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

.*JM5,mJ

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

~r

TJM'T- •'•• •• ~

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

*v

ik

I

m

mi

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

•"WBW

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

H \F

i^jfc^H

•

I i11

Z^i

11 i

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

««

*l

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.

^

rf

i

%

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.

•J>\W

•

./

^,.%—

k x

• • « • • • i

«••••••••• #• •

- * e 0

• - k • • •• « -

• • • M • •

<r *

m

•>•*

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

I

•

j

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

•N1

"̂•"

Alternative to the

conventional

construction

materials and

technologies forvarious applications in the

buliding industry

I %•

•iftifr

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

• • -

rzr t^-

44Z•>

3S&

v-

**-

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

1

>m

IflMl

• —

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

I i .

\

^ \

r • • » \ t

a '

RS

WSt

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.

^

-vrz

-^. b*t^t

~dfiE

5^ T«7

**m

*tf* ATl I

\I ' **V\*

H f

Fllllf

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

Eii

ffe

.\

WK

ft •' *-— ..^Ajrf-^*^-.. _SafcT

• »

« •• i

r i •»*

' ':!f*

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.

f fl/l

*

B«fcMMMMM«*M'ffWWt?

^ 1 , i . I • I <Tj%«-»h

SbttMfMfcBWWWIFItiM'

r

»»'*W*Ml

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.

M I

:.

•*•

*#

-*•**»

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.

r " '

1 T

BRICK PRESSIW1ECHNW.0GY DEVELOP

bmPc»»KUFKTUREO BY

NALDEHRABUILDING CENTRE

c

I^^3a^*

iflBsr?*-it

i

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