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Developing singly-curved earthen slab system for houses using mud-concrete

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 8th International Symposium on Advances in Civil and Environmental Engineering
Practices for Sustainable Development (ACEPS – 2021)

Proceedings of the 8th International Symposium on

Advances in Civil and Environmental Engineering

Practices for Sustainable Development
ACEPS - 2021

Developing singly-curved earthen slab system for houses using

mud-concrete
R.M. Anjana Kalindu Rathnayake1, Rohantha Rukshan Jayasinghe1, Rizna Arooz2,
K.I.U. Nanayakkara3, and R.U. Halwatura1
1Department of Civil and Engineering, Faculty of Engineering, University of Moratuwa, Katubedda, SRI LANKA
2Department of Architecture, Faculty of Built Environment & Spatial Sciences, General Sir John Kotelawala Defence University,
Southern Campus, Sewanagala, SRI LANKA
3Department of Civil and Structural Engineering, Faculty of Engineering, The University of Sheffield, Sheffield, UNITED

KINGDOM

ARTICLE INFO ABSTRACT

Available online 07 October 2021 Sustainable practices in construction industry have become a necessity in recent
times, especially in view of the climate emergency. Using earthen materials is one
more prominent solution. Using earthen materials is limited to flooring or walling
systems, although slabs accounts for 60-70% of embodied energy consumption of
conventional building. This paper discusses the development of a singly-curved
earthen slab system using mud-concrete technology by exploring the construction
Keywords: sequence with a prototype of a 1mx 1m slab having a thickness of 100 mm at the
Singly-curved apex. The construction cost of the proposed slab system was compared with that of
Earthen slabs a conventional reinforced concrete slab system, resulting in a 40% reduction in
Mud-concrete labour and material cost. A load test confirmed the structure could withstand the
compression-only design loading of 2kN/m2.

1. INTRODUCTION the reinforcing steel element. However,

Many novel construction techniques and
practices involving earthen materials have
been introduced in recent times to achieve
sustainability in construction industry.
Although there are many new techniques,
most of them are limited to applications in
walls—e.g. rammed earth walls (Walker et al.,
2005), CSEB block walls (Maïni, 2005), mud-
concrete blocks and walls (Arooz,
2019)(Udawattha et al., 2016a)— or flooring—
e.g. mud-concrete flooring (Galabada and
Halwatura, 2019). However, when the
embodied energy of building elements are
considered, slab systems contribute to 60%-
70% of the total (Foraboschi et al., 2014). If an
earthen slab system is to be developed, it will
be a significant step towards a fully earthen
structure.
Conventional reinforced concrete slab
system relies on tensile strength provided by
earthen materials have low tensile capacity
when compared with reinforcing steel. Thus,
to develop a suitable slab system with earthen
material, either a reinforcing material should
be used or a compression-only structural form
should be selected. The latter approach is
adopted here.
Catalan vaulting is one such slab system
using a compression-only structural form.
Catalan vaulting system (also known as
timbrel vaulting or Guastavino vaulting) is a
construction technique mastered by Romans
and widely used in gothic architectures which
uses thin tiles to build a compression-only
shell structure (Jayasinghe et al., 2019; López
López et al., 2014). The use of thin tiles in a
vaulting system in Sri Lanka has several
drawbacks including production and
transportation of thin tiles, quality issues in
local binding agents, higher labour cost, etc.
(Jayasinghe et al., 2019).

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 8th International Symposium on Advances in Civil and Environmental Engineering
Practices for Sustainable Development (ACEPS – 2021)
Mud-concrete is a novel development to
the traditional walling techniques. This
method is used as an in-situ cast walling
system (Arooz et al., 2017). In-situ casting
systems are labor-intensive and time-
consuming (Löfgren and Kutti, 2001).
However, the use of sustainable materials
makes these systems cost-effective.
This paper discusses the possibility of
using mud-concrete in construction of a singly
curved slab system, as a sustainable and a cost-
effective solution.
2. OBJECTIVES
The work presented in this paper is
primarily aimed towards developing an
earthen slab system using mud-concrete.
Thus, the main objectives of this research are
to;
• determine an appropriate
compression-only shell geometry for
an earthen slab system
• develop a construction process and
construction of a scaled prototype of
the proposed slab system
• assess the construction cost for the
proposed slab system and compare
with that of a conventional reinforced
concrete slab system
3. SHELL GEOMETRY
The geometry of the compression-only
slab system is as given in Figure 1, where the
profile is a barrel vault having a length of 3.0
m and a rise of 300 mm, and the minimum
vault thickness of 100 mm is at the apex. This
is following the Catalan vault of same
geometry proposed by (Jayasinghe et al.,
2019)).
Figure 1 Cross-section of the proposed slab
system
As an initial trial, a scaled down
prototype of 1.0 m span will be studied in the
remainder of the paper. The scaled down
prototype is of a 100 mm rise but has the same
minimum vault thickness of 100 mm,
considering the maximum particle size of the
mud-concrete mix.
4. STRUCTURAL ANALYSIS
Analysis of this structural form using
graphic static has already been done c Here,
analysis of the structural form using a Finite
Element Model is presented. Commercially
available ANSYS software package was used
for this. Following BS-EN-1991-1, an impose
load of 2kN/m2 is applied on top of the slab.
The maximum (compression) and
minimum (tension) stresses were identified as
0.065kN/m2 (near the supports) and
0.015kN/m2 (near mid-section), respectively
(see figure 2). With the distribution of stress
tensors observed in the results, it was
identified that crack formation would begin at
the centre plane of the bottom surface of the
slab system (see figure 3).
Figure 2 Stress distribution of the slab
system when the 2kN/m2 applied on top of
the surface
Figure 3 Vector representation of stress
distribution
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 8th International Symposium on Advances in Civil and Environmental Engineering
Practices for Sustainable Development (ACEPS – 2021)
5. CONSTRUCTION
For the construction, a 1.0 m width of
vault section was selected.
5.1. Formwork
Formwork was designed based on the
deflection of the formwork material and the
deflection under the self-weight of the poured
concrete omit the deformations underside of
the slab. Thus, with the calculation formwork
spacing of 330 mm was chosen. The joists were
cut into arch profile to get the corrected shape
of the formwork (see Figure (i)). The top
surface was formed with 5mm thick plywood
board (see Figure 4 (ii)).
(i) (ii)
Figure 4 (i) Skeleton of the formwork and
(ii) completed formwork
5.2. Construction of Wall Segments and
Fixing of Formwork
Two, 1m heigh wall segments were cast
1m apart. For each wall segment, small duct
pipes were placed near slab level to provide
spacing for the tie rods. Two supporting rods
were used to align the formwork in place
before supporting with props and fixing in
place (see figure 5).
Figure 5 Formwork placement using
supporting rods on the wall sections
216
5.3. Fixing Supports and Sideboards
Bamboo props at a 450mm spacing were
used to support the formwork. 400 mm heigh
sideboards were fixed and levelled, so the
mixture could be poured to achieve the
desired floor level. Thereafter, a thick paste of
grease and oil was applied over the curved
formwork and sideboards, as a release agent.
5.4. Placement of Tie Rods
Two tie rods (6mm in diameter) were
placed to resist the horizontal thrust
generated. To resist the punching load failure
at the wall-tie connection, a 50 mm x 50 mm x
4 mm angle sections were used, and ties were
fixed to the wall with nuts and bolts as shown
in Figure 6.
Figure 6 Placement of tie rods by
nut and bolt method
5.5. Preparation of the Mud-Concrete
Mixture
An air-dried soil sample was sieved to
obtain the suitable particle size for the mud-
concrete mixture. The required particle sizes of
the soil for the mud-concrete mix is as follows;
• Gravel: particles pass from 19mm
(3/4”) and retained in 4.75mm (No.4)
sieve
• Sand: particles pass from 4.75mm
(No.4) and retained in 0.425mm
(No.40)
• Fine: particles pass from 0.425mm
(No.40)
The mud-concrete mix design for the
proposed slab system was borrowed from
Arooz (2019). The weight batched mix is as
follows:
• Gravel (extracted from the soil) - 45%
• Sand (extracted from the soil) - 50%
 8th International Symposium on Advances in Civil and Environmental Engineering
Practices for Sustainable Development (ACEPS – 2021)

• Fine (extracted from the soil) - 5%
• Water - 20%
• Cement - 4%
To achieve self-compacting concrete
properties, water content is to be kept at 20%
of the dry mix (Arooz, 2019). Additionally, a
water-reducing admixture was added (1% by
weight of cementitious materials) to achieve
adequate workability.
Gravel, sand and cement were first mixed
thoroughly with half of the water requirement.
Then the remaining water and fine particles
were added, along with the water reducing
admixture. Mixture was thoroughly mixed to
obtain a consistent fluid mud-concrete.
5.6. Pouring the Mud-Concrete into the
Formwork and Levelling the Surface
The prepared mud-concrete mixture is
then poured on top of the formwork. Initially,
an equal quantity of mixture was poured at the
near supports, and compacted with a tamping
rod. This is to ensure that the stresses
generated during the construction are at a
minimum (see Figure 7).
the mud-concrete mixture was poured into the
mid-section of the formwork (see Figure 8i)
and levelled the surface (see Figure 8ii).
5.7. Curing and Removal of Formwork
Wet gunny bags were placed on top of the
finished surface when the surface was
hardened enough. Sideboards were removed
after 24 hours and curing was carried out for
21 days, using wet gunny bags and spraying.
Figure 9 shows the slab system after 24 hours
of casting.
After curing, the structure was kept dry
for another 7 days. As the initial step in the
formwork removal process, all the props were
loosened and formwork was decentered
carefully without applying sudden or
asymmetric loads. The completed slab system
and bottom face of the slab system are shown
in Figures 10 and 11, respectively.

Figure 9 Slab system 24 hours after casting

ready to be curing

Figure 7 Mud-concrete mixture poured at

the edge of the structure
Also, the tie rods were sequentially
tightened as the filling continued, increasing
the horizontal thrust. After filling the edges,

Figure 10 Completed singly curved slab

system

(i) (ii)

Figure 8 (i) Mud-concrete mixture poured on

top of the formwork and (ii) final finished Figure 11 The bottom face of the slab system
surface

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 8th International Symposium on Advances in Civil and Environmental Engineering
Practices for Sustainable Development (ACEPS – 2021)

5.8. Prototype Load Testing three different structural forms are, (i)
conventional reinforced concrete slab; (ii)
For easy identification of crack formation, singly-curved earthen slab system; (iii) singly
one side of the vault was painted in white. curved mass concrete slab. Total cost was
loading was gradually applied over the calculated to build the above slab systems for
surface to identify whether it satisfy the design 1m x 1m footprint area. All the rates were
criteria. Cement blocks, each weighing calculated from the Building Schedule of Rates
approximately 13.6kg, were used for loading. (BSR-2019/2020) in accordance with CIDA
Each cement block was carefully placed on the regulations in Sri Lanka. Table 1 shows the
slab surface to cover the whole area and cost comparison of the three slab systems. The
gradually increased the loading by stacking labour cost constitutes that for the
cement blocks in layers. construction as well as the material
preparation: e.g., drying and sieving of soil.
Initial crack was observed after stacking
45 blocks: three layers of cement blocks, each
layer consisting of 15 blocks. This corresponds Table 1 Cost comparison of three different
to a uniformly distributed load of 6.08 kN/m2 slab systems
(see Figures 12i and 12ii). The crack was
observed at the bottom mid-span of the vault, Singly- Singly-
where the thickness is minimum. With the R.C.C. curved curved
loading direction, the crack pattern was slab earthe concrete
identified as a tensile crack. system n slab slab
system system

Amount Amount Amount

(LKR) (LKR) (LKR)

Materials
Filling
6424.97 1646.88 6424.97
material
Reinforceme
3321.74 580.00 580.00
(i) nt
Raw
material
N/A 680.00 N/A
Preparation
& Sieving
Formwork 3024.66 3562.85 3562.85
Labour cost 2064.52 2419.72 1599.52
Total cost
14835.88 8889.45 12167.34
per sq.m
Cost 0% 40% 18%
reduction
(ii)

Figure 12 (i) Initial crack was observed
when 45 blocks were placed on top of the
slab system (ii) Initial tension crack at the
mid-section
6. COST COMPARISON
For three different slab systems, total cost
and embodied energy were calculated. The
Production and construction stage were
considered for embodied energy calculations
(Gibbons and Orr, 2020)(Udawattha et al.,
2016b). 25km and 50km distance to source
were assumed for soil and cement
transportation, respectively, considering local
conditions. (Fay and Raniga, 2000; Jayasinghe,
2011). These may vary based on where the
construction was done: Soil was obtained from

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 8th International Symposium on Advances in Civil and Environmental Engineering
Practices for Sustainable Development (ACEPS – 2021)

immediate vicinity with no transportation cost 8. FUTURE WORKS

for the prototype build discussed in the paper.
This paper presents work in an ongoing
project on developing an earthen slab system.
Table 2 Embodied energy calculations for The current paper focuses only on the
three different slab systems construction sequence of the singly-curved
earthen slab system using mud-concrete.
Embodied
Further research should need to be conducted
Energy in
MJ to identify the behavior of the proposed slab
system under dynamic loading and with an
R.C.C. slab system actual scale model (3mx3m vault section).
Material Also, with the minimum thickness at apex
Reinforced concrete slab 6570.00 being relaxed, the slab geometry may be
optimized to match the loading requirement.
Formwork material
To prevent disproportionate collapse, the slab
Plywood 1184.28 shall fail before the walls failing due to
Total EE 7754.28 horizontal thrust. Another important aspect to
Singly-curved earthen slab system be studied is the ductility of the proposed slab
Material system, and if the steel tie-rods add any
ductility to the system.
Soil 183.75
Cement 1170.00
Transport 10.00 9. CONCLUSIONS
Formwork material
In conclusion;
Plywood board (15mm) 1777.93
• Mud-concrete would be an
Plywood board (4mm) 26.57
appropriate construction material that
Total EE 3168.24 can be used to develop a compression
Singly-curved concrete slab system only shell slab system.
Material • Nearly 40% of cost reduction and 59%
reduction for embodied energy could
Concrete 1:2:4 3993.60
be expected, compared with
Formwork material conventional reinforced concrete slab
Plywood board (15mm) 1422.84 systems having identical footprint
Plywood board (4mm) 26.57 areas.
Total EE 5443.01 • A maximum tensile stress of
0.015kN/m2 at the bottom face of the
slab system was identified when
7. DISCUSSION 2kN/m2 load was applied over the top
surface.
Around 46% of the total cost of the singly
curved earthen slab system is spent on the
formwork system. Plywood formwork was
considered for the prototype design due to the 10. ACKNOWLEDGEMENT
ease of construction. However, a steel
formwork may be ideal for modular The authors would like to acknowledge
construction, considering reusability. the support given by the technical officer,
Tie rods were used to resist the horizontal Ms. W.B.U. Rukma from the Department of
thrust. With proper arrangement of rooms in a Civil Engineering, University of Moratuwa.
dwelling unit or a building, the requirement of
tie rods can be partially omitted. This is by
way of horizontal thrusts being resisted by
walls buttressing other interior walls.

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Practices for Sustainable Development (ACEPS – 2021)

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