COST EFFECTIVE HOUSING TECHNIQUES

UNIT III
PART I : Alternative Building Materials For Low Cost Housing

 Due to large-scale construction programmes in the country, the demand for

conventional building materials like cement, steel, bricks and timber has
outstripped their supply.
 Moreover, the exponential population growth and the existing housing.
shortage have made the situation even more alarming.
 There is a general shortage of conventional building materials like cement,
steel, bricks and timber in different parts of the country.
 In 1993, there was an estimated shortage of 55,000 million bricks, 17 million
Tonne of, cement, 285 million tonnes of stones, 2.7 million tonnes of steel
and 13milion cu.m. of timber.
 It is thus quite obvious that the present available stock of building materials
in the country is not in a position to meet the evergrowing demand of
housing.
 In the present situation, the country has very little option but to rely
increasingly on locally available cost-effective building materials and
components.
 The R&D efforts undertaken in the country by various research
organisations like
 CRBI, Roorkee;
 SERC, Madras;
 National Council for Cement and Building Materials (NCB),
Bailabgarh;
 Central Fuel Research Institute (CFRI), Dhanbad;
 NBO and BMTPC have led to development of various low cost, low
energy consuming building materials using several industrial and
agricultural wastes:

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 There is considerable potential for exploitation of the agro-industrial wastes

for their commercial production and large-scale application in construction
programmes.
Substitute for Scarce Materials:
 Research findings of various research institutions like CBRI, NCB and CFRI,
etc., have led to introduction of number of alternative building materials like
hydrated lime, asphaltic corrugated sheets, cellular concrete, flyash bricks,
plastic pipes, secondary species of timber, pozzolana cement and overhead
tanks, etc.
 The NB0 had prepared feasibility reports for setting up plants for
manufacture of such building products.
 Application of these substitute materials have resulted in the saving of scarce
materials like cenment and steel.
 Some of the alternative materials for low cost housing are discussed
below.
Hydrated Lime :
 It is normally assumed that 70% of the cement produced is consumed in
building construction out of which 40% is used for masonry mortars and
plasters.
 Out of this, quite a large percentage of cement can be profitably replaced by
lime alone or in conjunction with pozzolana.
 In recent times, the use of lime in building construction has decreased due to
the varying quality of material available in the market and its inherent defect
such as slow-setting and laborious preparation of mortars.
 An innovative process of hydration of lime has been developed which makes
available hydrated lime in dry form, standard quality and ready to use form
as in the case of cement. It can be stored in bags for 6 months without any
deterioration.
 NBO had set-up a demonstration-cum-production unit for demonstrating the
production of standard quality hydrated lime and lime pozzolana mix in
1976.

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 Consequently, over 50 hydrated lime plants of total capacity of half a million

tonnes have been established in various parts of the country over the past
one decade.
 These plants include 3 plants set up by public sector construction agencies,
one each at Srinagar, Itarsi and Raipur.
 It is estimated that 1 million tonnes of cement in building construction couid
be substituted by the materials produced in the afore- said units with
anticipated saving of over Rs. 20 crore per year.
 Lime pozzolana Mix:
 The clay pozzolana, available in the market, is known as surkhi which is
produced by grinding brickbats and is of variable quality.
 A new process of production of clay pozzolana has been developed in which
clays of suitable specifications are caloried to the optimum temperature and
then ground to a fine powder as per the IS specifications.
 The pozzolana, reactive surkhi, has lime reactivity 5 to 10 times that of
ordinary surkhi made powdering burnt bricks.
 The lime pozzolana mix conforming to LP-20 as per IS: 4098 is made by
grinding the mixture of hydrated lime, and clay pozzolana with a small
percentage of gypsum/sodium metasilicate, etc. to improve their early
characteristics.
 The investment required in production of hydrated lime/lime pozzolana mix
is about Rs 200 to Rs 250 per tonne as compared to a heavy investment of
Rs 1,400 per tonne required for productibn of cement.
 Ferrocement :
 Ferrocement is a highly versatile form of reinforced concrete made of
cement mortar and wire mesh reinforcement and possessing unique blend of
strength and serviceability.
 The major advantages accruing from its usage include thin and light
structure, the ease with which it can be cast, its amenability to repairs in case
of local damage, considerable saving in formwork and saving in cost.
 It is one of the possible substitutes for timber.

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 It can be moulded into any shape by applying suitable techniques.

 Partitions, doors, cupboards, service core units, decorative walls, ceiling
units in various designs and water tanks are some of the items which could
be made using ferrocement without any difficulty.
 Designs have been developed by SERC, Madras for ferrocement water tanks
of 800 litres, 5,000 litres, 7,500 litres and 10,000 litres capacity. These tanks
are economical compared to the traditional brick walled water tanks upto the
extent of 30%. They have been successfully tried out in many locations in
India.
Advantages and Disadvantages of Ferrocement
Advantages
 Basic raw materials are readily available in most countries.
 Fabricated into any desired shape.
 Low labour skill required.
 Ease of construction, low weight and long lifetime.
 Low construction material cost.
 Better resistance against earthquake.
Disadvantages
 Structures made of it can be punctured by collision with pointed objects.
 Corrosion of the reinforcing materials due to the incomplete coverage of
metal by mortar.
 It is difficult to fasten to Ferrocement with bolts, screws, welding and
nail etc.
 Large no of labors required.
 Cost of semi-skilled and unskilled labors is high.
 Tying rods and mesh together is especially tedious and time consuming.

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 Gypsum Boards
 Gypsum board is ideal substitute for conventional building boards in all
types of buildings.
 It can be used in several applications like panelling, wall-covering,
partitioning and false ceiling. It can give the effect of brickwork or a smooth
finishing like Plaster of Paris.
 Gypsum board is fire proof.
 It weighs one-tenth of the normal brick, the actual weight being between 6.5
to 15 kg/ m² depending upon the thickness.
 It is easy to use as it can be nailed, cut and screwed with ordinary tools.Such
boards are available in thickness of 9.5, 12.5 and 15 mm, width of 600, 900
and 1,200 mm, and length of 1,800 to 3600 mm.
 Timber Substitution
 There is presently an acute shortage of good quality timber due to which
timber prices have been rises.
 This is mainly because usually only half a dozen conventional or primary
species of timber such as teak, deodar, sal, shishum and rosewood, etc., are
preferred in building construction on account of their durability, decorative
appearance and high strength properties.
 A survey of forest reserves conducted recently reveals that about 27 million
acres of the world's forests disappear every year.
 In India, in 1900, forests covered 40% of the land area. As a result of
deforestation during the current century, the present level of forest cover in
the country has come down to the level of less than 13% of the land area.
 The present annual requirement of wood is estimated to be about 13 million
tonnes (MT). Against this, a supply of only 6 MT annum is available. The
present demand-supply position definitely points to only towards more and
more scarcity of timber in years to come.
 Apart from the problems of deforestation and steep rise in the prices of wood,
timber has always remained prone to attack by termites, fungi other

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organisms. Most of the wood varieties used in India are susceptible to such
attack.
 Teak, rosewood and white cedar are a few of such varieties that are durable
and resistant to organism attack to an appreciable
 These factors have led to the development of wood substitutes which are
cheaper, curbing deforestation, environment friendly and pest resistant.
Efforts in this direction have started bearing fruit. The largest construction
department in the country namely the Central Public Works Department
(CPWD) has alread taken a bold step in this direction by banning of THE
timber with effect from April 1, 1993.
Some of the wood substitutes are described below.

a) Secondary Species Of Timber

 The FRI has identified 117 secondary species of timber which could be
gainfully used in construction after proper seasoning and chemical treatment.
 The NBO has promoted use of secondary species of timber in construction
through their incorporation in the demonstration houses put up in different
geoclimatic regions of the country, under its Experimental Housing Scheme.
 Some housing boards particularly Tamil Nadu. Andhra Pradesh, -
Maharashtra, West Bengal, Jammu & Kashmir and Karnataka have set-up
integral plants for joinery, seasoning and treatment.
 It is estimated that 20% of the total timber used in building construction is
now Secordary timber.
b) Plywood :
 Plywood utilises the secondary species of timber.
 Shelvings of secondary timbers and synthetic resin are the two basic
materials.
 It is universally available in various grades, sizes and thickness.
 It is used for furniture making, wall panelling, door panels, shelves,
cupboards and other house-hold items.

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 Plywood allows easy and quick working as compared to the conventional

timber.
c) Metals :
 Hollow, pressed metal doors and windows have been used in India by major
construction departments/agencies such as the CPWD and DDA, etc., over
past one decade.
 These doors and windows possess the advantages of longer life, fire
resistance, high fatigue strength, lighter weight, freedom from warping and
swelling.
 Hinges, holdfasts, bolts and nuts are welded to the metal before installation.
 Another improvement over mild steel doors and windows are the recently
introduced galvanised steel doors and windowş.
 Aluminum doors are a popular choice for both residential and commercial
buildings due to their durability, lightweight nature, and modern aesthetic.
 Aluminum is resistant to corrosion, which makes it ideal for areas exposed
to moisture, like bathrooms, kitchens, and exterior doors.
 It withstands different weather conditions, making it great for exterior doors
that face sun, rain, and wind exposure.
 Aluminum doors require minimal maintenance. They don’t rust and can be
easily cleaned with a damp cloth. Periodic lubrication of hinges may be
needed.

d) Poly Vinyl Chloride (PVC)

 Another important wood-substitute that has made in India is the Poly Vinyl
Chloride (PVC).
 PVC wood substitutes are made from polyvinyl chloride (PVC) and are
designed to mimic the appearance of wood.
 They have become popular for a variety of applications due to their
durability, low maintenance, and resistance to moisture.

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 PVC is highly resistant to moisture, insects, and rot, making it an excellent

substitute for wood in areas exposed to high humidity or water, such as
bathrooms, kitchens, and outdoor installations.
 Unlike natural wood, PVC doesn’t crack, warp, or swell with changing
weather conditions.
 PVC wood substitutes require little to no maintenance. They don't need
painting, staining, or sealing and can be cleaned with soap and water.
 It can be used for various purposes, including decking, trim, wall panels, and
even cabinetry.
 It also provides sound insulation, which can be beneficial in interior
applications.
 It can be cost-effective over time due to reduced maintenance, repair, and
replacement needs
 PVC panels are used in cabinetry, especially in kitchens and bathrooms,
where moisture can damage wood over time.

Industrial Waste :
 Industrial waste refers to unwanted or residual materials generated from
industrial activities, including manufacturing, mining, and energy production.

 This waste can include solids, liquids, and gases, and it is often categorized
by its source, composition, or environmental impact.

 Repurposing industrial waste in construction reduces the demand for virgin

resources, lowers costs, and often enhances material properties.

 Here are some of the industrial wastes are :

Fly ash , Blast furnace slag , Red Mud , Red Mud Plastic , Lime sludge

a) Fly ash :

 Fly ash is a fine, powdery byproduct produced by burning pulverized coal in

electric power plants.

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 It is collected from the exhaust gases before they exit through the plant
smokestack.

 Fly ash is composed primarily of silica, alumina, calcium oxide, and iron
oxide, along with smaller amounts of other elements.

Applications of Fly ash :

 Fly ash has a range of beneficial uses, especially in construction and

environmental applications

 Fly ash is widely used as a supplementary cementitious material in concrete.

 Fly ash can be used in soil stabilization, as a filler material, and in the
construction of roads, embankments, and levees. It helps improve the
strength and stability of the soil.

 Fly ash is sometimes used in the reclamation of abandoned mines and

landfills, where it can fill voids, stabilize soil, and reduce erosion.

 Fly ash bricks and blocks are becoming a popular, eco-friendly alternative to
traditional clay bricks. They require less energy to produce and utilize
industrial waste.

 Fly ash is often cheaper than traditional materials like cement, offering
potential cost savings in construction projects.

b) Blast furnace slag

 Blast furnace slag is a byproduct of the iron-making process in a blast

furnace, where iron ore is reduced to iron.

 When iron ore, limestone, and coke are heated to high temperatures in the
furnace, impurities separate from the molten iron and form a layer of slag.

 This slag consists mainly of silicates and aluminosilicates of calcium and

other bases, and it is typically removed from the furnace as a molten
material.

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 When rapidly cooled by water quenching, it forms granulated blast furnace

slag (GBFS).

Uses of Blast furnace slag

 Ground granulated blast furnace slag (GGBFS) is used as a cementitious

material in concrete, where it can partially replace Portland cement.

 Blast furnace slag can be used as a road base and as an aggregate in asphalt
and concrete.

 slag is also used in land reclamation and as a material for encapsulating

industrial waste.

c) Red Mud :

 Red Mud is Also known as Bauxite .

 Alumina red mud is one of the important inorganic waste materials obtained
in large quantities from the aluminium producing plants.

 It is estimated that over 2 MT of red mud is produced annually in the

country from the various aluminium plants.

Uses of Red Mud :

 Red mud can be processed and used in the manufacture of cement, bricks,
and tiles. It can act as a partial replacement for raw materials in cement
production, potentially reducing waste.

 It can be used in wastewater treatment to absorb heavy metals and in acid

mine drainage remediation due to its neutralizing properties.

 presence of 4-5% of alkali in the red mud provides good fluxing action
resulting into good plasticity and better bond Characteristics in brickwork.

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d) Red Mud Plastic (RMP)

 The Red Mud Plastic, made by combining polymer (PVC) and red mud
Waste (from aluminium industry).

 The Red Mud waste is the sludge left after bauxite is refined to aluminium
oxide.

 The Red Mud waste and PVC are combined in the ratio of 25% :75% to
form RMP. Possessing a better heat stability, the material is claimed to
possess extra fire and thermal insulation.

 RMP is also claimed to be weather proof with a long exposure life.

 RMP sheets have been successfully adopted in Japan, China and tropical
countries.

 RMP characteristics make it a suitable material for roofing and cladding.

Lime Sludge

 Lime sludge, which essentially contains Calcium Carbonate with varying

amounts of free lime is a waste product from sugar, paper, fertiliser and
Calciumn Carbide industries.

 The annual production of lime sludge is ap proximately 4.8 MT.

 The utilities of lime sludge for the manufacture of cement and lime have
been investigated for commercial exploitation.

 lime sludge mixed with rice husk may be used as a cementing material.

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Agricultural Waste :
 In the rural areas 370 MT of agro-waste is available of which 50 MT
comprises Cotton stalks, jute stalks, maize stalks and other such crop
wastes.

 Another 50 MT comprise rice husk, bagassse, raw-dust groundnut shells and

such small wastes. These could be gainfully utilised as viable building
materials.

 Many agricultural waste products have excellent insulation properties,

helping reduce heating and cooling costs.

 Agricultural waste materials are often cheaper than conventional building

materials, making them accessible in low-cost housing.

 Using agricultural waste in building construction not only improves

sustainability but also promotes a circular economy.

a) Rice Husk

 About 25-30 MT of rice husk is produced annually in the country.

 The highly reactive pozzolana produced from rice husk and clay may be
used for making masonry mortar and plaster of different grades.

 Rice husk is obtained as a waste material from rice mill.

 The CBRI, Roorkee, has developed a method of production of rice husk

based building materials which can be used as a substitute for cement in
many ways.

 it can also be used for making building blocks and boards with suitable
binders.

 Rice husk being predominently siliceous in nature, has been utilised as on

additive with highly plastic soils in reducing the losses during drying of
bricks.

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 The National Building Research Station, Karachi (Pakistan) has successfully

tried out rice-husk ash (RHA) in combination with lime in production of
hollow load bearing blocks, mortar and plaster for construction of low cost
houses undertaken by the Institute.

 Thirty per cent of Portland cement was substituted by RHA in construction

of precast lintels and roof beams.

b) Coir Waste :

 The production of coconut waste in India is estimated at 2 MT.

 About 50 % of the coconut is used for making coir/mats/ cushions, etc.The

remaining raw material is mostly used as fuel.

 The CBRI, Roorkee, has developed a process for making corrugated roofing
sheets utilising coir, waste or wood-wool waste and cement.

 These sheets are light and tough, and possess good-bonding strength having
good thermal insulation properties.

 They are about 50% cheaper in comparison to asbestos cement sheets.

c) Bagasse :

 Bagasse is the fibrous residue from sugarcane processing (or) Bagasse is a

fibrous byproduct left after sugarcane stalks are crushed to extract their juice.

 The estimated annual production of bagasse in the country is around 5.30

MT.

 Due to its fibrous components, bagasse can be utilised for production of

insulation boards and building wall panels with the use of a suitable organic
binder.

 Bagasse can be processed into boards similar to particleboard or MDF

(medium-density fiberboard), which can replace traditional wood-based
materials in furniture, wall partitions, ceilings, and flooring.

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 Bagasse-based boards and panels are lightweight, making transportation and

installation easier.

 Bagasse is renewable and readily available in sugar-producing regions.

Using it reduces the need for wood and minimizes agricultural waste.

 It is generally cheaper than conventional building materials, making it

suitable for affordable housing projects.

 bagasse is a promising, eco-friendly building material that capitalizes on

agricultural waste to create sustainable, cost-effective, and energy-efficient
construction products

Other Agricultural Wastes

 Furthermore, about 10 MT of cotton stalks, 4 MT of jute stalks, 5.75 MT of

groundnut hulls, 2 MT of sawdust (saw mill waste) and 1 million of coconut
pith are available in the country for their exploitation as viable building
materials.

 The R&D efforts have been undertaken in the country for the development
of building materials, especially for production of roofing units and walling
boards by utilising these wastes.

 However, no indigenous technology has been developed in the country for

commercial production of building components based on these agro-wastes.

Future Strategy for Promotion of Alternative Building Materials

 Industrial and agricultural wastes like flyash, phosphogypsum, blast furnace

slag, red mud, rice husk and coir waste, etc., hold great promise as building
materials.

 Several governmental efforts have been undertaken in recent years the

country to popularise use of such materials.

 Some of the measures initiated in this regard are listed as below:

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1) The National Hocusing Policy (NHP) announced by the Government of

India in May 1992 has emphasised on economising the use of scarce
building materials and promoting use of cost-effective and environmentally
appropriate technology and indigenous resources.

2) the NHP advocates earmarking 10% of the total construction by public

construction agencies over the use of cost effective technologies and
materials.

3) The HUDCO and NHB are promoțing new building materials production
units based on agricultural and industrial wastes by participating in the
equity of new units.

4) The HUDCO is also extending term-loan support to entrepreneurs for

setting-up industry for production of building components based on agro-
industrial wastes.

5) While technologies for making clay bonded sand-lime and phosphogypsum

based building products have been developed at the CSIR laboratories, the
BIS has either developed or is in the process of developing national
standards on such bricks and other applications of flyash and
phosphogypsum in construction works.

6) The Building Material and Technology and Promotion Council (BMTPC),

under the Ministry of Urban Development (MUD), has undertaken
identification of potential technologies which could help larger utilisation of
industrial wastes like flyash, phophogypsum in construction industry.

7) The Building Material and Technology and Promotion Council has prepared
technical profiles in respect of clay,fly ash,burnt bricks, flyash-sand-lime
bricks, cellular concrete components, cement fibre roofing sheet, alumina-
red mud bricks and phosphogypsum based buildings components for their
larger exploitation in building

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