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Low Cost Materials
Low Cost Materials
Low Cost, Energy Efficient & EnvironmentEnvironmentFriendly Housing Technologies for Developing Countries
12th September,2007 R.K. Celly Executive Director
Severe shortage of houses in developing countries specially for poor people. Severe problem of management of agro industrial waste in developing countries. Mounting pressure on non renewable energy resources. Non-availability of energy efficient technologies for converting agro industrial waste and renewable local resources into alternative materials Expensive & scarce building materials and components.
Building Materials & Technology Promotion Council Ministry of Housing & Urban Poverty Alleviation Government of India
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There is need for adoption of : strong, durable, functional, aesthetic, environment friendly, ecologically appropriate,
energy efficient affordable and adaptable cost-effective materials appropriate technologies in construction.
Promotion of Technology for Low Cost Housing Materials the Collaborative Effort
Technology
Employment Generation
Environment Friendly
Energy Efficient
Utilization of agro industrial wastes Substitution of wood by composite materials made of waste and local natural resources Top soil preservation
Energy Efficient
Simple machines saves energy in production Raw Materials derived from agroagro-industrial wastes and natural fibres, requires less energy in production Products when used in house, buildings provide better thermal comfort that results in conservation of operational energy.
Environment Friendly
Converts agroagro-industrial waste into alternative material for low cost housing, thus improving waste management & environmental protection Utilises local resources Substitutes wood preserving forest cover Substitutes top soil preserving soil for agriculture
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Employment Generating
Simple machines with manual handling, increases employment for unskilled and semisemi-skilled workers Small enterprises can be set up at decentralized locations Production of components involves local people after short training
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Coir fibre-cement roofing sheet & panels Rick-husk- cement building board board timber 3. Ground nut Ground nut- hullhulls (oil mills) cement building board 4. Jute fibre Jute-fibre-polymer (jute mills) bonded panel; door and window 5. Cotton waste Cotton-lint-cement (textile mills) bonded board
Asbestos Resin (PF or UF) bonded particle Resin-bonded particle board timber Timber, metal Gypsum, timber
10 20 20 10 25
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Average Chemical Constituent (%) Source SiO2 Al2O3 Fe2O3 CaO MgO 55 25 15 1.0 5 3.5 40 12 1.5 2.0 10 2.5 30 2.5 40 1.5 12 80 5 4 2.5 10 5 70 2.0 6 0.5 5 5 5 5 1.5 5 5 3 Thermal power plants
Flyash
Blast furnace slag 35 Byproduct gypsum 95 Mine tailings Byproduct lime sludge Laterite waste Red mud 60 10 20 15
Metallurgical slag 32 Broken glass 70 & ceramics Stone quarry waste80 Limestone waste 10
18 35 (15 Tio2) 35 10 5 5 7 2 5 5
Aggregate, cement, brick, cellular concrete Steel plants Aggregate, cement, block Phosphoric acid Hydrofluoric Gypsum plaster, boards, acid plants cement additive, block Fl, Cu,Zn, Ni, Sn ore Blended cement, filler in beneficiation concrete, calcium silicate cellular concrete, brick Sugar, paper, leather, Lime, masonry cement, acety lime plants mortar, plaster Cutting of laterite blocks Building block, aggregate roads Aluminium plants Cement, Cement, brick paints, tiles, filler in FRP Alloys plants Aggregate, blended cement bricks and blocks Glass, ceramic, brick plants Aggregate, flooring, roofing Stone quarrying Limestone quarrying and lime kilns Blocks, aggregate, flooring paving Aggregate, flooring, masonry cement, blocks 16
Each mineral waste has variable composition according to source of the main rock.
1. Steel sheet 2. Aluminium sheet 3. Paper 4. Rubber 5. Plastics (PVC) 6. Glass 7. Wood products
Estimated Cost Saving on using Innovative / Cost Effective Building Materials/Technologies contd.
CostCost-Effective Technologies III. ROOFING 1. 2. 3. 4. 5. 6 7. 8. 9. 10. 11. 12. 13. 85 mm thick sloping RCC Tiles over RCC rafters Brick panel with joists Cuddapah slabs over RCC rafters L-panel sloping roofing RCC planks over RCC joists Ferrocement shell roofing Filler slab roofing Waffle roofing RCC channel units Jack arch brick roofing Funicular shell roofing Brick funicular shell roofing 110 mm RCC Tiles over timber rafters RCC CS over timber rafters RCC RCC RCC RCC RCC RCC RCC RCC RCC 30 25 2020-25 20 10 10 40 22 15 12 15 18 30
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Estimated Cost Saving on using Innovative / Cost Effective Building Materials/Technologies contd.
CostCost-Effective Technologies III. ROOFING ROOFINGcontd. 14. 15. Precast blocks over inverted TTbeams MicroMicro-concrete roofing tiles RCC Clay tile roofing AC sheet roofing 25 20 15 In place of Conventional options % of Saving
% of Saving
IV. MISCELLANEOUS ITEMS 1. 2. 3. 4. 5. 6. 7. RCC door frames Frameless doors (only inserts) Ferrocement door shutters RCC window frames RCC jallies Precast thin lintels Precast sunshades Timber Frames Frames and shutters Timber shutters (second class timber) Timber frames Timber windows/ventilators RCC lintels Cast sunshades 30 50 30 30 50 25 30
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Estimated Cost Saving on using Innovative / Cost Effective Building Materials/Technologies contd.
CostCost-Effective Technologies IV. MISCELLANEOUS ITEMS ITEMScontd. 8. 9. 10. 11. 12. 13. 14. 15. Ferrocement sun shadesshades-cumcumlintel Brick on edge lintels Corbelling for lintels Brick arch for lintels Precast RCC shelves units Precast Ferrocement shelves Ferrocement manhole covers Ferrocement water tank RCC lintellintel-cumcum-sunshades RCC lintels RCC lintels RCC lintels Timber/concrete Timber/concrete Casion/concrete Casion/concrete Rigid PVC 50 50 40 30 2020-35 3535-45 5050-40 60 In place of Conventional options % of Saving
20%
Walls
20%
Roofing
21% 6%
Wooden frame 135/- per RM MS Tee frame Wooden Shutter 1200/- per sqm. RCC Cast in situ 560/-
35%
Door Shutters
20%
25%
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BMTPC was established to bridge the gap between lab & land and facilitate low cost and safer constructions.
Disaster Mitigation & Vulnerability/ Risk Reduction Environmental Protection through technology intervention Cost Reduction & Employment Generation
BMTPC has developed and promoted more than 30 machines for producing costeffective, energy-efficient, environment-friendly building components which are easy to operate.
Employment generation varies from 4 to 14 per machine.
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27
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CBrick Machine
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Alternate Station Hydraulic brick Machine Bi-directional Vibro Press Coal/Stone Disintegrator Bar & Pipe cutting Machine Precast concrete Door Frame making Machine Precast concrete Window Frame making Machine
For production of stabilised soil bricks, flyash bricks For production of cement concrete bricks, blocks and pavers For crushing of large size stone boulders and coal For cutting of bars and pipes For making concrete door frames For making concrete window frames
3 2 1 1
11
8
Ferrocement Rafter Machine Ferrocement Purlins Machine Precast concrete Lintel & Shelves making machine RCC Plank casting machine RCC Joist casting machine L-Panel making machine
For making ferrocement rafter for roofing For making ferrocement purlins for roofing For making concrete lintel & shelves For making RCC plank For making RCC joist For making l-panels for roof
4 4 3 4 4 4 4
6 6 6 6 6 6 6
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7000 Nos.
18 Nos.
14
9
5 Nos.
5
10
4 5
2
11
4 Nos.
4 4
6 6
31
12 13
5 Nos.
Ferrocement roofing For making ferrocement channel making roofing channel machine
Ferrocement wall panel making machine Ferrocement door shutter making machine Solid/Hollow concrete block making machine (standing type) Solid/Hollow concrete block making machine (egg laying type) Solid/Hollow concrete block making machine (surface petrol vibrator)
For making ferrocement wall panels For making ferrocement door shutters For making solid/hollow concrete blocks For making solid/hollow concrete blocks For making solid/hollow concrete blocks
4 4 2 2 2 2
6 6 6 6 6 8
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For making sand cement bricks For making sand cement bricks
2 2 1 1 2
6 6 6 6 6
15
1 Nos.
21 22
16
500 Nos.
Compressed earth block For making stabilised making machine (Balram) soil blocks Compressed earth block making machine (Mardini) Solid/Hollow concrete block making machine (SAKAR) For making stabilised soil blocks For making solid/hollow concrete blocks
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1000 Nos.
23
500 Nos.
18
250 Nos.
24
1000 Nos.
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MCR tile making machine For making micro concrete roofing tiles
200 Nos.
TOTAL
65
151
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Assisted MHA for preparing Model Building ByeBye-laws Organising 11-day technical workshops on Model Building ByeBye-laws in 22 States including NE States Provided Training to 5000 masons and 50 engineers in Gujarat Involved in Training to 300 engineers in J&K 478 model houses constructed in Gujarat 445 public buildings retrofitted Hospital Building at Kupwara School Building at New Delhi
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Capacity Building
Reconstruction / Retrofitting
Initiated retrofitting of 12 MCD Schools at New Delhi Retrofitted Five MCD Schools at New Delhi.
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Exhibitions held
Thailand Turkey Trinidad & Tobago Kenya Uganda Trinidad & Tobago Tanzania Venezuela Bhutan 1995 1996 1997 1997 1998 1999 2000 2002 2005
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Seminar on Technology Options for Cost Effective and Earthquake Resistant Construction in Housing in Bhutan
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Organised 26 training programmes during last year and trained more than 700 professionals from leading organisations like CPWD, PWDs, Railways, NTPC, MES, GAIL, etc.
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252 demo units in Karnataka Constructing 540 demo houses under VAMBAY in Bilaspur (Chhattisgarh), Nagpur (Maharashtra), Bhilwara (Rajasthan), Trichy (Tamil Nadu), Koddalu (Karnataka), Dehradun (Uttranchal) 10 structures using bamboo based technologies in Mizoram 10 structures using bamboo based technologies in Tripura 3164 units in Bawana (Technical Assistance)
Few buildings in Andhra Pradesh, Haryana, Rajasthan, Punjab, Karnataka, Orissa, New Delhi
Demonstration Houses under VAMBAY in BANGALORE No. of Dwelling Units 252 Unit covered area 275 sq.ft. Cost per Unit Rs.60,000 Technologies Used Concrete Blocks Filler Slab Roof Wood alternate Doors
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Demonstration Houses under VAMBAY in NAGPUR, Maharashtra No. of Dwelling Units 70 Unit covered area 194 sq.ft Cost per Unit Rs.50,000 Technologies used Fly Ash Blocks Filler slab Roof Ferro Cement and Fly Ash Polymer Doors
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Demonstration Houses under VAMBAY in DEHRADUN, Uttranchal No. of Dwelling Units 100 Unit covered area 194 sq.ft Cost per Unit Rs.45,000 Technologies used
Solid/Hollow Concrete Blocks Pre cast Plank & Joist Roof RCC Door frame Wood substitute Doors
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Demonstration Houses under VAMBAY in BILASPUR, Chhatisgarh No. of Dwelling Units 100 Unit covered area 194 sq.ft. Cost per Unit Rs.40,000 Technologies Used Fly Ash Bricks Pre cast Plank & Joist Roof RCC Door frame
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Demonstration Houses under VAMBAY in Kudalu, Bangalore No. of Dwelling Units 70 Unit covered area 194 sq.ft. Cost per Unit Rs.60,000 Technologies Used
Solid/Hollow Concrete Blocks Filler slab Roof Ferro Cement and Fly Ash Polymer Doors
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Technology Demonstration-cum-Production Centre at Greater Noida, U.P. (producing cost-effective environment-friendly building components using agroindustrial wastes like flyash, gypsum and hydrated lime)
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Production Unit at Village Sikri, Faridabad, Haryana (Solid and hollow concrete blocks and pavers using flyash)
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BMTPC is promoting Bamboo A material for cost effective and disaster resistant housing used for construction of demonstration buildings and structures structures
Technology Demonstration-cum-Production Centre at Building Centre, R.K.Puram, New Delhi 55 (Chequered tiles using flyash and marble dust)
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Type II house at Luangmual, Aizawl - COMPLETED Picnic Hut at Tiangnuam, Aizawl - COMPLETED
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Main Objective
To establish appropriate mechanisms for promoting investment and technology transfer in the area of innovative and cost effective building materials based on agro industrial wastes in the African, Asian and Latin American regions.
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Eight Bamboo Mat Production Centres in Assam, Mizoram, Meghalaya and Tripura (2 each) are being established.
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Working Group with BMTPC - Ministry and ICAMT-UNIDO Identification of the Universities, R&D institutions, local enterprises in the area of innovative building materials and construction technologies. Establishing linkages for technical cooperation at UNIDO supported centres of developing countries of Asian and African regions.
Waste and local Secondary Resource material based Building Products. PrePre-fabricated building components. CostCost-effective and alternative building materials based housing technologies Technologies for Natural Disaster Mitigation & Management
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Identification of local resource based new Technologies. Skill development through demonstration & training. Saving in energy & material by adoption of prepre-fabricated building components. Skill upgradation of local workers for implementation of disaster resistant housing technologies.
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www.bmtpc.org
Strengthening the Technological base of Housing and Human Settlements Sector
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