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Technological
Base of the
This brochure provides
information on technical,
application and economic
aspects of some of
the viable technologies
Core 5A, First Floor
India Habitat Centre
Lodhi Road
New Delhi-110 003 INDIA
Phone: 91-11-3019367, 4638096, 4636747,
Fax: 91-11-3010145
E-Mail: bmtpc <§ del2.vsnl.net.inwebpage : www.bmtpc.org
SOURCE Application in Building Materialin MT/Yr.
Blast
furnace
slag
Cinder
Coal mine
& washerywaste
Coppertailings
Thermal powerstations
Portland pozzolanacement, bncks. lime pozzolana mixture,lightweight aggregate, cellular concrete door shutters, blocks,tiles, kerb stone, controlled low strength flowable slurry, aspartial replacement of fine aggregate in concrete
Production of Portland blast furnace slag cement, supersulfate cement, as an aggregate in concrete, as substitute forsand, light weight concrete. Road Construction.
Manufacturing of lime cinder mortar, production ofconcrete building blocks, production of bricks from blackcotton soil
Manufacture of bricks, tiles, lightweight aggregates, fuelsubstitute in burning of bricks.
For manufacture of stabilized and high strength0 bricks,cellular concrete and masonry cement, Pressed burnt claybricks, blended cement, calcium silicate bricks.
Steel plants
mi11
Thermal powerstations/
railways
1
Coal mines
«Copper mines
r^3.84
Gypsum Gypsum minesmine rm
1.50 Gypsum building plaster, ready made plaster with lime.
Iron tailing Iron ore mines *21 10.50 For making stabilized and burnt clay building bricks, highstrength bricks, masonry cement, mortar, concrete
Kiln dust Cement plants
B '
'
Limestone
waste
Limestone
quarry
b Lime Sludge Sugar, fertilizercalcium carbide
paper,
acetylene
Bui
PaperWaste
Paper, citygarbage
Phospho-gypsum
Hydrofluoric/phosphoricacid. amm.
phosphate
Illustrated
overview of
availability anduse of indus
trial, urban andagriculturalwastes in India.
Red mud Aluminium
extraction plant
5J
to
2.00 In the cement industry, as a hydraulic binder.
For production of masonry cement and activated limepozzolana mixture.
For the manufacture of Portland cement, masonrycement, sand lime bricks, building lime pozzolanamixture.
For manufacture of pitch fibre pipes, asphaltic corrugatedRoofing sheets, Egg/apple/fruit pack trays, pulp mouldedpackaging materials
For making gypsum plaster, fibrous gypsum boardsand blocks, cement clinker, as a solid retarder and formaking super sulfate cement.
For production of building bricks and tiles, lightweightstructural blocks, roofing sheets and as an additive toconcrete. Paint, Wood substitute, glass ceramic.
n^inc tailings ^inc mines •PJ.-'.y M 2.80 For making cellular concrete, sand lime bricks, precast
IjMpai P«M blocks, concrete flooring tiles, calcium silicate bricks, as fillerMmaLJAmJI in mortar, plaster and precast concrete products, cement
concrete tiles.
Bagasse Sugarindustries m m
90 For manufacture of insulation boards, wall panels, printingpaper, corrugating medium and other non-permanent paper.
- J
ITEM SOURCE
Waste glass Glass plant
Waterworks Waterworks
silts. Settingstanks.
Rice husk Rice mills
Banana Banana
leaves/stalk plants
Coconut Coir fibre
husk industry
Application in Building Material
in MT/Yr
In the manufacture of mosaic and
glazed tiles and lightweight aggregate, brick making, Glass silicatetiles, blunt sand.
For manufacture of structural clayproduct, lightweight bloated clayaggregate, high strength bricks.
As fuel, for manufacturing buildingmaterials and products for production of rice husk binder, fibrous
building panels, bricks, acid proofcement
In the manufacture of buildingboards, fire resistance fibre board.
In the manufacture of buildingboards, roofing sheets, insulationboards, building panels, as alightweight aggregate, coir fibrereinforced composite, cement board,geo-textile, rubberised coir
Groundnut
shell
Groundnut
oil mills K*1 11.00
IIn the manufacture of buildingspanels, building blocks, for makingchip boards, roofing sheets, particleboards.
Jute fibre Jute Industry
m14.40 For making chip boards, roofing
sheets, door shutters.
Rice/wheat
straw
Agriculturalfarm
12.00
1
Manufacture of roofing units andwalls panel / boards.
Saw mill
waste
Sawmills/
wood !ra2.00 Manufacture of cement bonded wood
chips, blocks, boards, particleboards, insulation boards, briquetts
Sisal fibres Sisal
plantationFor plastering of walls and formaking roofing sheets, compositeboard with rice husk, cement roofingsheet, roofing tiles, manufacturing ofpaper &pulp
Cotton stalk Cotton
plantation *z%\ 1.10 Fibre boards, panel, door shutters,roofing sheets, autoclaved cementcomposite, paper, plastering of walls
6 Walling and flooring tiles, bricks andblocks
Marble dust Marble
Industry
1
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From Lab to Land
Our research institutions have develo
large number of alternate materialconstruction systems, based on utilisaU.
agro-industrial wastes which otherwise causesevere environmental problems.
To improve the awareness about theseinnovative building materials, and to facilitatetheir transfer from lab to land, the BuildingMaterials & Technology Promotion Council(BMTPC) had been set up in 1990 by theGovernment of India as an inter-ministerial
apex organisation, under the aegis of theMinistry of Urban Development and PovertyAlleviation. The Council coordinates with
various institutions involved in R&D, financial
& industrial promotion and housing to promote
innovative technologies, scale up p^/entechnologies, materials & product:facilitate establishment of manufactfWng/production units.
BMTPC's working strategy:• Promotion of sound design practices based
on local materials and cost effecative.
innovative technologies.
• Promotion of building materials,
components, products and systems based
on indigenous raw materials, agro-industrialwastes and cost and energy efficientprocesses.
• Quality improvement and cost reductionthrough standardisation and adoption ofmodern information and management
systems.
• Technical, financial, and fiscal policysupportto enhance production & marketability.
Power station
chimneyVarious kinds
of buildingmaterials fromflyash
Flyashdumped onprime urbanland
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CWL
ash:
A Problem of
Pollution
and Disposal
Sources of Flyash72% of India's power plants are coalbased. These power stations generatenearly 95 million tonnes of flyashannually.
Nature of Pollution
Flyash causes severe pollution of airand water, and its disposal gobbles uplarge tracts of land. Well planned
programmes for proper management offlyash are therefore being undertakento enhance the use of flyash in various
lications, so that our alreadylously imbalanced environment can
,>rotected.
Recycling of Flyashks, Portland pozzolana cement,
cks, tiles, light weight aggre-gates.door shutters and hollow blocksare produced utilising flyash as raw
terial. Mechanised manufacture of
ish lime bricks is a major thrust area.The twofold aim is to utilise bulk
quantities of flyash and help bridge thehuge shortfall of bricks and otherbuilding materials required by theconstantly rising construction activity.
Advantages of flyashbricks:
• Several load bearing grades.
• Savings in mortar, plastering.
• Smart looking brickwork.
I * iJ^
* * • V
ITechnology
for the
Manufacture of
Flyash Bricks
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Material handling, storage,transportation equipment:
Material hoppers, vibratory feeders, weighhoppers; silos, screw and belt conveyors;
j brick transfer cars;brick wagons for chargingautoclaves.
Basic process equipment:High speed batch mixer; double shaft mixer,hydraulic brick press with automatic liftingand stocking; Industrial autoclaves of boilergrade steel designed to specified operatingsteam pressure; Industrial steam boiler for
continuous steam at pressure to the
autoclaves.
m Ancillary/auxiliary equipment:
Crane; fork lift, power supply, destination andcontrol station; air compressor; weigh bridge
for trucks; water tube well; piping for air andwater; air conditioners: spares; workshop
and control laboratory equipment; electricaland light fittings etc. Diesel generator.
iWiViriWil fe
Hardware fixingsystem for gypsumboard / ceilingpartitions
Office interiors with
phosphogypsumpanels for partitionsand false ceilingsGypsum slottedpanels
Sample pieces ofgypsum slotted tilesin various finishes
Partition panels inphosphogypsum
m
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Sources ofPhosphogypsumPhosphogypsum is generated as a byproduct of the phosphoric acid basedfertiliser industry. The interaction of
ind phosphate rock with sulphuric
acid produces 10-40% free moisturealong with phosphogypsum. 4 million
tonnes is generated per year in India.
Over 12 million tonnes has accumulated
at plant sites.
Nature of Pollution
The fluoride content of phosphogypsum
causes land and water pollution.
Recycling ofPhosphogypsumThis pollutant by-product from thefertiliser industry can be used to make
several building materials:
• Gypsum plaster, boards, tiles.
• As set controller in the manufacture
of Portland cement.
• Non-shrinking cement, super
sulphated/anhydride cement.
• As a hydraulic binder
• As mineraliser
• Simultaneous manufacture of
cement and sulphuric acid
• Artificial marble, fibre boards
ini;
v,
technology forManufacturing
Gypsum
Walling Panels
A plant has been set up in India to
produce walling blocks, ceiling tiles andbinder from Phosphogypsum.
The following steps convert
phosphogypsum to commerciallygypsum plaster boards:
1. Grinding of calcined gypsum, and itsstorage.
2. Proportioning and mixing of gypsum
plaster with water. Set controller andfiller is added to this slurry with asmall quantity of glass fibre asreinforcement;
3. Casting of board with the boardforming machine.
4. Carrying the 'green' board on a beltconveyor until the core sets andedges are stuck.
5. Cutting boards with a rotary knife intolengths of 1m to 6m before the'green' board reaches the end of the
machine belt.
6. Drying of boards by passing themthrough a tunnel kiln. Hot-air/steamallow recirculation of air. Natural
drying is possible for smallproduction. Drying is a very sensitive
operation requiring careful attention.
7. Transferring of dry boards on toportable platform and transportation
to the warehouse.
Various kinds
of
red mud
polymercomposite tilesand corrugatedsheets
Dry Red Mud -
material
Flow diagramof how
compositedoor panelsare made
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How Composite Doors andPanels areMade
fire lUurtwyTrfjuww
PROCESSING STEPS
AcceWatfd
Hanfcfwr
Mbing
Calendennf oljuteFibre Cloth
Cutinj
Demouldinf «fttrCuring
Aiwmbh/
• <-;! =-:•:>:
Gfh:..-.,- m
Sirring
Red Mud•
Resource for
Hiding
imponenets
rces of Red Mud:
During aluminium production, bauxite
— is digested with caustic soda, whent of the aluminium passes into
ion as aluminate. The muddy redue consists of alumina, iron oxide,
lium oxide and small quantities ofj, calcium oxide and alkali. India
jrates over 4 million tonnes of this
iroduct annually which is notrwise put to any use.
ture of Pollution
Red mud is usually disposed off inponds. During monsoons, the wastemay carry by run-off to surface watercourses and cause ground water
tamination due to leaching.
Recycling of Red Mud' mud can be used for making highlity exposable bricks, tiles,
ugated roofing sheets, and as binderseveral useful products includingiposite doors, panels etc.
rrcl
Red Mud shutter
Press for makingRFPC sheets
Manual applicationof binder
Testing apparatusat RRL, BhopalRed mud doors
being testedCompnents ofRFPC:
red morrum, Jutefibre cloth, lime,rice husk, laddoos,cementitious binder
and mixing ofbinder
*V
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ed Mud -
Resource lor
Ruilding
BMTPC has produced a composite from
red mud, polymer and natural fibres,called Red Mud Jute Fibre PolymerComposite (RFPC), to replace wood in
the wood based panel products in the
building industry. This product uses zeroenergy aided raw materials and
conserves energy by room-temperatureprocessing.
Known as Red Mud Jute Fibre Polymer
Composite (RFPC). this compositecontains ferric oxide, alumina and
titanium oxide from red-mud, 82.5%
cellulose and 11.3% lignin from its jutecomponent (jute is 15% of the total
volume of the shutter).
This newly developed material isparticularly suitable for door shutters,
ensuring significant savings in initial aswell as maintenance costs. There is a
huge market for composite doors andpanels, with the potential waiting to betapped both in developing and
developed countries.
RFPC can also be used for furniture,flooring and panelling work, electrical switch boxes and insulatingsheets for housing.
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BMTPC, in association with the RegionalResearch Laboratory. Bhopal has
developed a technology for themanufacture of flyash/red mud polymer
door shutters, panels etc. This technologyhas been licensed to M/s Dual Build Tech
Ltd.. Chennai for large scale commercialproduction of door shutters, panels etc.A pilot plant for the manufacture of flyash/
red mud polymer door shutters andpanels has been set up at Pondicherry.
Production CapacityThe pilot plant has a capacity to produce
12 to 15 door shutters of standard size
per day.
labour
At 100% utilisation, labour componentrequirement is 8 skilled and 12 unskilled
workers.
Pilot Resin Manufacturing
In order to produce the specific type andquality of polyester resin required tomanufacture red mud/flyash polymer
door shutters, panels etc., a pilot plant tolufacture polyester resin has been set
r at the door manufacturing unit itself.The capacity of this resin plant is 250 Kg(batchsize) per day. The resin so
duced will be used in the pilot plant
the manufacture of red mud/flyashpolymer door shutters. This has helped
reducing costs and improving theility and surface finish of red mud/
lyash polymer door shutters and panels.
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Agro Waste
Recycling into
Building
Materials
Agro waste as rawmaterial
India is primarily an agriculturalcountry. In the absence of organiseddata, exact estimates of the
agricultural wastes such as bagasse,banana leaves and stalks, saw mill
waste, sisal fibre, rice husk, jute stalk
etc., are not available, but their
availability in the country is more than500 million tonnes per year.
Recycling Agro WasteBuildin 1
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Thebuildingmaterialsindustryis
gainfullyutilisingthesewastesina
widerangeofapplications,manyof
whichcanserveas
timbersubstitutes
forwood-basedproducts.B
ytheirvery
nature,fibrouswastesalongwith
suitablebindersunderpressureare
eminentlysuitableformakingseveral
kindsofinsulationboards,panelsand
roofingsheets.Theseproductscanbe
strong,lightweightandalsofind
aestheticacceptance.
Agro-waste recycledinto
boards, mouldings, doors, panellingand
ceiling applications.
1
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Alternative to the
conventional
construction
materials and
technologies forvarious applications in the
buliding industry
I %•
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Composite
iterials
istoncally composite building materials forhousing and building needs were based ontimber, bamboo, jute and a large variety ofvegetable fibres such as reinforced mud-
blocks for walls, panels for partitioning androofing. In the modern context a vast varietyof industrially produced composites havecome into existence.
Multitude of metal composites are nowbeing used with a high degree of confidencefor the most intricate structures. Subsequentdevelopments in the discovery of very toughfibres such as glass, carbon, boron andkevlar made it possible to manufacture and
use several high performance compositeswith matrices of synthetic resins such aspolyesters, phenolics and epoxies.
Search for stronger and stiffer fibres andfeasibility to utilise widespread inorganicwastes and by-products have provideddirections to the production and use ofvegetable fibres, such as coir, banana,
sunhemp, jute, sisal etc., as quiteinexpensive and effective reinforcing fibres,and hydraulic binders as alternative to
cements made of industrial wastes like
flyash. waste limes, by-product gypsum andmine tailings. Technologies have beendeveloped to manufacture buildingcompoenets and products which areenvironment friendly and energy efficient.
These developments have mainly takenplace to meet housing and building
« requirements of ever growing worldpopulation, particularly in developing partsof the world.
Urban plasticwaste from
various sources
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Recycling of
Plastic Waste
for Ruilding
Products
Source of plastic wasteIn the latter half of the 20th century, theuse of plastics has become widespreadin all kinds of products and everydayobjects. Not surprisingly, plasticsconstitute a large part of a city'sgarbage, and are nearly impossible todispose of as plastic waste is not
biodegradable.
Recycling of PlasticsMixed & multilayer plastics containingseveral grades of plastic material can
be made into pallets. Pallets can take
the shape of tile flooring, waste
containers, planks, profiles, railwaysleepers etc.
Plastic Waste as Rinder
Plastic that cannot be further recycledcan be used with fillers for processingcomposites, useful for applications like
fence posts, park benches, pallets,street furniture, as substitute to timber
and concrete products.
Recycled PETUnsaturated polyester resin fromrecycled PET can replace the
conventional high cost resin for use inGRP products, polymer concrete/polymer mortar, and industrial floorings.
Temporary hut usingGRP/ compositebuilding productsTesting of GRP/composite doorshutters
Types of GRP/composite doorshutters
GRP / Composites: An ObuiousChoice for Building Products
The indiscriminate use of wood has led to
serious environmental and ecological crisisand the rapid reduction of the forest cover.Therefore, there is an urgent and imperativeneed to develop suitable substitutes to wood-
based building products. GRP andcomposite materials, with their superior
properties and lower costs, are the obviouschoice for making building products in
volumes.
Composites The Wonder Material
Glass Reinforced Plastics (GRP) and
composites material are being looked upon
now as the most popular and versatile man-made wonder materials which are
increasingly replacing wood, metals and
concrete in thousands of applications,
ranging from aerospace and defence tohousing, construction, transportation,chemical, energy and other engineeringindustries all over the world. It is reported
that about 40,000 GRP / composite productsare currently in use worldwide for manyapplications.
Technologies Developed for GRP /Composites Building Products
The RV-TIFAC Composites Design Centre,Bangalore, has successfully developed anumber of GRP/composite building products
- doors, door frames, window shutters and
frames, wall/partition panels, staircase
railings, roofing sheets, kitchen cabinets andother household furniture items etc.. at very
reasonable costs.
Hot press formanufacture of
bamboo mat
corrugated roofingsheet
Full size bamboo-
mat corrugatedroofing sheetSamples of bamboo |mat corrugatedroofing sheet with
.uv resistant coating |Sheds constructed
with bamboo mat
corrugated roofing' sheet
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bamboo growing regions, and diBister prone-~s, a technology for manufacture of
tated bamboo mat corrugated roofingheets has been developed at the Indian
Plywood Industries Research and TrainingInstitute. Bangalore in collaboration with theBuilding Materials and Technology PromotionCouncil, New Delhi.
This would be an alternative for existingroofing sheets like corrugated A.C. sheets.G.I. sheets, Aluminium sheets. FRP Red Mud
and Ashphaltic sheets.
The sheets possess exceller^physico-
amboo mat
Corrugated
oofing Sheet
ecognising the urgent need for anppropriate and cost effect^ roofing
renewable resources requiring loWenergy. Itmay also find use as value added products in
the areas as an aesthetically pleasingmaterial.
These sheets are not only highly water andweather resistant but also resistant to decay,
termites and insects.
For production of Bamboo mat CorrugatedRoofing sheets in sizes 1.8x0.9m and1.8x0.75m, a one day- light hydraulic hotpress and commercial model of the presshave been developed.
Alternative to theconventional
construction
materials and
technologies forvarious applications in the
buliding industry
Flyash sand lime bricks/
tiles, red mud bricks, tiles,
compressed earth blocks,
precast stone faced Mocks,
Red mud tiles, precast
concrete blocks.
Plastic/PVC, MDF boards,
gypsum fibre boards, ricehusk boards
Rolledsteel, pressed steel,extruded aluminium,
extruded PVC, Precast RCC,Ferrocement, rubber mod,poplar wood.
MCR tiles, red mud h
mat corrugated sheets,ferrocement channels,lurtcutar sheas,
Aluminium rolled and
extruded sections, gypsum
fibre boards, MDF boards.
Particle boards, MDFboards, aluminium, woodand plastic compositi
Red mudjute polymer/lyashpolymer composites, ferrocement, steel, alum
MDF board,noari,
-errocement, steel,
precast RCC, laminated
wood plastic components. |RCC, ferrocement, MDF,
_
oosing
nvironment
Friendly
terials
y and large, conventional buildingtechnologies like burnt bricks, steel andcement are high in cost, utilise largeamount of non-renewable natural
resources like energy, minerals, top-soil,forest cover etc. These increase
dependence on external materials and
manpower, harm the local economy andare generally polluting in nature.
The materials and technologieschosen for construction must, in addition
to functional efficiency, fulfil some ormore of the following criterion, for thecause of sustainability and a betterquality environment:
t endanger bio-reserves and benon-polluting;
• be self-sustaining and promote self-reliance.
• recycle polluting waste into usablematerials
• utilise locally available materials
• utilise local skills, manpower andmanagement systems
• benefit local economy by beingincome generating
jtilise renewable energy sources
• be accessible to the people
• be low in monetary cost
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Open prefab systems based on anappropriate production level and small,
easily to handle elements with
rationalised production methods havettracted the attention of housing expertss an important option for arresting the
rapidly rising escalation in the costs of
material and labour. Building Centres inifferent regions of India have beenistrumental in propagating several oflese prefab systems at the grass-root
artial prefabrication can be usefullymployed for practically every part of awilding - foundations, walling systems,oors and windows, roofing systems,itels and staircase elements. Costs of
roof being one of the major components[the construction outlay in any buildingroject, one of the thrust areas has beenie prefabrication of roofing elements.
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rrocement
ofing Components
chanization productionrrocement roofing channels areduced at manual scale. In this
ject technology development hasbeen limited to finalising designs,
imising production parameters suchmortar proportion, reinforcement,
our productivity, etc. Productionmethods with various degrees ofmechanisation have been explored.
e analysis has been subjected to.'erent economic scales of operation
wherein investment, operating costs,
and the complete productionDnomics will be different from that of
mual operation. The mechanisation
)cess not only enables scaling of
. Jduction from business economics
point of view but also enhancing qualityassurance considerations.
'vantages
Higher strength to weight ratio thanR.C.C
• 20% savings on materials and cost
• Prefabricated elements and light
structures
• Suitability for precasting
Flexibility in cutting, drilling and
jointing
• Very appropriate for developing
countries.
Production of
CLC blocks
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Cellular Light
weight Concrete
Cellular Lightweight Conctrete (CLC) hasbeen used in over 40 countries over the past
25 years to produce over hundred thousandhouses and apartments, apart from schools,hospitals, industrial and commercial buildings.CLC is an air-cured lightweight concrete withflyash as a major ingredient, that can beproduced at large project sites just like
ional concrete, utilising equipment and
-ds normally used for traditionalconcreting. It is especially suitable in India forlow-rise loadbearing constructions and forpartitioning work in multistorey blocks.
CLC behaves like conventional concrete. It
ages well, increasing in sretngth by 50%between 28 and 90 days after pouring. Itkeeps increasing in strength as long as itdraws humidity from the environment. CLCcan be easily nailed, sawed, drilld or grinded.Curing of CLC takes the same time as normalconcrete. If cast in the morning, demolding
can be done next morning. Heat, steam or
chemical accelerators can be used to speed
up curing. Ordinary mortar or plaster, or evenpaint is sufficient for finishing the surface. CLCmay even be pigmented and left exposed.
the use of flyash, CLC blocks are most.mpetetive in price and can be produced at
site, saving transport and multiple handlingcosts. Popular sizes are: 600x200x200mm:500x250x200mm; 500x400x100mm. In view
?e use of flyash (33%) in CLC and this beinggood substitute of ordinary clay bricks
(which use high energy and preciousagricultural topsoil) the Govt, of India hasgiven special import duty concessions forspecialised equipment.
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Concrete door and window frames are
comparable in strength, durability andlality to traditional timber door & window
rames at a substantial cost saving.Commercial levels of production can betaken up at a low level of investment andwith minimal training.
'cast Concrete Door/Window frames are
de out of cement, sand aggregates:ed in suitable proportions to obtain the•ired strength. The mix is vibrated to
compact the concrete. Steel bars are used
as reinforcement. Compared to timber
nes, this product is more durable andimmune to attack of termites, fungii widelyprevalent in most areas. The innovative
technology being demonstrated has beenrecently developed by BMTPC, using anew production methodology based onpatented machines. Advantages:• Conservation of forest reserves of
timber.
• Termite and white ant proof.High quality, long lasting and durable.Much cheaper than timber alternatives.
• High rate of production.
• Minimal requirement of raw materials.• Fire proof.• Water proof.
Produced utilising unskilled labour.Save on the cost of lintels.
Jmited mechanisation resulting in high3er capita output.
• Possibility of using waste industrialproduct like flyash. blast furnace slag,etc.
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Doors/Windows
from Plantation
hers
The ban on the use of timber for
government construction does not cover
the use of plantation timbers and rubberwood and poplar wood have been
recognised as sustainable timber specieswhich will be available without any futurescarcity. However, owing to the nature of
plantation timber, processing of the woodis necessary to enable its use in shutters
and other building applications.
Capabilities Ofthe Machine• That the machines is capable of
processing both soft woods and hard
woods.
• The largest dimension to be
processed is 110 mm x 100 mm.
• The machine is capable of both facefinger jointing as well as butt finger
jointing.
• The machines is capable of utilisingboth thermoplastic and thermo settingresin adhesive systems.
The finger jointing line consist of 2machines: THE FINGER SHAPERand
THE PRESS:
The Tools
There are different types of finger jointingthat is possible. Depending upon thedesign of the finger joints, suitable tools
have to be selected. At the moment, all
finger jointing tools have to be imported.But soon, finger jointing cutters will beavailable inlndia itself. The tools need to
be resharpened periodically for goodresults.
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BRICK PRESSIW1ECHNW.0GY DEVELOP
bmPc»»KUFKTUREO BY
NALDEHRABUILDING CENTRE
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Flyash Sand-Lime
Bricks
lectangular faced with sharp corners,
solid, compact and uniformly shaped with/without frog, sand lime bricks are free fromvisible cracks, warpage, organic matter,pebbles and nodules of free lime, and havea uniform color. These are high qualitymasonry units that can be used toadvantage in exposed brickwork.
Calcium Silicate Bricks are made of finelyground sand/siliceous rock with clay andsilt content less than 5 percent and class
C hydrated lime. Suitable additives can beused to provide early strength and or colour.
Dimensions and Tolerances
190 mm x 90 mm x 90 mm
190 mm x 90 mm x 40 mm
Frog size 100mmx40mm
(10mm to 20mm deep on one of its flat side)
Classification
Sand lime/calcium silicate bricks are of 4
classes depending on average
compressive strength:
Class
|0esig.
75
1100
150
200
Ave. Compressive
Strength (Kg/cm-)
Not less than Less than
75 100
100 150
150 200
Drying ShrinkageClass Designation Drying Shrinkage
(% ol Wet Length)75 0.06
100 0.06
150 0.04
200 0.04
Mechanised
production ofsolid/hollow
concrete blocks.
ssSlP
•• iiit it MM ll
' Solid/Hollow
J Concrete Blocks
itt
J
I WaT ^HH
Concrete block making machinedeveloped by Central Building ResearchInstitute (CBRI), Roorkee, can be used
for production of all types of concreteblocks including solid and hollow blocks(of different shapes and sizes), stone
blocks and large size aggregate blocksby replacing the mould.
Salient Features:
• Egg laying type portable machine
• Casts six blocks in one operation
• Capable of casting 1000 blocks ofsize 290 x 190 x 140 mm in one shift
of 8 hrs.
• Proper compaction of concrete bypressure vibration technique
• Simple technology
• Low investment with high return
• Crushing strength of blocks 70-100kg/cm2 can be economicallyproduced
• Generation of employmentopportunity
• Leaner mix 1:4:4:8 can be used
for production of blocks to achievedesired strength.
• The plant can be convenientlyshifted
• Uniform vibrations
• Less labour requirement
• Industrial wastes like flyash, blast
furnace slag etc. can also be used forproduction of blocks
1 •
111
—~ &X*J
f-
• ' ^nj3
H^b
Micro-Concrete
Roofing Tiles
li^fflwflri^i^rni^flS^^^KWIWK^^fflthe supply gap in roofing materialsbetween the expensive industryproduced (Corrugated galvanised ironsheets, Reinforced cement concrete,
Asbestos Cement Corrugated Sheets.)and traditionally produced materials
(Biomass, Country tiles, Slate, Burnt claytiles).
A technology for producing MicroConcrete Roofing Tiles have beendeveloped which help in optimisingresources, energy consumption andcosts.
Advantages• MCR is cheaper than ACC on steel
and country tiles roofing below spansof 5 mts.
• Decentralised production makes it
more energy efficient.
• Construction and finishing timereduced
• Manageable tile size makes thestructure relatively lighter.
• Upto 40% savings in cement, sandand steel, 100% savings inaggregates.
• Production under controlled
conditions.
I Special tiles are available in 4different types depending on theirfunctionality.
Priced publicationsDIRECTORY OF INDIAN
BUILDING MATERIALS &
PRODUCTS (withinformationon Nepal 8Bhutan) 2000-2001
— 550pages. Rs. 1000♦ 100
«e*3f..
MANUAL FOR REPAIR AND
RECONSTRUCTION OF
HOUSES DAMAGED IN
EARTHQUAKE of Oct.91 in
the Garhwal Regionof U.P.81 pages, Rs. 150 + 50postage
INSTRUCTION MANUAL
FOR APPROPRIATE
BUILDING SYSTEMS
64 pages. Rs. 150 + 50postage
BUILDING WITH
COMPRESSED EARTH
BLOCKS
28 pages, Rs, 60 ♦ 25postage
DIRECTORY OF
CONSTRUCTION
EQUIPMENT AND
MACHINERY
MANUFACTURED IN INDIA•
450 pages, Rs. 600 ♦ 50postage- Also available on CD-ROM
' BUILDING MATERIALS IN
INDIA: 50 YEARS - 560
pages, Rs.1500 * 200postage
GUIDELINES FOR DAMAGE
ASSESSMENT AND POST
EARTHQUAKE ACTION-JABALPUR
Part 1: Earthen Houses with
ClayTile Roofing;Part 2: Brick Houses with
ClayTile Roofing,Part 3: Brick Houses with RC
slab or Stone Parti Roofingor with RC frames
- Rs. 250 ♦ 50 postageforeach part
STANDARDS AND
SPECIFICATIONS FOR COST
EFFECTIVE INNOVATIVE
BUILDING MATERIALS AND i
TECHNIQUES
128 pages, Rs. 200 ♦ 50 postage
STABILISED MUD BLOCKS
AND THEIR USE - GUIDEBOOK
FOR TECHNICIANS AND
CONSTRUCTION WORKERS
(INHINDI)131 pages, Rs 80 +25 postage
HOUSING AND KEY BUILDING
MATERIALS IN INDIA- A LONG
TERM PERSPECTIVE-98
pages, Rs. 700 ♦ 50 postage
ARCHITECTURE OF SAARC
NATIONS.
196 pages. Rs. 250 + 50 postage
VULNERABILITY ATLAS OF
INDIA (1997)- Earthquake,Windstorm and Flood Hazard
Maps and Damage Risk toHousing, 712 pages, Rs. 3000 ♦
200 postage- State and Union Territories -
wise VULNERABILITY ATLASES
- Rs.800 * 50 postage for each
PRECAST BUILDING
COMPONENTS
• 28 pages, Rs. 150 +25 postageand packing
GUIDELINES FOR DAMAGEASSESSMENT AND POST
EARTHQUAKE ACTION
Part 2: Repair and Retrofittingof Buildings in the ChamoliEarthquake Affected Areas;
Part 3:Reconstruction & New
Construction of Buildings InChamoli Earthquake Affected
Areas
- Rs, 250 * 50 postageandpacking for each part
GUIDELINES FOR GUIDELINES FOR IMPROVING
IMPROVING EARTHQUAKE WIND/CYCLONE RESISTANCERESISTANCE OFHOUSING - OF HOUSING - 50 pages. Rs76 pages, Rs. 350♦ 50 350 ♦ 50 postagepostage
oJSSS
Unpriced publications1. Areas of activity
2. An IDNDR International And RegionalProject - Implementation of availableknow-how for the protection of non-engineered housing from NaturalHazards
3. BMTPC helps in commercialisation ofinnovative building materials technologies
4. BMTPC News Letters
5. Build Your Home with EarthquakeProtection
3. Environment Friendly Building Materials & Construction Technologies
7. Guidelines for Cyclone resistanthouses
8. Grah Nirman Mein VisheshSavdhaniyan
9. Investing in Building Materials andConstruction Industry in India
10. Reconstruction of Earthquake Resistant Houses in Garhwal Region -Guidelines in Hindi
11. Retrofitting of Stone Houses inMarathwada Area of Maharashtra
12. Saste Makan: Vibhinn Vikalp AvamSuvidhain - in Hindi
Technology Profiles
.-r. Useful tips for House Builders
15. Strengthening Technological Base ofthe Building Materials Industry
Local Vegetable Fibres + Industrial &
. Machines developed by BMTPC
18. An Introduction to the VulnerabilityAtlas of India
19. Performance Appraisal CertificationScheme
. Catalogue for Machines
MISSION STATEMENT
Develop and operationalise a comprehensive and inte
grated approach for technology development, transfer
and investment promotion to encourage application of
environment-friendly & energy-efficient innovative
materials manufacturing technologies and construc
tion practices for housing and buildings in urban and
rural areas.
OBJECTIVES
1. To promote development, production, standardisa
tion and large-scale application of cost-effective inno
vative building materials and construction technologies
in housing and building sector.
2. To undertake such activities as required for promot
ing manufacturing of new waste-based building materi
als and components through technical support, facili
tating fiscal concessions and encouraging entrepreneurs
to set up production units in different urban and rural
regions.
3. To provide support services to professionals, con
struction agencies and entrepreneurs in selection, evalu
ation, upscaling, design engineering, skill upgradation ,
marketing and technology transfer. To promote invest
ment and technical cooperation between India and other
countries.
El
THROST AREAS
• Improving the policy environment for sustained growth oflow cost building materials, production and availability.
• Promotion of production units ofbuilding materials /componentsbased on Flyash, Redmud,Phosphogypsum, agriculturalresidues and other wastes &byproducts.
• Modernisation of small scaleand village level building materials production units in ruraland urban areas.
• Promoting economy in construction costs.
• Formulation of standards for local building materials.
• Strengthening industrial exten-
and International agencies.
Upscaling of technologies,know-how acquisition, absorption and dissemination.
Assessing vulnerability and riskin natural disaster prone areas.
Promoting disaster resistantconstruction technologies.
Global technology search andencouraging joint ventures in
tion sector.
BMTPC's Activities
Interact, assist and collaboratewith R&D, standardisation andacademic institutions and indus
tries in India and abroad to ensurecontinuous development and promotion of alternate and cost effi
cient building materials and construction technologies.
Identifyand develop technologiesand building materials based onagricultural and industrial wastesand promote proven technologiesfor rural and urban housing construction.
Sponsor and assist financiallyandin other appropriate ways buildingmaterial industries and related ac
tivities in urban and rural areas.
Promote waste utilisation, wood
pilot plants and demonstrationunits/projects.
terns and make recommendations
to Government on matters of equity participation, venture capitalsupport.
Taking note of special needs ofeach region in the areas of building materials and constructiontechnologies, undertake studies
technologies and support furtherresearch and development.
Persuade Central & State Govern
ment agencies, housing development and construction anenr.ies
and organisations in private andcommunity sectors for applicationof proven cost and energy efficientbuilding materials and construction technologies.
Advise entrepreneurs in technologyselection, prototype development,commercial production and marketing and extend appropriate supportfor development of processes/technologies and procuring equipmentetc.
Identify, evaluate and undertakefeasibility studies on innovative energy-efficient building materials/products and construction systemsfor extension of grass-root levelthrough linkages with public, professionals, voluntary agencies and individuals.
Review the various laws, fiscal provisions and pricing of building materials and advise Government in
consultation with concerned Minis
tries/Departments on fiscal conces-
and technologies.
Promote appropriate institutions in
power development through Build-
tates, Housing Guidance Centresand Artisans/Management TrainingCentres.
Act as clearing house of technology transfer from lab to land,through production and application
veloped, under development in India and abroad.
Develop and promote disaster resistant construction technologies for
prone areas.
Promote new technologies throughPerformance Appraisal Certification Scheme and validation of new
technologies and building materials.
• An effective
tool for
transfer of new
innovative
technologiesto field
• for further
details contact
BMTPC
bmJpc
ObjectiveTo encourage and support introduction of innovations inthe building industry through systematic technicalinvestigations, testing, independent appraisal, assessmentand evaluation of building materials, products, componentsand systems for applications based on performance.
PERFORMANCE APPRAISAL CERTIFICATION PROCESS
INPUT
PreliminaryApplication(S)
.>any Profit,.ct Profile
• Expertise in Use• Quality Assurance• Social Benefits
• Environmental
Concerns
• Energy Concerns• Conservation
• User concerns
• Employmentgeneration
• Skill Development
PROCESS
Enquiry/Requestfor Appraisal
1Suitability onsubject for PACAssessment by
LAU/TAC
OUTCOME
Exchangeof Letters
Close
Application
TAC - Technical Assessment Committee; BRA - Building Regulating Authority
Source of AuthorityThe Ministry of Urban DevPoverty Alleviation, Governm.under the Gazette notification
5/99-H-ll in the Gazette of li
dated 4m December 1999, has ai
the Building Materials and TecPromotion Council to issue Perfr.
Appraisal Certificates (PACindependent opinion of the fitintended use of new buildinp rr
components, products.construction systems and as:yet covered by the Indian Stai• PACS is not mandatory but a '
Scheme for manufacturers and
of materials, components. :interested in exploring wpotential.
• BMTPC BOARD OF AGREEM
been constituted for mana<
scheme and providing authtechnical appraisal certifica'Board is a representative
decision makers, professior
experts of Central. State, Fstandardisation and major con
organisations, CIDC. BAI, CPC
Process of Certificationincludes:- Establishing criteria for perforr
the product- Verifying through lab and fi
conformity to requireme
satisfactory performance, dura
safety- Operation of a Quality
Scheme by the manufactinstaller
- Providing, necessary data
designers, engineers, users an<
- The operation of PACSmechanism for obtaining pfeedback
- Issuence of certificates will b
payment of fees by applies
Recommended