Modern Housing Construction Techniques

New Construction Techniques for Modern Housing Schemes
New Construction Techniques for Modern Housing Schemes OVERVIEW

Asoka Perera Professor of Civil Engineering Department of Civil Engineering University of Moratuwa
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Background Sri Lankas construction industry is yet to be benefited from technologies developed for housing Small scale applications are visible but largely the construction technology is reinforced concrete, bricks, blocks and other traditional methods. However many other countries have implemented new housing technologies and getting the benefits. For example Government of Thailand have decided to use pre-cast concrete methods to construct more than 500,000 housing units to solve the housing problem. Similarly in India the use of new methods have increased. Generally new methods are cost effective, fast, better appearance, better planned settlements and durable.
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New Construction Techniques for Modern Housing Schemes HOUSING TECHNOLOGIES :OVERVIEW
The main pitfall

Many believe alternative materials or methods is the way to reduce cost or to increase speed completely forgetting the design aspects. The design aspects are very poorly addressed or completely ignored due to the fact that Architects, Structural Engineers and Service Engineers need to work as a team. However main cost savings are in the area of design. It is no doubt that new materials and methods can be cost effective on top of the design aspects. Further alternative materials and methods can address some pressing problems such shortage of river, shortage of skilled labour (or high cost) etc.
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Three methods
Design methods, optimization programs etc. Structural Design optimization is a good example. Alternative construction materials. Materials such compressed earth blocks, fly ash blocks are good examples. New construction methods. New slab construction methods, Pre-cast concrete methods, Ferrocement methods
New Construction Techniques for Modern Housing Schemes HOUSING TECHNOLOGIES :OVERVIEW Technology Possible Cost savings Implementation Challenges 1. More design work 2. No additional fee, in fact the fee could get reduced 3. Lack of confidence 4. Lack of familiarity with design methods such as masonry design. 5. Naturally would like to be extra safe 6. Bill is paid by the client 7. No mechanism to check or to challenge the efficiency of the design. Very common system character 8. May require the use of advance methods such as value analysis A technique use USA military. 9. Getting and compiling technical information is difficult. 10. Most popular may not the best. 11. Similar reasons of structural design. 12. Most difficult area for cost applications. 13. People buy Maruti cars as well as Benz cars
Technology
Possible Cost savings Up to maximum of 20% cost savings. Generally claimed as cost effective or appear to be cost effective but not necessarily.
Implementation Challenges 1.Compliance with existing standards. Fore example CEB to comply with BS5628. 2.Lack or non-existence of standards particularly for manufacture. 3.General resistance to new materials. 4.Lack of knowledge / information on the new material.
1. Design methods Structural Design Services design such as electrical, plumbing Architectural Design Up to 30% savings Up to 20% savings
1.Alternative Construction Materials Compressed Earth Blocks (CEB) Waste related products such as fly ash blocks UPVC Cement tiles
Up to 20% savings
Up to a maximum of 1. Similar to new materials 1.New Construction 20% methods Ex. Pre-cast concrete panels New floor systems Interlocking blocks Rat-Trap Bond method
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New Construction Techniques for Modern Housing Schemes HOUSING TECHNOLOGIES :DESIGN METHODS
Three methods Most cost effective design method. For example a masonry design could be 30% cost effective than reinforced concrete frame arrangement. On the other hand for a building of 8 storeys reinforced concrete frame building could be more cost effective than a masonry design. Cost optimization within a design. Cost optimization can be done to find out the most economical steel and section arrangement considering the prices of concrete, steel and formwork. Use of value analysis for design of services such as electrical work, plumbing etc.
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Most Cost effective Design method

This could explain best with an example. For example any house of two storey and above can be taken. The example was taken form Tsunami housing project in Ratmalana. Each block is consist of 8housing units and four storeys
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Normal RC Design
Masonry Design Total Cost 217,338.0 71,884.0 223,680.0 84,460.0 0.0 1,075,480.0 1,672,842.0 1,124,823.0 40.2% 53,991,504.0 429,600,000.0 12.6%
Most Cost effective Design method

The initial arrangement was typical reinforced concrete frame buildings with independent footings with plinth beams, columns, beams and slabs. Table below shows the arrangement cost comparisons with masonry load bearing wall structure.
Element Footings in foundations Plinth Beams Rubble masonry in foundation Columns Beams Walls TOTAL Net Saving Saving % Net saving of the project Total Estimate
1.18Saving of the project %
Total Cost 346,546.0 104,591.0 79,650.0 467,265.0 759,133.0 1,040,480.0 2,797,665.0
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Elemental optimum Design :Example from a RC slab

Slab also an expensive element in buildings. The optimum slab thickness is the one just satisfies the deflection requirement and best reinforcement arrangement is the one just satisfies the bar spacing requirement (crack control). However when spans becomes larger the strength requirements supersedes the above requirements.
Elemental optimum Design :Example from a RC slab

Normal RC Design Total Cost Optimum Design Total Cost 248,500.0 186,960.0 203,550.0 639,010.0 77,544.0 10.8% 3,722,112.0
Slab - Concrete Slab - Reinforcement Slab - Formwork TOTAL Saving Saving % Total project cost saving
248,500.0 264,504.0 203,550.0 716,554.0
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New Construction Techniques for Modern Housing Schemes ALTERNATIVE CONSTRUCTION MATERIALS
New Construction Techniques for Modern Housing Schemes ALTERNATIVE CONSTRUCTION MATERIALS :EARTH CONSTRUCTIONS
Earth Related Technologies

Compressed Stabilized Earth blocks Adobe Blocks Rammed Earth
The use of compressed earth blocks in Sri Lanka

First attempt in 1960s with CINVA ram machines Some houses were constructed in Colombo, Batticaloa etc. Second attempt in 1980s NBRO building, some in Gampaha In 1990s by University of Moratuwa more than 2000 houses. There is growth of the application
Other new methods

Straw bale method Bamboo related methods Waste related methods

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Interlocking blocks
Concrete blocks Polystyrene interlocking blocks
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The use of compressed earth blocks in Sri Lanka There are three manufacturers now.
One well established and have fairly good demand. The start was very difficult and project in Horana helped to get established. One has just commenced the production using Hydraform machine a good machine but blocks seem expensive One in Galle planning to introduce plain blocks as well as interlocking blocks using Hydraform machine. Some NGOs Small scale manufacturers
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The use of compressed earth blocks in other countries

India, There is wide usage mainly in Kerala, Tamil Nadu and other places Thailand Initiatives of Habitec Centre Australia USA Germany France

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New Construction Techniques for Modern Housing Schemes SOIL BLOCK MACHINES Soil:cement block machine 1. CINVA ram machine This is a very simple machine. Can be transported from one project to the other very easily. However machine breaks quite often. Nature of projects Suitable for self-help rural projects. Good blocks can be made with good quality controlling measures Cost of Machine Rs. 15,000 (Normal block) Rs. 35,000 (Interlocking block)
1. Auram Machines Very good manual machines manufactured in India. Two sizes of machines are available. Moulds are available to manufacture normal blocks and interlocking blocks 3.0 Automated hydraulic machines
Suitable to general building projects. Machine ideal for setting-up of small-scale block manufacturing yards too. The small machine very suitable for the construction of rural buildings Large scale building projects and setting-up of block manufacturing yards
Rs. 170,000 (with all options three sizes of blocks) Rs. 90,000 (small machine)
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Rs. 2.0 million Medium machines Rs. 12 to 50 million large machines form USA and China
New Construction Techniques for Modern Housing Schemes SOIL BLOCK MACHINES
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Standards for Earth Construction

Sri Lanka now has a standard for Compressed Stablized Earth Blocks The use of provisions given in BS5628 Standard for masonry, this will cover wall construction but not the manufacture of earth blocks but does not cover the manufacture of blocks There is an Australian code of practice There is an appendix to the building code of USA
The Indian for manufacture of compressed earth blocks

Specify the sizes of blocks, 300X140X100, 240X240X100, 250X110X100 Specify the compressive strength expected from blocks, 2.5N/mm2 to 5.0N/mm2 General statements on machines for block manufacture General statements on manufacturing process
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The use of provisions in BS5628

Full scale wall panels and blocks need to be tested. Results were observed at
Load deformation behaviour of wall panels; Stress at 1st crack; and Stress at failure
Physical characteristics Dry density Total water absorption
Specified limits > 1750 kg /m3 < 15 % Grade 1 : > 6.0 N/mm2 Grade 2 : > 4.0 up to 6.0 N/mm2 Grade 3 : 2.8 up to 4.0 N/mm2 (not applicable for interlocking blocks) Grade 1 : > 2.4 N/mm2 Grade 2 : > 1.6 up to 2.4 N/mm2 Grade 3 : > 1.2 up to 1.6 N/mm2 (not applicable for interlocking blocks) > 0.5 N/mm2 < 10 mm < 0.10%
Dry compressive strength
Wet compressive strength
Flexural strength (bending strength)
Pitting depth (Erosion resistance)

Linear expansion of block upon saturation with water 1.37 1.38
The Australian code of practice

It is available in the CD given Let us go through the code
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Manufacture of Soil cement blocks

2. Transportation of soil; 3. Measuring of soil and cement; 5. Adding of water for humid mixing; 7. Curing of soil:cement blocks; and
1.Extraction of soil; 3.Screening of soil; 4. Dry mixing of soil and cement; 6. Moulding using a machine; 8. Storing of blocks.
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We could use
SLS Standards SLS1382 Machine manufacturers manuals Published manuals a good one in the CD Let us go through a good manual Published by GATE
Block Types
Different types are available
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Interlocking blocks (compressed earth blocks and concrete blocks) Three types are available
Hydraform type USA, South Africa and many other countries Thailand Habitech type Aureka type from India
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Hdydraform type Probably this may the best interlocking type. The blocks are made by pressing along the length. There it is possible obtain a uniform thickness.
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New Construction Techniques for Modern Housing Schemes ALTERNATIVE CONSTRUCTION MATERIALS :EART CONSTRUCTIONS
AIT Habitech centre interlocking blocks
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Rammed Earth method

Houses can be constructed with full rammed earth methods It is much easier to first erect concrete columns and then to rammed earth wall using slip form method Probably the best may be to first erect reinforced earth columns using interlocking blocks and then to do the rammed earth walls Forms could be purchased from government factory and private suppliers
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Rammed Earth method
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Rammed Earth method
Rammed Earth method
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Rammed Earth method
Rammed Earth method
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Rammed Earth method
Rammed Earth method
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New Construction Techniques for Modern Housing Schemes ALTERNATIVE CONSTRUCTION METHODS : RAT-TRAP BOND METHOD
New Construction Techniques for Modern Housing Schemes ALTERNATIVE CONSTRUCTION METHODS : RAT-TRAP BOND METHOD
Very widely used in India This is basically brick on edge
Very widely used in India This is basically brick on edge
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New Construction Techniques for Modern Housing Schemes ALTERNATIVE CONSTRUCTION METHODS :FLOOR SLABS
New Construction Techniques for Modern Housing Schemes ALTERNATIVE CONSTRUCTION METHODS :FLOOR SLABS
Wide range of floor slabs are now available for housing

In Sri Lanka ICC, NERD, University of Moratuwa Habitech centre has curved plans and integrated concrete slab
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New Construction Techniques for Modern Housing Schemes ALTERNATIVE CONSTRUCTION METHODS :OTHER METHODS
New Construction Techniques for Modern Housing Schemes ALTERNATIVE NEW CONSTRUCTION METHODS
Pre-cast concrete door and window frames Roof items Pre-cast purlins Steel roof structures for housing you will get more details during site visits Steel forms for staircases There are many more from Habitec centre
Formwork systems for concrete walls and slabs Polystyrene forms for walls Sprayed concrete on polystyrene boards Wide range of products are available for above methods
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Formwork system MASCON from Canada Similar systems are available from Germany, India etc.
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Polystyrene forms for walls available form USA, Australia etc. Generally expensive
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New Construction Techniques for Modern Housing Schemes PROCUREMENT OF TECHNOLOGY AND COST SAVINGS
New Construction Techniques for Modern Housing Schemes SUMMARY
Let us look at compressed earth blocks
Design methods Alternative construction materials Alternative construction methods Cost of setting out
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THANK YOU
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Modern Housing Construction Techniques

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New Construction Techniques for Modern Housing Schemes

New Construction Techniques for Modern Housing Schemes OVERVIEW

New Construction Techniques for Modern Housing Schemes

New Construction Techniques for Modern Housing Schemes OVERVIEW

New Construction Techniques for Modern Housing Schemes OVERVIEW

New Construction Techniques for Modern Housing Schemes OVERVIEW

New Construction Techniques for Modern Housing Schemes OVERVIEW

New Construction Techniques for Modern Housing Schemes OVERVIEW

New Construction Techniques for Modern Housing Schemes OVERVIEW

The main pitfall

Most Cost effective Design method

Most Cost effective Design method

Total Cost 346,546.0 104,591.0 79,650.0 467,265.0 759,133.0 1,040,480.0 2,797,665.0

Elemental optimum Design :Example from a RC slab

Elemental optimum Design :Example from a RC slab

248,500.0 264,504.0 203,550.0 716,554.0

Earth Related Technologies

The use of compressed earth blocks in Sri Lanka

Other new methods

The use of compressed earth blocks in other countries

Standards for Earth Construction

The Indian for manufacture of compressed earth blocks

The use of provisions in BS5628

Physical characteristics Dry density Total water absorption

Dry compressive strength

Wet compressive strength

Flexural strength (bending strength)

Pitting depth (Erosion resistance)

The Australian code of practice

Manufacture of Soil cement blocks

AIT Habitech centre interlocking blocks

Rammed Earth method

Rammed Earth method

Rammed Earth method

Rammed Earth method

Rammed Earth method

Rammed Earth method

Rammed Earth method

Rammed Earth method

Very widely used in India This is basically brick on edge

Very widely used in India This is basically brick on edge

Wide range of floor slabs are now available for housing

New Construction Techniques for Modern Housing Schemes

New Construction Techniques for Modern Housing Schemes

New Construction Techniques for Modern Housing Schemes

New Construction Techniques for Modern Housing Schemes SUMMARY

Let us look at compressed earth blocks

New Construction Techniques for Modern Housing Schemes

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