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Concretisation of roads: A path of durability and strength

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Concrete roads offer several distinct advantages over roads with bituminous surfaces. With barely 2 percent of the country’s road length constructed from concrete, there is tremendous scope for enhancing the durability and strength of roads through concretisation. A look at the technological advancements in concrete technology and the present scenario in IndiaThe importance of concrete roads can be gauged when one travels on the Mumbai-Pune Expressway which was built of concrete in the early nineties. Prior to that, people would travel on the old Mumbai-Pune road which was rugged, uncomfortable and would take a lot of time. However, with the opening of the Mumbai-Pune Expressway, time taken to traverse the distance has reduced, there is a saving of fuel and there is less wear and tear of vehicles due to the strong surface of the road, leading to lesser resistance.Case for concrete roads:In a vast country like India with a large geographical area and extreme weather patterns, the roads need to be built with a material which does not suffer from the frailties exhibited by bitumen. The material should be in a position to withstand pressure from petroleum and oil spillage, abrasion, high axle loads, aggressive pollutants and high traffic densities. It has been proved through technical studies in India and the world, that concrete roads satisfy all the aforementioned conditions. Commenting on the advantages of concrete roads over bituminous surfaces, Dr LR Kadiyali, CEO of LR Kadiyali & Associates stated, "roads made from concrete are practically maintenance free. They are comparable in initial cost to a flexible pavement on a new road with heavy traffic and cheaper on a life-cycle basis. It leads to a 15 percent saving of diesel in the case of commercial vehicles and a 10 percent saving in electricity for street lighting. Concrete roads ensure a better performance under conditions of heavy rainfall and water logging." Usage of concrete roads leads to a saving of around 40 percent in stone aggregates.Since the structural capacity in rigid pavements is ensured by the slab itself, the maintenance expenditure incurred on concrete roads is relatively low. New techniques and technologically advanced equipment have ensured that concrete roads are easy to build. There are lesser traffic disruptions as concrete roads remain maintenance free for a longer period. Concrete road surfaces offer better skid resistance and are not impacted due to water and the bad effects of oil and lubricant spillage.Elaborating on the advantages of concrete roads, Prof M.S.Shetty, Founder Chairman of the Pune Chapter of the Indian Concrete Institute (ICI) noted, "though the initial cost of making a concrete road is higher as compared to a bituminous road, it has a shelf life of around 25-30 years with minor repairs. The cost of concrete roads is lesser in the long term."Concretisation of roads also ensures savings in fuel consumption. It has been shown through trials undertaken by the Central Road Research Institute (CRRI) that around 15-20 % less fuel is consumed by goods carriers on concrete roads as compared to bituminous roads. Wear and tear for vehicle tyres, suspensions and shock absorbers is reduced.Through the application of life cycle cost analysis, one can deduce that the cost of concrete roads can match those of flexible pavements within 10 years. Though the initial cost of building a concrete road is higher, the scales begin to tilt in favour of concrete roads within a period of 5-10 years. In this time gap, flexible pavements require repairs to enhance their longevity. The life cycle cost of concrete roads becomes cheaper by 10-15 percent over a period of 20 years as compared to bituminous roads. Utilisation of fly-ash based blended cements enhances the cost competitiveness of concrete pavements.Concrete roads in India :The earliest example of a concrete road in India is Mumbai’s famous landmark Marine Drive which was constructed in 1939. This stretch of road is the most apt example of the durability and strength exhibited by concrete surfaces. There has scarcely been a day when Marine Drive was closed for repairs or maintenance. This seafront road has displayed resilience even seven decades after its construction.Commenting on the construction of concrete pavements in India, Dr L R Kadiyali stated, "around 2000 kms of concrete pavements have been constructed under the National Highway Association of India (NHAI) project. Other concrete road projects include the Mumbai-Pune Expressway which is around 100 kms and the Taj Expressway which is around 120 kms. All the concrete roads constructed are performing well."Elucidating on the construction of concrete roads in Mumbai, Mumbai Metropolitan Regional development Authority (MMRDA) Joint Project Director, Dilip Kawathkar stated, "a classic example of a concrete road is the Santacruz-Chembur Link Road (SCLR). It is expected to be completed by December 2012. The road will be a double decker flyover almost 6.5 km long. It will comprise of a 6 lane concrete road with a 3 metre wide footpath."Some prominent concrete roads in India includes the new carriageway of Delhi-Mathura road in Haryana/UP, it is 111 kms long and comprises of a new 2 lane carriageway in concrete, the Satara-Kolhapur section of NH-4 in Maharashtra is 133 kms long and has a new 2 lane carriageway in concrete, a 30 percent fly ash replacement has been used in the construction of the carriageway, the Yamuna Expressway is 165 kms long and has a new 2X4 lane carriageway in concrete under construction, the Khaga-Varanasi section of NH-2 in UP is 202 kms long and has a new 2 lane carriageway in concrete.Bitumen:In India, the material long preferred for road laying has been bitumen, a by- product of the petroleum industry. However, bituminous surfaces suffer from certain disadvantages. It rapidly deteriorates due to climatic conditions and rapid wear and tear. The most common signs of the drawbacks of bitumen roads are potholes. Bituminous surfaces also suffer on account of impact by water, oxidation, sunlight, spillage by petroleum and lubricants. The roads are also pressured by over laden vehicles such as heavy trucks and buses.Technological advancement:Road building in India has witnessed a tremendous technological advancement over the last few years. The pace of road construction has been accelerated alongwith an improvement in the quality of roads. This has been possible due to the evolution of advanced technology and sophisticated equipment. The use of Ready Mix Cement (RMC) has also led to the revolutionizing of road building. The major advantages accrued on account of the use of RMC are long term savings and faster construction. It also eliminates the disadvantages of hand mixed concrete which is dependent on traditional labour.Commenting on the latest technological developments in the construction of concrete roads, Dr Kadiyali stated, "developments in the construction of concrete roads comprise of continuously reinforced concrete pavement, which eliminates joints and whisper concrete which reduces noise levels. High volume fly-ash concrete has replaced cement by around 50 percent. Technological developments also comprise of manufacture of high strength concrete thro-ugh use of additives like silica fumes and white topping."The construction of concrete roads has become not only speedier but also economical through the deployment of different technological inputs. Elucidating on this aspect, Prof.Shetty stated, "one metre per minute of concrete road can be constructed in a day through what is known as the horizontal slip form technique. In this technique, used for pavement and traffic separation walls, concrete is laid down, vibrated, worked and settled in place while the form itself slowly moves ahead. This technique was used in the Delhi-Mathura road in 1992-93." The horizontal slip forming method finds its origin in the construction of interstate highways initiated by the Eisenhower administration in the USA during the 1950s.The Way Forward:Indigenous research on various aspects of concrete road design should be taken up. The performance of concrete roads already constructed should be monitored and any deficiencies observed should be identified. State public works departments (PWDs) should take up concrete road projects on the state highways just as the Central govt. is taking up projects on the national highways. The cement industry may fund a few pilot projects of white-topping in cities.A well developed and technologically advanced road network is absolutely essential to maintain and enhance the progress of a rapidly advancing economy like India. The building of a well heeled and efficient road system will result in the transportation and distribution of various goods and services across the country which is geographically vast and diverse. The utilisation of concrete in roads will not only ensure a long term investment in a strengthened road network but also lead to rapid economic progress.Cohesion needs to be maintained between the central and state governments as well as different organisations in order to ensure that a certain standard and quality of roads is maintained.

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Economy & Market

Power Build’s Core Gear Series

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A deep dive into Core Gear Series of products M, C, F and K, by Power Build, and how they represent precision in motion.

At the heart of every high-performance industrial system lies the need for robust, reliable, and efficient power transmission. Power Build answers this need with its flagship geared motor series: M, C, F and K. Each series is meticulously engineered to serve specific operational demands while maintaining the universal promise of durability, efficiency, and performance.

Series M – Helical Inline Geared Motors
Compact and powerful, the Series M delivers exceptional drive solutions for a broad range of applications. With power handling up to 160kW and torque capacity reaching 20,000 Nm, it is the trusted solution for industries requiring quiet operation, high efficiency, and space-saving design. Series M is available with multiple mounting and motor options, making it a versatile choice for manufacturers and OEMs globally.

Series C – Right Angled Heli-Worm Geared Motors
Combining the benefits of helical and worm gearing, the Series C is designed for right-angled power transmission. With gear ratios of up to 16,000:1 and torque capacities of up to 10,000 Nm, this series is optimal for applications demanding precision in compact spaces. Industries looking for a smooth, low-noise operation with maximum torque efficiency rely on Series C for dependable performance.

Series F – Parallel Shaft Mounted Geared Motors
Built for endurance in the most demanding environments, Series F is widely adopted in steel plants, hoists, cranes and heavy-duty conveyors. Offering torque up to 10,000 Nm and high gear ratios up to 20,000:1, this product features an integral torque arm and diverse output configurations to meet industry-specific challenges head-on.

Series K – Right Angle Helical Bevel Geared Motors
For industries seeking high efficiency and torque-heavy performance, Series K is the answer. This right-angled geared motor series delivers torque up to 50,000 Nm, making it a preferred choice in core infrastructure sectors such as cement, power, mining and material handling. Its flexibility in mounting and broad motor options offer engineers the freedom in design and reliability in execution.
Together, these four series reflect Power Build’s commitment to excellence in mechanical power transmission. From compact inline designs to robust right-angle drives, each geared motor is a result of decades of engineering innovation, customer-focused design and field-tested reliability. Whether the requirement is speed control, torque multiplication or space efficiency, Radicon’s Series M, C, F and K stand as trusted powerhouses for global industries.

http://www.powerbuild.in
Call: +919727719344

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Economy & Market

Conveyor belts are a vital link in the supply chain

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Kamlesh Jain, Managing Director, Elastocon, discusses how the brand delivers high-performance, customised conveyor belt solutions for demanding industries like cement, mining, and logistics, while embracing innovation, automation, and sustainability.

In today’s rapidly evolving industrial landscape, efficient material handling isn’t just a necessity—it’s a competitive advantage. As industries such as mining, cement, steel and logistics push for higher productivity, automation, and sustainability, the humble conveyor belt has taken on a mission-critical role. In this exclusive interview, Kamlesh Jain, Managing Director, Elastocon, discusses how the company is innovating for tougher terrains, smarter systems and a greener tomorrow.

Brief us about your company – in terms of its offerings, manufacturing facilities, and the key end-user industries it serves.
Elastocon, a flagship brand of the Royal Group, is a trusted name in the conveyor belt manufacturing industry. Under the brand name ELASTOCON, the company produces both open-end and endless belts, offering tailor-made solutions to some of the most demanding sectors such as cement, steel, power, mining, fertiliser, and logistics. Every belt is meticulously engineered—from fabric selection to material composition—to ensure optimal performance in tough working conditions. With advanced manufacturing facilities and strict quality protocols, Elastocon continues to deliver high-performance conveyor solutions designed for durability, safety, and efficiency.

How is the group addressing the needs for efficient material handling?
Efficient material handling is the backbone of any industrial operation. At Elastocon, our engineering philosophy revolves around creating belts that deliver consistent performance, long operational life, and minimal maintenance. We focus on key performance parameters such as tensile strength, abrasion resistance, tear strength, and low elongation at working tension. Our belts are designed to offer superior bonding between plies and covers, which directly impacts their life and reliability. We also support clients
with maintenance manuals and technical advice, helping them improve their system’s productivity and reduce downtime.

How critical are conveyor belts in ensuring seamless material handling?
Conveyor belts are a vital link in the supply chain across industries. In sectors like mining, cement, steel, and logistics, they facilitate the efficient movement of materials and help maintain uninterrupted production flows. At Elastocon, we recognise the crucial role of belts in minimising breakdowns and increasing plant uptime. Our belts are built to endure abrasive, high-temperature, or high-load environments. We also advocate proper system maintenance, including correct belt storage, jointing, roller alignment, and idler checks, to ensure smooth and centered belt movement, reducing operational interruptions.

What are the key market and demand drivers for the conveyor belt industry?
The growth of the conveyor belt industry is closely tied to infrastructure development, increased automation, and the push for higher operational efficiency. As industries strive to reduce labor dependency and improve productivity, there is a growing demand for advanced material handling systems. Customers today seek not just reliability, but also cost-effectiveness and technical superiority in the belts they choose. Enhanced product aesthetics and innovation in design are also becoming significant differentiators. These trends are pushing manufacturers to evolve continuously, and Elastocon is leading the way with customer-centric product development.

How does Elastocon address the diverse and evolving requirements of these sectors?
Our strength lies in offering a broad and technically advanced product portfolio that serves various industries. For general-purpose applications, our M24 and DINX/W grade belts offer excellent abrasion resistance, especially for RMHS and cement plants. For high-temperature operations, we provide HR and SHR T2 grade belts, as well as our flagship PYROCON and PYROKING belts, which can withstand extreme heat—up to 250°C continuous and even 400°C peak—thanks to advanced EPM polymers.
We also cater to sectors with specialised needs. For fire-prone environments like underground mining, we offer fire-resistant belts certified to IS 1891 Part V, ISO 340, and MSHA standards. Our OR-grade belts are designed for oil and chemical resistance, making them ideal for fertiliser and chemical industries. In high-moisture applications like food and agriculture, our MR-grade belts ensure optimal performance. This diverse range enables us to meet customer-specific challenges with precision and efficiency.

What core advantages does Elastocon offer that differentiate it from competitors?
Elastocon stands out due to its deep commitment to quality, innovation, and customer satisfaction. Every belt is customised to the client’s requirements, supported by a strong R&D foundation that keeps us aligned with global standards and trends. Our customer support doesn’t end at product delivery—we provide ongoing technical assistance and after-sales service that help clients maximise the value of their investments. Moreover, our focus on compliance and certifications ensures our belts meet stringent national and international safety and performance standards, giving customers added confidence.

How is Elastocon gearing up to meet its customers’ evolving needs?
We are conscious of the shift towards greener and smarter manufacturing practices. Elastocon is embracing sustainability by incorporating eco-friendly materials and energy-efficient manufacturing techniques. In parallel, we are developing belts that seamlessly integrate with automated systems and smart industrial platforms. Our vision is to make our products not just high-performing but also future-ready—aligned with global sustainability goals and compatible with emerging technologies in industrial automation and predictive maintenance.

What trends do you foresee shaping the future of the conveyor belt industry?
The conveyor belt industry is undergoing a significant transformation. As Industry 4.0 principles gain traction, we expect to see widespread adoption of smart belts equipped with sensors for real-time monitoring, diagnostics, and predictive maintenance. The demand for recyclable materials and sustainable designs will continue to grow. Furthermore, industry-specific customisation will increasingly replace standardisation, and belts will be expected to do more than just transport material—they will be integrated into intelligent production systems. Elastocon is already investing in these future-focused areas to stay ahead of the curve.

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Economy & Market

Impactful Branding

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Advertising or branding is never about driving sales. It’s about creating brand awareness and recall. It’s about conveying the core values of your brand to your consumers. In this context, why is branding important for cement companies? As far as the customers are concerned cement is simply cement. It is precisely for this reason that branding, marketing and advertising of cement becomes crucial. Since the customer is unable to differentiate between the shades of grey, the onus of creating this awareness is carried by the brands. That explains the heavy marketing budgets, celebrity-centric commercials, emotion-invoking taglines and campaigns enunciating the many benefits of their offerings.
Marketing strategies of cement companies have undergone gradual transformation owing to the change in consumer behaviour. While TV commercials are high on humour and emotions to establish a fast connect with the customer, social media campaigns are focussed more on capturing the consumer’s attention in an over-crowded virtual world. Branding for cement companies has become a holistic growth strategy with quantifiable results. This has made brands opt for a mix package of traditional and new-age tools, such as social media. However, the hero of every marketing communication is the message, which encapsulates the unique selling points of the product. That after all is crux of the matter here.
While cement companies are effectively using marketing tools to reach out to the consumers, they need to strengthen the four Cs of the branding process – Consumer, Cost, Communication and Convenience. Putting up the right message, at the right time and at the right place for the right kind of customer demographic is of utmost importance in the long run. It is precisely for this reason that regional players are likely to have an upper hand as they rely on local language and cultural references to drive home the point. But modern marketing and branding domain is exponentially growing and it would be an interesting exercise to tabulate and analyse its impact on branding for cement.

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