building materials in india

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Building Materials in India: 50 Years A 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,Government of India G-Wing,Nirman Bhawan,New Delhi - 110 011 (INDIA)

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Page 1: Building Materials in India

Building Materials in India: 50 YearsA COMMEMORATIVE VOLUME

Edited by

T .N. GuptaExecutive Director,

Building Materials & Technology Promotion Counciland Advisor (Technology),

Ministry of Urban Affairs & EmploymentGovernment of India, New Delhi

Associate Editors

Mohan RaiFormer Head

Building Materials DivisionCentral Building Research Institute,

Roorkee

S.P.GhoshFormer Director General

National Council for Cement andBuilding Materials,

New Delhi

V.S. ParmeswaranPresident and Chief Executive

Design Technology Consultants,Chennai

P .B. VijayFormer Director General

Central Public Works DepartmentNew Delhi

Building Materials and Technology Promotion CouncilMinistry of Urban Affairs & Employment, Government of India

G-Wing, Nirman Bhawan, New Delhi - 110 011 (INDIA)

Page 2: Building Materials in India

Copyright@ExecutiveDirector, Building Materials and Technology Promotion Council, Ministry ofUrban Affairs & Employment, Government of India, Nirman Bhawan, New Delhi - 110 Oil (India).

All rights reserved. This book, or parts there of, may not be reproduced, stored in a retrieval system,or transmitted in any form without the prior written permission of the publishers.

Published byBuilding Materials and Technology Promotion CouncilMinistry of Urban Affairs & Employment, Government of India

G-Wing, Nirman BhawanNew Delhi - 110011 (India)

Design and print productionWordSmithy, New Delhi

First edition, 1998

ISBN 81-86930-01-9

Notice to the readersThe information in this book has been derived and extracted from a multitude of sources includingstandard specifications, manufacturer's literature, engineering and materials encyclopedias andreference books and personal experience of eminent professionals. It is presented in good faith butthe authors and publishers do not assume any liability for lack of accuracy of the informationincluded in this book. It is primarily intended as an infonnation dissemination exercise, and not asa source for the actual design and manufacturing techniques. It is the responsibility of the users toapply their professional knowledge while utilising the infonnation presented in this book for anyspecific task.

A Commemorative VolumeTN Gupta

Page 3: Building Materials in India

Minister of Urban Affairs & EmploymentGovernment of India

FOREWORD

Soon after independence in 1947, India launched a massive programme of

economic development and adopted consciously 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 largeconstruction 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, andlack 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 for all' becomes a reality. Foremost of these

initiatives is the formulation 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 of private sector and strengthening of

the building materials and technology delivery mechanisms that provide crucial

inputs to the housing and infrastructure development.

I understand that there has been remarkable progress in the area of building

materials resulting from the excellent 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 ofworld-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. The new technologies based on recycling of industrial wastes

now increasingly utilised by the materials industry should help in achieving a

sustaInable consumption of natural resources thereby leading to environmental

protection and reduction in energy demand.

In the fiftieth year of our independence, it is heartening that BMTPC, with active

participation of CSIR, DST, BIS and other public and private organisations has

nucleated this study and produced this document which meticulously records

techno-industrial progress achieved by the building materials sector. I like to

congratulate Shri T.N.Gupta, Executive Director, Building Materials & Technology

Promotion Council, for bringing out this Commemorative Volume. I hope it would

provide an opportunity for introspection and catapult the efforts of researchers,

professionals and industry to meet the future challenges in the construction sector.

~ (~;~~'"I-1._~.Q ,

(Ram jethmalani)

Page 4: Building Materials in India

Minister of StateMinistry of Urban Affairs & Employment

Government of India

MESSAGE

With the rising industrialisation and population, problems of shortage of housingand infrastructure, increasing poverty and unemployment and vulnerability tonatural hazards are the foremost challenges which need to be addressed in thenational development process. Recognising that urbanisation and increase inpopulation is inevitable, the government has formulated several policies andprogrammes for socio-economic betterment of the deprived sectors of population byameliorating poverty and unemployment.

The urban population which was about 14 per cent at the time ofindependence, is likely to rise to 33 per cent by the turn of the century and isexpected 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 bea big challenge for our construction sector. Besides issues related to land andfinance, one of the critical issues that require to be tackled is the access to buildingmaterials 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. Theadvancements in science and technology during past five decades have resulted ina number of innovative build)ng materials and technologies which are environment

friendly, energy efficient and cost effective. Since the transfer of technology from labto land has been a complex process, the present Government has formulated theNational Housing and Habitat Policy, which lays emphasis on improving the accessof common man to crucial inputs to housing. I am sure the Policy will provide muchneeded reorientation and help in bringing about the attitudinal change amongvarious players of the construction sector. The emphasis on public privatepartnerships would encourage and expedite technology transfer and entrepreneurialinitiatives.

The Building Materials and Technology Promotion Council has been activelyengaged in enhancing the technology climate for efficient and effectiveimplementation of housing programmes. In the 50th year of our independence it isheartening that BMTPC is bringing out a Commemorative Volume on 'BuildingMaterials in India: 50 Years' which documents the progress achieved by the buildingmaterials sector during last five decades. I hope this publication will encourage allthose involved in the housing and building activity to take advantage of the cost-effective technologies for improving productivity and affordability in the housingsector. (j ~ ~

I wish the BMTPC all success in their efforts. C"l.£:O \\ /::!j)"))~~(Bandaru Dattatrava)

Page 5: Building Materials in India

SecretaryMinistry of Urban Affairs & Employment

Government of India

MESSAGE

In India art and science of construction are as old as its civilisation. However, in the

modern context construction is an activity that provides crucial inputs for

development in all sectors of economy. Implicit in the attainment of goals of

economic development is, provision of physical infrastructure like roads, railways,

bridges, canals power stations, industrial and institutional buildings and housing,

along with other civil engineering works. All these are the output of the construction

sector and important components in developmental process. Soon after

Independence, when the country launched various programmes of social and

economic development, the need to strengthen the construction 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 development and large scale field

application of innovative building materials and 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 of new technologies particularly those

based on agro-industrial wastes and bye-products. These new technologies have

been found to be more energy efficient and environment friendly compared to their

traditional counterparts which were both material and energy intensive.

I am happy to note that the BMTPC is bringing out this Commemorative Volume

to document the progress achieved in the building materials sector during the last

five decades. The publication reflects on the phenomenal proliferation of large

variety and volume of building materials that has taken place in the post-

independence era. Though India has attained an internationally competitive statusin several areas of technology development, yet its impact is still to be felt in the

housing sector. I am sure this Commemorative Volume will help all those concerned

with housing and building in identifying and introducing the appropriate building

material options to achieve the goals of sustainable housing development.

~Ir-- ~

(Kiran Aggarwal)

Page 6: Building Materials in India

Acknowledgements The author is highly grateful to Shri Ram Jethmalani, the Honourable Minister of Urban Affairsand Employment, for his continued encouragement and very kindly agreeing to write theForeword 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 ofUrban Affairs & Employment for their kind messages on 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, CMDHUDCO for their continued encouragement in bringing out this special publication.

The thirtY one topics, which constitute this book, have been possible through the excellentcontributions received in response to my request to the eminent scholars, experts andprofessionals. Special recognition is due to the following for contributing inputs relating totheir fields of expertise:

Dr. S.P. Ghosh, Director General, National Council of Cement and Building Materials, NewDelhi, Dr. V.S. Ramachandran, Distinguished Scientist, Former Head Building Materials,National Research Council of Canada, Ottawa, Shri DilipBiswas, Chairman, Central PollutionControl Board, Dr. P .S. Das, Director General, Bureau of Indian Standards, Dr. S.K. Chopra, formerAdditional Director General, NCB, New Delhi, Professor R.N. Iyengar, Director Central BuildingResearch Institute, Roorkee, (Late) Dr. A.K.Gupta, Director, Central Road Research Institute,Professor Prem Krishna, University of Roorkee, Professor T .R. Ramachandran, Director, JawaharLal Nehru Aluminium Research and Training Centre, Nagpur, Dr. Mohammed Yaseen, DeputyDirector 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. Joseph George, former Director, Indian PlywoodIndustries 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 Research Institute, Dehradun, Shri J. Sengupta, ChiefBuilding Materials, BMTPC; Shri R.K.Celly, Chief Technology Marketing, BMTPC, A.C.Khazanchi, Deputy Director, RRL, Bhopal, Dr. Mohini Saxena, Scientist, RRL, Bhopal and ShriO.P. Ratra, former Deputy Chief, BMTPC.

The untiring efforts made by my colleagues in the BMTPt::: in the compilation, checkingand verifying the entire text helped in successfully completing this book. Special efforts madeby 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 theirpatience, perseverance and dedicated support in the preparation of this publication.

The compilation of various chapters has been possible by taking some liberty in modifyingthe original contributions received, with the additions of relevant information from books,journals, directories, and encyclopedias which have been mentioned as sources, references and /bibliographies. I am also thankful to the Archaeological Survey of India for facilitating copiesof the p~otographs of some ancient buildings, reflecting the glorious culture of Indian buildingsarchitecture and heritage. Permission accorded the Pergamon Press, Oxford is acknowledgedfor utilising selected excerpts from the Concise Encyclopedia of Building & ConstructionMaterials, first edition 1990.

The efforts of Shri Anurag Gupta and colleagues Shri Ranesh Ray and Km. Urmi Goswamiof Wordsmithy are acknowledged for design and printing of the volume.

T.N.Gupta,Executive Director. BMTPC

Page 7: Building Materials in India

XI

Preface Post independence situation posed several challenges due to widening gap indemand and supply of building materials which were crucial inputs to thenational development programmes and projects. This necessitated a close studyof the existing base of the building materials industry with a view to imbibe newthinking and encourage innovation. A strong construction sector was imperativeto cope with the desired level of economic growth and the resulting demand forbuilding materials. Perhaps this marked the beginning of intensive search andrapid strides for enlarging the range and production of building materials farbeyond that existed in 1947 at the time of independence.

Recognising the role of research and development in various sectors, theGovernment of India had established in 1942, the Council of Scientific andIndustrial Research, an umbrella organisation which enabled R&D to flourish as anationally recognised activity. Besides research and development, the emphasison rapid industrialisation catalysed the need for standardisation and regulatorymechanisms to assist in the systematic growth of the industry and also to deal withthe emerging concerns for environmental protection and energy conservation.These concerns are reflected in the establishment of Indian Standards Institutionin 1947, the Department of Environment and Forests, and the subsequentenactments to tackle environmental problems. Since building and construction isthe largest consumer of natural material resources, it is worthwhile to mentionthat, India is the first country which has made provisions for the protection andimprovement of environment in its constitution through 42nd amendment in1976.

In this volume, attempt has been made to present a holistic picture of thesuccessive stages of growth and development in building materials sector,reflecting on the technology inputs, promotional efforts, policy level supportscreated in the country along with standardisation and regulatory instrumentsestablished during past five decades.

The Editor is personally responsible for the selection of topics and the expertswho contributed in various areas covered and the Associate Editors for helping incompleting this book. In both these tasks he had the benefit of advice of the seniorprofessionals, eminent experts and the decision makers associated with thisCouncil.

During past one and half years that I have been engaged in bringing out thisvolume, it was a great pleasure to interact closely with several eminent scholarsand professionals who have willingly contributed their time and efforts to realisethis undertaking which I, consider an obligatory task for the Council particularlyin 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 fromthem and the Associate Editors.

I like to record my special thanks and deepest appreciation to Dr. Mohan Raifor his valuable contribution, unwavering attention and dedicated effort inhelping me to complete this task.

T .N.GuptaEditor

Page 8: Building Materials in India

XIV

Indian Standards Organisation (ISI) (now Bureau of Indian Standards) was also set upin 1947. TheBIS was basically instrumental in the drafting and publication of IndianStandards on Building Materials and Codes of Practices in line with standardisationwork on other materials. An intensive exercise is already being undertaken forharmonisation of Indian standards with those brought out by ISO. Sometime ago aQuality Control Certification System has also been launched by BIS for someimportant factory-made building materials, such as cement, steel bars, paints, sanitarywares and items of glass and aluminium alloys. The standardisation process receivedits inputs from experts representing various interest gro~ps of technology developers,consumers and manufacturers. \

Construction industry being the largest consumer of material resources, of boththe 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 haphazardexploitation of the mineral resources -limestone, clay, iron ore, bauxite and coal. Theintense mining activities of the minerals produced a variety of mining wastes, orebenefication tailings, coal preparation/washing rejects. The growth in industrial andagricultural activities continued to throwaway huge quantities of wastes and by-products such as fly ash from power generation by burning pulverised coal, blastfurnace and other slags from iron steel, non ferrous metal smelters, alumina red mud,slate and marble wastes etc. These coupled with calcareous and suI phi tic wastes fromchemical industries - sugar, paper acetylene, tannery, phosphatic fertilisers,' soda ash

etc. amount today to nearly 250 million tonnes annually. Great emphasis has been laidin this publication on describing the results of R&D in waste utilisation. Researchefforts in this area have now established that (a) there could be ways and means todispose off the wastes and relieve pressure on land and environment (b) the wastecould form secondary resource materials for the production of alternative buildingmaterials, 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 thewastes free from the hazardous constituents and make them environment friendly.There is an increasing awareness that the manufacture of building materials fromwastes and by-products would reduce pollution and energy consumption levelscompared to traditional processes using the basic raw materials.

The Ministry of Environment and Forests, the Central and State Pollution ControlBoards, and the National Environmental Engineering Research Institute, have beenmaking vigorous attempts for establishing regulatory regimes to monitor and controlpollution levels. As a result of promotional efforts by organisations like BMTPCawareness for utilisation of industrial and mining-mineral wastes in the manufactureof building materials has increased and several waste based building materialtechnologies stand proven and amply demonstrated.

The range of materials produced in the country today, include, steel, aluminium,cement, glass, ceramics, alloys, sanitarywares, paints, plastics and a large variety ofbuilding chemicals, admixtures and composites. It is not only the range of materialswhich is impressive but most of these indigenously produced materials compare wellwith world-class quality and conform to the ISO standards.

Fly ash (70/75 million tonnes per year) and blast furnace slag (10 million tonnesper year) are the two most important wastes which are finding good application inconstruction sector. Concrete products, bricks and blocks and ready mixed concreteare being produced with fly ash or slag content up to 65 per cent. This is one of the

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4

various emerging technologies being practised in the country. Lime sludges,phosphogypsum, red mud and mine tailings are the next category of the wastesavailable in substantial quantities on which a good level of research work has alreadybeen undertaken, though commercialisation of these technologies has yet to happen.There is growing awareness about their utilisation in cement, concrete, lime-gypsum-pozzolana and blended masonry cements. The one of the important trends currentlybeing pursued is to use ordinary Portland Cement to the minimum and make bestexploitation of potential benefits of the mineralogical constituents of the wastes incement and cement concretes for specific applications.

Modern concepts of material science evolves around basic understanding of thestructure-property relationships of materials. Several advanced composite materials,now being produced are light-weight but structurally very strong, fracture resistantand highly impermeable. They are being produced using polymer as well as cementmatrix, 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 themanufacture of door and window shutters and frames, panelling and partitioningsystems. The concepts of composites have been extended to the amorphons <-->crystalline phases of materials for the development of glass-ceramics and refractoriesof outstanding structural properties and long durability.

Several varieties of new materials have now found well established recognition aspartial substitutes of timber, aluminium, steel and cement. The Building Materials andTechnology Promotion Council, during the last eight years have been responsible forthe upgradation and development of many of the new materials listed here, throughtechnical collaboration, developmental and consultancy efforts.

New materials, during the development stages have successfully crossed hurdlesand stand proven through standardisation, validation and are displaying increasinglywider acceptability. These are the well accepted teething troubles faced by any newindustry. Such problems, could not be settled in the meetings of the technicalcommittees or deliberations at the conferences and therefore required vigorous effortsfor technology transfer, demonstration, fiscal incentives to attract investment andwider dissemination of the range of innovative options. With the efforts of the BMTPCand the support of the Ministry of Urban Affairs and Employment, many well-meaningfiscal incentives for the promotion of new building materials based on industrial,mining, mineral and agro-wastes were provided by Government of India in terms ofexcise duty and lowering or exemption of import duties on the plant and machineryessentially required to be imported. These incentives not only helped in displaying apolicy support for waste based building materials but created a confidence amongstentrepreneurs and users thereby attracting greater investments in the buildingmaterials sector.

This book, covering 31 well established topics related to building materials, isintended to present the current status about the various aspects of research, technologydevelopment, standardisation, commercialisation and field applications andacceptability. Care has been taken, wherever possible to deal with comparativeinformation 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 recognisedprofessionals and eminent experts in their specific areas of specialisation.

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XVI

TABLE OF CONTENTS vvi

viiviii

xxi

xii

ForewordMessageMessageContributorsAcknowledgementsPrefaceIntroduction

2

14

40

52

64

74

84

1. Evolution of building materials1. Introduction. 2. The ancient period. 3. The medieval period .4. The Sultanate. 5. The Mughal Period. 6. The colonial period. 7. Unprocessed materials of common use. 8. Concluding remarks. 9. Bibliography

2. Burnt clay brick and tile1. Introduction; Progress in the colonial period. 2. Focus of research and development; Study of soils.3. Standardisation; Compressive strength and water absorption; Efflorescence; Bulk density; Fire resistance; Otherproperties. 4. Utilisation of waste in brick making; Red mud; Flyash; Stone dust; Coal washery rejects; Granulatedslag; Siliceous river sediments; Cinder; Rice-husk ash. 5. Process improvement; Improved hand-moulding;Semi-mechanised brick plant; High draught kiln; Fully mechanised brick plant. 6. Product range upgradingand expansion; Improved bricks from inferior soils; Product range expansion. 7. Environmental concerns;Energy audit; Environmental pollution. 8. Clay tiles; Mangalore patter!) roofing tiles; Prefab brick panel system;Burnt clay canal lining tiles; Standards on tiles. 9. Concluding remarks. 10. Standard specifications. 11.Bibliography

3. Stone1. Introduction. 2. Classification of building stones. 3. Uses of stones in building. 4. General properties. 5. Stone slab frames for doors/windows. 6. Occurrence of decorative stones in India. 7. Export of Indianstones. 8. Quarrying. 9. Finishing and polishing. 10. Stone as aggregate in concrete. 11. Effect of heat.12. Durability; Physical weathering; Effects of pollutants; Protection of stones. 13. Concluding remarks.14. Standard specifications 49 . 15. Bibliography 50

4. Building Lime1. Introduction. 2. Lime in construction industry. 3. Lime production technology. 4. Focus of researchand development; Process improvement; New process for making hydrated lime; New products; Pollutionin lime industry; Utilisation of waste. 5. Stagnation and continued backwardness of the lime industry. 6.Concluding remarks. 7. Standard specifications. 8. Bibliography

5. Gypsum1. Introduction. 2. Gypsum products. Plaster of Paris. Gypsum plaster. 3. Fibrous gypsum plaster board. 4. Gypsum blocks. 5. Acoustic tiles. 6. Process improvement. 7. Utilisation of by-product gypsum. 8.Concluding remarks. 9. Standard specifications. 10. Bibliography

6. Glass1. Introduction; History of glass-making technology. 2. The Indian glass industry. 3. Composition of glass. 4. Types of glass. 5. Glass as building material; Glass for door and window shutters; Glass tiles; Mirrors;Glass fibre; Glass wool; Glass blocks. 6. Research and development in India; Waste utilisation; New products. 7. Concluding remarks. 8. Standard specifications. 9. Bibliography

7. Ceramics1. Introduction. 2. Indian ceramic industry. 3. Classification of ceramics; Whiteware tiles; Structural clayproducts; Refractories; Vitreous enamels. 4. Kiln for ceramic production. 5. Focus of research anddevelopment; Indigenous processes developed by CG&CRI; Advanced ceramics. 6. Employment and educationin ceramics. 7. Concluding remarks. 8. Standard specifications. 9. Bibliography

96

112

8. Steel1. Introduction; Indian steel industry. 2. Determinants of the growth of steel industry; Domestic demandprojection; Projection of demand for steel alloys. 3. Global steel scenario; Export opportunities for Indiansteel. 4. New technologies in steel production; Energy consumption. 5. Infrastructure aspects; Coastaltransport; Power. 6. Research and development. 7. Structural steel; Universal beams (UB); Taper flangebeams (TFB); Parallel flange channels (PFC); Taper flange channels (TFC) . 8. Steel in buildings; Major structuralapplications; 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 gatesand welded grills; Weld mesh and expanded metal sheets. 9. Concluding remarks. 10. Standard specifications.11. Bibliography

9. Aluminium1. Introduction. 2. Technology. 3. Aluminium production and consumption; Consumption pattern. 4.User industries; Automobile industry; Packaging; Construction; Electrical. 5. Wastes of the aluminium industry;Red mud; Fluoride emissions; Spent pot lining (SPL) . 6. Indian scenario and efforts needed to achieveinternational standards. 7. Copper, zinc and their alloys; Copper; Zinc. 8. Recycling of aluminium andcopper scrap. 9. Concluding remarks. 10. Standard specifi<:ations . 11. Bibliography

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202

242

10. Cement1. Introduction. 2. The Indian cement industry; Production and consumption; Mini cement plants; GDPgrowth, demand and 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. Cementsto meet specific service conditions; Rapid hardening cement (RHC); Low heat cement (LHC); Oil wellcement (OWC); White cement (WC); Masonry cement (MSC); Expansive cement. 6: Research anddevelopment; Specific R&D in scientific institutions. 7. Energy conservation in cement; Quality control incement manufacture . 8. Efforts at environmental protection; Conservation of mineral resources; Recycling

of wastes. 9. Concluding remarks; Future planning in cement industry; Mining; Process. 10. Standardspecifications. 11. Bibliography

11. Concrete1. 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 heatcement. 4. Concrete as a structural material; Concrete mix design. 5. Aggregates; Coarse aggregate; Fineaggregate. 6. Ready mixed concrete (RMC) . 7. Precast concrete elements (PC) . 8. Prestressed concrete(PSC); Reinforcement steel; Reinforcement coyer blocks; Prestressing tendons. 9. Cement replacementmaterials; Pulverised flyash concrete; High volume flyash concrete; Condensed silica fume concrete; Rice-huskash 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 strengthlightweight aggregate concrete; Structural lightweight concretes; Whisper concrete. 12. Concluding remarks. 13. Standard specifications. 14. Bibliography

12. Recent advances in concrete technology1. Introduction. 2. Types of concrete; Polymer concrete; Sulphur concrete; Fibre reinforced concrete; Highperformance fibre reinforced concrete; Ferrocement; Roller compacted concrete; Very high strength concrete;Superplasticised concrete. 3. Concluding remarks. 4. Standard Specifications.5. Bibliography

13. Admixtures1. Introduction. 2. Classification of admixtures by source/origin; Natural and mineral admixtures; By-

products and wastes; Chemical admixtures. 3. Classification of admixtures by end-use; Air-entraining agents;Accelerators; Retarders; Gas-forming agents; Alkali-aggregate expansion inhibitors; Damp-proofing andpermeability-reducing agents; Water reducing and workability agents; Superplasticisers; Cement-superplasticiser compatibility; Grouting agents; Corrosion inhibiting agents; Bonding admixtures; Fungicidal

admixtures; Colouring admixtures; Miscellaneous admixtures. 4. Codes of practice. 5. Future directions.6. Standard specifications. 7. Bibliography

14. Utilisation of industrial wastes1. Introduction. 2. Development in the utilisation of wastes. 3. Waste as concrete aggregate; Slags, By-products from power plants; Recycling of concrete. 4. Mining and quarrying waste; Miscellaneous wastes asaggregates .5. Utilisation of waste in cement manufacture; As fuel; As raw material; Blended cement; Flyash;Slag. 6. Gypsum substitution; Waste gypsum and limestone dust additive in cement; Waste chemicaladmixtures; Utilisation of ore dressing tailings wastes. 7. Bricks and blocks using flyash; Flyash-clay bricks.8. Concluding remarks .9. Standard specifications .10. Bibliography

15. Materials for roads1. Introduction. 2. The R&D scenario. 3. Road construction materials; Surkhi as a pozzolana; Steel fibre

reinforced concrete (SFRC); Synthetic resins; Magnesium phosphate cement (MPC);Roller compacted concrete

pavement (RCCP);Magnesium oxychloride cement (MOC); Improved surface finish for cement concrete roads;Low quality aggregates in pavement quality concrete; Durability of concrete; Agro/industrial waste

materials;Municipal waste; Mining and quarrying wastes. 4. New construction techniques for pavements;Prestressed ~oncrete pavements; Continuously reinforced concrete pavement; Fibre reinforced concrete

pavement; Precast concrete block pavement. 5. Concluding remarks. 6. Standard specifications. 7.

Bibliography

16. Bitumen1. Introduction. 2. Kinds of bitumen and products; Solid bitumen and bitumen mastic; Liquid or cut-backbitumen; Bitumen emulsion ;Bitumen felts and fabrics; Oxidised or air-blown bitumen; Bitumen-polymercomposites; 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 construction-related R&D at CRRI; Limestone dust powder; Natural rubber and bitumen mixture. 6. Blown grade bitumenin roads. 7. Mastic asphalt. 8. Anti-stripping chemicals. 9. Waste thermoplastic in roads. 10. Concludingremarks. 11. Standard specifications. 12. Bibliography

17. Geotextiles1. Introduction. 2. Historical background. 3. Development in India. 4. Geotextile raw materials. 5. Typesof geotextiles; Geomembranes; Geogrids; Geotextile nets or geonets; Geotextile mats; Geotextile webs;Geocomposites . 6. Functions of geotextiles; Hydraulic functions; Mechanical functions; Protection; 5upport

. 7. Geotextiles in road construction. 8. Present R&D activities in the area of geotextiles . 9. Concluding

remarks. 10. Standard specifications. 11. Bibliography

18. Wood and other lignocellulosic products1. Introduction. 2. Research and development in India (FRI & IPIRTI);Timber Engineering; Seasoning oftimber; Timber mechanics; Preservation of timber; Wood working. 3. Panels and composites. 4. Plywood;

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Grades of plywood; General purpose plywood; Decorative plywood; Marine plywood; Shuttering plywood;Structural plywood; Preservative treated plywood; Fire retardant plywood; Other speciality plywood;Properties and uses of plywood; Flushdoor . 5. Particleboard; Particleboards from agricultural residue; Jutestick; 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; Temperedhardboard; Prefinished hardboard. 10. laminated veneer lumber; laminated lumber panel board; Gluedlaminated 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 plastics1. Introduction. 2. Petroleum industry. 3. Natural gas. 4. Petrochemical industry. 5. Shellac-naturalresin .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

20. Composite materials1. 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. Hybridfibre-resin composites. 6. Advanced ceramic composites. 7. Composites for common applications inbuildings. 8. Vegetable fibre reinforced composites in India. 9. Contribution of the BMTPC, India .10. ISSpecifications on composites. 11. Composites for special applications. 12. Mission on advancedcomposites. 13. Advanced materials; Semiconducting materials; Non-crystalline materials; Superconductingmaterials; Bioceramics; Optical fibre materials; Polymers; Aluminium alloys. 14. Concluding remarks. 15.Standard specifications .16. Bibliography

21. Protective and decorative coatings1. 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 substrates. 6. Coatings forfurniture and wooden structures. 7. Coatings on metallic structures in the building. 8. Coatings onstructures made of plastics. 9. Coatings on interior surfaces. 10. Coatings for concrete, wooden or steelfloors. 11. Fire retardant coatings. 12. Paint/coating systems for the automotive industry. 13. Protectionof substrate by organic coatings; Prospective performance of paints in protection of a substrate. 14. IndianR&D in protective and decorative coatings; Zinc rich paints; Phosphate treatments for mild steel; Corrosion infertiliser factories; Paint systems for wood and wood based materials; New formulations of cement paints;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 ofpaints in different sectors. 17. Regulatory restrictions; Enactment of Rule 66 on the use of organic solvents;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; Eco-friendly 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 materials1. Introduction. 2. Modern requirements of flooring 3. Research and development. 4. Industrial progress. 5. In situ floor finishes; Portland cement concrete; High alumina cement concrete; Rubber latex cementconcrete; Bitumen mastic; Polymer concrete. 6. Hardeners. 7. Jointed floor finishes. 8. Decorative marbletiles. 9. Granite floor tiles. 10. Agglomerated marble. 11. Gypsum marble; Technical specifications. 12.Cork floors. 13. Vinyl tiles and sheets; Technical specifications. 14. Glazed ceramic tiles; Technicalspecifications. 15. Concluding remarks. 16. Standard specifications. 17. Bibliography

23. Energy in building materials1. 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 consumptionin 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 miscellaneousbuilding 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. Concludingremarks and recommendations; Fuel, energy and environment; Improvement in the mining of ores, minerals andtheir beneficiation processes, transport and storage; Recycling of waste to save energy; Utilisation of waste forenergy saving; Real fuel value of organic waste to be exploited; Need for clean processing of materials and cleanerconstruction sites; . 8. Standard specifications. 9. Bibliography

24. Fire and building materials1. Introduction. 2. Cause of fire; Materials at high temperature; Reactions of some basic materials to fire. 3.Data base on fire and materials. 4. Modified building codes and standards. 5. Improvement in fireprotection through materials. 6. Spread of fire within the room of origin. 7. Spread of fire outside the roomof origin. 8. Fire retardant chemicals. 9. Mattresses and upholstered furniture fires. 10. Fire resistance;Fire detection. 11. Containment of fire. 12. Fire protection of structural elements. 13. Post-fireinvestigations and repair of damages. 14. Fire modelling and CBRI work. 15. Concluding remarks. 16. Testfacilities at CBRI, Roorkee . 17. Standard specifications. 18. Bibliography

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25. Building materials industry and pollution1. Introduction; Pollution potential .2. Carbon dioxide emission; Improved technologies and reduction incarbon dioxide emission; Carbon dioxide emission by other building materials. 3. Standards on emission.4. legislation for prevention and control. 5. Pollution control standards. 6. Incentives. 7. Utilisation andmanagement of waste. 8. Concluding remarks. 9. Standard Specifications. 10. Bibliography

26. Building materials in central public works1. Introduction. 2. History of public works in India. 3. Materials and construction practices in pre-independence period. 4. Building materials and their standardisation during post-independence period. 5.New materials-development and applications. 6. Wood substitutes; Need for wood substitutes; Developmentof wood substitutes; Wood substitutes approved by CPWD; Wood substitutes underfinalisation . 7. Use oftlyashfor different applications; Flyash-a national level problem; Utilisation of flyash in CPWD . 8. Constructionmaterials and technologies in highway sector; Roads--an important sector of public works; Roads in pre-independence period; Developments in the highway sector; Developments in road construction; Developmentsin bridge and flyover construction. 9. landmark events in the development of building materials and associatedtechnologies; Designed masonry for load bearing walls.Use of high strength deformed bars; Use of high strengthconcrete; Use of prestressed concrete; Use of precast elements; Improvement in specifications of public buildingsto provide permanent and durable finishes; Repairs and rehabilitation. 10. Future scenario; Ready mixedconcrete (RMC); High performance concrete (HPC); Composite materials as replacement of reinforcing steel; Useof polymers; Use of flyash; Energy efficiency and sustainable development

27. Standardisation in construction materials1. Introduction; Standardisation activities in India. 2. Standardisation of building materials; Cement andaggregates; Pozzolanas; Building lime; Stone; Clay products for buildings; Gypsum building materials; Timber;Wood products; Bitumen and tar products; Floor coverings and other finishes; Waterproofing and damp-proofing material; Sanitary appliances and water fittings; Doors and windows; Aluminium and aluminiumalloys; Concrete reinforcement and other steel sections; Other building materials; 3. Development in designand construction; Concrete and steel; Timber; Functional requirements in buildings; Measurement of civilengineering works; Construction practices and safety; Fire safety codes and equipment; National Building Codeand 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 ,

1.lntroductiQn . 2. Service life of materials. 3. Performance criteria. 4. Suggested methodology of performancecriteria. 5. Service stresses and working conditions of building materials; Surface hardening, fracture toughnessand fatigue; Fatigue strength; Creep. 6. Concrete; Chemical deterioration; Steel reinforcement; Aggregate. 7. Fibrecomposites; Glass fibre reinforced plastics (GRP); Polymer fibre reinforced cement and concrete; Compositematerials and fire; Composites and water. 8. Timber. 9. Surface coatings. 10. Adhesives and plastics; Naturaloutdoor weathering .11. Brick, tiles, stone and silicate cements; laterite; Deterioration of building stone; Stabilisedbricks. 12. Concluding remarks. 13. Standard specifications .14. Bibliography

29. Building materials in civil engineering education1. Introduction. 2. New materials. 3. Civil engineering education at different levels. 4. Changing patternof education in materials. 5. Research and continuing education programme; Impact of emerging researchareas on engineering education. 7. Concluding remarks

30. Technology transfer in building materials industry1. Introduction; Strengths; Weaknesses; Threats and opportunities for the industry; Strategic position of theindustry. 2. Resource base; Manpower resources; Institutional resources; lack of co-ordination betweentechnology producers and users; Contribution of scientific studies in educational institutions; The need for co-ordination: establishment of DST; National Research Development Corporation; Situation by the mid-1980s;Housing and Urban Development Corporation (HUDCO); National Network of Building Centres. 3. Thegenesis of technology transfer in building materials. 4. Formation of Building Materials and TechnologyPromotion Council; Corporate strategy of BMTPC (1993-98); Implementation strategy; Joint technologydevelopment programmes; IDNDR project on protection of non-engineered houses from natural hazards;Achievements; Innovative technologies developed by BMTPC and licensed to enterprises for commercialproduction; Publications of the Council. 5. Concluding remarks. 6. Bibliography. .31. Emerging trends in building materials1. 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 inconcrete; Waste as aggregates. 7. Composites; Man-made and natural fibres based composites; Woodsubstitutes; Composites from local materials; Use of bamboo for building components; Polymers, plastics andsurface coatings. 8. Metal matrix composites; Surface engineering. 9. Structure-property relationship;Property of engineering materials. 10. Search for materials and emerging technologies 11. Valorisation andrecycling of industrial wastes. 12. Ceramic materials obtained by recycling wastes: some considerationsand examples. 13. Glass ceramic materials obtained by recycling hazardous industrial wastes: state of theart. 14. Concludin2 remarks. 15. Biblio2raphv

Appendixes

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landmarksForeign CollaborationsAbbreviation and Unit s