AR 7.

2 Advanced Construction & Materials

Unit I

Advanced construction methods in RCC - pre-stressed concrete beams slabs frames, lift slab
construction- post tensioning, multi-storied building frames, circular slabs and beams. uses of
rapid-hardening cement, ready mix concrete [ RMC} ,light weight concrete surface finishes of
cement
Advanced construction methods in RCC
Now a days the construction technology and equipments becomes very advanced.
• Concrete walls and floors
• Precast cladding panels
• Precast flat panel system
• 3D Volumetric Modules
• Twin wall Technology
• Flat Slabs
• Thin Joint Masonry
• Insulating Concrete Formwork
• Post Tensioning
Precast flat panel system: Floor and wall units are produced off-site in a factory and erected on-site to
form robust structures, ideal for all repetitive cellular projects. Panels can include services, windows,
doors and finishes. Building envelope panels with factory fitted insulation and decorative cladding can
also be used as load-bearing elements. This offers factory quality and accuracy, together with speed of
erection on-site.
3D Volumetric Modules: 3D Volumetric construction (also known as modular construction) involves the
production of three-dimensional units in controlled factory conditions prior to transportation to site.
Modules can be brought to site in a variety of forms, ranging from a basic structure to one with all
internal and external finishes and services installed, all ready for assembly. The casting of modules uses
the benefits of factory conditions to create service- intensive units where a high degree of repetition and a
need for rapid assembly on-site make its use highly desirable.
Twin wall Technology:Twin wall construction is a walling system that combines the speed of erection
and quality of precast concrete with the structural integrity of in-situ concrete to provide a hybrid
solution. Twin wall is an adaptable wall system that provides the speed and quality of precast concrete
with the structural and waterproof reliability . The prefabricated panels comprise two slabs separated and
connected by cast-in lattice girders. The units are placed, temporarily propped, then joined by reinforcing
and concreting the cavity on site. Twin wall is usually employed in association with precast flooring
systems.
Flat Slabs: These are highly versatile elements widely used in construction, providing minimum depth,
fast construction and allowing flexible column grids. Flat slabs are particularly appropriate for areas
where tops of partitions need to be sealed to the slab soffit for acoustic or fire reasons. Flat slabs are
considered to be faster and more economic than other forms of construction. Flat slabs can be designed
with a good surface finish to the soffit, allowing exposed soffits to be used. This allows exploitation of
the building’s thermal mass in the design of heating, ventilation and cooling requirements, increasing
energy efficiency.
Thin Joint Masonry:Thin joint block work (thin joint masonry) is a fast, clean, accurate system for
construction using autoclaved aerated concrete blocks of close dimensional tolerance with 2mm- 3mm
mortar joints. Thin layer mortar is a pre-mixed cement- based product that only requires the addition of
water to make an easily- applied mortar. The benefits offered by thin layer mortars are provided by a
system with many of the characteristics of traditional block work construction. This means that familiarity
with the build process and flexibility are also inherent in the system.
Insulating Concrete Form work:(ICF) systems consist of twin- walled, expanded polystyrene panels or
blocks that are quickly built up to create formwork for the walls of a building. This formwork is then
filled with factory produced, quality assured, ready-mixed concrete to create a robust structure. The
expanded polystyrene blocks remain to provide high levels of thermal insulation and the concrete core
provides robustness and good levels of sound insulation.
Post tensioning is a technique for reinforcing concrete. Post-tensioning tendons, which are pre-stressing
steel cables inside plastic ducts or sleeves, are positioned in the forms before the concrete is placed.
In structural engineering, a shear wall is a structural system composed of braced panels (also known as
shear panels) to counter the effects of lateral load acting on a structure. ... Shear walls resist in-plane
loads that are applied along its height.
Circular Slabs and Beams
Uses of Circular Slabs:
1. Roof of a room or hall circular in plan
2. Floor of circular water tanks or towers
3. Roof of pump houses constructed above tube wells
4. Roof of a traffic control post at the intersection of roads.
In circular slab, Bending takes place indistinctly two perpendicular directions along the two spans.
Reinforcement is provided in the form of a mesh of bars having equal area of cross section in both the
directions.
The analysis of stresses in these slabs is generally based on elastic theory. Under uniformly distributed
loads, these slabs deflect in the form of a saucer and develop radial and circumferential stresses. Tensile
stresses develop on the convex surface and compressive stresses develop on the concave surface. Tensile
stresses must be provided in the radial and circumferential directions near the convex surface.
Alternatively, reinforcing bars can be provided in two mutually perpendicular directions instead of in the
radial and circumferential directions. Normally, near the Centre of the slab, reinforcement is provided in
the form of mutually right angle mesh; and near the edge of the slab, in the form of radial and
circumferential bars.
Curved Beam. ... A special variety of curved beam is the naturally twisted curved beam, whose plane
cross-sectional figure moves along its axis and simultaneously rotates around a tangent to the axis (for
example, the blade of an aircraft propeller or fan).
Uses of Rapid-Hardening Cement
Rapid hardening Portland cement is similar to Ordinary Portland cement but with higher tri-calcium
silicate (C3S) content and finer grinding. It gains strength more quickly than OPC, though the final
strength is only slightly higher. This type of cement is also called as High-Early Strength Portland
Cement. The one-day strength of this cement is equal to the three-day strength of OPC with the same
water-cement ratio.
a) It is used where formwork has to be removed as early as possible in order to reuse it.
b) It is used where high early strength is required.
c) It is generally used for constructing road pavements, where it is important to open the road to
traffic quickly.
d) It is used in industries which manufacture concrete products like slabs, posts, electric poles,
block fence, etc. because moulds can be released quickly.
e) It is used for cold weather concreting because rapid evolution of heat during hydration protects
the concrete against freezing.

Ready Mix Concrete (RMC)

Ready-mix concrete, or RMC as it's also known, refers to concrete that is specifically batched or
manufactured for customers' construction projects. It is a mixture of Portland cement, water and
aggregates: sand, gravel, or crushed stone. Ready-mix concrete is bought and sold by volume -
usually expressed in cubic meters.
First is the barrel truck or in–transit mixers This type of truck delivers concrete in a plastic state
to the site.
Second is the volumetric concrete mixer. This delivers the ready mix in a dry state and then
mixes the concrete on site.
Materials are combined using a batch plant, and the hydration process begins at the moment
water meets the Portland cement, so the travel time from the plant to the site is critical over
longer distances. Some sites are just too far away; however, the use of admixtures, retarders and
fly ash can be added to slow the hydration process, allowing for longer transit time.
Cracking and shrinkage. Concrete shrinks as it cures. It can shrink 1/16 inch (1.59mm) over a 10
foot long area (3.05 meters). This causes stress internally on the concrete and must be accounted
for by the engineers and finishers placing the concrete. Furthermore, access roads and site access
have to be able to carry the greater weight of the ready-mix truck plus load. (Green concrete is
approx. 3924 pounds per cubic yard.) This problem can be overcome by utilizing so-called "mini
mix" trucks which use smaller 4m³ capacity mixers able to reach more weight restricted sites.
Concrete has a limited life span between batching / mixing and curing. This means that ready-
mix should be placed within 30 to 45 minutes of batching process to hold slump and mix design
specifications.
Modern admixtures and plasticizer and water reducers can modify that time span. However, it is
limited in scope. The amount and type of admixture added to the mix is very important.
Light weight concrete surface finishes of cement
Characteristics of light weight concrete
• Thermal insulation
• Fire insulation
• Durability
• Rain penetration
• Acoustic properties
• Water absorption
Advantages:
 Rapid and relatively simple construction
 Economical in terms of transportation as well as reduction in manpower
 Significant reduction of overall weight results in saving structural frames, footing or
piles.
 Most of lightweight concrete have better nailing and sawing properties than heavier and
stronger conventional concrete.
Disadvantages:
• in the mixtures very sensitive with water content
• Difficult to place and finish because of the porosity and angularity of the aggregate.
• In some mixes the cement mortar may separate the aggregate and float towards the
surface.
• Mixing time is longer than conventional concrete to assure proper mixing.

Unit II
Folded plates like prismatic, V-type, trough type, pyramidal, prismatic and RCC folded plate and
geometrical staircases, Shell structures, cyclonical shells, hyperbolic paraboloids.
Folded plates
Folded plates are assemblies of flat plates rigidly connected together along their edges in such a
way that the structural system capable of carrying loads without the need for additional
supporting beams along mutual edges.
The principle of folding as a tool to develop a general structural shape has been known for a long
time. Folded structure systems which are analogous to several biological systems such as found
at broadleaf-tree leaves, petals and foldable insect wings, are adopted to be employed in a new,
technical way. Leaf of Palm Tree Beetle Insect With Foldable Wings Seashell.
THE PRINCIPLE OF FOLDING: The structural characteristics of folding structures depend on:
• The pattern of the folding. • Their geometrical basic shape. • Its material. • The connection of
the different folding planes. • The design of the bearings. • Movable form work can be employed.
• Form work required is relatively simpler. • Design involves simpler calculations.
Types of Folded Structures
Based on geometric shape folded structures can be divided into:
1. Folded plate surfaces structures
2. Folded plate frames structures
3. Spatial folded plate structures
Classification of folded structures based on the material they are made of
1. Folded structures made of reinforced concrete
2. Metal folded structures
3. Folded structures of wood
4. Folded structures of glass
5. Folded structures of plastic materials
6. Folded constructions made in combination of different materials
Application of Folded Structures
1. As Roof Structure
2. As Wall Structure
3. As Steel Sheet Piles
4. As Floor Structure
Types of folded plates :
1- Prismatic : if they consist of rectangular plates.
2- Pyramidal : when non-rectangular plates are used.
3- Prismoidal, triangular or trapezoidal.
Advantages & Disadvantages of Folded Structures
Advantages:
1. Very light form of construction.
2. To span 30 m shell thickness required is 60 mm only.
3. The use of concrete as a building material reduces both materials cost and a construction
cost.
4. Longer span can be provided.
5. Flat shapes by choosing certain arched shapes.
6. Aesthetically it looks good over other forms of construction.
Disadvantages:
1. Shuttering is difficult.
2. Greater accuracy in formwork is required.
3. Good labour and supervision necessary
4. Rise of roof may be a disadvantage.
RCC folded plate staircase
The folded plate staircase is a self-supporting construction without stringers. This means that the joint
between the treads and the risers must be very solid from a statical point of view. In addition,this staircase
must generally be fixed to the wall which is made by horizontal wall bolts in most cases. Due to these
preconditions, there is a high number of joining elements and consequently also of processing steps for
treads and risers.
Geometrical staircase
Continuous stairs that turn or wind about a central well hole which has rounded corners or is circular or
elliptical and that have the strings and rails arranged upon geometric principles and running continuously
from top to bottom.

Shell Structures
Thin-shell structures are also called plate and shell structures. They are lightweight constructions using
shell elements. These elements, typically curved, are assembled to make large structures. Typical
applications include aircraft fuselages, boat hulls, and the roofs of large buildings.
The most popular types of thin-shell structures are:
• Concrete shell structures, often cast as a monolithic dome or stressed ribbon bridge or saddle roof
• Lattice shell structures, also called grid shell structures, often in the form of a geodesic dome or a
hyperboloid structure.
• Membrane structures, which include fabric structures and other tensile structures, cable domes,
and pneumatic structures.
Concrete shell structures
A concrete shell, also commonly called thin shell concrete structure, is a structure composed of a
relatively thin shell of concrete, usually with no interior columns or exterior buttresses. The shells are
most commonly flat plates and domes, but may also take the form of ellipsoids or cylindrical sections, or
some combination thereof.
Most concrete shell structures are buildings, including storage facilities, commercial buildings, and
residential homes. Concrete shell construction techniques are well suited for complex curves.
Advantages:
Like the arch, the curved shapes often used for concrete shells are naturally strong structures, allowing
wide areas to be spanned without the use of internal supports, giving an open, unobstructed interior. The
use of concrete as a building material reduces both materials cost and construction costs, as concrete is
relatively inexpensive and easily cast into compound curves. The resulting structure may be immensely
strong and safe; modern monolithic dome houses, for example, have resisted hurricanes and fires, and are
widely considered to be strong enough to withstand even F5 tornadoes.
Disadvantages:
Since concrete is a porous material, concrete domes often have issues with sealing. If not treated,
rainwater can seep through the roof and leak into the interior of the building. On the other hand, the
seamless construction of concrete domes prevents air from escaping, and can lead to build-up of
condensation on the inside of the shell. Shingling or sealants are common solutions to the problem of
exterior moisture, and dehumidifiers or ventilation can address condensation.
Lattice shell structures
Lattice shell structures, also called grid shell structures, often in the form of a geodesic dome or a
hyperboloid structures.
A grid shell is a structure which derives its strength from its double curvature (in a similar way that a
fabric structure derives strength from double curvature), but is constructed of a grid or lattice.
The grid can be made of any material, but is most often wood (similar to garden trellis) or steel.
Membrane Structures
Membrane structures are spatial structures made out of tensioned membranes. The structural use of
membranes can be divided into pneumatic structures, tensile membrane structures, and cable domes.
In these three kinds of structure, membranes work together with cables, columns and other construction
members to find a form.
The common membranes used in membrane structures include:
PVC coated polyester fabric
Translucent Polyethylene fabric
PVC coated glass fiber fabric
PTFE coated glass fiber fabric; foils like
ETFE foil
PVC foil.

Unit V
Advanced Building Materials- plastic, PVC, metals, synthetic boards, fire proof/resistant
boards/tiles, acoustic materials, glass, composite panels and their applications, non- load bearing
gypsum blocks
Modern Construction Materials
Now –a- days many new innovative materials are being invented and many new materials are being in
research. New innovative thinking and new invention is necessary to save our valuable time and energy.
Some of the innovative materials are listed below;
1. Fly ash brick
2. Translucent concrete.
3. Sensi tiles.
4. Liquid granite.
5. Carbon Nano-tubes.
6. Unfired clay bricks.
7. Bendable concrete.
8. Richlite.
9. Radiant barriers.
10. Transparent aluminum.
11. Carbon fiber.
12. Solar panel roofing tiles
Fly ash Bricks
Fly ash bricks are building materials containing classic fly ash. The composition of fly ash bricks are fly
ash, lime, gypsum, sand, cement. These bricks are environment friendly and they can be manufactured at
construction site itself.
Translucent Concrete
This have been developed by Hungarian architect ARON LOSONCZI. It is mostly same as the regular
concrete, visually appealing by mixing concrete with optical glass fibres and thus the result was light
transmitting concrete. The glass fibre in the concrete act like a slit and carry the light across and the light
carried maintains its original colour. It carries the same amount of light through it, no matter how thick it
is.
Sensi Tile
If you walk across your kitchen the floor to get something from the refrigerator, the floor twinkles with
light path that guides your way through the dark room. The concrete of the tile is embedded with acrylic
fibre optic channels that transfer the light from one point to another. As shadow move across terrazzo’s
surface , the light channels flicker with a randomized.
A fine concrete mix embedded with light conducting channels and formed into slabs or tiles that shift,
shimmer, and twinkle in response to light, movement and shadows. Playful and eye-catching
Liquid Granite
The material is light weight and has the same load bearing capacity of the cement, but it is made of
recycled materials. It is not only fire resistant beyond 1100 degrees Celsius, it can also with stand high
temperature for longer periods. It is also having moisture resisting property also. It can be used as fast
setting repair material.
It sets in minutes and adheres to a wide range of building materials including concrete, metal and
asphalt. Use Liquid Granite to repair crumbling brickwork, loose bolts or posts, cracked floors or
general wear and tear. Liquid Granite is exceptionally strong and hard wearing and is ready to use
after simply mixing with water. Either pour or trowel on Liquid Granite and your repair will
become permanent in minutes.
Carbon Nanotubes
Carbon Nanotubes (CNT) in Construction Material Reinforcement. Carbon Nanotubes (CNTs) are
incredibly strong hollow strings of carbon atoms that bond together in a tube or pipe-like fashion with
unique properties which can be added to a multitude of materials to enhance durability or strength.
Heralded as one of the “Top ten advances in materials science” over the last 50 years, Materials Today,
2016. Major use – electronics and composites.
Carbon fiber
Carbon fibre is made up of carbon strands that are thinner than human hair. The strands can be woven
together, like cloth, and then that can be moulded to any shape you might want. Carbon fibre is extremely
strong, light weighted material. It is five times strong as steel, two times as stiff and weight is about two-
thirds less.
Carbon fibre is used primarily in the strengthening and reinforcement of concrete, steel, timber, and
masonry. The versatile properties of carbon fibre include high stiffness, high tensile strength, high
chemical resistance, high temperature tolerance and low thermal expansion. ... Carbon fibers consist of a
high elastic modulus and fatigue strength when compared to glass fibers, making them ideal for the
construction industry
Unfired clay bricks
Unfired clay bricks are made up of earthy materials and are air-dried instead of fired like conventional
bricks. It is eco- friendly and with additional construction properties. It have the benefit of reducing the
energy used in manufacturing and increases strength and decreases shrinkage. .
Bendable Concrete
A new type of fibre reinforced bendable concrete is used in various places. This new concrete is around
500 times more resistant to cracking than regular. The fibres slide within the concrete when bending
occurs, providing with it is enough to prevent breakage.
Richlite
It is a dense material made from partially recycled paper and phenolic resin. The 70 percentage of the
material is made with recycled paper. It has high strength and has resistance to high temperature up to
350 F.
Radiant Barriers
It can be applied anywhere in attic space of house. It keeps heat out in summer and warm in during
winter. It is usually made up of aluminium. Radiant barriers are widely used in many areas.
Transparent Aluminum
It is extremely durable material with excellent optical transparency. To be used for windows, domes,
plates, rods and tubes with a wide range of sizes and varieties. It has excellent clarity. Outstanding
strength and hardness. Cost effective advanced material solution. It is used in aerospace, security,
defence ,energy and consumer products.
Solar panel roofing tiles
It transforms the solar energy into usable electricity which is required for our homes. Receives rebate
from the government for installing them. Solar panel roofing tiles play an important role in our field or
profession.
Non- load bearing gypsum blocks
Gypsum block is a massive lightweight building material composed of solid gypsum, for building and
erecting lightweight fire-resistant non-load bearing interior walls, partition walls, cavity walls, skin walls
and pillar casing indoors. Gypsum blocks are composed of gypsum plaster, water and in some cases
additives like vegetable or wood fibre for greater strength. Partition walls made from gypsum blocks
require no sub-structure for erection and gypsum adhesive is used as bonding agent, not standard mortar.
Synthetic Panels
Wood-plastic composites (WPCs) are composite materials made of wood fibre/wood flour and
thermoplastic(s)
In addition to wood fibre and plastic, WPCs can also contain other ligno-cellulosic and/or inorganic filler
materials. WPCs are a subset of a larger category of materials called natural fibre plastic composites
(NFPCs), which may contain no cellulose-based fibre fillers such as pulp fibres, peanut hulls, bamboo,
straw, digestate, etc.
Chemical additives seem practically "invisible" (except mineral fillers and pigments, if added) in the
composite structure. They provide for integration of polymer and wood flour (powder) while facilitating
optimal processing conditions.
Wood-plastic composites are still new materials relative to the long history of natural lumber as a building
material. The most widespread use of WPCs in North America is in outdoor deck floors, but it is also
used for railings, fences, landscaping timbers, cladding and siding, park benches, moulding and trim,
window and door frames, and indoor furniture. Wood-plastic composites were first introduced into the
decking market in the early 1990s. Manufacturers claim that wood-plastic composite is more
environmentally friendly and requires less maintenance than the alternatives of solid wood treated with
preservatives or solid wood of rot-resistant species. These materials can be moulded with or without
simulated wood grain details.
Acoustic Panels
Acoustic foams are sponge-like materials. Such materials possess the ability to absorb sound energy by
changing it into heat. The capacity of acoustic foams to absorb acoustic energy depends primarily on their
permeability and thickness of the cellular structure and, to a lesser extent, on the pore size and surface
treatment. On the other hand, the rigidity of the foam has very little or no effect on its acoustic
performance.
Composite Panels
Composite panels are factory engineered panels used mainly for exterior cladding, partitioning, load
bearing walls and roofing elements in a wide range of non-residential buildings. Panels are manufactured
on a continuous lamination basis with metal facings - usually steel or aluminium - encapsulating a foamed
polyurethane core. This composition offers a high degree of stability, rigidity and excellent load-bearing
capacity.
The thickness of the polyurethane foam can range from 30mm to 200mm depending upon application and
required insulation characteristics.
These versatile products are also known as 'sandwich' panels due to the physical interaction of the two
materials.
The choice of composite panels as a building solution supports important environmental considerations.
From an environmental perspective composite panels are: outstanding providers of thermal insulation;
reducing heating and cooling costs for the lifetime of a building; long life applications, maximizing
natural resources used in manufacture; contributing to reduced emission of greenhouse gases -
in production, transportation and installation.
Applications of Modern Materials
Several modern construction materials have more strength, hardness, toughness and durability. For
example, fly ash bricks have these characters when compared with normal bricks. From the above
discussions the modern materials are mostly used in all over the world. We can make our nation as Hi-
tech using these innovative materials.
These new emerging building materials should be replaced with the old ones to improve the properties of
materials and helps in recycling of the materials to save energy, time, money and make our country as
pollution free. So more innovative materials should be created and make construction of the building
simpler with more strength.