Training Report

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Low Carbon Construction Training Report

Artisan Training – Himachal Pradesh

22nd – 28th April 2013

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Contents

1. Background ................................................................................................................................................................ 2

2. Training Approach ...................................................................................................................................................... 2

3. Training Process ......................................................................................................................................................... 3

4. Observations and Lessons learnt ............................................................................................................................. 14

5. Annexure 1 : List of Participants .............................................................................................................................. 15

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Figure 1: Settlements in wet & hilly regions of Himachal Pradesh

1. Background

A mason training on Low Carbon Construction techniques was held from 22nd to 28th April 2013 at the Appropriate

Technology Centre, Sundernagar, Himachal Pradesh. It was organised by State Council for Science and Technology in

collaboration with the Development Alternatives Group, New Delhi and supported by the Climate and Development

Knowledge Network (CDKN), UK. The 7 day workshop aimed to build capacities of artisans and masons and

demonstration of low carbon cost effective construction techniques in wet and hilly spaces like Himachal Pradesh.

The training was attended by 16 skilled and semi-skilled masons from varying districts of Himachal Pradesh - Solan,

Bilaspur, Sirmour, Mandi, Hamirpur and Kullu.

Climate change impacts are now being felt at a local and global level. The construction sector sustainably contributes

to this. Simultaneously, it also bears the brunt of these impacts. The practices in the construction sector of Himachal

Pradesh that aggravate climate change need to curb their impact on the local environment by,

Reducing ecologically detrimental methods of sourcing building materials.

Using more energy efficient construction technologies.

Ensuring minimum amounts of energy used in the operation of buildings constructed.

Alternate technologies and materials offer a solution to deal with this challenge. The Government of India has

recognised the need for action in the Low Carbon, Climate Resilient (LC-CR) sector. However, there is a lack of

attention towards the 70 million strong rural spaces and small towns which are emerging as areas of high growth.

This training workshop aimed to bridge this gap

by generating knowledge support for LC-CR

solutions for small towns and rural spaces to

build capacity for masons and artisans.

The training is part of a larger initiative that

seeks to generate knowledge support for LC-CR

solutions for small towns and rural spaces by

building capacity at three levels, viz. Policy

Makers, Building Professionals and Artisans. It

also attempts to influence policies and building

practices in response to imminent climate

change trends and need for low carbon

construction.

The objective of the workshop were to :

Understand concepts and dynamics of climate change and the construction sector

Learn about alternate building materials and technologies

Demonstrate these technologies and gain hands on experience.

2. Training Approach

The Appropriate Technology Centre (ATC) has a long history in the training of mason groups in various alternate

technologies. The ATC is situated in the campus of the Government Polytechnic, Sundernagar. The training team

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included engineers Kalit Bhardwaj (ATC), who supervised as well, Pankaj Khanna (DA), architects Amol Mangrulkar

(DA), Rita John (DA) and faculty from the Government Polytechnic. Master masons who conducted demos were

Prakash Chand and Amarnath.

The technologies taught/demonstrated during the 10 day training were:

Interlocking compressed earth blocks

Cavity wall masonry

Hollow concrete blocks

Rat trap masonry

Stone masonry

Stone filler blocks

Ferro-cement channel roofing & water tank

Plank and joist roofing

Rain water harvesting techniques

Thermo-siphoning air heating panel.

3. Training Process

Over the seven day period, the DA and ATC team worked closely together to create a step by step training agenda

that covered theoretical as well as practical aspects of various alternate technologies. The workshop employed the

teaching staff of the Govt. Polytechnic’s civil engineering department to conduct classes for the masons on various

topics. These lectures were followed up by demos of the technologies on site and replication of the same by the

masons themselves.

Day 1: Introduction to the Training

An introductory session was conducted for the entire

workshop group of masons to be trained. Er. Kalit Bhardwaj

(ATC), gave a brief welcome to the participants followed by

individual introductions by the masons explaining where

they hailed from and what kind of work they specialized in.

From this it was evident that the group had a mixed set of

skills varying from masonry, carpentry and building material

production.

Pankaj Khanna conducted an orientation session to

elaborate to the masons the aims of the overall project and

specifically the workshop at hand. In the local language and

in lay-man terms he explained what climate change is, what LC-CR construction means and the role and importance

of masons in the completing the cycle of low carbon

growth in the construction sector.

He asked the masons what they thought were climate

change impacts locally. The major observations

mentioned by the masons were varying rainfall

patterns, with drought some years, an overall rise in the

“Water sources are getting depleted with tube wells draining

out water from underground sources. This is affecting the

growth of plants that are used as animal fodder.”

- Vikram Singh, Sirmour district.

“As more permanent construction has been

happening, as many problems have cropped up.

The earlier vernacular style of construction was

much better. It kept us warm in the winter and cool

in the summer.”

- Sh. Jagdish Sharma, Bilaspur district.

Figure 2: Introductory session

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temperature triggering the need for fans and even ACs in place that previously didn’t require them. Reduction in the

intensity of cold during the winter seasons was noted, too.

Also discussed was the existing building practices in

Himachal Pradesh and list was made of the challenges

and issues faced by the local construction sector. Timber

construction, in spite of various thermal and earthquake-

proof advantages, is no longer prevalent in the area due

to the ban on use of timber in building construction.

Earlier timber distribution rights existed, but they don’t

anymore.

In an interactive manner with the masons, Pankaj

Khanna drew out the following points that masons felt

were issues with the current modes and rate of

construction in Himachal Pradesh:

Excessive construction – lack of space

Earth quake risks

Landslide risks

Prevalence of RCC construction

Water shortages

Urban heat islands due to the use of heavy materials

Sourcing of building materials over long distances

After this followed a detailed discussion of the

advantages and relevance of multistoried vernacular

structures that Himachal Pradesh has a rich tradition of.

Mud construction in particular was taken up as a

technology based on the vernacular, but has now been adapted (by the use of stabilized earth blocks) to suit modern

needs. Built examples of varying scales were shown to the masons through photographs and drawings, including

those of the process of Stabilized Earth Block manufacture. Some of the masons noted down the names and prices of

the equipment required for this manufacture process with an interest of possibly setting up manufacture units in

their local towns.

Day 2: LC-CR Masonry Techniques, Earth-quake

Resistant Construction

Pankaj Khanna conducted an interactive session with the

masons elaborating upon various LC-CR masonry techniques.

He touched upon some incorrect practice that takes place in

choosing the right masonry block. Stone filler blocks were

introduced as a way to utilize waste stone pieces and also

provide a chance for the mason to develop the aesthetic of the

building material.

“In Shimla, there are bye laws that state that any new construction must have a minimum of 4 storeys, thus

creating a need for RCC structures.” - Sh. Umesh Kumar, Mandi district

Figure 3: Construction Practice in HP

Figure 4: Interactive sessions with the masons

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The rat trap bond masonry technique was introduced as a cost and material saving measure. He asked participants to

identify what is different about a rat trap masonry elevation from a

conventional English bond one. Using this comparison he explained

how it is constructed and the main concerns of material efficiency

and earthquake resistant features. He also showed them numbers

indicating quantity of material used in rat trap masonry comparison

with conventional masonry.

On the topic of traditional use of random rubble stone masonry, one

of the masons, Sh. Sharvan Kumar, noted that stone masonry walls

constructed today aren’t as strong as their predecessors. This led to a detailed discussion on quality control and good

practice in constructing such masonry.

This was followed by a lecture by Ar. Hans Raj on the construction details of earthquake resistant housing. He

elaborated, in lay man’s terms, what happens to a building when a earthquake shakes it and how the unnatural

pressures exerted upon it in such a situation can be dealt with effectively. With a number of diagrams and example

he showed them the do’s and don’ts in building earthquake resistant structures.

After lunch, the practical sessions of the technologies discussed so far were begun. Some masons set out applying the

quality control principles of random rubble stone masonry by assembling an L-Junction in the same. The remaining

group used a 6-block mould to cast stone filler blocks with different patterns generated on them by the specific

arrangement of stone chips. A T-junction in rat-trap wall masonry was construction with reinforcement in the

junction for earthquake resistance.

The base of a ferrocement water tank to be cast the next day was also prepared.

Figure 5 : Figure 5: Base of water tank being laid(left) Random rubble stone masonry(right)

“Often the load bearing capacity of the block is considered the main criteria even in frame structures, where walls are non-load bearing,

when the actual main area for concern should be their ability to withstand

weathering.” - Pankaj Khanna .

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Figure 6: Stone filler blocks being cast(left) and after the mould was removed(right)

Figure 7: Rat trap masonry being explained and assembled

Day 3: LC-CR Masonry Techniques, Earth-quake Resistant Construction

The ferro-cement water tank started the previous day was continued. The wire mesh reinforcement was put in place

under the supervision of the master mason, Sh. Prakash Chand, who taught the other masons how to cut, assemble

and trim the mesh. After this the right mortar mix was applied onto the outer surface of the structure formed.

The stone filler blocks in the meanwhile, had set and now, the patterns made by the stone chips were evident on

them. The rat trap and stone masonry junctions were completed. The carpenters in the groups, under the

supervision of a master carpenter, Sh. Amarnath, began work on a thermo-siphonic air-heating panel.

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Figure 8 : Casting the ferrocement water tank

Figure 9: Stone filler blocks (left) Rat trap masonry junction (right)

Figure 10 : Stone masonry (left) Carpentry work begins (right)

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Day 4: LC-CR Masonry Techniques, Earth-quake Resistant Construction(Practical)

After four courses of rat-trap masonry were complete, a reinforced band was laid demonstrating how such bands are

to run all along the building periphery for earthquake resistance. Work continued on the ferrocement tank and the

frame of the air-heating panel was completed.

Figure 11 : Earthquake resistant band being cast

Figure 12:Frame of the thermo-siphoning air heating panel being completed

Day 5: Solar Passive Technologies, Ferro-cement Roofing and Water Tanks

Kalit Bhardwaj, ATC, conducted a lecture on Solar Passive technologies. He began with an introduction about the ATC

and the relevance of climate appropriateness of technologies used in building activity. He showcased work already

done by the ATC in the form of greenhouses and poly-houses constructed all over Himachal Pradesh in various

materials and scales utilised for efficient production of crops by providing a thermally controlled environments.

The basics of solar passive design were explained to the masons. On being asked which orientation of the building

receives maximum sun, the masons incorrectly responded “east”. This view was quickly correctly and the path of the

Sun in the wet and hilly regions of Himachal Pradesh were shown to the them through diagrams and simple

explainations of how the Sun behaves in various seasons.

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Figure 13: : Session on ferrocement technologies (left) and solar passive technologies (right)

After these basic solar passive concepts, some system heating systems like trombe walls and air heating panels were

touched upon. Questions were asked about what kind of appropriate insulation materials could be used to make the

building envelope more thermally effective. A number of case studies were shown demonstrating how the concepts

were to be applied locally and the various learnings from each

project were shared.

Next, Er.Dhingra, ATC, conducted a lecture on ferrocement

technologies. He began the lecture by first explaining was the

conventionally used Reinforced Cement Concrete(RCC) technology is and did away with many myths about its

construction and performance. He greatly stressed on the need to minimize the use of excess steel as not only would

this be wasting a highly energy intensive material, it often doesn’t necessarily increase the durability of the structure.

He also explained the role of reinforcements in concrete and about how there are many alterntaives to steel in this

area including bamboo. This led to many queries about the usability and treatment of bamboo. After this he

explained the workings of the ferrocement technology and its versatility in constructing building elements of any

required profile. The masons then completed with the practical work on the ferrocement water tank and a base

mould was made to cast a ferrocement roofing channel the next day. Carpentry work on the air heating panel

continued in parallel.

Figure 14: Completed ferrocement water tank

“The wrongest notion is that more steel means greater strength.”

– Er. Dhingra

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Figure 15:Layers of insulation and conducting material being installed in the air heating panel

Figure 16 : Mould for ferrocement channel being made

Day 6: Rainwater harvesting Air Heating Panel, Ferro-cement Roofing Channel

M K Sharma, ATC, conducted a lecture on rain water harvesting where he explained water cycle and the importance

of rain in the cycle. The process of implementation of rainwater harvesting was elaborated upon and he taught

masons the method of calculation of amount of incident rainfall which is needed to ascertain the size of water

storage tanks to be built. He also introduced them to various types of water filters that use local materials. Questions

were asked on how to maintain such filters, their cost and feasibility.Ways to return water to the water table through

various types of wells were also discussed.

The masons then continued the practical work and completed some ferrocement water tank lids while the

carpenters proceded with installing the double glazing in the air heating panel. Special measures were taken in the

joining details to prevent condensation between the glass panels.

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Figure 17: Ferrocement water tank storage lids (left) Construction of air heating panel.

Hollow conrete block masonry was done over the earlier rat-trap bond T-junction. Masonry methods of saving

mortar were explained in this process along with how to tie reinforcement through the blocks.

Figure 18: Mould for ferrocement channel being made

Ferrocement channels were cast by the whole group using the mould from the previous day as well as special

wooden profiles made by the carpenters the previous day.

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Figure 19: Casting of ferrocement roofing channel

Day 7: Feedback & Valedictory Session

The completed thermo-siphoning air heating panel was placed in a sun facing direction to test its effectiveness in

passive solar heating.

Amol Mgrulkar and Rita John then conducted a session on a number of alternate technologies usable in other

climatic zones of the country. This was because, during the course of the training, a number of questions had arisen

about these. Also, good practice examples of buildings employing the technologies taught were also shown.

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Figure 20: Valedictory and feedback session

A valedictory session was conducted by Er. Vinita Arya, the principal of the Government Polytechnic. A feedback

session was included in this where each mason was asked what they had learnt in the past week. Most of the

masons mentioned one technology or the other that they had not known of earlier and were now confident to use

them. In particular some masons wished to take up building material manufacture. The ferrocement technologies

were particularly of interest to all the masons uniformly.

After certificates were distributed the group was taken back to the work space and the readings of thermometers

placed at the top and bottom of the air heating panel were reading. They showed a marked difference in

temperature between the two showing how the panel passively generated heat in the sun.

Figure 21: Testing of thermo-siphoning air heating panel

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4. Observations and Lessons learnt

The local masons are keen to experiment in the various technologies taught and wanted technical specification they

could use ahead, for which they were asked to utilize the

facilities provided at the ATC. To maintain quality of

construction, more such masons need to be trained more strictly

in basic good construction practice.

The masons held a notion that mud construction was only for the

poorer sections of society because of the issues of quality of the

material as well as aesthetics. But upon showing them modern

examples of buildings across the country built using stabilized

earth blocks, they were quick to change their point of view. This

goes to show, exposure to examples of good practice and design

have an impact on the mason’s confidence in a material. This was

similar across most vernacular based technologies

“I used to work only with RCC systems, but now gained a lot of knowledge about lighter systems

better suited for earthquake resistance.”- Sh.Ludermani, Mandi district

“ I will return to my district and train my partners in similar technologies as most of the materials require for them are locally available in my district.”- Sh. Jiya

Lal, Solan district.

“ I own a stone production unit and I am now thinking of using stone waste generated in

manufacturing stone filler blocks.” - Sh.Ramesh Kumar, Mandi district

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5. Annexure 1 : List of Participants

S. No. Name Address Ph. No

1 Sh. Aman Deep Vill. Sarog, P.O Jobri Tehsil Arki Distt. Solan.

9459786744

2 Sh. Jagdish Sharma Vill. Manjhot, P.O Brahmpukhar Tehsil Sadar Distt. Bilaspur

----

3 Sh. Jiya Lal VPO Punnardhar Tehsil Sangrah Distt. Sirmour

98164-57669

4 Sh. Vikram Singh VPO Punnerdhar Sub tehsil Nohra Distt. Sirmour

9805348155

5 Sh. Umesh Kumar VPO Barswan Tehsil Sadar Distt. Mandi 9805343798

6 Sh. Keval Ram Vill. Kuddi P.O Gurukhotha Tehsil Sadar Distt. Mandi

9816471307

7 Sh. Chetan Thakur Vill. Karnala P.O. Jachh Tehsil Gohar Distt. Mandi

98827-55236

8 Sh.Lokesh Raj Vill. Serikother P.O. Jachh Tehsil Gohar Distt. Mandi

98822 80142

9 Sh. Sharvan Kumar Vill. Draman P.O. Chambi Tehsil Sundernagar Distt. Mandi

8988069572

10 Sh. Ludermani Vill. Dadyal P.O Jaidevi Tehsil Sundernagar Distt. Mandi

98054 83930

11 Sh. Prakesh Chand Vill. Haryol P.O. Awahdevi Tehsil Bhorang Distt. Hamirpur

8894413259

12 Sh.Pinku Vill.Sakahal P.O Bhog Tehsil Karsog Distt. Mandi

8261855824

13 Sh.Yamanand Vill. Sai P.O. Mahog Tehsil Anni Distt. Kullu.

----

14 Sh.Ramesh Kumar Vill. Sakal P.O Bhog Tehsil Karsog Distt. Mandi

----

15 Sh. Khajana Ram Vill. Saryon , P.O Maloh , Tehsil Sundernagar Distt. Mandi

---

16. Sh Amarnath Vill Bhangla, P.O Jarol, Tehsil Sundernagar Distt. Mandi

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