Building Alternative

A LT E R N AT I V E B U I L D I N G T E C H N O L O G I E S
A LT E R N AT I V E
BUILDING TECHNOLOGIES
D emand for new buildings as well as the cost of building construction is
growing at a steady pace. Bricks, cement, steel, timber, plastics, glass,
etc. represent some of the commonly used conventional materials for the
construction of buildings and other structures. Generally these materials are
transported over great distances spending fossil fuel energy. Manufacture of
such conventional materials requires expenditure of energy in various forms
and many of these manufacturing processes are detrimental to the environment.
On the other hand we have cost effective, labour intensive and energy efficient
traditional building materials and techniques like mud walls, thatch roofs, etc.
Some of these traditional building techniques like mud walls, thatch roofs
require frequent repairs. Use of conventional materials alone to satisfy the
demand for new buildings, can drain the available energy resources and cause
environmental degradation/pollution. Also, such energy intensive building
materials are expensive. This clearly indicates the need for energy efficient,
environment friendly, economical alternative building materials and
technologies.
Centre for ASTRA (Application of Science and Technology to Rural Areas)

was formed in the Indian Institute of Science, Bangalore in 1974. Developing
affordable, environment friendly, energy efficient, simple technologies utilising
maximum local resources and skills was one of the main thrust areas of ASTRAs
activities. R&D in alternative building technologies was immediately taken up
by the Department of Civil Engineering at Indian Institute of Science as a part
of ASTRAs activities. The emphasis in R&D into alternative building technologies
was in looking at utilisation of local materials and reducing energy consumption
to achieve cost reduction. ASTRA and Department of Civil Engineering have
developed and disseminated several alternative building technologies over the
past 2.5 decades. Brief details of some of these techniques and technologies
are furnished below.
STABILISED MUD BLOCKS (SMB)
Concept/Process
Soil, sand, stabiliser (cement/lime) and water mixture is compacted into a

high-density block using a machine. These blocks are cured and then
used for wall construction.
Type of soil
Soils containing predominantly non-expansive clay minerals are suited for
cement stabilised blocks. For example, most of the red loamy soils are
suitable with minor modifications. Expansive soils such as black cotton

The Indian Institute of Science, Bangalore
soils require addition of lime and the process of making SMBs is cumbersome
using black cotton soil. Highly silty soils also pose problems of green strength
and compaction. Soil with ~10% clay and >65% sand is ideal for SMB
production using cement as a stabiliser. If some soils contain more clay
fraction, then it is advisable to bring down the clay fraction by addition of
sand or inert materials like stone quarry dust.
Machines
Mechanised as well as manually operated machines can be employed.
Manually operated machines are ideal in rural areas for decentralised
production. Mardini soil block press is one such manually operated machine.
Block sizes
Two blocks sizes (305 X 143 X 100mm and 230 X 190 X 100mm) have been
standardised. These two sizes can be used to construct walls of thickness
305mm, 230mm, 190mm, 143mm or 100mm. These blocks are 2.5 to 2.8 times
bigger in volume when compared with conventional bricks.
Block strength
Compressive strength of the block greatly depends upon the soil
composition, density of the block and percentage of stabiliser (cement/
lime). Sandy soils with 7% cement can yield blocks having wet compressive
strength of 3 - 4MPa. This kind of strength will be sufficient to construct
2 storey load-bearing buildings with spans in the range of 3 4m.
Cost of SMB
The cost of SMB depends on a number of factors such as: (1) machine
depreciation cost, (2) cost of soil and sand, (3) cost of cement and
(4) labour cost. Cost of one block of size: 230 X 190 X 100mm (2.5 to 2.8
times brick volume) will be in the range of Rs. 3 to Rs. 5 depending upon
the above factors. Cost can be drastically reduced by the use of local
materials and self-help labour.
Advantages of SMB
1. Energy efficient, ~70% savings when compared to burnt bricks
2. Economical (20 40% when compared to brick masonry)
3. Plastering to walls can be eliminated
4. Highly decentralised production
5. Better block finish and aesthetically pleasing appearance

Stabilised Mud block production using Mardini press
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FINE CONCRETE BLOCKS
The concept and process is similar to the one employed for SMB production
except that the mix contains more sand and some fines. Inert fines like fly
ash, polished stone waste, etc. or lower percentage of soil fraction (<25%),
are mixed with either sand or quarry dust, along with cement and water.
The mixture is then compacted into blocks using a machine (manual or
mechanised) and then cured for 28 days. Inert fines (like fly ash, polished
stone waste, etc.) in the range of 20% by weight of sand and 6 to 7%
cement can result into a good quality block with wet strength >3MPa. In
addition to inert fines about 10% red soil addition can result in some
natural mud colour for the block.
The major advantage of fine concrete block is the utilisation of waste

products like fly ash, polished stone waste, etc. which otherwise cause
pollution and environmental degradation. Cost of the block will depend
on several factors as mentioned for SMB cost.
STEAM CURED BLOCKS
Concept/process
Raw materials like lime are easily available. A mixture of lime, industrial
waste products like fly ash/soil and sand can be compacted into a
high-density block. Expansive soils like black cotton soil are also suitable.
Lime reacts with fly ash/clay minerals forming water insoluble bonds
imparting strength to the block. These reactions are slow at ambient
temperatures (~30OC) and hence steam curing for about 10 hours at 80OC
can accelerate these reactions leading to high strength for the block.
The process involves:
1. Mixing of raw materials like lime, cement, fly ash or black cotton soil,
sand and water in a mixer
2. Converting the mixture into a dense block using soilblock press
3. Stacking blocks in a steam chamber and steam curing for 10 12 hours
Block sizes
Blocks of any convenient size can be manufactured. Experiments and field
demonstration has been carried out using blocks of size: 305 X 143 X 100mm
and 230 X 190 X 100mm. Bigger blocks have several advantages like higher
masonry efficiency, lower labour cost, savings in mortar for wall
construction, etc. It is difficult to produce the block sizes bigger than
those suggested above using manually operated machines.
Block strength
Compressive strength of the block depends upon the composition of the
mix, density of the block and percentage of stabiliser (cement/lime). With
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a combination like 25% fly ash and 75% sand or quarry dust, and using
7% lime + 2% cement can yield blocks having wet compressive strength
of >6MPa. This kind of strength will be sufficient to construct 3 storey
load-bearing buildings with spans in the range of 3 4m. Blocks of higher
strength can be easily achieved by adjusting the mix proportions.
Cost of block
Block cost depends on a number of factors such as: (1) machines
depreciation cost, (2) cost of fly ash and sand, (3) cost of lime/cement
and (4) labour cost. Cost of one block of size: 230 X 190 X 100mm (2.6 times
brick volume) will be about Rs. 5-6 depending upon the above factors. It
should be noted here that the block quality is much superior when
compared to local bricks and SMB.
Advantages
1. Ideal process for a small-scale or cottage industry
2. Utilisation of industrial waste products like fly ash and problematic
soils like black cotton soil and high clay soils
3. Energy efficient and environment friendly
4. Higher strength for the blocks
5. Better block finish and aesthetically pleasing appearance
Steam curing plant (capacity:1300 blocks per shift)

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MUD CONCRETE BLOCKS
This is a low cost concrete, which can be used for foundations, base
course for floorings and building blocks. Its economic advantage can be
fully utilised wherever stone boulders and irregular shape coarse aggregates
are locally available. It is a mixture of soil-cement-sand and coarse aggregate.
Two types of mud concrete blocks can be prepared depending upon the
availability of the type of stone pieces.
a) Irregular shape stone pieces (coarse aggregate) of sizes ranging

from 20 to 50mm are available, such stone pieces in combination with
cement-soil-sand mixture can be utilised to make mud concrete blocks.
Prepare a mixture of cement : soil : sand in the ratio of 1:4:4 by
volume. If the soil is too clayey increase the sand proportion keeping
the overall proportion the same. Now add this mixture to the coarse
aggregate and convert into a workable concrete mix with
adequate quantity of water. This concrete can now be poured
into a wooden mould, compacted into a block and then cured. The
proportion of cement-soil-sand mixture and coarse aggregate can be
1:1.5 by volume. Wet compressive strength in the rage of 3 5MPa can
be achieved for the blocks of size 305 X 150 X 125mm. The block sizes
can be easily manipulated by selecting a suitable mould size.
b) Irregular shaped stone boulder pieces of bigger sizes (>50mm) can also
be utilised for producing mud concrete blocks. The process involves
keeping the stones into the mould first and then packing the crevices
between these stones by using a mortar of cement : soil : sand (in the
ratio of 1:4: 4 by volume). This kind of block will have >60% of the block
Manufacture of mud concrete blocks
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volume occupied by the bigger stone pieces there by saving the

quantity of cement to be used for block production. Blocks of size
305 X 150 X 125mm or even bigger can be made using a suitable mould.
In this case also wet compressive strength in the rage of 3 5MPa can
be achieved.
Mud concrete block building
Mud concrete block boundary wall
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COMPOSITE MORTARS
Mortars play an important role in bonding the masonry units (bricks/blocks

etc.) and imparting strength and stability to the masonry walls. Mortars
should possess good workability, helping the mason in laying the bricks
and develop good adhesion with the brick or block thereby providing
good bond strength to masonry. Ordinary cement mortars are deficient in
these two important characteristics. Composite mortars like cement-lime
mortars and cement-soil mortars are superior to cement mortars in many
aspects. Cement-lime mortars are more expensive than cement-soil mortars.
Several investigations carried out at Indian Institute of Science reveal that
composite mortars like cement-soil mortars are ideally suited for the
construction of masonry using stabilised blocks or bricks. Mortar
proportions like cement : soil : sand in the ratio of 1:2 – 3:6 – 8 by volume
can be used for the construction of stabilised block masonry and plastering.
It must be noted here that the soil should be sieved through a 5mm mesh
and thoroughly mixed with cement and sand to produce a good quality
mortar. Red loamy soils can be used for mortars. Presence of clay lumps
and improper mixing of soil can lead to poor quality mortars. Experiments
have shown that a properly made cement soil mortar of 1:2:6 proportion
can result in 70 90% increase in bond strength for the masonry when
compared to 1:6 cement mortar.
ALTERNATIVE ROOFING SYSTEMS

A number of roofing alternatives have been developed and disseminated.
Brief details of some of these roofing systems are highlighted here.
COMPOSITE BEAM AND PANEL ROOFS
This concept exploits the efficiency of beam and slab construction. The
roofing system consists of partially precast or cast-in-situ ribs/beams at
certain spacing covered with panels as shown in the following figure. The
panels and beams are connected through shear connectors to achieve
composite action. Varieties of options are available for the beams and
panels as given in the Table below. The profile for the panels could be
curved, folded plate or flat. Use of curved shape panels results in a
composite jack-arch roof. The beam cross section can also be adjusted to
minimise the material consumption. Partially precast beam of T-shaped or
trapezoidal cross section can be easily generated in the field. The major
advantages of the roofing system are: (a) possibility of prefabrication and
quick erection (b) better quality assurance due to prefabrication
(c) savings in volume of materials and hence cost effective (d) possibility of
using hollow panels to increase thermal comfort. The cost of the roof
greatly depends on the roof span, materials selected, labour cost, etc.
Cost of composite beam and panel roof is compared with other type of
roofs in the following sections.
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Materials/technologies for the beams and panels
BEAM/RIB PANEL
R.C. CAST-IN-SITU R.C. - CAST-IN-SITU
R.C. PART PRECAST R.C. PRECAST
STEEL (ROLLED SCTION) REINFORCED BRICKWORK
STEEL (TRUSSED) CUDDAPAH STONE
TIMBER SHAHABAD STONE
STEEL & R.C. COMPOSITE HOLLOW HOURDI TILE
TRUSSED TIMBER ARCHED BRICK/TILE
TIMBER & STEEL COMPOSITE HOLLOW R.C. PANEL
SMB PANEL
Cross-section of a jack-arch roof
Details of composite jack-arch panel roof

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Composite jack-arch roof assembly
Composite beam panel roof building

Reinforced tile-work jack-arch roof ceiling
Jack-arch panel roof with decorative clay tile ceiling

Reinforced brick-work flat panel roof
FILLER SLAB ROOFS
Filler slab roofs are basically solid reinforced concrete slabs with partial
replacement of the concrete in the tension zone by a filler material. The
filler material could be cheaper or cheaper and lighter. A number of
alternative materials can be thought of: (a) Brick or brick panel (b) Mangalore
tile (c) Stabilized mud block, (d) Hollow concrete block, (e) Hollow clay
tile/block, etc. Typical cross-section showing the details of filler slab roof
is shown in the figure below. Quantity of concrete in the tension zone of
the slab that can be replaced by a filler material depends upon the shape
of the filler material available and the thickness of the solid slab.
For example in a solid concrete slab of 125mm thickness, a filler block of
60 70mm thickness can be easily accommodated. In a typical situation,
by using a stabilized mud block, 25% of the concrete volume can be replaced
by a material, which costs 1/3rd of the cost of concrete. This means that
15 – 20% of the cost of concrete can be saved by this operation. It must
however be noted that this is not a prefabricated roof. Other versions of
filler slabs are possible using lightweight concrete inserts.

Typical cross section of a filler slab roof
SMB filler blocks with reinforcement
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Ceiling of SMB filler slab roof before finishes
Mangalore tile filler slab roof ceiling
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Cost analysis of roofing systems

The following Table gives the cost analysis for the three types of roofing systems
viz. R.C. slab, composite beam & panel roof and filler slab roof using SMB filler.
The costs shown in the Table are based on the then prevailing market rates
for materials and labour at Bangalore. The cost of the composite beam and
panel roof is 26% less than that of R.C. solid slab, whereas SMB filler slab is 18%
less than that of R.C. slab roof.
Cost analysis per m2 of roof area (2002)

LL: 200 kg/m2, Two way slab size: 3.8m X 4.8m,
Type of roof Cost (Rs.) Savings
per m2 in cost
R. C. Solid slab 829.
R. C. Filler slab (SMB filler blocks) 680. 18%
Composite beam-panel roof 613. 26%
(curved/jack-arch panels)
FERROCONCRETE ROOF UNITS

Ferroconcrete is defined as concrete with smaller size coarse aggregate
(<10mm) reinforced with thinner diameter (2 – 8mm) reinforcement bars.
The mix proportion for such a concrete is generally of 1:2:2 (cement:
sand: coarse aggregate), in order to achieve 20MPa strength for concrete
using small size coarse aggregates. Thinner units (2025mm thickness) for
roofing application can be made using ferroconcrete. A number of precast
products for various types of roofing systems can be made using
ferroconcrete. Details of some of the roofing systems using ferroconcrete
have been illustrated below.
FERROCONCRETE CHANNEL TILE & L-BEAM TILE ROOFS
These are thin ferroconcrete tile units used as alternative to traditional

tiles like Manglaore tiles. Following figure shows the configuration of roofs
using ferroconcrete tiles, viz. (a) channel tile and (b) L-beam tile. The
thickness of these tiles is kept at 20mm. The channel tile requires the use
of rafters and reepers as in Mangalore tiled roof. The L-beam tile rests
directly on the rafters and the rib of the tile performs the function of a
reeper thus eliminating the need of reepers.
The channel tile size is about 0.6m X 0.75m. The size of L-beam tile is about
0.6m X 1.2m. These tiles when manufactured properly will have enough
strength and permit a person to walk on the roof. Cost of the channel tile
and L-beam tile roof will depend upon the type of supporting structure,
labour costs, etc. Cost of typical channel tile is about Rs. 110 per m2 of
roof area, whereas it is Rs. 175 per m2 for L-beam tile. Adding the cost of
supporting structure will give the total cost of the roof.
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Channel tile
L-beam tile
Channel tile roof
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L-beam tile roof
FERROCONCRETE CHANNEL FLOOR UNIT
The cross section and reinforcement details of a typical floor unit

designed for 2.5kN/m2 live load spanning 1.7m are shown in the following
figure. The depth of the channel unit and the steel quantity will mainly
depend upon the span and the load. The elements can be cast on a
level platform using wooden moulds. The channel units can be placed
adjacent to each other spanning across the walls, beams or trusses.
Then the top of the roof or floor can be finished with a screed concrete.
A laboratory building was constructed at I.I.Sc., where the supporting
members for the channels is a truss spanning 12m. The channel roof
cost was Rs. 500 per m2 in 1999.
Cross-section of ferroconcrete channel floor unit

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Casting of ferroconcrete channel floor units
Casting of ferroconcrete channel floor units
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Ceiling of ferroconcrete channel roof
Casting of ferroconcrete T-beam floor unit and finished unit
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T-BEAM FLOOR
Instead of a channel shape the roofing unit can also be made resembling a
T shape. The depth of the T- beam unit and the steel quantity will mainly
depend upon the span and loads. The elements can be cast on a level
platform using minimal wooden moulds. Details of casting of T-beam units
and the ceiling of finished T-beam floor unit are shown in the following
figures. The cost of this floor is about Rs. 550 per m2 (2000), where the
span of the T-beam unit is 4m.
Ceiling of T-beam floor unit
FERROCEMENT ROOFING UNITS
Ferrocement is a composite material consisting of rich cement mortar

(1:2 or 1:3) (matrix) reinforced with layers of small diameter wire meshes.
A skeleton of steel bars of requisite shape of the element is prepared and
then wrapped with layers of small diameter wire meshes before applying
the cement mortar. The wire mesh reinforcement is uniformly distributed
across the thickness of the element, which helps in achieving
improved mechanical properties like fracture and tensile strength as well
as fatigue and impact resistance. It also helps to eliminate the formwork.
Ferrocement elements are thin walled, where strength and rigidity are
derived from the form and shape of the element. Ferrocement has wide
range of applications like manufacture of boats, water tanks, silos, beams,

lintels, chajjas, roofing elements, etc. Typical cross section of ferrocement

channel unit for roofs is shown in the following figure. This kind of roofing
channels can be designed for any span. The area of longitudinal steel
reinforcement will depend upon the roof span and size and shape/profile
of the roofing unit. For sloping roof with a clear span of 3.3m the tension
steel area required will be 50mm2 with 3mm G.I. wire stirrups for a channel
width of 600mm. Roofing channel unit of size 0.6m width and 3.5 – 4m
length will be convenient for lifting and assembling the roof without use of
any machinery. The cost of ferrocement channel sloped roof for
3 – 3.5m span will be about Rs. 400 – 450 per m2 of roof area.
Typical cross section of ferrocement roof unit
Ferrocement roof

UNREINFORCED MASONRY VAULTED ROOFS
Vault and dome construction using unreinfroced masonry is known in India

for more than six centuries. Due to the advent of steel and reinforced
concrete these techniques were abandoned during British period. Because
of the advantages like aesthetics, cost, durability and savings in energy,
vaults and dome constructions have been revived. Recent work and
expertise developed at I.I.Sc., has shown that unreinforced masonry vaults
can be constructed using the concept of moving formwork. A metal formwork
of about 1m width defining the vault shape can be repetitively used to
construct such vaults. The following figures show this concept of roof
construction. Various shapes can be adopted for the vaults. Catenary shaped
vault is the most efficient. The thickness of the vault is dependent on the
span of the vault. A vault thickness of about 100mm can be used for spans
upto 4m. It is also possible to construct the intersecting vaults as well as
hipped vaults.
Masonry vault construction under progress

Masonry vault roof
Intersecting vaults
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PRECAST LINTELS AND CHAJJAS
Openings in external walls are provided with lintels and chajjas. Generally,
R.C. lintel and Chhajja is considered satisfactory from the point of view of
performance. The cost of the lintel and chajja is a function of the opening
size and length of the chajja. For smaller openings (<1.4m, where shear
stresses are low) with at least 0.75m of masonry above the lintel, reinforced
brickwork or reinforced block-work (R.B.) lintels are ideal alternatives for
R.C. lintel beam. The R.B. lintels consist of a thin reinforced ferroconcrete
layer (~40mm) in the tension zone and brickwork or block-work in the
compression zone. Masonry is good for resisting compressive stresses and
hence the reinforced masonry is ideally suited for such lintel beams.
Obviously the cost of such lintel will be cheaper than R.C. lintel. R.C.
Chajjas are generally provided with fascia and other such decorative
elements for aesthetic reasons. Precast ferroconcrete brackets and chajja
can provide the necessary cost reduction and gives enough scope for
designing aesthetically pleasing brackets/chajjas. The cost of R.C.
lintel chajja and the R.B. lintel and precast chajja is given in the Table
below. The cost of R.B. lintel and precast chajja is about half that of
conventional R.C. lintel-chajja.
Cost of Lintel Chajja for 1.35m opening (2002)
Sl. Details of lintel - chajja Cost
No. (Rs.)
1. Precast chajja bracket & RB lintel
a) Reinforced block-work lintel 88.
b) Precast brackets 2 Nos. 149.
c) Precast chajja 118.
d) Labour cost of erection 50.
Profit @ 15% 60.
Total cost 465.
2. R.C. lintel beam and chajja
a) R. C. lintel beam 274.
b) R. C. Chajja 508.
Profit @ 15% 118.
Total cost 900.
Reinforced block-work Lintel

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Precast brackets, Chajjas and

RB Lintel
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FUEL EFFICIENT KILNS
a) Lime Kiln
Traditional lime kilns are often extremely small in size and have features,
which lead to inefficient burning. ASTRA hence developed lime kiln
designs to burn ½ ton and 1 ton limestone capacity per batch. Greater
efficiency is achieved by controlling air flow. The smaller kiln uses 45%
wood fuel while the bigger one can manage with about 35% wood fuel.
The ½ ton kiln design has been disseminated by the TIDE (an NGO) in
several locations. The cost of the ½ ton capacity kiln is about
Rs. 10,000/-.
½ ton capacity lime kiln
b) Pottery Kiln
Improved, fuel-efficient pottery kiln is important to upgrade and promote
pottery activity in rural areas. A simple, up-draught pottery kiln has
been designed and demonstrated in several locations. Uniform flow is
achieved by using two layers of bricks with gaps to slow down movement
of hot gases. The resistance to flow is also increased by having a narrow
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outlet at the top of the kiln. The field demonstrations have shown
improved burning quality and reduced wastage.
Pottery kiln
c) Pozzolana Kilns
Two types of pozzolana kilns have been developed. The first one uses
clay briquettes burnt by wood. This is similar to a lime kiln in operation.
About 15% by weight of the clay is used as fuel while burning a ton of
clay.
The second type of kiln is of the form of an annular cylinder with

honeycomb brickwork. Alternate layers of rice husk and clay are used
to load the kiln. The entire mass is set fire to from below. Rice husk to
the tune of 40 45% of the weight of clay may be used.
The pozzolana, whether it is burnt clay or of burnt clay and rice husk
ash is to be ground in a ball mill up to about 75micron size.
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LIME POZZOLANA CEMENT
This cement is made by mixing calcium hydroxide (lime) and pozzolana

in the ratio of 1:1.5 or 1:2. If the lime is of poor quality the richer mix is
to be used. Ideally calcium hydroxide and pozzolana have to be
interground in a ball mill. But such mixtures have poor shelf life (about
15 days). The other technique uses site mixing of freshly slaked calcium
hydroxide and pozzolana in the form of slurry in a concrete mixer. A few
pieces of coarse aggregate could be added to provide better mixing.
The aggregate may be removed subsequently and lime pozzolana (LP)
slurry poured over sand to make mortar. Volume of proportion of 1:3 or
1:4 (LP cement : sand) may be used. Strength in the range of 1.0
3.0MPa may be expected from the mortar.
Examples of alternative buildings
(1) Residential building of Prof. K. C. Patil

Location: No. 440, 6th Main Road, JRD Tata Nagar, Kodigehalli,
Bangalore-94, Year of completion: 2001
Specifications:
Foundation: Size stone masonry (in composite mortar) on a soft clayey
soil (total height of foundation is 2.5m due to low-lying area) with
R.C. plinth beam of 150mm thickness.
Walls: 230mm thick load bearing masonry walls using soil-cement blocks
(7%cement) in 1:2:6 cement-soil-sand mortar. Partition walls are 100mm
thick. Average wet compressive strength of the block is 4.7MPa (7%
cement). External surfaces of walls have flush pointing in 1:1:3 composite
mortar. Internal surfaces have plaster with 1:2:6 cement-soil-sand mortar.
Lintels & Chajjas: Reinforced blockwork lintels for openings upto 1.25m
and R.C. lintels for bigger openings. Mangalore tile chajjas supported
on metal brackets.
Doors & windows: Teakwood and Padauk wood for frames. Teakwood,
Padauk wood and block board for door shutters. Glazed window shutters.
Steel doorframe and shutter for the garage.
Floor & Roof slabs: R.C. precast composite jack-arch roof for living and
dining and soil-cement block filler slab for the rest of the portion. The
roof has Mangalore tile weatherproof course for sloping portions and
Flat weatherproof tile for flat roof portions. Mangalore tiles (small size)
supported on steel sections for the garage and jagali portion.
Floor: Kitchen has polished shahabad stone floor and grey mosaic tile
floor finish in other places. Glazed tiling in bathrooms.
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Finishes: Exposed external wall surfaces are coated with transparent

silicone paint and internal wall surfaces with emulsion paint. Kitchen
platforms have polished granite top and granite sink. Doors and windows
have melamine polish.
Ground floor plan
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First floor plan
Prof. Patils residence

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Cost analysis
Effective plinth area = 163.15 m², Carpet area = 117.69 m²,

Cost of construction per m² of plinth area = Rs. 6976/ m² (Rs. 649/Sft)
Component Cost (Rs.) % of

total cost
1. Structure
a) Foundation 1,15,228.00 10.1
b) Plinth 12,502.75 1.1
c) Walls/beams 3,24,000.00 28.5
d) Roof & floor slabs
Precast/ Filler slab 85,080.00 7.5
Mangalore tile roof 40,890.00 3.6
Sub-total 5,77,700.00 50.8
2. Openings
a) Doors & Windows 1,28,339.00 11.3
b) Lintel & Chajjas 15,355.00 1.3
Sub-total 1,43,649.00 12.6
3. Finishes
a) Flooring 47,394.00 4.2
b) Painting 40,006.00 3.5
Sub-total 87,400.00 7.7
4. Services
a) Plumbing & Sanitary 1,15,882.00 10.2
b) Electrical 43,053.00 3.7
Sub-total 1,58,935.00 13.9
5. Technical assistance 1,30,400.00 11.5
6. Architect fee 40,000.00 3.5
Miscellaneous 1,11,054.00
Total cost 12,49,183.00
Labour cost in civil works 2,55,298.80 22.4
Materials used :
a) Cement: 845 bags,
b) Steel: 1500Kgs (excluding steel used for fabrication of Mangalore tile
roof).
1) Volume of bed concrete (1 : 4 : 8 ) : 14.74 m³
2) Size stone masonry in foundation : 126 m³
3) Plinth beam : a) concrete : 2.74 m³, b) steel : 255 Kgs
4) Volume of masonry walls (load bearing) : 58.11 m³
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5) a) Concrete Roof/Floor area : 130.4 m², b) Floor area : 117.69 m²

6) Roof/Floor slab : a) concrete : 18 m³, b) steel : 912 Kgs
7) Area of : a) Doors : 16.75 m², b) Windows : 20.02 m²
Miscellaneous items: a) Sump, b) Temporary shed, c) Gate, d) Paving,
e) Solar water heater, f) Outside steel grill work,
g) Boundary wall.
(2) Residential building of Prof. Sudhakar M. Rao

Location: No. 24, 2nd Main Road, JRD Tata Nagar, Kodigehalli, Bangalore
560 094
Year of completion: 2002
Specifications:
Foundation: Size stone masonry in composite mortar (total height of
foundation is 1.75m due to low-lying area) with R.C. plinth beam of 150mm
thickness.
Walls: 230mm thick load bearing masonry walls using soil-cement blocks
(size: 230 X 190 X 88mm and 7.5%cement) in 1:2:6 cement-soil-sand mortar.
Partition walls are 88mm thick. Average wet compressive strength of the
block is 7.45MPa (7.5% cement). External surfaces of walls have flush pointing
in 1:1:3 composite mortar. Internal surfaces have plaster with 1:2:6 cement-
soil-sand mortar and recessed pointing in the entrance corridor and few
other places.
Lintels & Chajjas: Reinforced blockwork lintels with ferroconcrete precast

chajjas, supported on precast ferroconcrete brackets.
Staircase: Internal staircase constructed with precast ferroconcrete steps,

cantilevered from the wall. Thickness of the step is 40mm.
Doors & windows: Padauk wood for frames for doors and windows. OST
block board for door shutters except main door, which has padauk wood
shutter. Glazed window shutters and rolling shutter for the garage.
Floor & Roof slabs: R.C. precast composite jack-arch roof for living room
and soil-cement block filler slab for the rest of the portion. The roof has
weatherproof course using tiles.
Floor: Glazed ceramic tile flooring except in FF corridor. FF corridor has

terracotta tile floor. Bathroom walls (up to 2.1m) and floor have been
provided with ceramic glazed tiling.
Finishes: Exposed external wall surfaces and internal wall surfaces are
plastered have paint. Kitchen platforms have polished granite top and
stainless steel sink. Doors and windows have melamine polish.
!
Ground floor
plan
First floor plan
!!
Cost analysis
Effective plinth area = 163.04 m², Carpet area = 120.37 m²,
Cost of construction per m² of plinth area = Rs. 6337/m² (Rs. 590/Sft)

total cost
1. Structure
a) Foundation 70,201.00 6.8
b) Plinth 11,218.00 1.1
c) Walls/beams 3,07,216.00 29.7
d) Roof & floor slabs 1,24,357.00 12.2
Sub-total 5,12,992.00 49.6
2. Openings
a) Doors & Windows 1,36,583.00 13.2
b) Lintel & Chajjas 21,676.00 2.1
Sub-total 1,58,259.00 15.3
3. Finishes
a) Flooring 75,295.00 7.3
b) Painting 54,344.00 5.3
Sub-total 1,29,639.00 12.6
4. Services
a) Plumbing & Sanitary 60,340.00 5.8
b) Electrical 60,520.00 5.9
Sub-total 1,20,860.00 11.7
5. Technical assistance 1,05,481.00 10.2
Architect Fee 6,000.00 0.6
Miscellaneous 1,52,176.00
Total cost 11,85,407.00
Labour cost in civil works 2,20,175.00 21.4
Materials used :
a) Cement: 831bags, b) Steel : 2.41MT
2) Size stone masonry in foundation : 55.32 m³
3) Plinth beam : a) concrete : 2.95 m³, b) steel : 288 Kgs
5) a) Roof area : 188.37 m², b) Floor area : 120.37 m²
6) Roof/Floor slab : a) concrete : 22.65 m³, b) steel : 1.52 MT
!"
Miscellaneous items:
a) Sump, b) Temporary shed, c) Gate, d) Bore well,
e) Hand pump, f) Steel grill work, g) Motor pump,
h) Boundary wall, I) Granite slabs.
Prof. Sudhakar M. Raos residence
(3) New ASTRA building

Location: Centre for ASTRA, Indian Institute of Science, Bangalore 560 012
Year of completion: 1999
New ASTRA building

!#
Specifications:
Foundation: Size stone masonry in composite mortar. 40mm thick R.C. plinth
band provided 0.6m below the top of foundation.
Walls: 230mm thick load bearing masonry walls (designed for

3 floors) in 1:2:6 cement-soil-sand mortar, using steam cured stabilised
blocks for the GF walls and soil-cement blocks (8% cement with wet strength
of 5.4MPa) for the FF. Partition walls are 100mm thick. Average wet
compressive strength of the steam cured blocks is 6.89MPa with a SD of
0.74MPa. External surfaces of walls have flush pointing in 1:1:3 composite
mortar. Internal surfaces in corridors are exposed with recessed pointing
and other internal walls have plaster with 1:2:6 cement-soil-sand mortar.
Lintels & Chajjas: Reinforced blockwork lintels and ferroconcrete precast

chajjas are supported on precast ferrocement brackets. Soil-cement block
arches have been provided in the corridors.
Doors & windows: Pressed metal sheet frames with block board shutters
for doors. Pressed metal sheet frames and glazed shutters for windows.
Floor & Roof slabs: Soil-cement block filler slab for roof and floor. The
roof has weatherproof course using tiles. Staircase headroom has precast
ferroconcrete channel roof.
Floor: Cement mortar floor. In corridor the cement floor has some
terracotta tile embedded in some portions. Glazed tiling in toilets.
Finishes: Exposed external wall surfaces are coated with transparent

silicone paint and internal wall surfaces (except in corridors) with emulsion
paint. Doors and windows are painted using enamel paint.
Ground floor plan & First floor plan
!$
Cost analysis
Effective plinth area = 280 m², Carpet area = 223.64 m²,

Cost of construction per m² of plinth area = Rs. 4247/ m² (Rs. 395/Sft)

total cost
1. Structure
a) Foundation 1,01,799.00 8.8
b) Plinth 6,797.00 0.59
c) Walls/beams 3,28,022.00 28.2
d) Roof & Floor slabs 1,88,811.00 16.3
e) Staircase 10,828.00 0.93
Sub-total 6,36,257.00 54.8
2. Openings
a) Doors & Windows 1,08,720.00 9.4
c) Lintel & Chajjas 16,039.00 1.4
Sub-total 1,24,759.00 10.8
3. Finishes
a) Flooring 38,233.00 3.3
b) Painting 32,377.00 2.8
Sub-total 70,610.00 6.1
4. Services
a) Plumbing & Sanitary 1,40,861.00 12.1
b) Electrical 1,58,829.00 13.7
Sub-total 2,99,690.00 25.8
5. Architect fee 30,000.00 2.5
Miscellaneous 27,942.00
Total cost 11,89,258.00
Materials used:
a) Cement: 842 bags b) Lime : 5.5 tonnes c) Steel: 2.661MT
2) Size stone masonry in foundation : 71.68 m³
3) Plinth beam : a) concrete : 1.497 m³, b) steel : 420 Kgs (Reinforced
masonry)
5) a) Roof area : 271.56 m², a) concrete: 34.03 m³, b) Steel: 2.241MT
b) Floor area : 223.64 m²
Miscellaneous items:
Jali works, Parapet.
!%
ACKNOWLEDGEMENT
The Chairman and Staff of are grateful to the HIVOS (Humanist Institute for
Cooperation with Developing Countries, The Netherlands, Bangalore Regional Office South
Asia) for their generous financial assistance for organizing the National Workshop on
Rural Technology - A 25 year retrospect on the occasion of Silver Jubilee of and
the Proceedings of the Conference, as well as brochures of technologies.
FOR FURTHER DETAILS, PLEASE CONTACT:
Chairman
Centre for Sustainable Technologies,
(Formerly known as astra)
Indian Institute of Science, Bangalore - 560 012
Phone: 091-80-334 8575, 293 2447
Fax: 091-80-334 8575 / 091-80-360 0683, 360 0085
e-mail: [email protected]
website: www.iisc.ernet.in~astra
Dr. B.V. Venkatarama Reddy

Department of Civil Engineering
Indian Institute of Science, Bangalore - 560 012. INDIA
Phone: 91-080-293 3126, Fax: 91-80-360 0404, 360 0683
E-mail: [email protected]
!&

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A LT E R N AT I V E B U I L D I N G T E C H N O L O G I E S

Centre for ASTRA (Application of Science and Technology to Rural Areas)

STABILISED MUD BLOCKS (SMB)

Soil, sand, stabiliser (cement/lime) and water mixture is compacted into a

The Indian Institute of Science, Bangalore

Stabilised Mud block production using Mardini press

FINE CONCRETE BLOCKS

The major advantage of fine concrete block is the utilisation of waste

STEAM CURED BLOCKS

Steam curing plant (capacity:1300 blocks per shift)

MUD CONCRETE BLOCKS

a) Irregular shape stone pieces (coarse aggregate) of sizes ranging

Manufacture of mud concrete blocks

volume occupied by the bigger stone pieces there by saving the

Mud concrete block building

Mud concrete block boundary wall

Mortars play an important role in bonding the masonry units (bricks/blocks

ALTERNATIVE ROOFING SYSTEMS

COMPOSITE BEAM AND PANEL ROOFS

Materials/technologies for the beams and panels

Cross-section of a jack-arch roof

Details of composite jack-arch panel roof

Composite jack-arch roof assembly

Composite beam panel roof building

Reinforced tile-work jack-arch roof ceiling

Jack-arch panel roof with decorative clay tile ceiling

Reinforced brick-work flat panel roof

FILLER SLAB ROOFS

Typical cross section of a filler slab roof

SMB filler blocks with reinforcement

Ceiling of SMB filler slab roof before finishes

Mangalore tile filler slab roof ceiling

Cost analysis of roofing systems

Cost analysis  per m2 of roof area (2002)

FERROCONCRETE ROOF UNITS

FERROCONCRETE CHANNEL TILE & L-BEAM TILE ROOFS

These are thin ferroconcrete tile units used as alternative to traditional

Channel tile roof

L-beam tile roof

FERROCONCRETE CHANNEL FLOOR UNIT

The cross section and reinforcement details of a typical floor unit

Cross-section of ferroconcrete channel floor unit

Casting of ferroconcrete channel floor units

Casting of ferroconcrete channel floor units

Ceiling of ferroconcrete channel roof

Casting of ferroconcrete T-beam floor unit and finished unit

Ceiling of T-beam floor unit

FERROCEMENT ROOFING UNITS

Ferrocement is a composite material consisting of rich cement mortar

lintels, chajjas, roofing elements, etc. Typical cross section of ferrocement

Typical cross section of ferrocement roof unit

UNREINFORCED MASONRY VAULTED ROOFS

Vault and dome construction using unreinfroced masonry is known in India

Masonry vault construction under progress

The Indian Institute of Science, Bangalore

Masonry vault roof

PRECAST LINTELS AND CHAJJAS

Cost analysis per m2 of roof area (2002)

Prof. Patils residence

Prof. Sudhakar M. Raos residence