Building Materials in India: 50 Years A COMMEMORATIVE COMMEMORATIVE
VOLUME
Edited by T .N. Gupta Executive Director, Building Materials & Technology Promotion Council and Advisor (Technology), Ministry of Urban Affairs & Employment Government of India, New Delhi
Associate Editors Mohan Rai Former Head Building Materials Division Central Building Research Institute, Roorkee
S.P.Ghosh Former Director General National Council for Cement and Building Materials, New Delhi
V.S. Parmeswaran President and Chief Executive Design Technology Consultants, Chennai
P.B. Vijay Former Director General Central Public Works Department New Delhi
Building Materials and Technology Promotion Council Ministry of Urban Affairs & Employment Employment,,Governmentof Government of India G-Wing,Nirman G-Wing,Nirman Bhawan,New Bhawan,New Delhi 110 011 (INDIA)
A CommemorativeVolume TN Gupta Copyright@ExecutiveDirector,Building Materials andTechnologyPromotionCouncil, Ministry of Urban Affairs & Employment, Governmen of India, Nirman Bhawan,New Delhi 110 Oil (India). All rights reserved.This book, or parts there of, may not be reproduced,storedin a retrieval system, or transmitted in any form without the prior written permissionof the publishers.
Published by Building Materials and Technology Promotion Council Ministry of Urban Affairs & Employment, Government of India G-Wing, Nirman Bhawan New Delhi 110011 (India) Design and print production WordSmithy, New Delhi
First edition, 1998 ISBN 81-86930-01-9
Notice to the readers Theinformation in this book hasbeenderived and extractedfrom a multitude of sourcesincluding standard specifications, manufacturer's literature, engineeringand materials encyclopediasand referencebooksand personal experienceof eminent professionals.It is presentedin goodfaith but the authors and publishers do not assumeany liability for lack of accuracy of the information included in this book.It is primarily intended asan infonnation disseminationexercise,and not as a sourcefor the actual designand manufacturing techniques.It is the responsibility of the usersto apply their professionalknowledgewhile utilising the infonnation presentedin this book for any specific task.
Minister of Urban Affairs & Employment Government of India FOREWORD Soon after independence economic
development
in 1947,
India
launched
and adopted consciously
a massive programme
of
a path of mixed economy with
huge investments in public sector enterprises. The successive Five Year Plans laid progressively increasing 'emphasis on development planning involving large construction programmes and projects in various social and economic sectors. The Ninth Plan of the country has been drawn in the backdrop of widespread economic changes that permit rolling back the public sector investment from those sectors of economy where private sector can increasingly
play more significant
role
While country has become self.,sufficient in food and clothing and can boast of achievements
on several fronts, most public efforts in housing and infrastructure
development got frustrated largely due to uncontrolled growth of population, and lack of policy emphasis on integration of public and private sectors in the shelter process. It is a matter of great satisfaction that now the Government has taken several initiatives
to ensure that 'housing
initiatives is the formulation
for all' becomes a reality.
Foremost of these
of the National Housing and Habitat Policy laid in the
Parliament recently. Besides addressing a spectrum of areas, the Policy, i~ter alia, recognises the need for massive participation the building
materials and technology
of private sector and strengthening of
delivery
mechanisms that provide crucial
inputs to the housing and infrastructure development. I understand that there has been remarkable materials
resulting
from
the excellent
progress in the area of building
contributions
made
by our
scientists,
technologists and the progressive' corporate sector. It is remarkable that the country today not only produces almost all materials like steel, aluminium,
cement, glass,
ceramics, alloys, sanitary wares, paints, plastics and composites but many of them of world-class quality, conforming to the ISO standards. Today India produces 70 million tonnes of cement and 22 million tonnes of steel and globally ranks fourth in cement production. now increasingly
The new technologies utilised
sustaInable consumption protection
by the materials
industry should
of natural resources thereby
of industrial wastes help in achieving
leading to environmental
and reduction in energy demand.
In the fiftieth year of our independence, participation nucleated
based on recycling
of CSIR, DST, BIS and other public
this study and produced
techno-industrial congratulate
it is heartening that BMTPC, with active
progress achieved
Shri T.N.Gupta,
and private organisations
this document by the building
which
materials
sector.
records I like to
Executive Director, Building Materials & Technology
Promotion Council, for bringing out this Commemorative provide an opportunity
meticulously
has
for introspection
Volume. I hope it would
and catapult the efforts of researchers,
professionals and industry to meet the future challenges in the construction
sector.
(~;~~'"I-1._~.Q (Ram jethmalani)
Minister of State Ministry of Urban Affairs & Employment Government of India MESSAGE With the rising industrialisation and population, problems of shortage of housing and infrastructure, increasing poverty and unemployment and vulnerability to natural hazards are the foremost challenges which need to be addressed in the national development process. Recognising that urbanisation and increase in population is inevitable, the government has formulated several policies and programmes for socio-economic betterment of the deprived sectorsof population by ameliorating poverty and unemployment. The urban population which was about 14 per cent at the time of independence, is likely to rise to 33 per cent by the turn of the century and is expected to rise to 50 per cent by 2025. While we are on the threshold of the next millennium, maintaining quality of life, particularly in urban centres, is going to be a big challenge for our construction sector. Besides issues related to land and finance, one of the critical issuesthat require to be tackled is the access to building materials and technologies, which is a crucial input for the planned growth of housing. Soon after independence the national planners recognised the need to integrate science and technology with the social and economic development process. The advancements in science and technology during pastfive decades have resulted in a number of innovative build)ng materials and technologies which are environment friendly, energy efficient and cost effective. Since the transfer of technology from lab to land has been a complex process, the present Government has formulated the National Housing and Habitat Policy, which lays emphasis on improving the access of common man to crucial inputs to housing. I am sure the Policy will provide much needed reorientation and help in bringing about the attitudinal change among various players of the construction sector. The emphasis on public private partnerships would encourage and expedite technology transfer and entrepreneurial initiatives. The Building Materials and Technology Promotion Council has been actively engaged in enhancing the technology climate for efficient and effective implementation of housing programmes. In the 50th year of our independence it is heartening that BMTPC is bringing out a Commemorative Volume on 'Building Materials in India: 50 Years' which documents the progressachieved by the building materials sector during last five decades. I hope this publication will encourage all those involved in the housing and building activity to take advantage of the costeffective technologies for improving productivity and affordability in the housing sector.
(j ~
I wish the BMTPC all success in their efforts.
C"l.£:O \\
/::!j)"))~~
(Bandaru Dattatrava)
Secretary Ministry of Urban Affairs & Employment Government of India MESSAGE In India art and science of construction modern
context
development economic
construction
are as old as its civilisation.
is an activity
in all sectors of economy.
development
that
Implicit
provides
However, in the
crucial
inputs
in the attainment
is, provision of physical infrastructure
bridges, canals power stations, industrial and institutional
for
of goals of
like roads, railways,
buildings
and housing,
along with other civil engineering works. All these are the output of the construction sector
and
important
Independence, economic
when
components the country
development,
in
developmental
launched
various
process.
programmes
the need to strengthen the construction
Soon of social
after an
and building
materials sector was realised. The successive governments, therefore, laid emphasis on the integration of scientific and technological
advancements
in the construction
activities. Recognising the gap between laboratory application
of
innovative
building
development
materials
and
and large scale field
construction
technologies
developed by our R&D institutions, this Ministry established Building Materials and Technology
Promotion Council
in 1990 to strengthen the technology
transfer and
delivery systems in the building sector. The Council has been actively engaged in the evaluation,
validation
and dissemination
based on agro-industrial
of new technologies
wastes and bye-products.
have
friendly compared to their
counterparts which were both material and energy intensive.
I am happy to note that the BMTPC is bringing out this Commemorative to document the progress achieved in the building five decades. The publication variety
those
These new technologies
been found to be more energy efficient and environment traditional
particularly
and volume
materials sector during the last
reflects on the phenomenal
of building
materials
that
Volume
proliferation
has taken
place
of large
in the post-
independence era. Though India has attained an internationally competitive status in several areas of technology development, yet its impact is still to be felt in the housing sector. I am sure this Commemorative with housing and building
in identifying
Volume will help all those concerned
and introducing
the appropriate
building
material options to achieve the goals of sustainable housing development.
~Ir--
~
(Kiran Aggarwal)
Acknowledgements The author is highly grateful to Shri RamJethmalani, the Honourable Minister of Urban Affairs
and Employment, for his continued encouragement and very kindly agreeing to write the Foreword for this Commemorative Volume. Grateful thanks are conveyed to Shri Bandaru Dattatraya, Hon 'ble Minister of State, Ministry of Urban Affairs & Employment, and Smt. Kiran Aggarwal, Secretary, Ministry of Urban Affairs & Employment for their kind messageson the completion of this volume. Special thanks to Shri G.C. Bhandari, Addl. Secretary (Finance), Shri J.P. Murty, Jt. Secretary (Housing) Ministry of Urban Affairs and Employment and Shri V. Suresh, CMD HUDCO for their continued encouragementin bringing out this special publication. The thirtY one topics, which constitute this book, havebeen possible through the excellent contributions received in response to my request to the eminent scholars, experts and professionals. Special recognition is due to the following for contributing inputs relating to their fields of expertise: Dr. S.P.Ghosh,Director General,National Council of Cementand Building Materials, New Delhi, Dr. V.S. Ramachandran, Distinguished Scientist, Former Head Building Materials, National ResearchCouncil of Canada,Ottawa, Shri DilipBiswas, Chairman, Central Pollution Control Board, Dr. P.S.Das,Director General,Bureauof Indian Standards,Dr. S.K.Chopra,former Additional Director General,NCB, New Delhi, ProfessorR.N. Iyengar, Director Central Building ResearchInstitute, Roorkee, (Late) Dr. A.K.Gupta, Director, Central Road Research Institute, ProfessorPrem Krishna, University of Roorkee,ProfessorT.R.Ramachandran,Director, Jawahar Lal Nehru Aluminium Researchand Training Centre,Nagpur, Dr. Mohammed Yaseen, Deputy Director Indian Institute of Chemical Technology, Hyderabad, Shri S.A. Reddi, Director, Gammons India Pvt. Ltd., Dr. V.S. Parmeswaran,Director, Design Technology Consultants, Chennai, Shri P.B. Vijay, Former Director-General, CPWD, New Delhi, Shri Jose Kurien, Suprintending Engineer, CPWD,New Delhi, Dr. JosephGeorge,former Director, Indian Plywood Industries Research& Training Institute, Bangalore,Prof. K.N.Vaid, Director General,NICMAR,
Bombay, Dr.R.S.Bisht, Director, Archeological Survey of India, New Delhi, Dr. T.P. Sharma, Deputy Director, CBRI, Roorkee,Shri Arun Shrivastava,Consultant, New Delhi, Professor T.C. Rao,Director, RRL, Bhopal, Dr. Mohan Rai, former Deputy Director and Head, Building Materials, CBRI,Shri N.C. Majumdar, former Senior Scientist, CBRI,Shri S.C.Gupta, Former Chief Engineer, CPWD, Shri K.S.Pruthi, Scientist, Forest ResearchInstitute, Dehradun, Shri J.Sengupta,Chief Building Materials, BMTPC; Shri R.K.Celly, Chief Technology Marketing, BMTPC, A.C. Khazanchi, Deputy Director, RRL, Bhopal, Dr. Mohini Saxena,Scientist, RRL,Bhopal and Shri O.P. Ratra,former Deputy Chief, BMTPC. The untiring efforts made by my colleagues in the BMTPt:::in the compilation, checking and verifying the entire text helped in successfully completing this book. Special efforts made by Sarvashri H.C.Matai, S.K.Gupta, V.K.Sethi, D.P.Singh, M.Ramesh Kumar, Dalip Kumar, M.M.Arora, Praveen Suri, Anita, Sukhpal Pundir, merit my personal appreciation for their patience, perseveranceand dedicated support in the preparation of this publication. The compilation of various chaptershas beenpossible by taking some liberty in modifying the original contributions received, with the additions of relevant information from books, journals, directories, and encyclopedias which have beenmentioned as sources, referencesand / bibliographies. I am also thankful to the Archaeological Survey of India for facilitating copies of the p~otographs of someancient buildings, reflecting the glorious culture of Indian buildings architecture and heritage. Permission accorded the Pergamon Press,Oxford is acknowledged for utilising selected excerpts from the Concise Encyclopedia of Building & Construction Materials, first edition 1990. The efforts of Shri Anurag Gupta and colleagues Shri RaneshRay and Km. Urmi Goswami of Wordsmithy are acknowledged for design and printing of the volume. T.N.Gupta, Executive Director. BMTPC
XI
Preface
Post independence situation posed several challenges due to widening gap in demand and supply of building materials which were crucial inputs to the national development programmes and projects. This necessitated a close study of the existing base of the building materials industry with a view to imbibe new thinking and encourage innovation. A strong construction sector was imperative to cope with the desired level of economic growth and the resulting demand for building materials. Perhaps this marked the beginning of intensive search and rapid strides for enlarging the range and production of building materials far beyond that existed in 1947 at the time of independence. Recognising the role of research and development in various sectors, the Government of India had established in 1942, the Council of Scientific and Industrial Research, an umbrella organisation which enabled R&D to flourish as nationally recognised activity. Besides research and development, the emphasis on rapid industrialisation catalysed the need for standardisation and regulatory mechanisms to assist in the systematic growth of the industry and also to deal with the emerging concerns for environmental protection and energy conservation. These concerns are reflected in the establishment of Indian Standards Institution in 1947, the Department of Environment and Forests, and the subsequent enactments to tackle environmental problems. Since building and construction is the largest consumer of natural material resources, it is worthwhile to mention that, India is the first country which has made provisions for the protection and improvement of environment in its constitution through 42nd amendment in 1976. In this volume, attempt has been made to present a holistic picture of the successive stages of growth and development in building materials sector, reflecting on the technology inputs, promotional efforts, policy level supports created in the country along with standardisation and regulatory instruments established during past five decades. The Editor is personally responsible for the selection of topics and the experts who contributed in various areas covered and the Associate Editors for helping in completing this book. In both these tasks he had the benefit of advice of the senior professionals, eminent experts and the decision makers associated with this Council. During past one and half years that I have been engaged in bringing out this volume, it was a great pleasure to interact closely with several eminent scholars and professionals who have willingly contributed their time and efforts to realise this undertaking which I, consider an obligatory task for the Council particularly in the Golden Jubilee year of the country's independence. It is with great pleasure that I convey my deepest gratitude to the contributors. The task would not have been completed without the guidance and inputs from them and the Associate Editors. I like to record my special thanks and deepest appreciation to Dr. Mohan Rai for his valuable contribution, unwavering attention and dedicated effort in helping me to complete this task. T .N.Gupta Editor
XIV
Indian StandardsOrganisation (ISI) (now Bureau of Indian Standards)was also setup in 1947. TheBIS was basically instrumental in the drafting and publication of Indian Standards on Building Materials and Codes of Practices in line with standardisation work on other materials. An intensive exercise is already being undertaken for harmonisation of Indian standards with those brought out by ISO. Sometime ago Quality Control Certification System has also been launched by BIS for some important factory-made building materials, such ascement, steel bars, paints, sanitary wares and items of glassand aluminium alloys. The standardisation processreceived its inputs from experts representing various interest gro~ps of technology developers, consumers and manufacturers. Construction industry being the largest consumer of material resources, of both the natural ones (like stone, sand, clay, lime) and the processed and synthetic ones. During the last 50 years there has been some unplanned, unchecked and haphazard exploitation of the mineral resources-limestone, clay, iron ore, bauxite and coal. The intense mining activities of the minerals produced a variety of mining wastes, ore benefication tailings, coal preparation/washing rejects. The growth in industrial and agricultural activities continued to throwaway huge quantities of wastes and byproducts such as fly ash from power generation by burning pulverised coal, blast furnace and other slagsfrom iron steel, non ferrous metal smelters, alumina red mud, slate and marble wastes etc. Thesecoupled with calcareousand suIphi tic wastesfrom chemical industries sugar,paper acetylene, tannery, phosphatic fertilisers,' soda ash etc. amount today to nearly 250 million tonnes annually. Greatemphasis hasbeen laid in this publication on describing the results of R&D in waste utilisation. Research efforts in this area have now established that (a) there could be ways and means to dispose off the wastes and relieve pressure on land and environment (b) the waste could form secondary resource materials for the production of alternative building materials, and thus make effective savings in primary grade raw materials, energy, labour and capital investment in plant and machinery, and (c) it is possible to make the wastes free from the hazardous constituents and make them environment friendly. There is an increasing awareness that the manufacture of building materials from wastes and by-products would reduce pollution and energy consumption levels compared to traditional processesusing the basic raw materials. The Ministry of Environment and Forests,the Central and StatePollution Control Boards, and the National Environmental Engineering ResearchInstitute, have been making vigorous attempts for establishing regulatory regimes to monitor and control pollution levels. As a result of promotional efforts by organisations like BMTPC awarenessfor utilisation of industrial and mining-mineral wastesin the manufacture of building materials has increased and several waste based building material technologies stand proven and amply demonstrated. The rangeof materials produced in the country today, include, steel, aluminium, cement, glass, ceramics, alloys, sanitarywares, paints, plastics and a large variety of building chemicals, admixtures and composites. It is not only the range of materials which is impressive but most of these indigenously produced materials compare well with world-class quality and conform to the ISO standards. Fly ash (70/75 million tonnes per year) and blast furnace slag (10 million tonnes per year) are the two most important wastes which are finding good application in construction sector. Concrete products, bricks and blocks and ready mixed concrete are being produced with fly ash or slag content up to 65 per cent. This is one of the
xv
various emerging technologies being practised in the country. Lime sludges, phosphogypsum, red mud and mine tailings are the next category of the wastes available in substantial quantities on which a good level of researchwork has already been undertaken, though commercialisation of these technologies has yet to happen. There is growing awarenessabout their utilisation in cement, concrete, lime-gypsumpozzolana and blended masonry cements. The one of the important trends currently being pursued is to use ordinary Portland Cement to the minimum and make best exploitation of potential benefits of the mineralogical constituents of the wastes in cement and cement concretesfor specific applications. Modern concepts of material science evolves around basic understanding of the structure-property relationships of materials. Several advanced composite materials, now being produced are light-weight but structurally very strong, fracture resistan and highly impermeable. They are being produced using polymer as well as cement matrix, with both the manmade and the natural fibres. Many types of composites, using jute, sisal, coir, bagasse,mixed with steel and glass fibres, have been used in the manufacture of door and window shutters and frames, panelling and partitioning systems. The concepts of composites have been extended to the amorphons <--> crystalline phasesof materials for the development of glass-ceramicsand refractories of outstanding structural properties and long durability. Severalvarieties of new materials have now found well established recognition as partial substitutes of timber, aluminium, steel and cement.The Building Materials and Technology Promotion Council, during the last eight years have been responsible for the upgradation and development of many of the new materials listed here, through technical collaboration, developmental and consultancy efforts. New materials, during the development stageshave successfully crossed hurdles and stand proven through standardisation, validation and are displaying increasingl wider acceptability. These are the well accepted teething troubles faced by any new industry. Such problems, could not be settled in the meetings of the technical committees or deliberations at the conferences and therefore required vigorous efforts for technology transfer, demonstration, fiscal incentives to attract investment and wider dissemination of the range of innovative options. With the efforts of the BMTPC and the support of the Ministry of Urban Affairs and Employment, many well-meaning fiscal incentives for the promotion of new building materials based on industrial, mining, mineral and agro-wasteswere provided by Government of India in terms of excise duty and lowering or exemption of import duties on the plant and machinery essentially required to be imported. These incentives not only helped in displaying policy support for waste based building materials but created a confidence amongst entrepreneurs and users thereby attracting greater investments in the building materials sector. This book, covering 31 well established topics related to building materials, is intended to present the current status about the various aspectsof research,technology development, standardisation, commercialisation and field applications and acceptability. Care has been taken, wherever possible to deal with comparative information on developments in the world and India - during the past 50 years. The material presented in the book is based on the inputs provided by the recognised professionals and eminent experts in their specific areas of specialisation.
XVI
TABLE OF CONTENTS
Foreword Message Message Contributors Acknowledgements
vi vii viii xi xii
Introduction
1. Evolutionof building materials
1. Introduction. 2. Theancientperiod. 3. Themedievalperiod.4. TheSultanate. 5. TheMughalPeriod . 6. Thecolonialperiod. 7. Unprocessed materialsof commonuse. 8.Concludingremarks. 9. Bibliography
2. Burnt clay brick and tile
1. Introduction;Progress in the colonial period. 2. Focusof researchanddevelopment;Studyof soils.
14
3. Standardisation;Compressivestrengthand water absorption;Efflorescence;Bulk density; Fire resistance;Other properties. 4. Utilisation of waste in brick making; Redmud; Flyash;Stonedust; Coal washeryrejects;Granulated slag; Siliceous river sediments; Cinder; Rice-husk ash. 5. Processimprovement; Improved hand-moulding; Semi-mechanisedbrick plant; High draught kiln; Fully mechanised brick plant. 6. Product range upgrading and expansion; Improved bricks from in ferior soils; Product range expansion. 7. Environmental concerns; Energyaudit; Environmentalpollution. 8. Clay tiles; Mangalore patter!)roofing tiles; Prefabbrick pane l system; Burnt clay canal lining tiles; Standardson tiles. 9. Concluding remarks. 10. Standard specifications. 11. Bibliography
3. Stone
1. Introduction. 2. Classification of building stones. 3. Usesof stones in building. 4. General properties . 5. Stone slab frames for doors/windows. 6. Occurrence of decorative stonesin India. 7. Export of Indian stones. 8. Quarrying. 9. Finishing and polishing. 10. Stone as aggregate in concrete. 11. Effect of heat .12. Durability; Physical weathering; Effectsof pollutants; Protection of stones. 13. Concluding remarks. 14. Standard specifications 49 15. Bibliography 50
4. Building
Lime
1. Introduction. 2. Limein constructionindustry. 3. Limeproductiontechnology. 4. Focusof research anddevelopment;Process improvement;Newprocessfor makinghydratedlime; Newproducts;Pollution of the lime industry. 6. in lime industry; Utilisation of waste. 5. Stagnationandcontinuedbackwardness Concludingremarks. 7. Standardspecifications. 8. Bibliography
5. Gypsum
1. Introduction. 2. Gypsum products. Plasterof Paris. Gypsum plaster. 3. Fibrous gypsum plaster board 4. Gypsum blocks. 5. Acoustic tiles. 6. Processimprovement. 7. Utilisation of by-product gypsum. 8.
40
52
64
Concludingremarks. 9. Standardspecifications.10.Bibliography
6. Glass
74
7.Ceramics
84
1. Introduction; History of glass-makingtechnology. 2. The Indian glassindustry. 3. Composition of glass . 4. Typesof glass. 5. Glass as building material; Glassfor door and window shutters;Glass tiles; Mirrors; Glassfibre; Glasswool; Glassblocks. 6. Researchand development in India; Waste utilisation; New produ cts . 7. Concluding remarks. 8. Standard specifications. 9. Bibliography
1. Introduction. 2. Indianceramicindustry. 3. Classificationof ceramics;Whitewaretiles;Structuralclay products;Refractories;Vitreousenamels. 4. Kiln for ceramic production. 5. Focusof researchand
development; Indigenous processes developed by CG&CRI; Advanced ceramics.
6. Employment a nd education
in ceramics. 7. Concludin remarks. 8. Standardspecifications. 9. Bibliography
8. Steel
1. Introduction;Indiansteelindustry. 2. Determinantsof the growth of steelindustry;Domesticdemand projection;Projectionof demandfor steelalloys. 3. Globalsteelscenario;Exportopportunitiesfor Indian steel. 4. New technologiesin steel production;Energyconsumption. 5. Infrastructureaspects;Coastal transport;Power. 6. Researchand development. 7. Structuralsteel;Universalbeams(UB);Taperflange
96
beams (TFB); Parallel flange channels (PFC); Taper flange ch annels (TFC). 8. Steel in buildings; Major structural
applications; Non-structural applications; Steel bars/rods for reinforcement; Prestressing steel; Steel sections; Steel doors, windows, ventilators and frames; Galvanised steel sheets; Rolling shutters and grills; Steel gates and welded grills; Weld mesh and expanded metal sheets. 9. Concluding remarks. 10. Standard specifications .11. Bibliography
9. Aluminium 1. Introduction. 2. Technology. 3. Aluminiumproductionandconsumption;Consumptionpattern. 4.
User industries; Automobile industry; Packaging; Construction; Electrical. 5. Wastes of the aluminium industry; Red mud; Fluoride emissions; Spen t pot lining (SPL) . 6. Indian scenario and efforts needed to achieve international standards. 7. Copper, zinc and their alloys; Copper; Zinc. 8. Recycling of aluminium copper scrap. 9. Concluding remarks. 10. Standard specifi<:ations 11. Bibliography
and
112
XVII
10. Cement
1. Introduction. 2. The Indian cement industry; Production and consumption; Mini cement plants; GDP growth, demand an d forecast; Levies on cement; Exports. 3. Properties of cement; Grades of cement; Additional requirements; Initial and final setting times; Functional requirement; Chemical properties; Fineness of cement. 4. Types of cement; Ordinary Portland cement (OPC); Blended cement. 5. Cements to meet specific service conditions; Rapid hardening cement (RHC); Low heat cement (LHC); Oil well cement (OWC); White cement (WC); Masonry cement (MSC); Expansive cement. 6: Research and development; Specific R&D in scientific institutions. 7. Energy conservation in cement; Quality control in 8. Efforts at environmental protection; Conservation of mineral resources; Recycling cement manufacture of wastes. 9. Concluding remarks; Future planning specifications. 11. Bibliography
in cement industry; Mining;
Process.
10. Standard
11. Concrete
1. Introduction. 2. Types of cement. 3. Cements other than OPC; Portland pozzolana cement (PPC); Portland blast furnace slag cement (PBFSC); Sulphate resisting cement (SRC); Low alkali cement; Low heat cement. 4. Concrete as a structural material; Concrete mix design. 5. Aggregates; Coarse aggregate; Fine aggregate. 6. Ready mixed concrete (RMC) 7. Precast concrete elements (PC) 8. Prestressed concrete (PSC); Reinforcement steel; Reinforcement coyer blocks; Prestressing tendons. 9. Cement replacement materials; Pulverised flyash concrete; High volume flyash concrete; Condensed silica fume concrete; Rice-husk ash concrete; Ground granulated blast furnace slag (GGBS) 10. Lightweight concretes; No-fines concrete; Aerated concrete. 11. Low density concretes; Low density lightweight aggregate concrete; Moderate strength lightweight aggregate concrete; Structural lightweight concretes; Whisper concrete. 12. Concluding remarks 13. Standard specifications. 14. Bibliography
12. Recent advancesin concrete technology
1. Introduction. 2. Types of concrete; Polymer concrete; Sulphur concrete; Fibre reinforced concrete; High performancefibre reinforced conc rete; Ferrocement; Roller compacted concrete; Very high strength concrete; Superplasticised
concrete.
3. Concluding remarks. 4. Standard Specifications.5. Bibliography
13. Admixtures 1. Introduction.
of admixtures by source/origin; Natural and mineral admixtures; By3. Classification of admixtures by end-use; Air-entraining agents; agents; Alkali-aggregate expansion inhibitors; Damp-proofing and Accelerators; Retarders; Gas-forming permeability-reducing agents; Water and workability agents; Superplasticisers; Cementreducing superplasticiser compatibility; Grouting agents; Corrosion inhibiting agents; Bonding admixtures; Fungicidal products
and
admixtures; 6. Standard
2. Classification
wastes;
Chemical
admixtures.
Colouring admixtures; Miscellaneous specifications. 7. Bibliography
14. Utilisation
of industrial
admixtures.
4. Codes
of practice.
5. Future
directions.
wastes
1. Introduction. 2. Development in the utilisation of wastes. 3. Waste as concrete aggregate; Slags, Byproducts from power plants; Recycling of concrete. 4. Mining and quarrying waste; Miscellaneous wastes as aggregates .5. Utilisation of waste in cement manufacture; As fuel; As raw material; Blended cement; Flyas h; Slag. 6. Gypsum substitution; Waste gypsum and limestone dust additive in cement; Waste chemical admixtures; Utilisation of ore dressing tailings wastes. 7. Bricks and blocks using flyash; Flyash-clay bricks. 8. Concluding
15.
remarks
.9.
Standard
specifications
Materialsfor roads
1. Introduction. reinforced
2. The R&D scenario.
concrete
(SFRC); Synthetic
pavement (RCCP);Magnesium Low quality aggregates in materials;Municipal Prestressed ~oncrete pavement;
Precast
oxychloride pavement
block
Bibliography
3. Road construction
resins; Magnesium
pavement.
materials; Surkhi
phosphate
cement (MOC); quality concrete;
waste; Mining and quarrying pavements; Continuously concrete
.10.
202
wastes. reinforced
cement
as a pozzolana; Steel fibre (MPC);Roller compacted concrete
Improved surface finish for cement concrete Durability of concrete; Agro/industrial 4. New construction concrete pavement;
5. Concluding
remarks.
roads; waste
techniques for pavements; Fibre reinforced concrete
6. Standard specifications.
7.
Bibliography
16. Bitumen 1. Introduction.
2. Kinds of bitumen and products; Solid bitumen and bitumen mastic; Liquid or cut-back bitumen; Bitumen emulsion ;Bitumen felts and fabrics; Oxidised or air-blown bitumen; Bitumen-polymer composites; Bitumen mortar and concrete; Bitumen-paper board roofing sheets. 3. Bitumen for roads; Additives to asphalt concrete. 4. Antioxidants for bitumen. 5. Rubbers and polymers in road constructionrelated R&D at CRRI; Limestonedust powder; Natural rubber and bitumen mixture. 6. Blown grade bitumen in roads. 7. Mastic asphalt. 8. Anti-stripping chemicals. 9. Waste thermoplastic in roads. 10. Concluding remarks. 11. Standard specifications. 12. Bibliography
17. Geotextiles 1. Introduction.
2. Historical background. 3. Development in India. 4. Geotextile raw materials. 5. Types of geotextiles; Geomembranes; Geogrids; Geotextile nets or geonets; Geotextile mats; Geotextile webs;
6. Functions of geotextiles; Hydraulic
Geocomposites
7. Geotextiles remarks.
in road construction.
10. Standard specifications.
functions;
8. Present R&D activities
timber;
Timber
functions;
Protection;
in the area of geotextiles
5upport
9. Concluding
11. Bibliography
18. Wood and other lignocellulosic products
1. Introduction.
Mechanical
2. Researchand development in India (FRI & IPIRTI);Timber Engineering; Seasoningof Preservation of timber; Wood working. 3. Panelsand composites. 4. Plywood;
mechanics;
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XVIII
Grades of plywood; General purpose plywood; Decorative plywood; Marine plywood; Shuttering plywood; Structural plywood; Preservative treated plywood; Fire retardant plywood; Other speciality plywood; 5. Particleboard; Particleboards from agricultural residue; Jute Properties and uses of plywood; Flushdoor stick; Rice husk; Portland cement bonded particleboard ;Properties and uses of particleboards. 6. Blockboard . 7. Fibreboard; Medium density fibreboard (MDF). 8. Insulation board. 9. Standard hardboard; Tempered hardboard; Prefinished hardboard. 10. laminated veneer lumber; laminated lumber panel board; Glued laminated wood. 11. Bamboo mat board; Properties and uses. 12. Biomass as building materials. 13. Durability of bamboo and thatch; Impact of treatment on cost; Empirical evidence of treated bamboo; Treatment of bamboo; Technology used. 14. ~oncluding remarks. 15. Standard specifications. 16. Bibliography
19. Polymers and plastics
1. Introduction. 2. Petroleum industry. 3. Natural gas. 4. Petrochemical industry. 5. Shellac-natural resin .6. Plastics industry; Raw materials for plastics; Characterisation of polymers & plastics. 7. Diversification and organised marketing. 8. Major applications in buildings; Water tanks and sanitaryware; Plastics for waterproofing and damp-proofing;Plastics and rubber for damp-proofing ;Alternative to timber; Moulded furniture; Temporary shelter; Plastics glass; Composite materials. 9. Recycled plastics waste .10. Performance-in-use concept; Standard specifications .11. Export of plastics goods. 12. Concluding remarks .13. Standard specifications .14. Bibliography
294
20. Composite materials
1. Introduction. 2. Components of composites. 3. Particulate composite. 4. Fibre reinforced composite; Compatibility of fibre with matrix; Characteristics of fibre reinforced composites; Matrix properties. 5. Hybrid fibre-resin composites. 6. Advanced ceramic composites. 7. Composites for common applications in buildings. 8. Vegetable fibre reinforced composites in India. 9. Contribution of the BMTPC, India .10. IS Specifications on composites. 11. Composites for special applications. 12. Mission on advanced composites. 13. Advanced materials; Semiconducting materials; Non-crystalline materials; Superconducting materials; Bioceramics; Optical fibre materials; Polymers; Aluminium alloys. 14. Concluding remarks. 15. Standard specifications .16. Bibliography
21. Protective and decorative coatings
1. Introduction. 2. The past and present scenario. 3. Growth in market. 4. Architectural coatings. 5. Coatings for buildings; Paint coatings for exterior use; Coatings for mineral subs trates. 6. Coatings for furniture and wooden structures. 7. Coatings on metallic structures in the building. 8. Coatings on structures made of plastics. 9. Coatings on interior surfaces. 10. Coatings for concrete, wooden or steel
floors. 11.Fireretardantcoatings. 12. Paint/coatingsystems for the automotiveindustry. 13. Protection of substrate by organic coatings; Prospective performance of paints in protection of a substrate. 14. Indian R&D in protective and decorative coatings; Zinc rich paints; Phosphate treatments for mild steel; Corrosion in fertiliser factories; Paint systems for wood and wood based materials; New formulations of cement pa ints; Resins and paint coatings formulations; Curing aid for concrete; Polyurethane formulations; IPN coating. 15. Modern progress; Quality; Breakthrough in paint and coatings industry. 16. The prospective consumption of paints in different sectors. 17. Regulatory restrictions; Enactment of Rule 66 on the use of organic s olvents; Safety, health and environment; Environmental protection agency (EPA); Compliant or VOC exempt solvents; The United Nations VOC Protocol; VOC in Indian paint industry. 18. Strategy of the paint industry; Ecofriendly paint formulations. 19. Water-borne coatings. 20. Powder coatings. 21. High solids coatings (HSC) 22. Global scenario and concluding remarks. 23. Standard specifications. 24. Bibliography
22. Flooring 1. Introduction.
materials
4. Industrial progress 2. Modern requirements of flooring 3. Research and development. . 5. In situ floor finishes; Portland cement concrete; High alumina cement concrete; Rubber latex cement concrete; Bitumen mastic; Polymer concrete. 6. Hardeners. 7. Jointed floor finishes. 8. Decorative marble tiles. 9. Granite floor tiles. 10. Agglomerated marble. 11. Gypsum marble; Technical specifications. 12.
Cork floors. 13. Vinyl tiles and sheets;Technicalspecifications. 14. Glazed ceramictiles; Technical specifications.
15. Concluding
remarks.
16. Standard specifications.
17. Bibliography
23. Energy in building materials
1. Introduction. 2. Energy and the environment. 3. Studies on energy in building materials; Cement industry; Energy efficiency in cement industry in India; Energy content in burnt clay bricks and tiles; Energy consumption in the manufacture of metals; Energy content in lime and gypsum; Energy requirement for production of sand, aggregate and stone; Energy requirements of concrete and concrete blocks; Energy requirement in miscellaneous building materials and components. 4. Energy in building. 5. Recycling of materials. 6. Energy supply; Coal ; Hydrocarbons; Liquified petroleum gas; Production of electric power; Renewable energy. 7. Concluding remarksand recommendations;Fuel,energy and environment; Improvement in the mining of ores, minerals and their beneficiation processes, transport and storage; Recycling of waste to save energy; Utilisation of waste for energysaving;Realfuel value of orga nic wasteto be exploited; Need for clean processing of materials and cleaner 8. Standard specifications. 9. Bibliography construction sites;
24. Fire and building materials 1. Introduction.
2. Causeof fire; Materials at high temperature; Reactions of some basic materials to fire.
3.
Data baseon fire and materials. 4. Modified buildingcodes and standards. 5. Improvementin fire protectionthroughmaterials. 6. Spreadof fire within the roomof origin. 7. Spreadof fire outsidethe room of origin. 8. Fireretardantchemicals. 9. Mattressesandupholsteredfurniturefires. 10. Fireresistance; Fire detection. 11. Containmentof fire. 12. Fire protection of structural elements. 13. Post-fire
investigations and repair of damages. 14. Fire modelling and CBRI work. 15. Concluding facilities at CBRI, Roorkee . 17. Standard specifications. 18. Bibliography
remarks.
16. Test
xix
25. Building materials industry and pollution
1. Introduction; Pollution potential .2. Carbon dioxide emission; Improved technologies and reduction in carbon dioxide emission; Carbon dioxide emission by other building materials. 3. Standardson emission. 4. legislation for prevention and control. 5. Pollution control standards. 6. Incentives. 7. Utilisation and management of waste. 8. Concluding remarks. 9. Standard Specifications. 10. Bibliography
26. Building materials in central public works 1. Introduction.
2. History of public works in India.
3. Materials and construction practices in pre-
independence period. 4. Building materials and their standardisatio n during post-independenceperiod. 5. New materials-development and applications. 6. Wood substitutes; Need for wood substitutes; Development of wood substitutes; Wood substitutes approved by CPWD; Wood substitutes underfinalisation . 7. Use oftlyash for different applications; Flyash-a national level problem; Utilisation of flyash in CPWD 8. Construction materials and technologies in highway sector; Roads--an important sector of public works; Roads in preindependence period; Developments in the highway sector; Developments in road construction; Developments in bridge and flyover construction. 9. landmark events in the development of building materials and associated technologies; Designed masonry for load bearing walls.Use of high strength deformed bars; Use of high strength concrete; Use of prestressed concrete; Use of precast elements; Improvement in specifications of public buildings to provide permanent and durable finishes; Repairs and rehabilitation. 10. Future scenario; Ready mixed concrete (RMC); High performance concrete (HPC); Composite materials as replacement of reinforcing steel; Use of polymers; Use of flyash; Energy efficiency and sustainable development
27. Standardisationin constructionmaterials
1. Introduction; Standardisation activities in India. 2. Standardisation of building materials; Cement and aggregates;Pozzolanas;Building lime; Stone;Clay products for b uildings; Gypsum building materials; Timber; Wood products; Bitumen and tar products; Floor coverings and other finishes; Waterproofing and dampproofing material; Sanitary appliances and water fittings; Doors and windows; Aluminium and aluminium alloys; Concrete reinforcement and other steel sections; Other build ing materials; 3. Development in design and construction; Concrete and steel; Timber; Function al requirements in buildings; Measure ment of civil engineering works; Construction practicesand safety;Fire safetycodes and equipment; National Bu ilding Code and Handbook. 4. Innovative building materials. 5. Quality control. 6. BIS Certification Marks Scheme . 7. Role at international level . 8. Concluding remarks
28. Performance and durability of building materials
2. Servicelife of materials. 3. Performancecriteria. 4. Suggested methodology of performance
1.lntroductiQn
criteria. 5. Service stresses and working conditions of building materials; Surface hardening, fracture toughness and fatigue; Fatigue strength; Creep. 6. Concrete; Chemical deterioration; Steel reinforcement; Aggregate. 7. Fibre composites; Glass fibre reinforced plastics (GRP); Polymer fibre reinforced cement and concrete; Composite materials and fire; Composites and water. 8. Timber. 9. Surface coatings. 10. Adhesives and plastics; Natural outdoor weathering .11. Brick, tiles, stone and silicate cements; laterite; Deterioration of building stone; Stabilised bricks. 12. Concluding remarks. 13. Standard specifications .14. Bibliography
29. Building materials in civil engineering education
1. Introduction. 2. New materials. 3. Civil engineering education at different levels. 4. Changing pattern of education in materials. 5. Researchand continuing education programme; Impact of emerging research areason engineering education. 7. Concluding remarks
30. Technologytransfer in building materialsindustry
1. Introduction; Strengths;Weaknesses;Threats and opportunities for the ind ustry; Strategic position of the industry. 2. Resource base; Manpower resources; Institutional resources; lack of co-ordination between technology produce rs and users;Contribution of scientific studi es in educational institutions; The need for coordination: establishment of DST; National ResearchDevelopment Corporation; Situation by the mid-1980s; Housing and Urban Development Corporation (HUDCO); National Network of Building Centres. 3. The genesis of technology transfer in building materials. 4. Formation of Building Materials and Technology Promotion Council; Corporate strategy of BMTPC (1993-98); Implementation strategy; Joint technology development programmes; IDNDR project on protection of non-engineered houses from natural hazards; Achievements; Innovative technologies developed by BMTPC and l icensed to enterprise s for commercial production; Publications of the Council. 5. Concluding remarks. 6. Bibliography
.
31. Emerging trends in building materials
1. Introduction. 2. Nature of changing needs and effective materials utilisation. 3. Current status. 4. Traditional materiars. 5. Burnt clay bricks. 6. Cement and concrete; Blended cement; Use of wastes in concrete; Waste as aggregates. 7. Composites; Man-made and natural fibres based composites; Wood substitutes; Composites from local materials; Use of bamboo for building components;
484
Polymers, plastics and
surface coatings. 8. Metal matrix composites; Surface engineering. 9. Structure-property relationship; Property of engineering materials. 10. Search for materials and emerging technologies 11. Valorisation and recycling of industrial wastes. 12. Ceramic materials obtained by recycling wastes: some considerations and examples. 13. Glass ceramic materials obtained by recycling hazardous industrial wastes: state of the art. 14. Concludin2 remarks. 15. Biblio2raphv Appendixes
landmarks ForeignCollaborations
Abbreviation and Unit s
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