FLY ASH: A RESOURCE MATERIAL FOR INNOVATIVE BUILDING MATERIAL

- INDIAN PERSPECTIVE 

C. N. Jha* & J. K. Prasad**

1.0     INTRODUCTION

India’s present housing shortage is estimated to be as high as 31.1 million units as per 2001 Census and out of this shortage 24 million units are in rural area and 7.1 million unit in urban areas. The Govt. of India has targeted the year 2010 for providing Housing for All. In 1998, Government of India announced a National Housing and Habitat Policy which aims at providing “Housing for All” and facilitating the construction of 20 lakh additional housing units (13 lakh in Rural Areas and 7 lakh in Urban Areas) annually, with emphasis on extending benefits to the poor and the deprived. Apart from the above housing needs, nearly 1% of the housing stock in the country is destroyed every year due to natural hazards.

Such large scale housing construction activities require huge amount of money running into thousands of crores of rupees. Out of the total cost of house construction, building materials contribute to about 70 percent cost in developing countries like India.  Therefore, the need of the hour is replacement of costly and scarce conventional building materials by innovative, cost effective and environment friendly alternate building materials.  The new material should be environment friendly and preferably utilize industrial/agro wastes because as a result of rapid industrialization, the generation of wastes has increased several fold during the last few years, which needs to be utilized/disposed safely on priority.  Large number of innovative alternate building materials and low cost construction techniques developed through intensive research efforts during last three to four decades satisfies functional as well as specification requirements of conventional materials/techniques and provide an avenue for bringing down the construction cost. Fly Ash, a industrial by-product from Thermal Power Plants (TPPs), with current annual generation of approximately 108 million tonnes and its proven suitability for variety of applications as admixture in cement/concrete/mortar, lime pozzolana mixture (bricks/blocks) etc. is such an ideal material which attracts the attention of everybody. Cement and Concrete Industry accounts for 50% Fly Ash utilization, the total utilization of which at present stands at 30MT (28%). The other areas of application are Low lying area fill(17%), Roads & Embankments(15%), Dyke Raising(4%), Brick manufacturing(2%) etc. The life cycle cost of Fly Ash based building

materials/constructions is much lower taking into account the environmental benefits and durability aspects.

2.0      FLY ASH CHARACTERISTICS AND UTILISATION POTENTIAL  Ash is a residue resulting from combustion of pulverised coal or lignite in Thermal Power Plants. About 80% of total ash is in finely divided form which is carried away with flue gases and is collected by Electrostatic precipitator or other suitable technology. This Ash is called (dry) Fly Ash or chimney Ash or Hopper Ash. The balance 20% of the Ash gets collected at the bottom of the boiler and is referred as Bottom Ash. When Fly Ash and Bottom Ash is carried to storage pond in the form of water slurry and deposited, it is termed as Pond Ash. Fly Ash consists of inorganic materials mainly silica and alumina with some amount of organic material in the form of unburnt carbon. Its fineness is comparable to cement, however, some particles have size less than 1 micron in equivalent diameter. It possess pozzolanic characteristics. However, all kind of Ashes are sometimes referred as Fly Ash by common people. The different kind of Ashes are suitable for different applications as given below: Fly Ash                                     -        For use as pozzolana and admixture in

cement, mortar, concrete (/Cellular light weight concrete)

 Fly Ash                                     -        Lime pozzolana Mixture Applications

(Bricks, Blocks etc.)  (The quality parameters are not as stringent as in above application)

 Bottom Ash / Pond Ash          -        Sintered Applications, Geotechnical

Applications, Structural Fills, Clay- Fly Ash bricks (burnt type),Agricultural Applications, etc.

2.1             Fly Ash as Pozzolana 

Pozzolans are defined as silicious and aluminous materials which in themselves possess little or no cementitious value but, will in finally divided form and in the presence of moisture chemically react with calcium hydrauxide at ordinary temperature to form compounds possessing cementitious properties.

The properties of pozzolananic materials which are to be used for the manufacture of pozzolana Cements, Concrete, Lime/Cement based bricks/blocks are governed by stipulated standards which differ from country to country. The requirement of Fly Ash for these applications in terms of pozzolanic properties is as follows:

S. No.Component/

Characteristics

Unit British Standard BS:3892

American Standard

ASTM :C618

Indian Standard:

3812 (Part 1) : 2003

Fly Ash^

SPFA CPFAChemical Requirements1.                     SiO2 + Al2O3 +

Fe2O3

% - 70 70 50

2.                     Sio2 Min % - - 35 253.                     Reactive SiO2

Min (Optional)% - - 20 20

4.                     CaO, Max % - - - -5.                     MgO, Max % 4 - 5 56.                     Total S as

SO3, Max% 2.5 5 3 5

7.                     Alkali as Na2O, Max

% - 1.5 1.5 1.5

8.                     Total CI, Max % - - 0.05 0.059.                     Loss on

Ignition, Max% 7 12 5 5

10.                 Moisture content, Max

% 1.5 3 2 -

Physical Requirements1.                     Specific

surface (Blaine), Min

M2/kg Variable 325 320#

2.                     Sieve residue on 45 um sieve, Max

% - 32 34 (Optional)

3.                      Control figure (Product of loss and sieve residue on 45 µm sieve), Max

% - 255 -

4.                     Lime reactivity** (Average compressive strength), Min

N/mm2 - - 4.5

5.                     Compressive strength at 28 days, Min

N/mm2 - - Not less than 80% of the strength of

corresponding plain cement mortar cubes

 

6.                     Drying shrinkage, Max

% - - -

7.                     Soundness (Autoclave), Max

% - - 0.8

                 ^Part I    :               For use as pozzolana in cement, cement mortar and concrete

^Part II   :               For use as admixture in cement, cement mortar and concrete

SPFA :                    Silicious Pulverised Fuel Ash

CPFA :                   Calcareous Pulverised Fuel Ash

#Fly Ash of fineness 250 M2/kg (Min) is also permitted to be used in the manufacture of Portland pozzolana cement by intergrinding it with Portland cement clinker if the fly ash when ground to fineness of 320 m2/kg or to the fineness of the resultant Portland pozzolana cement whichever is lower, meets all the chemical and physical requirements.

** The method of test covers the procedure for determining the reactivity of the pozzolanic material with hydrated lime, as represented by compressive strength of standard mortar test cubes prepared and tested under specific conditions as per IS 1727:1967.

2.2             Fly Ash collection and storage in the Thermal Power Plant

The fly ash is collected in most of the old power plants in India through wet system, since it is cheaper than any other mode of transport. In the wet system, fly ash is mixed with water and sluiced to the settling ponds or dumping areas near the plant. However, due to limited disposal area many of the TPPs are in the process of converting to dry collection system (through ESP’s) particularly the NTPC Power Plants.

ESP’s are most popular equipment and widely used for emission control today which enables the collection of dry fly ash. In the dry collection system, after arresting the fly ash in the ESP, it is taken to the silos for storage by pressurized or vacuum pneumatic system. When required, this can be obtained in a container for further transportation directly from the silos or conveyed further to the delivery point by pneumatic pressurized system. All new plants commissioned recently/being commissioned have provision for dry fly ash collection system.

Fly ash collected through dry collection system is preferred for pozzolanic applications (i.e. in Building Industry).

2.3             Need for “Processing of as received Fly Ash

The chemical composition and physical characteristics of a fly ash from a coal fired furnace are controlled by the type pf coal and processing conditions of the furnace. These vary not only from one plant to another but also within the same plant. Large variation in the chemical composition of fly ashes is, therefore, natural. Fortunately, however, the pozzolanic properties of a fly ash are not governed so much by the chemistry but by the mineralogy and the particle size of the fly ash. It may be noted that modern coal fired thermal power plant generally produce good quality fly ash that is characterized by low carbon and high glass content with 75%  or more particles finer than 45 microns. For coarse fly ashes or those with high carbon content, a number of beneficiation technologies are available to improve their suitability for use by the cement and concrete industries.

Another road block to the increased use of fly ash as a component of cement and concrete is the uniformity of ash from a single source of supply. With industrial by-products, the variability in physical and chemical characteristics are unavoidable. However, this need not be an un-surmoutable task to make the product suitable for its desired use. As for years, the cement and concrete plants have practiced the art of blending inhomogeneous batches of material to obtain end-products of acceptable and uniform quality.

As can be seen from the above there is a need to provide the fly ahs in graded form so that the needs of the individual industries can be catered to. The fly ash is available from different fields of ESP (also varies from plant to plant) from 1000 blaines to 6000 blaines. It will not be economical to collect the ash from different fields and moreover is required to classify the fly ash after dry collection in the plant and also to grind the surplus amount of coarse ash.

Hence, to increase the market of the fly ash it is required to grade and grind the fly ash to meet the requirement of wide spectrum of market.

3.0     FLY ASH BASED INNOVATIVE & COMMONLY PRODUCED BUILDING PRODUCTS IN INDIA

Some of the innovative and commonly manufactured environmental friendly building materials utilizing Fly Ash are covered below;

3.1     Cellular Light Weight Concrete (CLC) Blocks

Cellular Light Weight Concrete (CLC) blocks are substitute to bricks and conventional concrete blocks in building with density varying from 800 kg/m3 to 1800 kg/m3. The normal constituents of this Foaming Agent based technology from Germany are cement, Fly Ash (to the extent 1/4th to 1/3rd of total materials constituent), sand, water and foam (generated from

biodegradable foaming agent). Using CLC walling & roofing panels can also be produced. Foaming agent and the Foam generator, if used for production of CLC with over 25% fly ash content invites concession on import duty by Govt. of India.

Advantages of Cellular Light Weight Concrete;

Better strength to weight ratio Reduction of dead load resulting in saving of steel & cement and

reduction in foundation size Better Acoustics and thermal insulation (Air conditioning requirement is

considerably reduced) Saving in consumption of mortar  and Higher Fire Rating 

3.2     Development of Fly Ash Based Polymer Composites as Wood Substitute

Fly ash based composites have been developed using fly ash as filler and jute cloth as reinforcement. After treatment, the jute cloth is passed into the matrix for lamination. The laminates are cured at specific temperature and pressure. Number of laminates are used for required thickness. The technology on fly ash Polymer Composite using Jute cloth as reinforcement for wood substitute material can be applied in many applications like door shutters, partition panels, flooring tiles, wall paneling, ceiling, etc.

With regard to wood substitute products, it may be noted that the developed components / materials are stronger, more durable, resistant to corrosion and above all cost effective as compared to the conventional material  i.e. wood.

This technology has been developed by Regional Research Laboratory, Bhopal in collaboration with Building Materials & Technology Promotion Council (BMTPC) and TIFAC. One commercial plant has also been set up based on this technology near Chennai.

3.3             Portland Pozzolana Cement (Fly Ash based)

Upto 35% of suitable fly ash can directly be substituted for cement as blending material. Addition of fly ash significantly improves the quality & durability characteristics of resulting concrete.  In India, present cement production per annum is comparable to the production of Fly Ash.  Hence even without enhancing the production capacity of cement; availability of the cement (fly ash based PPC) can be significantly increased.

3.4     Ready mixed Fly Ash concrete

Though Ready Mix concrete is quite popular in developed countries but in India it consumes less than 5 percent of total cement consumption. Only recently its application has started growing at a fast rate. On an average 20% Fly ash (of cementitious material) in the country is being used which can easily go very high. In ready mix concrete various ingredients and quality parameters are strictly maintained/controlled which is not possible in the concrete produced at site and hence it can accommodate still higher quantity of fly ash.

3.5     Fly Ash- Sand-Lime-Gypsum (/Cement) Bricks /Blocks

Fly Ash can be used in the range of 40-70%. The other ingredients are lime, gypsum (/cement), sand, stone dust/chips etc. Minimum compressive strength (28 days) of 70 kg/cm2 can easily be achieved and this can go upto 250 Kg/cm2 (in autoclaved type).

Advantage of these bricks over burnt clay bricks:

Lower requirement of mortar in construction Plastering over brick can be avoided Controlled dimensions, edges, smooth and fine finish & can be in

different colours using pigments Cost effective, energy-efficient & environment friendly (as avoids the

use of fertile clay)

3.6     Clay-Fly Ash Bricks

Fly Ash content can be 20 to 60% depending on the quality of clay.  Process of manufacturing is same as for the burnt clay bricks.

Advantages:

Fuel requirement is considerably reduced as fly ash contains some percentage of unburnt carbon

Better thermal insulation Cost effective and environment friendly

 4.0      DURABILITY OF FLY ASH BASED PRODUCTS 4.1      Blended Cement (Fly Ash based)/Concrete using Fly AshUse of blended cement has now become quite popular world over from durability and environmental benefits point of view. For example, blended cement constitutes 91% of the total cement production in Italy. In India also 45% of total cement manufactured is fly ash based blended cement. Now the

advantages achieved with the use of blended cement in concrete quite well documented;

Reduced heat of hydration Improved workability & Ease of pumping Superior microstructure leading to lower permeability Higher long term strength Better performance in aggressive environment (Sulphates, Chlorides

etc.) Reduced risk of alkali silica reaction Higher Electrical Resistively leading to lesser chances of reinforcement

corrosion

4.2      Fly ash bricks viz-a-viz clay bricks A lot of studies have been conducted on durability aspects of Fly Ash bricks in many CSIR Labs, IITs, etc. Recently a study was sponsored by Fly Ash Mission, TIFAC and implemented by four CSIR Labs namely: CBRI - Roorkee, RRL-Bhopal, ERADA-Vadodara and CFRI-Dhanbad to assess the durability of Fly Ash brick viz-a-viz clay brick. In this study all kind of aggressive environment as acidic, saline etc. were quantified (in terms of its concentration and exposure duration) to conduct accelerated tests on Fly Ash bricks and clay bricks both. The study has been completed and it has concluded that Fly Ash bricks are as durable as clay bricks and in fact in certain aggressive environments perform better than clay bricks.

 5.0      ENERGY SAVINGS AND ENVIRONMENTAL BENEFITS Most of the developing countries face energy scarcity and huge housing and other infrastructure shortage. Ideally in these countries materials for habitat and other construction activities should be energy efficient (having low energy demand). The following table shows some examples of energy savings achieved through the use of Fly Ash in the manufacture of conventional building materials. It should be noted that use of Fly Ash also improves the properties of building material, as mentioned above: 

Energy Savings in the Manufacture of Building Materials through Use of Fly AshBuilding Material Composition Material Compared Energy

savings (%)Portland pozzolana cement

75% Ordinary Portland cement

25% Fly Ash

100% Ordinary Portland Cement

20

Lime-pozzolana mixture 25% Acetylene gas lime

75% Fly Ash

25% Lime

75% Calcined brick

75

Calcium silicate brick 90% Fly Ash tailings

10% lime

(waste source)

Burnt Clay brick 40

Burnt brick 75% Clay

25% Fly Ash

Burnt Clay brick 15

Source: Building Materials in India: 50 Years – A Commemorative Volume, Building Materials & Technology Promotion Council, New Delhi, India, 1998

 Studies show that one tonne of Portland cement production discharges 0.87 tonne of CO2 into the atmosphere. One Japanese study indicates that every year barren land area approximately 1.5 times of Indian territory need to be afforested to compensate for the total global accumulation of carbon dioxide discharged into the atmosphere because of total global cement production. Utilisation of fly ash in cement/concrete minimises the Co2 emission problem to the extent of its proportion in cement. Use of Fly Ash – Sand-lime-gypsum bricks also brings similar environmental benefits if used in place of burnt clay bricks.6.0     SOME OF THE INITIATIVES TAKEN BY VARIOUS GOVT.

DEPARTMENTS IN INDIA 6.1     Initiatives by Ministry of Environment and Forest, Govt. of India

(This Ministry is primarily responsible for preserving environment and forest in the country)

MOEF recently issued notifications containing directive for greater Fly Ash utilization, some of which are as follows;

i.   Within a radius of 100 kms from coal or lignite based thermal power plants, manufacturers of bricks/blocks/tiles would use at least 25% of ash in their product.

ii. Every construction agency engaged in the construction of buildings within a radius of 50 to 100 kms  of TPP have to use 100% fly ash based bricks/blocks in their construction project by the end of August 2007. Within 50 kms of radius of TPP the deadline for use of 100% fly ash based bricks/blocks is end of August 2005. It is pertinent to mention here that any brick/block containing more than 25% fly ash is designated as fly ash brick/block.

6.2     Status of Standardisation in the country

Several initiatives taken by country’s standardization body (BIS) regarding

higher utilization of fly ash are as follows:

i.   Updation of Indian Standard on “Portland Pozzolana Cement – Specification Part 1 Fly Ash based”( IS 1489 (Part 1): 1991)

In the amended form, the Fly Ash constituent to be used shall not be less than 15% (from earlier 10%) and not more than 35% (from earlier 25%) by mass of Portland Pozzolana Cement.

ii. Revision of basic Indian Standard Design Code for Plain and Reinforced Concrete (IS 456:2000)

This revised Code lays emphasis on the use of PPC/Fly Ash in concrete in aggressive environmental conditions.

iii. Revision of Indian Standard on “Specification for Fly Ash for use as Pozzolana and Admixture” (IS 3812-1981)

Updation of standard has been done keeping in view the change in technologies leading to generation of better quality of Fly Ashes and wider applications of Fly Ashes. In the revised standard, the concept of improvement of Fly Ash properties through beneficiation/segregation/processing has also been introduced.

6.3     Circular by Country’s Premier Govt. Construction Agency (CPWD)

CPWD has taken a decision for use of fly ash as part replacement of cement where concrete is obtained from RMC manufacturers for large projects in concrete grade M30 and above:

7.0      ROLE OF BMTPC IN PROMOTING FLY ASH BASED BUILDING MATERIALS  In order to bridge the gap between research and development and large scale application of new building material technologies, the erstwhile Ministry of Urban Development, Government of India, had established the Building Materials & Technology Promotion Council in July 1990. The Council strives to undertake identification of potential technologies with emphasis on utilisation of agricultural and industrial wastes. For promoting fly ash based products, BMTPC has taken several initiatives some of which are as follows:

7.1     Machines developed by BMTPC

BMTPC has developed more than 30 machines for cost-effective building

products through its associated agencies. This has been done to popularize the cost-effective building materials at grass root level. Some of these can be used for manufacturing fly ash based products.

        Alternate station hydraulic brick making machine:

This machine has capacity of 10,000 bricks per day and can produce Fly Ash – sand lime (/cement) bricks and clay/clay Fly Ash bricks.

        Bi-Directional Vibro Presses of different capacities (AS 1824, AS 1818, AS B 189, etc.)

The same vibro press can be used for manufacturing fly ash based solid blocks, hollow blocks and pavers by just changing the moulds. These presses are available for different capacities.

        Pan Mixer

As normal concrete mixer is not suitable for mixing raw materials used for fly ash based products, Pan Mixer has been developed which ensures kneading action also.

7.2   Role of Advisory Body to Govt. of India and in conducting training and Entrepreneurship Development Programme

BMTPC is represented in various Govt. Committees responsible for issuing notification related to utilization of industrial and agricultural wastes. It is also represented in various standardisation committees. Regular training and entrepreneurship development programmes are conducted to popularize the waste based and cost-effective building materials and technologies at grass root level from time to time.

7.3             Initiatives taken in the direction of creating Fly Ash Grading facility at Thermal Power Plant

As circular by CPWD, IS 456:2000 etc. specifies certain grade of fly ash (conforming to IS 3812) for cement/concrete applications which is not easily available at Thermal Power Plants. Even products like fly ash based bricks, blocks, tiles, pavers, etc. require fly ash of graded quality. Therefore, it was felt necessary to create some fly ash processing facility at TPP so that graded fly ash can be made available to end user. In this regard, letters have been issued to many Thermal Power Stations detailed presentation has been made to Central Electricity Authority and discussions are in progress with some of the TPPs.

7.4             Publications by BMTPC particularly the “Standard and

Specification of certain Cost-effective, and Environment-friendly Building materials / Techniques

BMTPC has published over 30 publications covering a wide spectrum of housing sector. Despite a number of innovative cost-effective building materials, components and construction techniques developed through extensive research, the housing and building agencies have not adopted them in their construction practices because of number of reasons. Lack of standardization and non-listing of the above techniques in Indian Standard Codes is quoted as one of the foremost reasons by construction agencies for non-adoption of these techniques in their practices. Realising this Building Materials and Technology Promotion Council (BMTPC) has published “Standards & Specifications for Cost effective Building Materials and Techniques” which outlines detailed specifications for the cost effective building materials, components and construction techniques including Fly Ash based. The detailed specifications have been so formatted that these can be readily inducted in the schedules and specifications by public and private construction agencies.

7.5             Performance Appraisal Certification Scheme (PACS)

Under a notification issued by Ministry of Urban Development & Poverty Alleviation, Govt. of India, BMTPC has also been entrusted with the responsibility of running an innovative scheme called ‘Performance Appraisal Certification Scheme (PACS)’. Under this scheme any new product, system or technique related to housing/building not covered so far by Bureau of Indian Standards in the form of any IS Code may be certified after detailed evaluation. Such certification will develop confidence among the users of the new product/system/technique and provide marketing tool to the manufacturers. The evaluation parameters and their results may later form the basis for the formulation of new IS Code on the specific product/system/technique.

REFERENCES

Census of India 2001. MOEF Notification dated September 14, 1999 regarding Utilisation of

Fly Ash and Amendments to this dated August 27, 2003.  “Building Materials in India: 50 Years” A commemorative volume

published by BMTPC. Circular by CPWD No. CDO/SE (RR)/Fly Ash (Main)/387 dated May 13,

2004. Proceedings of the International Symposium on “Concrete Technology

for Sustainable Development in the Twenty First Century” edited by P. Kumar Mehta, Hyderabad, India, February, 1999.

Singh G. B. “Cellular Light Weight Concrete”, The Construction Journal of India, September-October 1998, Vol. 1 issue 4.

Saxena Mohini and Prabhakar J. “Emerging Technologies for Third Millennium on Wood Substitute and Paint from coal ash” 2nd International conference on “Fly Ash Disposal & Utilization”, New Delhi, India, February 2000.

Managing Low Cost & Innovative Housing Technologies”

International Centre for Advancement of Manufacturing Technology (ICAMT)

In cooperation with

Building Material & Technology Promotion Council

&

Entrepreneurship Development Institute (EDI)Organize

International Seminar

&

Exhibition

On

“Managing Low Cost & Innovative Housing Technologies”

22-27 August 2004

Ahmedabad, India

AIDE-MEMOIRE

Download brochure (pdf format)BACKGROUND

 

In every country the housing industry is a fundamental and strategic sector linked to improving the standard of living. The housing sector

depends highly on technological innovation as a constant driving force. Technological innovation creates added value, it improves the product,

and cuts the costs, thus allowing for a greater distribution of the product

on the market and an extension in the distribution range.

 

Two main problems faced by developing countries are – creating sustainable livelihoods and preserving the environment. There are also severe problems of agro-industrial wastes and their management.  Over the years, energy efficient technologies have been developed, which not

only convert waste into value-added composite materials for low cost housing but also generate employment in rural areas. 

.

The construction industry in the developing economies is facing an immense and apparently worsening problem of required materials shortage aggravated by rising prices.  In most countries, frequent

shortages have often led to further increases in prices and profiteering, thus marginalizing more and more people beyond the affordability level. 

The consequent impacts are severe: skyrocketing housing costs and expanding unplanned settlements in urban areas, and an ever-

deteriorating housing quality in both urban and rural settlements. 

 

One strong option is to promote use of innovative composite materials based on local resources from forestry, agriculture, natural fibres, plant

materials, and other local resources like agricultural and industrial wastes available within small geographical regions.  Such alternative materials can be manufactured using the fibres as reinforcement in a

binder such as cement or polymer.  Besides meeting the needs of housing sector, the industrial production of the composite materials would greatly help in environmental protection, energy efficiency and

employment generation in the manufacturing sector.

 

Research and development efforts in past 2 to 3 decades in several countries, especially in India, have led to the development of various scientific and engineering aspects of composite materials from local

resources.  Such efforts have reasonably demonstrated and established that many of these materials from local resources can effectively

substitute traditional materials like cement, steel, and wood.  However, these technologies, except in a few countries, have not widely gone to

industrial enterprises.  The performance evaluation from field application of these materials indicates their usefulness in other

developing countries too.

 

JUSTIFICATION

 

With rapid urbanization, population growth and industrialization, the skills, materials and financing for the planning, design, construction, maintenance, and rehabilitation of housing, infrastructure and other

facilities are often not available or are of inferior quality.  Public policy and private investment should, together, facilitate an adequate supply of cost-effective building materials, construction technology and bridging

finance to avoid the bottlenecks and distortions that inhibit the development of local and national economies.  By improving the quality and reducing the cost of production, housing and other structures will last longer, be better protected against disasters, and be affordable to low-income populations and accessible to persons with disabilities,

which will provide a better living environment. 

 

Especially in developing countries there is an urgent need to be better acquainted with new techniques on composites and new materials for

low cost housing design and their production processes.

 

Having a mind that UNIDO-ICAMT is implementing an Inter-Regional Programme on Capacity Building for Transfer of Energy-Efficient and Eco-Friendly Technologies and Promotion of Local Investments in the Area of Materials based on Local Resources for Low Cost Housing in

Africa, Asia and Latin America, UNIDO International Centre for Advancement of Manufacturing Technology (ICAMT) in cooperation with

Building Materials & Technology Promotion Council (BMTPC) and Entrepreneurship Development Institute (EDI), Ahmedabad  will organize

an International workshop and exhibition on "Managing Low-cost & Innovative Housing Technologies" that will be held in Ahmedabad, India

from 22-27 August 2004.

 

OBJECTIVES

 

·    To present a global perspective on low cost housing technologies

·    To present the state of the art of the latest innovative technologies for manufacturing pre cast building components

·    To disseminate up-to-date information, knowledge and experience on design, production, certification and application of low cost and

innovative housing materials

·    To present the country perspective on status of low cost housing technologies.

·    To promote and encourage networking and cooperation between countries of the region, for the adoption of appropriate and affordable

technologies on low-cost housing

·    To arrange display of innovative & low cost housing materials developed & promoted by Building Materials & Technology Promotion

Council (BMTPC).

 

OUTPUTS

 

·    Awareness and capacity development of about 30 technologists, from both R&D institutions and enterprises on managing low cost building

materials based on Agro Industrial wastes.

·    Networking of enterprises, R&D and Standardization institutes, counterpart agencies operating in the housing sector in order to

strengthen South-South Cooperation.

·    Develop an action plan for implementation by UNIDO-ICAMT and Building Material & Technology Promotion Council (BMTPC) for

commercialization & transfer of proven technologies in India, South East Asia & Africa.

 

PROFILE-OF PARTICIPANTS

 

There will be approximately 30 experts from industrial R&D institutions, researchers and technologists from developing countries. A number of

senior level decision-makers will be encouraged to participate. Participants will be required to present a short report of the state-of-the art of the building materials production industry using local materials in

their country of origin and/or company where they are employed.

 

PROFILE OF RESOURCE PEOPLE

 

The resource persons will be from renowned National & International institutions. The resource persons will be invited to deliver key lectures

on the main topics of the programme.

 

DOCUMENTATION:

 

The basic documentation for the Training Course will consist of the following:

 

·    Aide-Memoire of the training workshop and agenda

·    Illustrative brochures / publications of Building Materials & Technology Promotion Council (BMTPC) on innovative building

materials and construction technologies.

·    EDI publication on Entrepreneurship development

·    List of participants

·    Lecture notes.

 

LANGUAGE:

 

All Lectures and their related documentation will be in English

 

PROGRAMME – STRUCTURE AND CALENDER

 

Day 1 (22nd August 2004)

 

1600 h – 1730 h        Inaugural session – Inauguration of International Seminar & Exhibition. (Inauguration by Kumari Selja, Hon’ble Minister of

Urban Employment & Poverty Alleviation, Government of India in presence of Mr. A.J.J. Rwendeire, Managing Director, UNIDO Vienna)

 

1730 h – 1830 h        High Tea

 

Day 2 (23rd August 2004)

 

 

0930 h – 1000 h        Fly Ash:  A useful resource for Innovative Building Materials :An Indian perspective

 

1000 h – 1100 h        Low Cost Housing – Indian perspective

 

1100 h – 1130 h        Tea

 

1130 h – 1215 h        Need and Relevance of Entrepreneurship

Development

1215 h – 1300 h       EDP Input and sequencing

 

1300 h – 1400 h        Lunch

 

1400 h – 1445 h        Promotional Strategies

 

1445 h – 1530 h        Selection of Entrepreneurs

 

1530 h – 1600 h        Tea

 

1600 h – 1730 h        Country presentation – Status of low cost housing technologies ( 3 countries – 30 minutes each)

 

Day 3 (24th August 2004)

 

0930 h – 1030 h        Opportunity identification

 

1030 h – 1100 h        Tea

 

1100 h – 1200 h        Business Plan Preparation

 

1200 h – 1300 h        Major Managerial Interventions

 

1300 h – 1400 h        Lunch

 

1400 h – 1530 h        Standardization and Certification for low cost Building Technologies

 

1530 h – 1600 h        Tea

 

1600 h – 1730 h        Country presentation – Status of low cost housing technologies ( 3 countries – 30 minutes each)

 

Day 4 (25th August 2004)

 

0930 h - 1030 h         Private - Public   Partnership : Cost-effective Housing Construction – A GSDMA Perspective

 

1030 h - 1100 h         Tea Break

 

1100 h - 1200 h         Application of the Glass Fibre Composites Innovative Technology Options for Housing

 

1200 h - 1300 h         Waste Based Building materials – Environment Friendly Technology Options for Housing

 

1300 h - 1400 h         Lunch

 

1400 h - 1530 h         Ferro cement Technologies: A viable solution for

Low Cost Housing.

 

1530 h - 1600 h         Tea Break

 

1600 h - 1730 h         Country presentation – Status of low cost housing technologies ( 3 countries – 30 minutes each)

 

Day  5 (26th August 2004)

 

0930 h - 1030 h         Role of Building Centres in propagating low cost  building technologies.

 

1030 h - 1100 h         Tea Break

 

1100 h - 1200 h         Social and Environmental Aspects of low cost Building Technologies                              

 

1200 h - 1300 h         Alternative Technologies : Construction with Economy

 

1300 h - 1400 h         Lunch

 

1400 h - 1530 h         Technology Options for Low cost Disaster Resistant Housing

 

1530 h - 1600 h         Tea Break

 

1600 h - 1730 h         Country presentation – Status of low cost housing technologies ( 3 countries – 30 minutes each)

 

 

Day 6 (27th August 2004)

 

0930 h - 1030 h         Quality Aspects of Low Cost Building Technologies and the issues involved in training.

 

1030 h - 1100 h         Tea Break

 

1100 h - 1130 h         Low Cost Housing – A Global perspective

 

1130 h – 1200 h        Low Cost Housing –Chinese perspective

 

1200 h - 1300 h         Community level Participation in Low Cost Housing Technologies

 

1300 h - 1400 h         Lunch

 

1400 h - 1430 h         Inter-Regional Programme on Capacity Building for Transfer of Energy-Efficient and Eco-Friendly Technologies and

Promotion of Local Investments in the Area of Materials based on Local Resources for Low Cost Housing in Africa, Asia and Latin America – An

Introduction

 

1430 h - 1530 h         Post Programme follow-up and discussions

 

1530 h - 1600 h         Tea Break

                                   

1600 h – 1730 h        Feedback Session & Valedictory  

 

VENUE AND DATES

 

The workshop and the exhibition will be held from 22nd August to 27th August 2004 at EDI premises in Ahmedabad. The address is as under:

 

Entrepreneurship Development Institute

Via Ahmedabad Airport & Indira Bridge), P.O. Bhat 382 428, Dist. Gandhinagar,

Gujarat, India

+91 - 79 - 23969159 +91 - 79 - 23969161 +91 - 79 – 23969163

Fax: +91-79-23969164

 

PARTICIPANTS:

 

·    24 international participants to be sponsored under India-ASEAN initiative.

 

·    6-8 international participants to be sponsored by UNIDO-ICAMT.

 

 

FINANCIAL/ADMINISTRATIVE ARRANGEMENTS FOR ICAMT FINANCED PARTICIPANTS:

 

For the participants that are invited by ICAMT to attend the workshop, round trip air/train economy transportation from the airport/station of

departure will be arranged and prepaid tickets issued where necessary according to UNIDO standards (i.e. the most direct and economical route). Room will be provided upon arrival at EDI, Ahmedabad. The

Breakfast, Lunch and Dinner will be provided at EDI. Invited participants will be provided US $ 20 per day as pocket allowance to cover

miscellaneous expenses. No other expenditure will be reimbursed.

 

The participants will be required to bear the costs of all expenses in their home country incidental to travel abroad, including expenditure for

passport, visa, and any other miscellaneous items as well as internal travel to and from the airport/station of departure in their home-country.

 

The organization will not be responsible for any of the following costs that may be incurred by the participant while attending the training

course:

 

·    Compensation for salary or related allowances during the period of the course;

·    Any cost incurred with respect to insurance, medical bills and hospitalization fees;

·    Compensation in the event of death, disability or illness;

·    Loss or damage to personal property of participants while attending

the course.

 Low Cost HousingPosted in Building, Civil Engineering Information | Email This Post

Low Cost Housing is a new concept which deals with effective budgeting and following of techniques which help in reducing the cost construction through the use of locally available materials along with improved skills and technology without sacrificing the strength, performance and life of the structure.There is huge misconception that low cost housing is suitable for only sub standard works and they are constructed by utilizing cheap building materials of low quality.The fact is that Low cost housing is done by proper management of resources.Economy is also achieved by postponing finishing works or implementing them in phases.

Building CostThe building construction cost can be divided into two parts namely:Building material cost : 65 to 70 %Labour cost : 65 to 70 %Now in low cost housing, building material cost is less because we make use of the locally available materials and also the labour cost can be reduced by properly making the time schedule of our work. Cost of reduction is achieved by selection of more efficient material or by an improved design.

Areas from where cost can be reduced are:-1) Reduce plinth area by using thinner wall concept.Ex.15 cms thick solid concrete block wall.

2) Use locally available material in an innovative form like soil cement blocks in place of burnt brick.

3) Use energy efficiency materials which consumes less energy like concrete block in place of burnt brick.

4) Use environmentally friendly materials which are substitute for conventional building components like use R.C.C. Door and window frames in place of wooden frames.

5) Preplan every component of a house and rationalize the design procedure for reducing the size of the component in the building.

6) By planning each and every component of a house the wastage of materials due to demolition of the unplanned component of the house can be avoided.

7) Each component of the house shall be checked whether if it’s necessary, if it is not necessary, then that component should not be used.

Cost reduction through adhoc methodsFoundationNormally the foundation cost comes to about 10 to 15% of the total building and usually

foundation depth of 3 to 4 ft. is adopted for single or double store building and also the concrete bed of 6″(15 Cms.) is used for the foundation which could be avoided.

It is recommended to adopt a foundation depth of 2 ft.(0.6m) for normal soil like gravely soil, red soils etc., and use the uncoursed rubble masonry with the bond stones and good packing. Similarly the foundation width is rationalized to 2 ft.(0.6m).To avoid cracks formation in foundation the masonry shall be thoroughly packed with cement mortar of 1:8 boulders and bond stones at regular intervals.It is further suggested adopt arch foundation in ordinary soil for effecting reduction in construction cost up to 40%.This kind of foundation will help in bridging the loose pockets of soil which occurs along the foundation.

In the case black cotton and other soft soils it is recommend to use under ream pile foundation which saves about 20 to 25% in cost over the conventional method of construction.

PlinthIt is suggested to adopt 1 ft. height above ground level for the plinth and may be constructed with a cement mortar of 1:6. The plinth slab of 4 to 6″ which is normally adopted can be avoided and in its place brick on edge can be used for reducing the cost. By adopting this procedure the cost of plinth foundation can be reduced by about 35 to 50%.It is necessary to take precaution of providing impervious blanket like concrete slabs or stone slabs all round the building for enabling to reduce erosion of soil and thereby avoiding exposure of foundation surface and crack formation.

WallingWall thickness of 6 to 9″ is recommended for adoption in the construction of walls all-round the building and 41/2 ” for inside walls. It is suggested to use burnt bricks which are immersed in water for 24 hours and then shall be used for the walls

Rat – trap bond wallIt is a cavity wall construction with added advantage of thermal comfort and reduction in the quantity of bricks required for masonry work. By adopting this method of bonding of brick masonry compared to traditional English or Flemish bond masonry, it is possible to reduce in the material cost of bricks by 25% and about 10to 15% in the masonry cost. By adopting rat-trap bond method one can create aesthetically pleasing wall surface and plastering can be avoided.

Concrete block wallingIn view of high energy consumption by burnt brick it is suggested to use concrete block (block hollow and solid) which consumes about only 1/3 of the energy of the burnt bricks in its production. By using concrete block masonry the wall thickness can be reduced from 20 cms to 15 Cms. Concrete block masonry saves mortar consumption, speedy construction of wall resulting in higher output of labour, plastering can be avoided thereby an overall saving of 10 to 25% can be achieved.

Soil cement block technologyIt is an alternative method of construction of walls using soil cement blocks in place of burnt bricks masonry. It is an energy efficient method of construction where soil mixed with 5% and above cement and pressed in hand operated machine and cured well and then used in the

masonry. This masonry doesn’t require plastering on both sides of the wall. The overall economy that could be achieved with the soil cement technology is about 15 to 20% compared to conventional method of construction.

Doors and windowsIt is suggested not to use wood for doors and windows and in its place concrete or steel section frames shall be used for achieving saving in cost up to 30 to 40%.Similiarly for shutters commercially available block boards, fibre or wooden practical boards etc., shall be used for reducing the cost by about 25%.By adopting brick jelly work and precast components effective ventilation could be provided to the building and also the construction cost could be saved up to 50% over the window components.

Lintals and ChajjasThe traditional R.C.C. lintels which are costly can be replaced by brick arches for small spans and save construction cost up to 30 to 40% over the traditional method of construction. By adopting arches of different shapes a good architectural pleasing appearance can be given to the external wall surfaces of the brick masonry.

RoofingNormally 5″(12.5 cms) thick R.C.C. slabs is used for roofing of residential buildings. By adopting rationally designed insitu construction practices like filler slab and precast elements the construction cost of roofing can be reduced by about 20 to 25%.

Filler slabsThey are normal RCC slabs where bottom half (tension) concrete portions are replaced by filler materials such as bricks, tiles, cellular concrete blocks, etc.These filler materials are so placed as not to compromise structural strength, result in replacing unwanted and nonfunctional tension concrete, thus resulting in economy. These are safe, sound and provide aesthetically pleasing pattern ceilings and also need no plaster.

For more on filler materials check Filler Materials Used in Concrete

Jack arch roof/floorThey are easy to construct, save on cement and steel, are more appropriate in hot climates. These can be constructed using compressed earth blocks also as alternative to bricks for further economy.

Ferrocement channel/shell unitProvide an economic solution to RCC slab by providing 30 to 40% cost reduction on floor/roof unit over RCC slabs without compromising the strength. These being precast, construction is speedy, economical due to avoidance of shuttering and facilitate quality control.

Finishing WorkThe cost of finishing items like sanitary, electricity, painting etc., varies depending upon the type and quality of products used in the building and its cost reduction is left to the individual choice and liking.

ConclusionThe above list of suggestion for reducing construction cost is of general nature and it varies

depending upon the nature of the building to be constructed, budget of the owner, geographical location where the house is to be constructed, availability of the building material, good construction management practices etc. However it is necessary that good planning and design methods shall be adopted by utilizing the services of an experienced engineer or an architect for supervising the work, thereby achieving overall cost effectiveness to the extent of 25% in actual practice.

 

  S&T Extension Programme   A NATIONAL S&T EXTENSION PROGRAMME IN INNOVATIVE  BUILDING MATERIALS AND HOUSING IN INDIA

One of the demonstration - Construction of cost effective housing units using alternative building materials under the programmeIndia has always had an acute housing problem, especially for the poor who can hardly afford the cost of conventional building materials. At the same time technology was available for the production of alternative building materials, which could be used to build low-cost houses in rural and semi- urban areas. The need was for an effective mechanism of transferring the technology to those who needed it most. It was with this objective that a 5-year Action Plan was launched by Government of India on Innovative Building Materials and Housing in 1990. The nodal responsibility was entrusted to the Central Building Research Institute (CBRI), Roorkee. Several national agencies concerned with low cost building technologies were also involved.

Key features of the action plan included (1) Integrated training programmes for trainers at various locations in the country(2) Setting up of demonstration units for local production of innovative building materials, and demonstration - construction of cost effective housing units in semi-urban and rural areas spread throughout the country.

The technologies selected were such that they led to employment generation, especially for the poor and women, decentralization of production, and development of human resource. As far as possible the demonstrations were organized at sites where the beneficiaries could set up their own production units or houses with their own funds, although sites earmarked by other collaborating organizations and agencies were also used.

During the 5-year period that the Action Plan was implemented, 34000 housing units were constructed for the rural and suburban poor, 30,000 people were trained, and thousands of masons, builders, social workers, contractors, engineers and architects got first hand experience of what innovative technology could do for the poor. It brought about a new awareness among the people about low cost housing in the country. It was a rewarding experience.

BACKGROUNDImprovement in housing has never been a matter of high priority for the poor in India because it does not bring them any tangible returns, while adopting improved scientific

methods of farming; fishing or cattle rearing can increase their income substantially. That does not, however, mean that the poor do not believe in the dictum, ‘durable and hygienic shelters contribute to better health and improved quality of life’. It is only that it ranks rather low in their ‘objects of desire’.

It was therefore felt necessary that any programme aimed at improving the housing lot for the poor should emphasize on poverty alleviation and tangible economic upliftment as a major component. Keeping this objective in view, the programme was launched in April 1990 by the Council of Scientific & Industrial Research (CSIR), India with nodal responsibility for implementing the programme, entrusted to CBRI.

In 1990, a wide range of low-cost technologies for building construction and housing developed by CBRI and several other R&D establishments over a period of more than four decades were available. But, in the absence of an appropriate mechanism, benefits of these innovations had not reached the target user. Some on-site extension and technology transfer efforts had been made earlier, but they were mostly symbolic and selective and did not involve large participation. These efforts were unable to make any sustainable impact for want of desired thrust and focus of a programme. The Action Plan (1990-95) was designed to involve mass participation to disseminate the innovative technology as widely as possible among the rural and semi-urban population, to achieve a high multiplier effect.

ISSUESThe main issues to be addressed were: (1) Lack of motivation to improve dwelling units(2) Lack of adequate trained manpower(3) Lack of awareness about the benefits of using innovative low-cost technology.

It is universally accepted that for real progress, developments in science and technology should be relevant to majority of the people in society. In the present context it implied that the new technology should be acceptable to people both from socio-cultural as well as economic point of view. Keeping these in view, the programme was devised in such a way as to disseminate only appropriate technology among the rural poor who could then propagate it further.

The programme had direct linkages with the neglected and downtrodden youth, women folk and the poor landless in villages. Stress was laid on a self- employment, and entrepreneurship development apart from improving sanitation and solving the basic requirement of shelter.

The programme demonstrated the tremendous potential for generating employment opportunities in production units which could utilize material such as non-agricultural soils, mineral wastes, mine tailings, flyash, industrial waste, and lime sludge, etc. to manufacture building materials such as bricks, blocks, binders and aggregates. It led to demonstration construction of low cost houses and setting up of low-cost demonstration production units in different parts of the country using local materials and improved technologies.

As a step towards generating trained manpower capable of handling the innovative construction technologies at all levels, integrated training programmes for site engineers, architects, trainers, masons and others were organized at different locations in the country.

To create mass awareness and acceptability of the innovative technologies and materials among the people, a series of public awareness campaigns through mass media, get-togethers and exhibitions were organized on a large scale all over the country. Land and finances for implementation of the programme were mobilized mostly through collaborative involvement of state, voluntary, private and cooperative agencies. Financial contributions of CBRI/CSIR were only nominal. CBRI facilitated these affirmative actions as the nodal Institution.

THE PROGRAMME

The main features of the Action Plan were the following:

Priority (greater than 50%) to the rural sector Curb on ostentatious and elitist bias and consumption Benefits for scheduled castes, scheduled tribes, women and the poor Direct participation of the beneficiaries Appropriate structural changes for dispersal of incomes to the beneficiaries Shift from large-sized capital-intensive urban-based to small-scale rural-based

industry with focus on employment and production for consumption by the masses.

The target was to put up 100 demonstration-units and take up six integrated programmes each year in a mission mode apart from organizing awareness campaigns through mass media, get-togethers and exhibitions.

DEMONSTRATIONSIn order to avoid the problem of land acquisition for demonstration units, the activity was organized in such a way that the demonstrations could be given directly for the entitled beneficiaries either at their land plots with their own funds and labor, or at suitable location available with the agencies directly participating in the programme, or at sites earmarked by other interested organizations for production units of building materials and components and/or for putting up regular housing. Linkages were established with Government supported autonomous financing bodies, not only to ensure funding of the demonstrations construction but also to encourage use of innovative appropriate technologies in housing projects funded by them. Laboratories of CSIR were the major source of the relevant technologies, the bulk of know-how coming from CBRI. The intended S&T inputs were thus assimilated into the efforts of several organizations utilizing their funds and with their direct involvement; the CBRI playing the role of principal organizer, chief consultant and trainer. Thus the direct cost component to be met by CBRI for the programme was notional and the beneficiaries were expected to meet the major expenditure on these demonstrations.

Integrated Training ProgrammesTo develop trained manpower; integrated training programmes were organized throughout the country for trainers, drawn from the major collaborating agencies, who were supposed to carry the imparted skills deeper for greater multiplier effect. Finances for organizing integrated training programmes were shared by CSIR and its laboratories and by the local collaborating agencies. In most of the cases the agencies owning the land utilized for putting up demonstration constructions also acted as the construction agencies.

The countrywide network of Building Centres supported by the Housing and Urban Development Corporation (HUDCO), India was utilized for production and supply of precast components. These building centres also conducted further training programmes for local artisans and entrepreneurs resulting in greater diffusion of innovative technologies among the users. At many locations newer areas of entrepreneurship got developed in the production of prefabricated building components and low-cost innovative building materials.

Awareness CampaignsEven after mobilizing all the above resources, no effective outcome would have been achieved without the beneficiaries accepting these innovative construction technologies and building materials. Exhibitions, press publicity, radio & TV programmes were extensively used to create mass awareness. On-site demonstrations and training programmes held throughout the country helped the beneficiaries and users to clearly see and understand the new technologies for ready acceptance.

PARTNERSHIPSTo enable the Central Building Research Institute to successfully carry out the nodal responsibility of implementing a S&T extension programme of such a huge dimension, the following institutions actively participated as a cohesive team, contributing to the programme their respective infrastructural, administrative, financial and technological

support:

Council of Scientific and Industrial Research (CSIR), New Delhi, India along with its following constituent establishments.

Central Building Research Institute, Roorkee Structural Engineering Research Centre, Ghaziabad Central Road Research Institute, New Delhi National Environmental Engineering Research Institute, Nagpur. Regional Research Laboratory, Bhopal Regional Research Laboratory, Thiruvananthapuram Central Glass & Ceramic Research Institute, Calcutta National Chemical Laboratory, Pune Department of Science & Technology, New Delhi. Housing & Urban Development Corporation, (HUDCO) New Delhi, along with a

countrywide network of Building Centers supported by HUDCO. Council for Advancement of People’s Action and Rural Technology, (CAPART),

New Delhi. Department of Rural Development, New Delhi. Ministry of Urban Development, New Delhi. Khadi & Village Industries Commission, New Delhi. State Public Works Departments. State Housing & Development Boards, and Several private and voluntary organizations from all over the country.

RELEVANCE TO OTHER COUNTRIESOTHER THIRD WORLD COUNTRIES CAN DERIVE BENEFITS FROM EXPERIENCE GAINED IN INDIA - A VAST COUNTRY OF SOCIO-ECONOMIC AND GEOCLIMATIC DIVERSITIESHousing the poor is a major problem in most of the Third World Countries. So the experience gained from the implementation of the 5-year Action Plan in a vast country like ours, with great geo-climatic, socio-economic and agro-industrial diversities and with high illiteracy and poor communication network can be a valuable guide for others to follow. Decision-makers and field personnel had often had to face hostility, suspicion and indifference from the villagers during the initial stages, and had to win them over by gentle persuasion and patience. A similar situation may be prevailing in other Third World countries too, where the Indian experience will be valuable.

LESSONSWOMEN ARE MORE RECEPTIVE TO INNOVATIVE SELF-HELP TECHNOLOGIES

The 5-year programme provided very interesting insights into technology transfer mechanism in the building sector targeted towards the poor:

Non-governmental voluntary agencies with proven credentials command much respect and their support is of immense value within their respective areas.

Rural women, once convinced, remain more enthusiastic and consistent in utilizing innovative S&T than their male counterparts.

The traditional practices in rural areas are more conducive to sustainable development.

The local politicians and leaders can be very useful at times but generally they are more interested in enhancing and consolidating their own power base rather than in community’s development and therefore they do not generally act as good change-agents.

In some areas where people had tasted the advantages and thrills of new technology earlier, replication of technology progressed quite fast.

The main agents of change -- the youth and the women, rush towards those fruits of S&T which are perceived to be status symbols or towards those technologies which can bring the quick economic returns.

In absence of any past experience with new technologies individuals feel threatened by possible economic losses or failures.

Building material and construction techniques are ideal for purposes of skill development and employment generations in rural areas and are easily absorbed.

Non-availability of technology packages in regional languages is a major hurdle affecting the acceptability of technologies such as bricks and blocks from waste and locally available inferior soils.

The implementers learnt a number of lessons through this experience. Some of them are:

Technology transfer through personal contact is most economical, has higher multiplier effect and creates ready acceptability.

Women and tribal absorb self-help technology faster Low -cost housing generates high levels of employment for unskilled youth There can be no unique solution to the housing problems in a country like India. As

such a basketful of innovative solutions are needed to match different local/regional conditions.

       IMPACTPEOPLE ADOPTED INNOVATIVE TECHNOLOGIES IN 34,000 HOUSING UNITS SAVING US$ 2.3 MILLION & GENERATING ADDITIONAL EMPLOYMENT OF 6.3 MILLION MANDAYS FOR UNSKILLED YOUTH & WOMENImplementation of the programme led to the setting up of demonstration units (Table 1 - Examples of construction units, Table 2 – Examples of production units) at 436 locations

Table 1. DEMONSTRATION CONSTRUCTION OF HOUSES (1990-95)

S&T INPUTSIMPLEMENTATION

TECHNOLOGIES ADVANTAGES OVER

CONVENTIONAL TECHNOLOGIES

NO. OF HOUSES LOCATIONS (States of India)

Improved mud and thatch constructionNon erodable mud plaster

Self help technologies, Low investment, and Low energy, Improved Quality of life.

205 W.B., U.P., M.P.

Fire retardant thatch roof

40

Improved rural sanitationDouble pit sanitary latrine

Low investment, Hygienic

5006 Maharashtra, Gujarat, Kerala, M.P., U.P.

Waste water disposal system

163

Prefabricated walling and roofing technologies

Stone masonry blocks/solid concrete blocks

Quality improvement Saving in time, 20% economical, Saving in cement and steel Labor intensive

26000

 

U.P, A.P., Maharashtra, Rajasthan, Kerala, Meghalaya, Orissa, Karnataka, M.P., W.B., Delhi.

Thin R.C. lintels cum sun-shades

8000

Pre cast channel unit roofing

650 Tamil Nadu (T.N.), U.P., Kerala, A.P.

Precast brick panel roofing

4800

Precast R.C. plank and joist roofing

1900 U.P, Rajasthan, A.P., T.N., W.B., Orissa.

Precast cored unit roofing

400 Gujarat

Precast L-panel roofing

4800 Orissa, A.P., U.P.

Thin ribbed slab for roofing

650 U.P., Kerala, Delhi, Maharashtra

Frameless doors Saving in timber and cost

60 Kerala, U.P., A.P.

Under-reamed piles for foundation

Effective in expansive /black cotton soilsLabor intensive construction 40-50% economical

10770 Gujarat, Maharashtra, A.P., M.P., U.P.

Pedestal piles for foundations

        Table 2. DEMONSTRATION PRODUCTION UNITS

S&T INPUTSPRODUCTION UNITS

TECHNOLOGY ADVANTAGES NOS. LOCATIONS(States of India)

Ferro-cement boards for door and window shutters

Cost effective, durable timber replacement, labor intensive

5 Orissa, Kerala

Bricks from inferior soils with/without machine

Improved quality, economy in construction

29 Andhra Pradesh (A.P.), Madhya Pradesh (M.P.), Maharashtra

Precast walling roofing components

Labor intensive, economical, saving in steel, cement & time

314 Rajasthan, M.P., A.P., Orissa, Maharashtra, Delhi, Uttar Pradesh (U.P.), Assam, West Bengal (W.B.), Punjab, Haryana, Karnataka, Tamil Nadu (T.N.)

Energy efficient brick, gypsum and lime kilns

Fuel saving, non-polluting, improved product quality

17 Haryana, Maharashtra, A.P., M.P., Himachal Pradesh.

Throughout India, each demonstration unit being different in volume ranging from a small production unit or a simple hut to a cluster of as many as 2000 dwelling units. Innovative low-cost technology and materials were used to construct a total of 34000 housing units (costing Rs. 860 million/US $ 25 million). It not only led to a national saving of Rs. 80 million/US$ 2.3 million but also saved scarce building material like cement and steel. 30,000 People were trained both through the integrated training programmes and the demonstration constructions. The programme also generated employment opportunity of 6.3 million man-days for unskilled youth and women in 18 states of India.

Assessment of total impact of S&T Extension programme on the poor, however, is a difficult task. Firstly because the impact spreads much beyond the confines of building materials and housing. Any such successful effort tends to set in motion the processes of change of world-view of the poor. The speed of this change varies very widely in a country of India’s size.

SUSTAINABILITY

THE DEMONSTRATED ECONOMIC ADVANTAGES FOR THE POOR SHALL MAKE THE PROGRAMME SELF-EXPANDINGThis programme was conceived, right from the beginning, largely as self-sustainable and self-expanding. It revolved around locally available waste, low-cost materials and locally available manpower. Only the S&T inputs at marginal financial cost were provided from CBRI/CSIR. These external inputs would soon be internalized and the multiplier effect of the programme would make it totally self-sustaining and self-propelling.

Concurrent to and in close cooperation with the above S&T Extension programme, the Housing & Urban Development Corporation (HUDCO) has further expanded and consolidated its chain of urban and rural building centres all over the country. At the start of the programme there were an estimated 100 Building Centres in their initial stages of formation/operation. The Building Centre movement got a tremendous boost from the programmes resulting in setting up of more than 500 Building Centres in the rural and semi-urban locales spread throughout the country. These Centres are now manufacturing and marketing new building materials and prefabricated building components to local people in their respective areas on a big way. These Building Centres have, in fact, become cooperative nodal agencies, which are also validating and propagating appropriate building materials and technologies in their respective zones of influence. It is hoped that these Building Centres would continue to maintain and enhance the tempo of innovative building material manufacturing, utilization of innovative construction technologies, and training the local artisans in building trade.

CBRI on its part has gained immensely from the experience to venture into development of newer technological option for application in rural areas.