Projects
Afcons has successfully used 20-35% of fly ash in its projects since 2005
Published
11 years agoon
By
admin
Deepak Gaikwad, DGM – QAQC, Afcons Infrastructure
Starting with the Tata coal berth project in 2005, Afcons has successfully completed many projects which used 20-35 per cent of fly ash. According to Deepak Gaikwad, DGM – QAQC, Afcons Infrastructure, the decision on using fly ash in concrete should come in the initial/tendering stage of the project. Excerpts from the interview…
Could you brief us on some of your projects which have used fly ash?
Afcons has completed over a dozen projects in India and abroad by replacing 20-35 per cent of cement with fly ash. We started with Tata coal berth project in 2005, where we used 35 per cent of fly ash. In 2006, we used fly ash for the construction of a flyover project in Pune in M75 Grade High performance concrete. In 2007, in MIHAN project near Nagpur, we used fly ash up to 20 per cent.In Kol dam project in 2008, we used 30 per cent fly ash; and in 2010 in Pipavav Drydock, we used 35 per cent fly ash. In Chennai metro project, we are using 28 per cent of fly ash and we are also using fly ash in the Kolkata metro rail project.
What should be the preferred practice of using fly ash?
The decision on using fly ash in concrete should come in the initial stage of the project contract. One has to understand why fly ash is being added to the concrete; what are the properties of fly ash; what kind of fly ash is available in the nearby area; and this needs to be tested by a recognized laboratory. Based on the results, we need to design and develop the concrete mix. We have to analyse the results and accordingly decide on the amount/percentage of fly ash to be added into the concrete. Simultaneously, there are many tests we have to carry out for the fresh and hardened concrete, and come to a conclusion on the use of fly ash.
What are the economic benefits of using fly ash in concrete?
This depends on how far is the thermal power plant from the project site. If it is far away, then the transportation cost will go up. Most of the time, it will come to the same cost of the cement or little bit lower. Normally, even though the cost of fly ash is lower compared to cement, other factors like separate silos for storage of fly ash, a stringent quality control system, etc add to the cost. Proper attention of concrete placing, compaction and curing is needed. Proper curing will ensure presence of moisture which is necessary for the secondary reaction in fly ash based concrete.
How do you procure fly ash for your projects?
We will make available the fly ash depending on the progress of the project. We keep stock of certain quantity of fly ash in advance so that even if there is a delay in getting the fly ash due to certain issues, the project will not stop. Normally, we source fly ash through suppliers. Currently we get fly ash through two suppliers, Ashtech India and Dirk. We select the nearby plants to source fly ash and do testing to match with our requirement as per IS 3812.
What are the key factors to be taken care of while using fly ash in concrete?
The fly ash has to be tested before using. If the requirements are as per IS 3812, ensure that all these parameters are met with then only you can proceed with mix design, take trials and see the results. Fresh and hardened concrete property requirements are important aspects to be taken care of. Proper storage of fly ash is of utmost importance and fly ash should be stored like cement. If fly ash is stored for a longer time, then before using it, you need to retest to ensure the parameters stipulated are met. Another factor is the lime reactivity. the percentage of strength achieved in comparison with OPC mix need to be checked.
What is the awareness level of using fly ash in concrete?
The awareness is gradually increasing; however, people are stuck because many contracts do not specify the use of fly ash properly in the tender document. If the owner is specifying it clearly in the contract document, it will be used in the concrete as a cement replacement, to the percentage he wants. There are two types of fly ash concrete – normal fly concrete and high volume fly ash concrete. In high volume fly ash concrete normally more than 30 per cent fly ash is used. To design and develop fly ash based concrete mixes proper R&D has to be carried out. This will be project-specific and can vary from project to project. One has to carry R&D at his project and come out with proper concrete mix design, and then go ahead with it. At Afcons, we have laboratories at every project sites for testing and R&D. Once the project is over, then we shift to another project.
What is the scope of using fly ash in concrete? What are Afcon?s initiatives towards this?
Certain government organisations have amended the norms for contracts making the use of fly ash mandatory in concrete. The use of fly ash by partially replacing cement in concrete mix helps in minimising carbon emission which happens in manufacturing cement. At Afcons, one of our objectives is to use fly ash or ground granulated blast furnace slag (GGBS), a byproduct of steel industry, in our projects.
When we take up a new project, if the contract does not mention about the use of fly ash, we go to the client to make them understand the benefits of using fly ash and how this will improve the quality of their structure. We make them aware of the benefit of using fly ash or slag in terms of the durability of the structure. We have also worked with a number of government projects where we have used fly ash.
What additional benefits the use fly ash brings to concrete?
The addition of fly ash, a byproduct of thermal power plants into concrete has many advantages especially in terms of durability and strength of concrete. In normal concrete mix containing only OPC, when water and cement comes in to contact, chemical reaction takes place producing binding material and consolidates the concrete mass. The process is exothermic and heat is released which increases the temperature of the mass causing concrete to crack. Fly ash is very light fine particles with cementitious properties. When fly ash is present in the concrete mass, it plays dual role – fly ash reacts with the free lime in concrete mix and produces binder and renders additional strength to the concrete mass and making it denser.
When water is added into concrete, chemical reaction (hydration) starts between water and cement. In this reaction, the unreacted calcium hydroxide creates capillaries in the concrete and destroys the durability of the concrete. It becomes more permeable and external particles attack the concrete through this path. So, in order to enable a secondary reaction for calcium hydroxide, we add fly ash. When fly ash is added into concrete, the silica in the fly ash takes part in the secondary reaction with the free calcium hydroxide in the concrete and forms C-S-H gel. After this reaction, there will be minimum or very little free calcium hydroxide remain unreacted. Thus the concrete becomes more durable.
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Economy & Market
RAHSTA Roundtable Sets Agenda for Smarter, Safer Highways
Published
4 weeks agoon
March 16, 2026By
admin
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.
Concrete
Turning Downtime into Actionable Intelligence
Published
2 months agoon
February 19, 2026By
admin
Stoppage Insights instantly identifies root causes and maps their full operational impact.
In cement, mining and minerals processing operations, every unplanned stoppage equals lost production and reduced profitability. Yet identifying what caused a stoppage remains frustratingly complex. A single motor failure can trigger cascading interlocks and alarm floods, burying the root cause under layers of secondary events. Operators and maintenance teams waste valuable time tracing event chains when they should be solving problems. Until now.
Our latest innovation to our ECS Process Control Solution(1) eliminates this complexity. Stoppage Insights, available with the combined updates to our ECS/ControlCenter™ (ECS) software and ACESYS programming library, transforms stoppage events into clear, actionable intelligence. The system automatically identifies the root cause of every stoppage – whether triggered by alarms, interlocks, or operator actions – and maps all affected equipment. Operators can click any stopped motor’s faceplate to view what caused the shutdown instantly. The Stoppage UI provides a complete record of all stoppages with drill-down capabilities, replacing manual investigation with immediate answers.
Understanding root cause in Stoppage Insights
In Stoppage Insights, ‘root cause’ refers to the first alarm, interlock, or operator action detected by the control system. While this may not reveal the underlying mechanical, electrical or process failure that a maintenance team may later discover, it provides an actionable starting point for rapid troubleshooting and response. And this is where Stoppage Insights steps ahead of traditional first-out alarm systems (ISA 18.2). In this older type of system, the first alarm is identified in a group. This is useful, but limited, as it doesn’t show the complete cascade of events, distinguish between operator-initiated and alarm-triggered stoppages, or map downstream impacts. In contrast, Stoppage Insights provides complete transparency:
- Comprehensive capture: Records both regular operator stops and alarm-triggered shutdowns.
- Complete impact visibility: Maps all affected equipment automatically.
- Contextual clarity: Eliminates manual tracing through alarm floods, saving critical response time.
David Campain, Global Product Manager for Process Control Systems, says, “Stoppage Insights takes fault analysis to the next level. Operators and maintenance engineers no longer need to trace complex event chains. They see the root cause clearly and can respond quickly.”
Driving results
1.Driving results for operations teams
Stoppage Insights maximises clarity to minimise downtime, enabling operators to:
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• View initiating events and all affected units in one intuitive interface.
• Access complete records of both planned and unplanned stoppages
- Driving results for maintenance and reliability teams
Stoppage Insights helps prioritise work based on evidence, not guesswork:
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• Replace manual logging with automated, exportable records for CMMS, ERP or MES.(2)
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A future-proof and cybersecure foundation
Our Stoppage Insights feature is built on the latest (version 9) update to our ACESYS advanced programming library. This industry-leading solution lies at the heart of the ECS process control system. Its structured approach enables fast engineering and consistent control logic across hardware platforms from Siemens, Schneider, Rockwell, and others.
In addition to powering Stoppage Insights, ACESYS v9 positions the ECS system for open, interoperable architectures and future-proof automation. The same structured data used by Stoppage Insights supports AI-driven process control, providing the foundation for machine learning models and advanced analytics.
The latest releases also respond to the growing risk of cyberattacks on industrial operational technology (OT) infrastructure, delivering robust cybersecurity. The latest ECS software update (version 9.2) is certified to IEC 62443-4-1 international cybersecurity standards, protecting your process operations and reducing system vulnerability.
What’s available now and what’s coming next?
The ECS/ControlCenter 9.2 and ACESYS 9 updates, featuring Stoppage Insights, are available now for:
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- ECS system upgrades.
- Brownfield replacement of competitor systems.
Stoppage Insights will also soon integrate with our ECS/UptimeGo downtime analysis software. Stoppage records, including root cause identification and affected equipment, will flow seamlessly into UptimeGo for advanced analytics, trending and long-term reliability reporting. This integration creates a complete ecosystem for managing and improving plant uptime.
(1) The ECS Process Control Solution for cement, mining and minerals processing combines proven control strategies with modern automation architecture to optimise plant performance, reduce downtime and support operational excellence.
(2) CMMS refers to computerised maintenance management systems; ERP, to enterprise resource planning; and MES to manufacturing execution systems.
Economy & Market
FORNNAX Appoints Dieter Jerschl as Sales Partner for Central Europe
Published
2 months agoon
February 5, 2026By
admin
FORNNAX TECHNOLOGY has appointed industry veteran Dieter Jerschl as its new sales partner in Germany to strengthen its presence across Central Europe. The partnership aims to accelerate the adoption of FORNNAX’s high-capacity, sustainable recycling solutions while building long-term regional capabilities.
FORNNAX TECHNOLOGY, one of the leading advanced recycling equipment manufacturers, has announced the appointment of a new sales partner in Germany as part of its strategic expansion into Central Europe. The company has entered into a collaborative agreement with Mr. Dieter Jerschl, a seasoned industry professional with over 20 years of experience in the shredding and recycling sector, to represent and promote FORNNAX’s solutions across key European markets.
Mr. Jerschl brings extensive expertise from his work with renowned companies such as BHS, Eldan, Vecoplan, and others. Over the course of his career, he has successfully led the deployment of both single machines and complete turnkey installations for a wide range of applications, including tyre recycling, cable recycling, municipal solid waste, e-waste, and industrial waste processing.
Speaking about the partnership, Mr. Jerschl said,
“I’ve known FORNNAX for over a decade and have followed their growth closely. What attracted me to this collaboration is their state-of-the-art & high-capacity technology, it is powerful, sustainable, and economically viable. There is great potential to introduce FORNNAX’s innovative systems to more markets across Europe, and I am excited to be part of that journey.”
The partnership will primarily focus on Central Europe, including Germany, Austria, and neighbouring countries, with the flexibility to extend the geographical scope based on project requirements and mutual agreement. The collaboration is structured to evolve over time, with performance-driven expansion and ongoing strategic discussions with FORNNAX’s management. The immediate priority is to build a strong project pipeline and enhance FORNNAX’s brand presence across the region.
FORNNAX’s portfolio of high-performance shredding and pre-processing solutions is well aligned with Europe’s growing demand for sustainable and efficient waste treatment technologies. By partnering with Mr. Jerschl—who brings deep market insight and established industry relationships—FORNNAX aims to accelerate adoption of its solutions and participate in upcoming recycling projects across the region.
As part of the partnership, Mr. Jerschl will also deliver value-added services, including equipment installation, maintenance, and spare parts support through a dedicated technical team. This local service capability is expected to ensure faster project execution, minimise downtime, and enhance overall customer experience.
Commenting on the long-term vision, Mr. Jerschl added,
“We are committed to increasing market awareness and establishing new reference projects across the region. My goal is not only to generate business but to lay the foundation for long-term growth. Ideally, we aim to establish a dedicated FORNNAX legal entity or operational site in Germany over the next five to ten years.”
For FORNNAX, this partnership aligns closely with its global strategy of expanding into key markets through strong regional representation. The company believes that local partnerships are critical for navigating complex market dynamics and delivering solutions tailored to region-specific waste management challenges.
“We see tremendous potential in the Central European market,” said Mr. Jignesh Kundaria, Director and CEO of FORNNAX.
“Partnering with someone as experienced and well-established as Mr. Jerschl gives us a strong foothold and allows us to better serve our customers. This marks a major milestone in our efforts to promote reliable, efficient and future-ready recycling solutions globally,” he added.
This collaboration further strengthens FORNNAX’s commitment to environmental stewardship, innovation, and sustainable waste management, supporting the transition toward a greener and more circular future.
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