Concrete
Concrete repair and corrosion control
Published
13 years agoon
By
admin
Corrosion of concrete happens due to various factors but it is necessary to repair the damage caused by such corrosion. In Part-1 of the two-part series, Upen Patel, Business Director, BASF India, dwells at length on the causes of deterioration and the remedy thereofOnce concrete repairs and strengthening was considered as an activity of rejuvenating the old structures and making them capable of loadings and environmental stresses in the future life. Today we are constructing more advanced and ever more-demanding structures with complex detailing and concrete repairs and strengthening starts during the construction stage itself. The complex and fast pace construction methods with reduced emphasis on adequate quality assurance results in to construction errors and creates needs for repairs and strengthening during construction. With the complex performance demands of the new structures and ever longer life expectancies makes concrete repairs, strengthening and protection procedures more and more demanding. This article is an attempt to present the fundamentals of concrete repairs and strengthening in a step-by-step process and focuses on the advantages and disadvantages of current practices and provides an insight in the futuristic but more simple to adopt techniques.Basic DefinitionsRepairs: To replace or correct deteriorated, damaged or faulty materials, components or elements of a concrete structure.Strengthening: The process of restoring the capacity of weakened components or elements to their original design capacity or increasing the strength of components or elements of a concrete structure.Protection: Making the structure capable to resist the likely deterioration due to the surrounding/ environment.Why concrete needs repairs?There are many factors which lead to the need of repairs such as:??Corrosion of reinforcement due to carbonation, chlorides??Sulphates??Alkali silica reaction??Environmental pollution??Deicing salts??Acid rains??Marine environment??Oils??Freeze thaw cycles??Abrasion or erosion from wind or water borne agents??Plants or microorganisms??Overloading??Physical settlement??Impact??Earthquake??Fire??Chemical attack by aggressive chemicals, sewerage or even soft waterAlso the deterioration gets aggravated due to errors/mistakes/poor workmanship during construction such as:??Higher w/c ratio??Honeycombs and compaction voids??Bleeding and segregation??Plastic shrinkages and hardening stage shrinkage cracks??Inadequate or no curing??In sufficient concrete cover??Cast-in chlorides from contaminated water/aggregates??Inadequate or excessive vibration during the concerting??Shutterwork or reinforcement movement during placement of concreteGenerally concrete structure requires repairs in the two events- New construction and during the service life. Repairs in the new construction require different approach then the repairs during service life and we shall deal one by one to better understand. The repairs during service life have more steps and we shall deal with it first. The repairs during service life arise due to certain deterioration taken place and understanding of the same is very vital in the design of the repair solution.Why concrete deteriorates?The reinforced concrete was designed with a basic understanding that its a marriage of two carrying spouses – concrete and steel. Concrete protects steel from getting corroded and steel protects concrete from getting cracked due to bending. The marriage was designed to last forever but the environment facilitates entry of many agents who leads the marriage to divorce…Major agents and their activities are described as under:-Carbonation: The high pH of concrete passivates steel reinforcement from getting corroded. The carbon dioxide / sulphur dioxide present in the atmosphere gets dissolved in the water and forms weak carbonic /sulphuric acid and enters the concrete reducing the pH, resulting in the loss of passivation layer around reinforcement. The reinforcement states getting corroded resulting in to the rust. The rust formed has 4- times the original volume of the metal creating bursting pressure in the concrete mass. The build up of the pressure eventually cracks the concrete and makes the access for ingress of corrosive water and other water dissolved agents easily. The quicker access aggravates the corrosion and structure starts deteriorating rapidly. Spalling of the concrete cover and formation of brown colored rust is a visual indication of the carbonation attack. The carbonation attack can be checked by phenolphthalein liquid. The reaction is at its best at 50-75 % relative humidity.Chloride attack: The main source of chlorides is the contaminated water or aggregates during construction and marine environment – direct contact with sea water or through wind borne chlorides in the splash zone. Chlorides ions are the passivating ferrous oxide layer on the steel reinforcement. Once reinforcement loses its passivation layer, it is highly susceptible to electro-chemical corrosion further induced by chlorides ions. The water dissolved chlorides ions form electro-chemical corrosion cell and establishes anodic and cathodic sites on the re-bar.The electro-chemical corrosion results in to pitting corrosion-reduction in the cross section of the re-bar at specific sites without noticeable deterioration of the concrete cover. The hidden reduction in the cross-section of the reinforcement can results in to sudden failure of the structure member-making this as one of the most dangerous deterioration in the concrete structure. There is no ‘net use’ of chloride ions during the corrosion process. Therefore, once enough chloride ions reach the steel to break the passivation layer only water, oxygen and a conductive medium is needed to maintain the corrosion reaction. Also note that since corrosion is a chemical reaction, temperature plays a role in the process. The higher the temperature the faster the corrosion reaction occurs. The general rule for the rate of chemical reactions is that for every 25 degree F increases, the reaction rate doubles.Sulphate attack: The main source of sulphates is the ground water. The sulphates attack on concrete, by reacting with the C3A in the concrete. The reactive product is larger in the volume resulting in to the expansive cracking in the concrete mass. The spalling and cracking of concrete takes place without any deterioration of the reinforcement to start with. With the time other forms of corrosion such as carbonation, chlorides becomes aggravated due to quicker access to the reinforcement. The sulphate attack can be reduced by using sulphate resistant cement which has low C3A content; but this reduces the resistance of chloride attack and hence no more a preferred option in the marine situation.Alkali-silica reaction (ASR): In the case of ASR the alkali-reactive aggregates forms expansive gels in the concrete structure resulting in to cracking and spalling.Step-by-step process to successful repairs:-Following steps are essential for successful repairs:-??Evaluation??Relating observations to causes??Selecting methods and material for repairs??Preparation of drawings and specifications??Selection of contractor??Execution of the work??Quality control??Preserve records for futureEvaluationEvaluate the current condition of the concrete structure. Structural analysis of the structure in its deteriorated condition, review of records of any previous repair work accomplished, review of maintenance records, visual examination, destructive and noon-destructive testing and lab analysis of concrete samples. Some of the popular tests used during the evaluation are summarised as under:-??Visual inspection and recording??Hammer sounding / Rebound hammer test??Phenolphthalein test for carbonation??Silver-nitrate test for chloride attack??Half-cell potential measurement??Core-cutting??Chemical analysis of concrete at different depthsRepair philosophyIt is most important to consider the full load envelope, which has been acting on the structure during the complete service life and in the future. The repair materials must have compatibility with the existing structure. The compatibility may be defined as a balance (equilibrium) of physical, chemical, electrochemical and dimensional properties between the repair material and the existing substrate in structural exposure conditions for a determined period of time.1st Compatibility: Physical/Permeability??Allow substrate to breath??Prevent entry of water and waterborne salts – Sulphate, Chlorides, SO2, CO2 2nd Compatibility: Chemical??No negative chemical interaction with the substrate??Absence of potentially dangerous substances such as chlorides, alkalies??No expansive ettringite formation of sulphate3rd Compatibility: Electro-chemical??Higher resistance to corrosion current??Must have conductivity and should not isolate substrate??Effective passivation of re-bars4th Compatibility: Dimensional stabilityCoefficient of Thermal Expansion: Different Coefficients of Thermal Expansion causes differential movement and hence shall be avoided.Modules of Elasticity: Under compression materials of different module will cause stress at the interface and hence shall be avoided.Drying shrinkage: Drying shrinkage of fresh mortar causes stresses at interface; hence needs to be controlled to minimum.(Extract from the paper presented by the author at the Construction Chemicals International Conference 2012 held in Mumbai)(Extract from the paper presented by the author at the Construction Chemicals International Conference 2012 held in Mumbai)
Concrete
Adani’s Strategic Emergence in India’s Cement Landscape
Published
5 days agoon
September 16, 2025By
admin
Milind Khangan, Marketing Head, Vertex Market Research, sheds light on Adani’s rapid cement consolidation under its ‘One Business, One Company’ strategy while positioning it to rival UltraTech, and thus, shaping a potential duopoly in India’s booming cement market.
India is the second-largest cement-producing country in the world, following China. This expansion is being driven by tremendous public investment in the housing and infrastructure sectors. The industry is accelerating, with a boost from schemes such as PM Gati Shakti, Bharatmala, and the Vande Bharat corridors. An upsurge in affordable housing under the Pradhan Mantri Awas Yojana (PMAY) further supports this expansion. In May 2025, local cement production increased about 9 per cent from last year to about 40 million metric tonnes for the month. The combined cement capacity in India was recorded at 670 million metric tonnes in the 2025 fiscal year, according to the Cement Manufacturers’ Association (CMA). For the financial year 2026, this is set to grow by another 9 per cent.
In spite of the growing demand, the Indian cement industry is highly competitive. UltraTech Cement (Aditya Birla Group) is still the market leader with domestic installed capacity of more than 186 MTPA as on 2025. It is targeted to achieve 200 MTPA. Adani Cement recently became a major player and is now India’s second-largest cement company. It did this through aggressive consolidation, operational synergies, and scale efficiencies. Indian players in the cement industry are increasingly valuing operational efficiency and sustainability. Some of the strategies with high impact are alternative fuels and materials (AFR) adoption, green cement expansion, and digital technology investments to offset changing regulatory pressure and increasing energy prices.
Building Adani Cement brand
Vertex Market Research explains that the Adani Group is executing a comprehensive reorganisation and consolidation of its cement business under the ‘One Business, One Company’ strategy. The plan is to integrate its diversified holdings into one consolidated corporate entity named Adani Cement. The focus is on operating integration, governance streamlining, and cost reduction in its expanding cement business.
Integration roadmap and key milestones:
- September 2022: The consolidation process started with the $6.4 billion buyout of Holcim’s majority stakes in Ambuja Cements and ACC, with Ambuja becoming the focal point of the consolidation.
- December 2023: Bought Sanghi Industries to strengthen the firm’s presence in western India.
- August 2024: Added Penna Cement to the portfolio, improving penetration of the southern market of India.
- April 2025: Further holding addition in Orient Cement to 46.66 per cent by purchasing the same from CK Birla Group, becoming the promoter with control.
- Ambuja Cements amalgamated with Adani Cement: This was sanctioned by the NCLT on 18th July 2025 with effect from April 1, 2024. This amalgamation brings in limestone reserves and fresh assets into Ambuja.
- Subject to Sanghi and Penna merger with Ambuja: Board approvals in December 2024 with the aim to finish between September to December 2025.
- Ambuja-ACC future integration: The latter is being contemplated as the final step towards consolidation.
- Orient Cement: It would serve as a principal manufacturing facility following the merger.
Scale, capacity expansion and market position
In financial year-2025, Adani Cement, including Ambuja, surpassed 100 MTPA. This makes it one of the world’s top ten cement companies. Along with ACC’s operations, it is now firmly placed as India’s second-largest cement company. In FY25, the Adani group’s sales volume per annum clocked 65 million metric tonnes. Adani Group claims that it now supplies close to 30 per cent of the cement consumed in India’s homes and infrastructure as of June 2025.
The organisation is pursuing aggressive brownfield expansion:
- By FY 2026: Reach 118 MTPA
- By FY 2028: Target 140 MTPA
These goals will be driven by commissioning new clinker and grinding units at key sites, with civil and mechanical works underway.
As of 2024, Adani Cement had its market share pegged at around 14 to 15 per cent, with an ambition to scale this up to 20 per cent by FY?2028, emerging as a potent competitor to UltraTech’s 192?MTPA capacity (186 domestic and overseas).
Strategic advantages and competitive benefits
The consolidation simplifies decision-making by reducing legal entities, centralising oversight, and removing redundant functions. This drives compliance efficiency and transparent reporting. Using procurement power for raw materials and energy lowers costs per ton. Integrated logistics with Adani Ports and freight infrastructure has resulted in an estimated 6 per cent savings in logistics. The group aims for additional savings of INR 500 to 550 per tonne by FY 2028 by integrating green energy, using alternative fuel resources, and improving sourcing methods.
Market coverage and brand consistency
Brand integration under one strategy will provide uniform product quality and easier distribution networks. Integration with Orient Cement’s dealer base, 60 per cent of which already distributes Ambuja/ACC products, enhances outreach and responsiveness.
By having captive limestone reserves at Lakhpat (approximately 275 million tonnes) and proposed new manufacturing facilities in Raigad, Maharashtra, Adani Cement derives cost advantage, raw material security, and long-term operational robustness.
Strategic implications and risks
Consolidation at Adani Cement makes it not just a capacity leader but also an operationally agile competitor with the ability to reap digital and sustainability benefits. Its vertically integrated platform enables cost leadership, market responsiveness, and scalability.
Challenges potentially include:
- Integration challenges across systems, corporate cultures, and plant operations
- Regulatory sanctions for pending mergers and new capacity additions
- Environmental clearances in environmentally sensitive areas and debt management with input price volatility
When materialised, this revolution would create a formidable Adani–UltraTech duopoly, redefining Indian cement on the basis of scale, innovation, and sustainability. India’s leading four cement players such as Adani (ACC and Ambuja), Dalmia Cement, Shree Cement, and UltraTech are expected to dominate the cement market.
Conclusion
Adani’s aggressive consolidation under the ‘One Business, One Company’ strategy signals a decisive shift in the Indian cement industry, positioning the group as a formidable challenger to UltraTech and setting the stage for a potential duopoly that could dominate the sector for years to come. By unifying operations, leveraging economies of scale, and securing vertical integration—from raw material reserves to distribution networks—Adani Cement is building both capacity and resilience, with clear advantages in cost efficiency, market reach, and sustainability. While integration complexities, regulatory hurdles, and environmental approvals remain key challenges, the scale and strategic alignment of this consolidation promise to redefine competition, pricing dynamics, and operational benchmarks in one of the world’s fastest-growing cement markets.
About the author:
Milind Khangan is the Marketing Head at Vertex Market Research and comes with over five years of experience in market research, lead generation and team management.
Concrete
Precision in Motion: A Deep Dive into PowerBuild’s Core Gear Series
Published
1 month agoon
August 16, 2025By
admin
PowerBuild’s flagship Series M, C, F, and K geared motors deliver robust, efficient, and versatile power transmission solutions for industries worldwide.
Products – M, C, F, K: At the heart of every high-performance industrial system lies the need for robust, reliable, and efficient power transmission. PowerBuild 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’ freedom in design and reliability in execution.
Together, these four series reflect PowerBuild’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.

Klüber Lubrication India’s Klübersynth GEM 4-320 N upgrades synthetic gear oil for energy efficiency.
Klüber Lubrication India has introduced a strategic upgrade for the tyre manufacturing industry by retrofitting its high-performance synthetic gear oil, Klübersynth GEM 4-320 N, into Barrel Cold Feed Extruder gearboxes. This smart substitution, requiring no hardware changes, delivered energy savings of 4-6 per cent, as validated by an internationally recognised energy audit firm under IPMVP – Option B protocols, aligned with
ISO 50015 standards.
Beyond energy efficiency, the retrofit significantly improved operational parameters:
- Lower thermal stress on equipment
- Extended lubricant drain intervals
- Reduction in CO2 emissions and operational costs
These benefits position Klübersynth GEM 4-320 N as a powerful enabler of sustainability goals in line with India’s Business Responsibility and Sustainability Reporting (BRSR) guidelines and global Net Zero commitments.
Verified sustainability, zero compromise
This retrofit case illustrates that meaningful environmental impact doesn’t always require capital-intensive overhauls. Klübersynth GEM 4-320 N demonstrated high performance in demanding operating environments, offering:
- Enhanced component protection
- Extended oil life under high loads
- Stable performance across fluctuating temperatures
By enabling quick wins in efficiency and sustainability without disrupting operations, Klüber reinforces its role as a trusted partner in India’s evolving industrial landscape.
Klüber wins EcoVadis Gold again
Further affirming its global leadership in responsible business practices, Klüber Lubrication has been awarded the EcoVadis Gold certification for the fourth consecutive year in 2025. This recognition places it in the top three per cent
of over 150,000 companies worldwide evaluated for environmental, ethical and sustainable procurement practices.
Klüber’s ongoing investments in R&D and product innovation reflect its commitment to providing data-backed, application-specific lubrication solutions that exceed industry expectations and support long-term sustainability goals.
A trusted industrial ally
Backed by 90+ years of tribology expertise and a global support network, Klüber Lubrication is helping customers transition toward a greener tomorrow. With Klübersynth GEM 4-320 N, tyre manufacturers can take measurable, low-risk steps to boost energy efficiency and regulatory alignment—proving that even the smallest change can spark a significant transformation.

Adani’s Strategic Emergence in India’s Cement Landscape

Precision in Motion: A Deep Dive into PowerBuild’s Core Gear Series

Driving Measurable Gains

Reshaping the Competitive Landscape

CCU testbeds in Tamil Nadu

Adani’s Strategic Emergence in India’s Cement Landscape

Precision in Motion: A Deep Dive into PowerBuild’s Core Gear Series

Driving Measurable Gains

Reshaping the Competitive Landscape
