored the evolving economics of road development. Phani Prasad Mandalaparthy, Associate Director, CRISIL Intelligence, noted that the slowdown in project awards reflects a shift towards higher-value logistics corridors rather than simple road widening projects. However, private participation through BOT and TOT models remains limited.

From the contractors’ perspective, Sudhir Hoshing, Whole-Time Director, Ceigall, said companies are becoming more selective in bidding, favouring projects with clearer payment mechanisms and efficient processes. While NHAI continues to offer greater operational clarity, states such as Uttar Pradesh and Bihar were cited as relatively supportive environments for project execution.

Durability and sustainability also emerged as key themes. Himanshu Agarwal, COO – Road & Infrastructure, Zydex Group India, highlighted the need to prioritise lifecycle performance and resilient pavements, while participants discussed the potential of alternative materials such as plastic waste, steel slag and industrial by-products in road construction.

Dr LR Manjunatha, Vice President, JSW Cement, emphasised that India has abundant fly ash, slag and other industrial materials that can improve durability and sustainability if integrated into specifications and policy frameworks.

Technology and equipment challenges were also discussed. Dr Lakshmana Rao Mantri, Dy General Manager, Afcons Infrastructure, highlighted the shortage of tunnel boring machines (TBMs), which is delaying several underground infrastructure projects. Participants agreed that developing domestic TBM manufacturing capabilities will be critical for future infrastructure expansion.

The future of concrete pavements was another area of discussion. Dr V Ramachandra, President, Indian Concrete Institute, stressed that the debate should focus on lifecycle performance rather than material choice alone, noting that evolving design standards are improving the feasibility of concrete roads.

Prof Dharamveer Singh of IIT Bombay added that while India has made significant progress in infrastructure development, stronger capacity building and better execution practices are essential to ensure consistent road quality.

The discussion also touched upon technology adoption in the sector. Rushabh Mamania, Partner & CBO, Roadvision, highlighted the growing role of AI in road infrastructure, noting that AI-driven monitoring systems are already being deployed across large stretches of national highways.

Overall, the roundtable underscored that the future of highway infrastructure will depend not only on the pace of construction but also on durability, safety, technology integration and sustainable materials. The discussions offered valuable insights that will help shape the agenda for RAHSTA 2026 and guide future collaboration within the industry.

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Economy & Market

CTS Roundtable Charts Tech-Led Roadmap for Construction

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CTS Roundtable Maps Technology Roadmap for Construction

Ahead of the Construction Technology Show (Con Tech Show) 2026, industry leaders, technology innovators and academia came together in Mumbai to deliberate on how digitalisation, automation and industrialised construction can reshape the sector. The discussion made one thing clear: construction can no longer afford to treat technology as optional.

Held on 12 March 2026 at Courtyard by Marriott, Mumbai, alongside the Infrastructure Today Airport Conclave, the CTS Roundtable served as a precursor to the Construction Technology Show 2026, scheduled for 19–20 August 2026 at NESCO, Mumbai.

A platform to move from discussion to deployment

Opening the session, Pratap Padode, Founder and Editor-in-Chief, ASAPP Info Global Group, said construction technology has long remained close to his heart, especially given the sector’s traditionally slow pace of technology adoption. He noted that over the years, the Construction Technology Summit had steadily built interest, and the next step was now to expand it into a larger, more meaningful platform that could bring together technology providers, users, startups and innovators under one roof.

Padode said the vision for CTS is not limited to software alone. The platform aims to embrace all forms of technology that can improve construction efficiency, quality and execution—from digital tools and project management systems to lean construction, off-site fabrication and startup-led innovation. He also highlighted plans to deepen startup participation and create space for young companies to showcase emerging construction solutions.

Industry at a turning point

Moderating the roundtable, Naushad Panjwani, Chairman, Mandarus Partners, set the context by pointing out that the global construction industry, despite being a multi-trillion-dollar sector, continues to lag in productivity. He noted that while manufacturing has consistently improved efficiency, construction has remained slow to modernise.

Referring to both global and Indian trends, Panjwani underlined that the industry is now at a decisive moment. India, he said, is entering a major build cycle, and delivering the next phase of infrastructure and real estate growth through traditional methods alone is no longer viable. The goal of the roundtable, therefore, was not to debate technology in isolation, but to identify the most critical conversations that would bridge the gap between innovation and implementation.

His central message was clear: CTS 2026 must be shaped around themes that make CEOs, CIOs and CTOs feel they cannot afford to miss the event.

From BIM to AI, data to governance

A major theme that emerged through the discussion was the need for better data, better visibility and better decision-making. Dr Venkata Santosh Kumar of IIT Bombay echoed this, saying that the underlying data infrastructure itself needs attention. Construction projects, particularly remote ones, often face issues around connectivity, data collection and data use. Without this foundation, more advanced technologies cannot deliver their full value.

Chandra Vasireddy, CEO & Co-founder, Inncircles, expanded the discussion to governance, arguing that technology must help connect the many moving parts of a construction business. For him, the real value of digital transformation lies in creating better governance, clearer visibility and stronger business outcomes.

Tejas Vara of Inncircles stressed the importance of timely site data for leadership teams, especially in large and remote projects where decisions on materials, machinery and manpower often get delayed because information does not reach headquarters in time.

The role of AI also featured prominently. Rushabh Mamania, Partner and CBO, Roadvision said that while AI and machine learning are now common terms, vision intelligence and language intelligence have still not deeply penetrated the construction sector. He emphasised that startups in India are building relevant AI-led solutions and are already attracting international interest, showing that innovation need not be imported—it can be built locally and scaled globally.

Industrialised construction gains ground

The roundtable also placed strong emphasis on industrialised construction methods. Kalyan Vaidyanathan, CTO – Construction & R&D, Tvasta, called for greater focus on off-site fabrication and the broader industrialisation of construction. Bhargav Jog, General Manager, Dextra, highlighted precast technology and alternative sustainable materials as areas with immediate relevance.

Several participants agreed that modular, precast and pre-engineered approaches are no longer niche ideas. They are increasingly becoming practical responses to the sector’s challenges around labour shortage, timelines, quality control and predictability.

Anup Mathew, Sr VP & Business Head, Godrej, argued that the industry needs a fully integrated approach—from design and procurement to execution and asset management. Unless these are connected, technology adoption will remain fragmented and sub-optimal. He pointed to pre-engineered and modular systems as examples of how industrial thinking can compress timelines, improve quality and reduce dependence on difficult on-site conditions.

Adoption remains the biggest hurdle

While there was broad agreement on the promise of technology, the discussion repeatedly returned to one fundamental challenge: adoption.

Abhishek Kumar, COO, LivSYT, observed that the market is crowded with solutions, but many buyers still struggle to evaluate which technology suits which use case. According to him, the industry needs clearer frameworks to help users select, compare and adopt solutions, rather than expecting a single platform to solve every problem.

Dr Tenepalli JaiSai, Associate Professor, School of Construction(SoC), NICMAR University, noted that isolated technologies will not solve the productivity problem by themselves. What is required is an integrated Construction 4.0 approach, where digital, physical and cyber-physical systems work together rather than in silos.

That concern around silos was reinforced by Subodh Dixit, former Director, Shapoorji Pallonji, who said the issue is not just that technologies are disconnected, but that stakeholders are as well. Clients, consultants, contractors and partners often operate with different priorities. Unless these silos are broken, technology will struggle to percolate across the full project value chain.

Harleen Oberoi, Project Management, Tata Realty shared a practical perspective from the client side, saying that successful BIM implementation requires investment across the ecosystem, not just within one organisation. Trade partners, vendors and other stakeholders must also be trained and aligned if the technology is to deliver its intended results.

Beyond buzzwords

A notable takeaway from the session was that the industry is moving past the phase of treating technology as a buzzword. Participants repeatedly stressed that the real question is not whether technology should be used, but where it creates measurable value and how that value can be scaled.

The conversation also expanded beyond mainstream themes to include repairs and rehabilitation, construction and demolition waste, sustainability, circular economy, green sourcing, carbon measurement, design interoperability, generative design, robotics, and the role of horticulture and greener built environments.

Setting the agenda for CTS 2026

By the close of the session, the roundtable had surfaced a strong set of themes for the upcoming show: BIM and digital twins, AI and data platforms, industrialised construction, startup innovation, governance-led technology adoption, robotics, sustainable materials, and integrated project delivery.

More importantly, the session established CTS 2026 as more than an exhibition. It is shaping up to be a serious industry platform where users, technology providers, researchers and policymakers can collectively define the future of construction.

As Padode noted in his closing remarks, the conversation will continue through further consultations and possibly webinars in the run-up to the show. If the roundtable is any indication, CTS 2026 will aim not merely to showcase technology, but to push the industry towards meaningful adoption at scale.

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Concrete

Human Factor in Grinding Optimisation

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Ponnusamy Sampathkumar, Consultant – Process Optimisation and Training, discusses the role of skilled operators as the decisive link between advanced additives, digital control and world-class mill performance.

The industry always tries to reduce the number of operators in the Centre Control Room. (CCR) Though the concept was succeeded to certain extent, still we need a skilled person in the CCR.
In an era where artificial intelligence (AI) grinding aids, performance enhancers, and digital optimisation tools are becoming increasingly sophisticated, it’s tempting to believe that chemistry alone can solve the challenges of mill efficiency. Yet plants that consistently outperform their peers share one common trait: highly skilled operators who understand the mill as a living system, not just a machine.
Additives can improve flowability, reduce agglomeration, and enhance separator efficiency, but they cannot replace the nuanced judgement that comes from experience. Grinding is a dynamic process influenced by raw material variability, moisture, liner wear, ball charge distribution, ventilation, and separator loading. No additive can fully compensate for poor control of these fundamentals.

Operators see what additives cannot
When I joined the cement industry in 1981, not much modernisation was available then. Mostly the equipment was run from the local panel. Once I was visiting the cement mills section. The cement mills were water sprayed over the shell to reduce the temperature to avoid the gypsum disintegration.
The operator stopped the feeding for one of the mills. When I asked the reason, he replied that mill was getting jammed, and he added that he could understand the mill condition by its sound. I also learned that and it was useful throughout my career. In another plant I saw the ‘Electronic Ear,’ which checked the sound of the mill and the signal was looped with feed control!
Whatever modernisation we achieve, it is from the human factor that the development starts.
Additives respond to conditions; operators interpret them.
A skilled operator can detect subtle shifts, like a change in mill sound, a slight variation in circulating load, or a drift in separator cut point. It’s long before instrumentation flags a problem. These micro-observations often prevent major efficiency losses.
Additives work best when the process is stable
I would like to share one real time incident. The mill was running on auto mode looped with the mill outlet bucket elevator kilowatt. (KW)There was a decrease in the KW, and the mill feed was increased by the auto control (PID). After a while, the operator stopped both the feed and the mill. He asked the local operator to check the airslide between mill outlet and the elevator. They found the airslide was jammed and no material flow to the elevator!
The operator deduced the abnormality by his experience by seeing the conditions and the rate of increase of the feed by the auto control.
It’s always the human factor that adds value to the optimisation.

Grinding aids are multipliers,
not magicians.
They deliver maximum benefit only when:
• Mill ventilation is correct
• Ball charge is balanced
• Feed moisture is controlled
• Separator speed and loading are improved
• Blaine targets are realistic
Without these fundamentals, even advanced additives may become costly investments. The operator is responsible for ensuring process stability, whether using a ball mill or a vertical mill. After ensuring the system is stable, the operator observes it briefly before transitioning to automatic control. If there is any anomaly in the system the operator at once takes control of the system, stabilises and bring back to auto control.

Skilled operators adapt in real time
It will be interesting to note that the operators who operate from local panel start to operate from DCS also. They have the experience and the ability to adapt the changes. Operator checks each parameter deeply. Any meagre change in the parameters is also visible to him.
Raw materials change. Weather changes. Wear patterns change.
A skilled operator adjusts:
• Feed rate
• Water injection
• Separator speed
• Grinding pressure (in VRMs)
• Mill load distribution.
These adjustments require intuition built from years of experience, something no additive can replicate.

Human insight prevents over reliance on additives
Plants sometimes increase additive dosage to mask deeper issues like:
• Poor clinker quality
• Inadequate drying capacity
• Incorrect ball gradation
• High residue due to worn separator internals.


A knowledgeable operator finds root causes instead of chasing temporary chemical fixes.
The real optimisation sweet spot is reached when:
• Operators understand how additives interact with their specific mill.
• Additive suppliers collaborate with plant teams.
• Process data is interpreted by humans who know the mill’s behaviour.
This constructive collaboration consistently delivers:
• Lower kWh/t
• Higher throughput
• Better product consistency
• Optimum standard deviation.

Advanced additives are powerful tools, but they are not substitutes for human ability. Grinding optimisation is ultimately a human driven discipline, where skilled operators make the difference between average performance and world class efficiency. Additives enhance the process but operators
control it.

About the author:
Ponnusamy Sampathkumar, Consultant – Process Optimisation and Training, is a seasoned cement process consultant with 43+ years of global experience in plant operations, process optimisation, refractory management, safety systems and training multicultural teams across international cement plants.

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