ABSTRACT:

Housing is an important sector of the country which is largely determined by the

Government policy and interventions. The housing policy aims to cut short the
construction cost by using different methods and technologies. Construction of low-cost
houses by using the low cost materials increases the access to buildings by low income
group.

Housing at low cost is a new concept which deals with efficient budgeting by adopting the
techniques that help in reducing the cost of construction through the use of materials
available locally along with updated skills and technology without compromising the
strength, performance and life of the structure, abide by the state legislations towards
environmental and inhabitant friendly constructions.

Low cost houses can be considered affordable for low income people if they can acquire
dwelling units, by rent or EMI (Equated monthly installment) of housing loan, with not
higher than 30% (approx.) of their domestic income. The low-income groups in developing
countries are generally unable to access the housing facility. This shows the necessity to
implement innovative and environment-friendly housing technologies that enable the
common people to construct the houses that can match with their income.

About 25- 30 percentile of the construction cost can be reduced by using the low cost
housing technologies. Discussions in this dissertation heading towards the use of three
technologies, GFRG Technology, Precast Technology and Wienerberger Brick
Technology, to prove the extent of cost effective but eco-friendly to the living of the
Average. These technologies are discussed in the context how far these are acceptable to
the ‘Average’ and ‘Below Average’ to build up their ‘dreams’. These technologies can be
applied universally and can encourage people for its acceptance as it is friendlier to the
ecology.

This dissertation intends to have a comparative learning to suggest the possible ways to
introduce housing for the less income and affected groups of the society with a special
emphasis on the above technologies.

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 CHAPTER 1: INTRODUCTION

1.1 BREIF DESCRIPTION

Low cost housing refers to those housing units that are affordable to the lower income groups.
‘Affordability’ is indexed based on the ability to own / build a home from the average income
of the society. Low income groups spare their whole life to build a house and spend their
major part of earning to pay back the funds availed from many sources.

Hence, own a house is a herculean task of the lower income groups in the present economic
situation. The necessity of adopting cost- effective and modern construction technology
developed to support the low cost housing for the society.

Cement is blamed for 8 per cent of the global carbon emissions and ‘AJ Will Hurst’
commented as “Cement’ the material that is killing the Planet” in the AJ Architects Journal
(2016). Sourcing cost-effective and environment friendly technologies for the construction of
houses and buildings become necessary to overcome this social issue.

Different types of technologies are used in India to construct houses and buildings to
minimize the cost of construction. Mainly three technologies are emphasizing here to find
how it can cater the requirements of constructions at a lower cost effectively to support the
society.

1. GFRG Technology- GFRG is concrete that uses Glass fibers for reinforcement
instead of steel. The technology protects the lives and properties of people as these
buildings are resistant to natural disasters like earthquakes, cyclone, fire etc.

It is the name of a new building panel product made essentially of gypsum plaster,
toughened with glass fibers. This product is suitable for rapid large scale building
construction, was originally developed and widely used in Australia since 1990. The
advantages of using GFRG enhance the usage of it in recent times.

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 2. Precast Technology- Precast concrete is the form of construction that concrete is cast
in molds that can be reused, cured in a controlled environment in a precast plant,
transport to the project site and fix it in appropriate place. Precast uses less cement,
less water, less steel and less labour as it cast in the controlled environment, reduces
the waste at the work site and gets proper monitoring to cure the casting.

3. Porotherm Clay Bricks-Wienerberger Brick Technology is most popular among the

various bricks using for the construction. Its strength, cost and energy savings, speed
and cleanliness in work and easy maintenance brings extensive use. It is
aesthetically beautiful and functionally smart, eco friendly as it is made of clay
mixed with natural additives such as coal ash, rice husk and sawdust.

There are many factors that affect the use and popularity of a construction product. Price,
strength, duration, good living, eco-friendly are the primary selective measures followed by
the good-looking, aestheticism, socio-economic, regional etc. Most of the low cost building
materials are produced either from industrial waste products or by-products that can curb the
prices in the market.

Housing in India has been a great challenge as houseless are millions in number. Most of the
houseless is with very low incomes that are unable to build homes, resulting in growing slums
especially in cities. Eradicate slums by providing enough housing is a great challenge of the
Government and can count as one of the factor for the existence of any Government. Need for
the low cost construction arises from this economic situation and the scope of research on low
cost construction technology will be extensively high in the generation ahead.

1.2 RESERCH AIMS AND OBJECTIVES

1.2. i RESEARCH AIMS

Unemployment and poverty are the major two hurdles that India faces on her development
path. Outcome of the above two social evils are the non availability of food, clothing and
shelter (housing). As an aspiring architect, I assume that I would contribute, in whatever
possible way towards the housing problems of our country.

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I believe that build houses at an affordable price using alternate construction methods to
reduce the cost is the best solution to provide maximum houses. Seek the alternate
construction technology and methods to fulfill the housing requirements are the prime aim
of this project.

The study leads to a comparison of the selected Technologies to find how these
technologies are suit for different regional and social requirements. Finally, to suggest
better means of low cost construction that can access the lower economical groups of the
society.

1.2. ii OBJECTIVES

Housing is the prime requirement to pilot a social life after food and clothing. Scarce
resources augment the cost of construction and therefore the main object of the study is to
source the best technology for the affordable construction.

1. Identify the existing low-cost construction materials and the techniques used for it.
2. Study the different aspects of these techniques, regional and social acceptability, in the
Indian context.
3. Comparative study of the identified products to match best for the conditions of
construction, especially in Kerala.
4. Understand the response of the product from the specific climate and environmental
force on implementing these technologies in Kerala.

1.3 HYPOTHESIS OF TECHNOLOGY SELECTION

Rich and the elite segment always look for the elegant structures. Architects, Civil
Engineers and Builders promote their visualization to service these elite groups as they
want to show case their talent. On the contrary, lower income groups always prefer the
durability and strength of the structure rather than the aestheticism of it. Construction cost
has to be reduced to the extent of minimum 25% to 30% to access the below average and
marginalized segment of the society.

Inquiry to find such alternate technology to reduce the cost but without compromising the
qualities of construction ends up with the usage of Glass Fiber Reinforced Gypsum, Precast

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Concrete and Porotherm Clay Bricks. Further, scrutinize the technical aspects of these
products to ensure that it meets the standards of construction industry.

1.4 SCOPE OF THE RESEARCH

The study deals with the different techniques that help to reduce the cost of a project. The
main inspiration for the research is to control the cost of construction and increase the
availability of houses at a reasonable price for the dwelling of the ordinary people.

New methodologies and alternate techniques of construction are necessary in India to cope
up with the increasing demands of the houses. Further, all these innovations are expected to
be sustainable and eco-friendly. The construction technique proposed by making use of
Glass Fiber Reinforced Gypsum panels to build homes, promises as a solution for rapid
affordable mass housing in India.

GFRG is a technology of prefabricated wall panel load bearing material used for
construction. It is an eco-friendly building material which can be manufactured out of
either natural or industrial gypsum. Vertical structures are most common in urbanization as
tall building can accommodate the density of cities. Global recession and Government
policies are the hindrance to the growth of construction Industry during 2007-2012. This
cause much hike in the total outlay of the projects. Research for faster delivery of projects
ends up with technologies that can be of readymade use, precast structures gained
importance on this thoughts.

Porotherm bricks are perforated unfilled and good for non load bearing structures. The
product is apt for the high rise apartments and acts as heat resistant to the interiors for a
comfortable living. The learning of the subject tries to cover from finding the alternate
technologies of construction at a low price to its benefits and limitations. Efforts are being
extended to analyse the production cycle of these products and the cost effectiveness of
each of the selected products.

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 Furthermore, I tried for a comparative analysis of cost–benefit effect of these products to
opt the best alternative in the context of South India and especially that of Kerala.

1.5 METHODOLOGY

LITERATURE REVIEW ANALYSIS

BACKGROUND OF SYNOPSIS
STUDY
 Low cost construction and
The effective
 Abstract techniques.
 Introduction use of GFRG
 Aim,  GFRG, Weinberg brick,
 Scope of low-cost precast technology – its
filler slab,
Objectives precast
construction background.
 Scope and
 Study of GFRG  Drawbacks.
technology from
limitations
technology live and
 methodology  Determine the site-specific
literature study
response and climatic
conditions
CASE STUDY  Research on building
system using GFRG,
Weinberg brick and
precast technology.

LITERATURE CASE STUDY LIVE CASE STUDY Comparison

 Two story residential
building where all the walls
and roofing is done using
GFRG panels – ALUVA
 Case studies taken from Silpi
architect firm – filler slab
and precast technology.
and critical
 Two story residential analyze live
building where all the walls
and roofing is done using and
GFRG panels – ALUVA literature
INFERENCE
study
 Case studies taken from The effective use of GFRG filler
Silpi architect firm – filler
slab and precast technology. slab, precast technology from
live and literature study.

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1.6 CHALLENGES

Indigenous constructions in Kerala are mostly of traditional and people are not inspired for
adopting change of technology unless it is proven to them. The role of Builders can’t be
ignored in this subject. Hence, educate the Constructors is challenging and public
propaganda needs to be initiated to build the awareness of the new alternate technologies of
the construction. The major challenge was to undertake case studies of these technologies.
Expert advices of my guide and assistance of my mender in Silpi Architects made possible
for conducting the case studies.

1.7 LOW COST CONSTRUCTION AND TECHNOLOGIES

Cost effective housing is a relative concept and has to do more with budgeting and
economic planning, seeks to reduce construction cost through applying management
techniques, apt use of indigenous materials and skills without compromising the quality and
life of the structure (Tiwari et al.,). The concept, ‘low cost construction’ does not mean that
the materials used are cheap and substandard to reduce the cost, but reduce the cost by its
design and use of locally available resources accepted by the industry (Miles, 2000).

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The identified two facts in the Indian context are- 1) technology of production and erection
be suitable to the level of skills available and 2) the regional acceptance of the technology,
ie: to the metropolitan, urban and rural conditions. For better understanding and for
analytical purpose, cost of construction can be separated to foundation, walling, roofing,
flooring, plastering and fixtures. The study in this paper is heading mainly with three
technologies depict for foundation and walling of structures. These are:

1. GFRG Technology
2. PRECAST Technology
3. POROTHERM, WIENERBERGER BRCK Technology. Further, this research paper
will be limited to but emphasizing the below two types of studies on the above three
technologies;
1. Case study
2. Comparative study

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 LITERATURE STUDY OF TECHNOLOGIES

CHAPTER 2: GLASS FIBER REINFORCED GYPSUM TECHNOLOGY

(GFRG)

2.1 HISTORY

GFRG Technology was originally developed and used since 1990 in Australia for mass
building construction. It is the latest building technology introduced by Building
Materials & Technology Promotion Council (BMTPC) constituted under the auspices
of ‘Ministry of Housing & Urban Poverty Alleviation’.

Glass fiber reinforced concrete or GFRC is fiber-reinforced concrete that uses glass
fibers to strengthen instead of steel. It is termed as GRC in United Kingdom and
Rapid wall in Kerala. It’s a panel made -up of calcined gypsum plaster, reinforced with
glass fibers. Glass fiber concretes are mainly used in exterior building façade panels
and architectural precast concrete. Fiber cement siding and Board is similar to GFRC, a
compound material made of cement reinforced with cellulose fibers.

Increasing demand for structure materials to meet the shortages of houses in India
urges alternate and fast substitutes for the bricks and concrete blocks. Shortage of
traditional materials forced the people to source best alternative and GFRG panels hold
the place of the traditional materials. This cause the large scale production of panels in
India and it has also been developed in Kerala.

2.2. THE BACKGROUND STUDY

The cost of building or houses can be reduced using methods that can reduce the cost such
as cost control tools of management, use of low cost conventional style of construction
materials or using new techniques of construction. Cost control tools of Management are
not taking into account in this dissertation but emphasis more on the discussion of new
technologies of construction.

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GFRG panels can have a life span of more than 60 years. It is stronger and long life span
than the traditional building. Rapid wall was recognized by awarding “2009 Global
Gypsum Product of the Year” and was recognized by the United Nations with ‘Habitat
Business Award’ for sustainable urbanizations as ‘good practice’. The product is
internationally identified and recognized as a low cost construction technology for the
good living.

Efforts to identify an alternative of alkali-resistant macro glass fibers as concrete

corroboration in structural elements ends up in GFRG. Structural glass fibers reinforced
concrete provide a simple and attractive alternate to conventional steel bars and steel
fibers reinforced concrete. Cost reduction by 20-30 percentiles will be examined to justify
the selection of study and test of time saving will be conducted to prove the duration of
construction reduced to a minimum 50% of the project period. The raw material for glass
fiber is a waste material of fertilizer industry named as Phosphogypsum. GFRG boards
are usually made of 124 mm thick with diameter of 3mx12m using natural gypsum or
from the waste product of chemical industry.

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‘Beat the heat’ is the global challenge and especially in the context of Kerala as the region
is experiencing such an atmospheric temperature. Reinforced gypsum boards are less
absorbent of heat and keeps interior cool. GFRG is good water, fire and corrosive
resistant. It is advisable for the seismic zone IV & V areas for earthquakes as the weight is
low compared to other alternative of GFRG. Benefit more carpet area by bringing down
the cost is highly preferable in urban region.

Reduction of Mass for use of GFRG Building Tested % Weight

panels weight reduction
Weight of 1 Sq.M. 9" Brick wall with cement
plaster in 2 sides 400 Kg -
Weight of 1 Sq.M. Rapid Wall panel 40 Kg 90.0%
Weight of 1 Sq.M. Panel with concrete refil 250 Kg 37.5%

(Fig 2: Comparison of weight of GFRG with Brick wall)

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It facilitates high speed construction with less involvement of labour. Use of GFRG
minimizes consumption of cement, sand, steel and water. It helps to reduce the overall
construction costs and due to the reduced building weights results in reduced earthquake
forces.

2.3. THE TECHNICAL STUDY

2.3 .i. MANUFACTURING PROCESS

GFRG Panels are being manufactured at FACT-RCF Building Products Ltd in Kochi, a
joint venture between Fertilizers & Chemicals Travancore Ltd (FACT) and Rastriya
Chemicals and Fertilizers, Mumbai, in collaboration with the Australia’s Rapid wall
Building Systems. The process of production is done in an automatic environment. Slurry
of calcined gypsum plaster is mixed with chemicals and water repulsive emulsion and glass
fiber rovings. Further, spread and imbed the slurry uniformly by a screen roller. This is
molded to a size of 12 meters by 3 meters with 124 millimeters thick.

More than 275 °C temperatures are using to dry the GFRG panels. Once it is dried, it can
shift to store after cutting of the required size. Transporting of these panels is in collapsible
frames. These frames are called stillages. Stillages are used for transporting to work site to
avoid the damages of the panels. Proposals are under consideration with the Government to
sanction manufacturing units for the production of GFRG panels in the different parts of
the country. This can cut down the transport cost of the panels. So that lower income
groups can also make use of it.

This standard specifies the limits and test methods for radiation specific activity of such
natural radionuclides as radium-226, potassium-40, and thorium-232 in the building
materials. This standard applies to inorganic nonmetal building materials for use in
construction of all kinds of buildings, including building materials mixed with industrial
waste slag.

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As lightweight load bearing walling in building (single or double storey construction) up to
two storey construction: the panel may be used with or without non-structural core filling
such as insulation, sand polyurethane or lightweight concrete, suitably designed to resists
the combined effect of lateral and gravity loading.

Partition infill wall in multi-storey framed building and use as Horizontal floor/ roof slabs
with reinforced concrete micro beams and screed (T-beam action). Panels are used for
pitched (sloped) roofing and also as cladding for industrial building. Also panel has best
use for compound walls.

2.3 .ii. SEQUENCE OF MANUFACTURING PROCESS

 Phosphogypsum is a byproduct of phosphoric acid. Store the raw gypsum, after

converting in the powder form, for calcinations process. Calciner is a steel cylinder

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 to furnace the object in a controlled atmosphere for a thermal decomposition.
Calcination of the gypsum took place at 140-150 °C and calcined plasters are store
in silos.
 The batch hoppers of panel move to casting tables deliver the slurry and glass
fibers. Chemicals mix with water and add to plaster to form slurry.
 At first, one slot of plaster slurry pour on the table to put another layer of glass fiber
above on it.
 Again another slot of slurry embeds on it and presses with the help of a roller to
strengthen it. Push the slurry inside the ribs to temper it.
 The wall panel will be transferred from the casting table to the drier once it is
cured. The drying of the panels is at 275 °C and it last for minimum one hour.
Dried panels move to stores.

2.4 CONDITIONS REQUIRED

2.4. i. CONSTRUCTION

The foundation for construction done on site is conventional and Stripped Footing is
particularly designed on specific soil conditions. At different stages waterproofing is

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required; it is an essential requirement during construction process. Fixing of wall panels
are in the foundation and therefore interaction with soil is not subjected.

2.4.ii. CLIMATIC STATE

This technology can take up the climatic zone of Kochi. The climatic conditions and soil
do not affect the construction. Humid warm climate of the region is not affecting the
product. GFRG is less heat absorbent and less than 5% water absorbent.

2.5 DESIGN STRATERGY

2.5. i. ON SIGHT IMPLELEMENTATION

The transport of GFRG panels from factory to the respective distributors or to the
respective work site is through trailers or trucks. The panels are placed in a vertical
position using “stillages” to move to the project site. Cranes or Forklifts are using to
offload and fix it in the appropriate place. Quick completion of the project is possible as
the walls can be fitted at a fast pace helps in the reduction of total outlay of the project.

Conventional construction method is using for the foundation of the buildings that use
GFRG. Foundation is based on the structure designing and soil test. Fix the starter bars in
the plinth beams, where the panels are been placed with the help of a crane. Panels are
placed vertically with the help of supports. Doors and Window frames have to be placed on
the cuttings designed; electrical points need to be marked.

Fill the cavities of the panels with concrete one for every three and the rest of the cavities
can be left vacant or fill with materials mix of reduced percent of cement. Lintel
reinforcement is done on top of the windows and doors to ensure the strength. Fill the
height with additional panels using ‘Joints” (L, T, Star etc.) to reach at roofing. GFRG
panels can also be used for roofing, fixing by concrete and weld mesh to build further floor
on top of it.

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2.5 .ii. REDUCED BUILT AREA

Panels of GFRG are with only 124 mm thick which means that the carpet area will be more
for the same size of built up area constructed in the conventional method. In other words,
building blue prints are much lesser for the same size of GFRG construction than the
conventional method. Thickness of each wall is reduced to less than half of the
conventional size, hence reduce the total area and price there on. This is particularly
beneficial in multi storey mass housing and housing at urban region as it provides more
living space at a lower price.

2.6 SPEED OF CONSTRUCTION

Walls of the buildings can be finished within no time by using GFRG considering the
conventional methods. Fast construction delivers many unaccountable benefits. Due to the
timely completion reduce the interest factor of the project cost and hardly affects the price
fluctuations of materials. It reduces the cost of labour for construction and additional
savings / incomes in respect of rent and lease. IIT Madras experimented by constructing a
two storey building (Sq.Ft. 1,981 with flour flats in it) by using the GFRG. Prof. Bhaskar
Ramamurthy, the Director of IIT Madras commented that "We have not compromised on
anything. These structures are as sturdy and long lasting as any building built today. The
designs have been approved."

2.7 REDUCE EARTHQUAKE FORCES

Panels of GFRG are light weight compared with conventional structures. It has only 43kg
weight per Sq. meter. Overall weight of the structure will be much less even though some
of the hollow spaces are filled with concrete. Construction without burdening the
environment contributes significantly towards reducing the earthquake forces and
casualties there on. Furthermore, reduced buildings weight cause cost saving in the
foundation.

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2.8 HOW DOES USING OF GFRG TECHNOLOGY DECREASE COST OF
CONSTRUCTION

The main element that goes into construction of GFRG Panels is a powder that is a residual
of many fertilizer industries and is available at very cheap rate in market. Apart from the
cost factor, it is easier to assemble and does not require curing time (like normal OPC
concrete). It therefore decreases the time required for construction and hence savings in
labour cost.

The core features of GFRG technology are-

 Provide cheaper substitute than Concrete and Bricks for construction
 Reduce the length of overall construction time and hence save cost

“Save up to 50% on construction cost on an overall with GFRG technology” is the motto of
the studies. Wall panels can be sized based on room measures to ease the fixing and finish
the project very quickly. In this kind of construction, very less amount of concrete is used
which in turn decreases the total load of the building. As the panels come with a smooth

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finish, plastering is not required to smoothen the walls. Because of the light weight, the
building is prone to lesser earthquake forces. Foundation cost also gets
reduced with the execution of this system. The cost spent on the new demonstration
building is 25 percent lesser than that of conventional ones.

2.9 USES & LIMITATIONS OF GFRG TECHNOLOGY

2.9. i. USES

 Fast Construction: Faster construction is possible in this technology compared to

the conventional methods.
 Reduce material handling hassles: a reduced amount of material handing reduces
the botheration of construction. Stocking much material in the site is not needed.
 Savings in freight: Reduces the transport expenses of cement and sand as its usage
will be much lesser than the brick work.
 Savings in labour cost: Less number of workers are only required compared to
other methods of construction.
 Environment friendly: Raw materials are natural gypsum or residuals of other
productions to become eco-friendly. High thermal efficient as it absorb less heat.
 More built up area: Building foot print is lesser than conventional buildings is a
factor for lesser per sq. meter cost of construction.
 Less weight: Total weight of the structure is far below than the conventional
structures which results in reduced earth quake forces.

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A two storied building (total 1981 sq. Ft with four flats) constructed by IIT Madras in one
month using FGRG.

Wall panels are light weight and approximate weight per sq. meter is 40kg. Overall
building weight is much less even after filling some of the hollow space of the panel with
concrete. GFRG as a GEP (Green Environmental Protection) material has no odor, and its
Radioactive Nuclide Limit is accord with A-style decoration material standard of GB6566-
2001, which can be used for recycling.

1.9 .ii. LIMITATIONS

 Not suitable for wall with circular or higher curvature like arch.
 Clear span shall be limited to 5m for residential buildings but pans are limited
to as per the design specifications for non residential buildings.
 Not economical and cumbersome for complicated design in structure.
 Skilled labors who are expertise only can handle it fix it.
 Need specific vehicles with stillages for transport and machineries like cranes
and forklifts for handling of the panels.
 Handle carefully not to damage as it cannot be repaired easily. Much space is
required at site as machineries are required to move and fix.
 Need specific machinery for cutting GFRG panels at site.
 Need proper storage space at site to store the panels.

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 CHAPTER 3: PRECAST TECHNOLOGY

3.1. HISTORY

Builders of Rome were used concrete to built intricate structures by using moulds and fix it
at the site. They were constructed the bridges, aqueducts and tunnels by using these pre
casted structures. Alexander Brodie, an Engineer from England, was accredited with the
modern design and use of concrete precast. He was designed and started using it in 1905.

Present uses of precast technology comprise of variety of architectural and structural

designs which includes different parts or even entire building structure. In 1905, the precast
technology has efficiently paneled buildings in Liverpool by ‘Engineer Alexander Brodie’,
as become the architect of present day precast. The idea was come into practice in
worldwide and it has come up broadly in India also. Gradually it was adopted in
Scandinavia and East Europe.

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Precast Pre-stressed Concrete Institute (PPCI) is representing for the research and
development of precast industry. The industry has shown an annual growth rate of 3.2%
from 2016, parting a slow down during the downturn from 2017. The global precast is
targeted to achieve 58 billion in 2023 against the market data of 47 billion US Dollar in
2015. A set back faced by the industry during recession and started recovery by 2012. The
recommencements of the projects again boosted its growth.

Now a day the precast industry has been spread into many different regions such as North
America, Europe, Asia Pacific, and Latin America & Middle East & Africa. The study
facilitates a detailed view of country-level aspects of the market on the basis of application
segments and estimates the market in terms of revenue and volume during the forecast
period.

3.2. BACKGROUND STUDY

Rapid growth of Indian cities marked high rise buildings than the horizontal constructions
to adjust with the affordable land availability. These high-rise projects are usually overrun
for its costs due to slowdown of economic growth and Government interventions that
ultimately on the shoulders of tenants or occupants. To cut short the project time and cost
hike, developers consider emerging means to cover up the issues.

The Construction industry that has been developed in India has undergone a pattern this
would shift from the traditional methods of construction technologies to modern
technologies. Precast is one such promising construction process under cut the time
limitation for the faster accomplishment of the project. Even though precast technology is
widely accepted, India is not penetrated the convenience of it. Least waste generation and
saving of time and labour are considered as the boosting factors of this technology in the
industry.

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Now a day the precast concrete has been used broadly in many residential and commercial
projects. It is because of this major factor that it affects the property of the precast concrete.
High durability, thermal properties and handling comfort promotes its acceptance of the
Builders. The quality of the precast concrete is high as it is manufactured under the
supervision of production control team.

Low public awareness of the precast technology is the main cause of it’s seldom use in the
construction industry. More study and research of the challenges faced by the technology
and publish journals can enhance the public awareness of the use of this technology.

3.3 TECHNICAL STUDY

3.3. i. MANUFACTURING PROCESS

Precast concrete frames are cast in the same way as precast concrete cladding, but as they
are designed as structural elements they have heavier reinforcement than required for non-
structural cladding. Elegant connections are required between columns and beams to
transfer considerable forces without affecting the visual appearance of the frame.

Precast concrete products are made in factories having production control system under
stipulated standards. Precast is casting of concrete in a mold, curing it in a guarded
condition, and shifting the product to the site where the installation and fix it appropriately.

Precast concrete products include load-bearing precast elements, foundation walls,

reinforced concrete pipes, floor and roof slabs, architectural panels, sound-barrier walls,
retaining walls, box culverts, utility boxes, modular houses, manholes, paving elements,
grease and oil interceptors, precast tanks, septic tanks, bridges, piers and tunnels.

Variety of admixtures and chemicals are using to standardize the precast as per the
requirement of the structure. Design of the reinforcement standards are depending on the
use, duration, place and climatic conditions where the structure is installing. Depending on

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the needs, strength of the steel, type of cement, size of mesh, other compounds such as
GGBS, plasticizers and bonding compounds are used as per the requirements.

3.3 .ii. THE SEQUENCE OF MANUFACTURING PROCESS

 Manufacture of molds and jig-built reinforcing cages and connections.

 Position reinforced cages in the assembled mold to shape the structure. Precast
products have to exhibit high accuracy of dimensions and finishing as it cannot be
altered or modified easily.
 Pour mixes in to the mold, using fillers and poker vibrators. This is to ensure the
required density and specified strength is achieved.
 Allow curing of the concrete as per the required standards. Chemicals such as
accelerating admixtures, super plasticizers, bonding admixtures and Ground granulated
blast furnace slag (GGBS) are used to standardize the strength and duration of the
precast as per the requirements.
 Move to the storage area from where it can be easily transported to the project site.
Vertical stacking is preferred to avoid damages.
 Transport and erection should be as per the predetermined sequence to ensure the
smooth flow of the work at the site.

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3.4 CONDITIONS REQUIRED

3.4 .i. CONSTRUCTION

The precast concrete structures are suited well for any type of the buildings located in India
and also outside India. The types of buildings that use precast are residential, commercial,
and industrial, especially for the mass construction. In this technology the precast concrete
is been made into different shapes and colours and this structures have an acceptable
finishing for which several techniques involved together during the process. Skilled labour
is a primary requirement for the design and construction of precast.

Use of precast is primarily based on the structural requirements like size, location, type of
construction, scope and use. Precast technology with the longer extent gives an architect
and other designers more viability to find out and get into the scope of this technology. It
can be used as the building material, but it can also be obtained with the steel and is
utilized as composite structures. The utility of precast structures as composite structures
mainly depends on local building traditions and restrictions.

3.4 .ii. PRECAST PRODUCTS ON SITE

The most common and important precast products are:

 The front elevation that are from sandwich to cladding and gray walls
 Floors having the shape of hollow-core, half, ribbed or solid slabs
 Partition and internal walls that are taken from Acotec to solid walls
 The Foundations and concrete piles that can sustain longer.
 The Frames such as beams, columns, slabs, etc.
 Stairs, shafts and other special products including structural designs.

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 3.5 DESIGN STRATERGY

3.5 .i. QUALITY

1. One of the major strategies as an industrially produced building material to meet the
quality at a high level.
2. High standards are fixed for the production line and for the product design. The
Production process is in a controlled environment and experts care is always available.
3. Selection of apt raw material and mix is possible.
4. Use of adequate and appropriate raw material can only qualify the standards fixed for
structure. Perpetual supervision ensures the quality of the production. The controlled
environment enables real time monitoring and easy adjustments.
5. Precast get strength as per the standards as it cure appropriately in the production table.
The benefit of adequate curing of concrete is its strength and durability. Hence, its strength
and durability is not comparable with the conventional casting.
6. The precast structures are harder for many longer years; it doesn’t burn, melt, or rot. It has
a High quality of precast structures and does not breed any of the harmful micro-
organisms.

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3.5 .ii. COST

It seems that cost of using this technology is little high compared to the conventional
casting at the work site. But in practical, considering the other factors it is much beneficial
than the onsite casting. Wastage free and time saving are the two major merits of this
product. Superior quality is the unmatched benefit to the clients together with no repair or
maintenance cost compared to conventional construction.

3.5 .iii. INVESTMENT-FRIENDLY

Precast technology is considered investment-friendly as the quality of the products will be

enhanced without affecting the margin of the investors. It enables on time delivery of the
project and can gain the good faith of the clients. Due to these reasons Governments also
promoting this technology. Many of the development corporations are depending on this
technology as it can meet their time frame.

3.6 CHALLENGES FACED BY PRECAST TECHNOLOGY

Adoption of precast technology is sustained by facing a lot of challenges in this stage level
and also take up to the industrial level. Even though precast industry is best among the
solution to feed the increasing housing demands, it has not been given attention to promote.

Unlike developed countries, densely populated countries like India is not make use of the
advantages of precast industry. ‘A round table discussion” at IIT Madras observes that
“lack of standardization, inadequate certification and testing facilities, Contractual issues
and Taxation, non availability of tools, technology and equipment, limited knowledge of
builders and clients and lack of promoting incentives from Government are the main
challenges faced by the precast industry in India. The challenges are grouped into 4
categories.

 The Standardization, Procurement and the Technological aspects

 The Documentation and Design aspects
 The Skill Development and development of technology and equipment
 The End-user perspective, propaganda and promotion

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27 | P a g e
3.7 ANALYSIS OF PRECAST TECHNOLOGY AND ITS METHOD

Production cost Transportation cost

Sub structure cost

Material cost
Super- structure cost-
civil works

Cost would be negligible in case of precast

Super- structure cost-
finishing and MEP
Different cost and not accounted
in cost
Analysis
Indirect cost

Similar cost and not accounted in

Markup
cost

Analysis
12.36%Production
cost

Total cost of a precast building

14%Production cost

3.8 USES AND LIMITATIONS

3.8 .i. USES

The merits of precast concrete structures are discussed below.

1. Saves project period
Each casting takes 15-20 days to cure to gain its strength and durability if it does it in

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 the site. Precast concrete cast and cure in precast plant as per the pre-designed plans
saves time of casting and curing at the work site. This eliminates the tension of project
delays as the casting take place in the yard and other work at site can be carried out at
the same time.

2. Product Quality
Casting at precast yard always takes place in strict supervision to ensure the product
quality. Standardized methods are adopting in mix designs, reinforcement,
temperature and curing of the concrete are adopted for the best results of the product.

3. Pre-stressed Concrete
High load bearing capacity spans with strength structures, filling with vibrator and
stressing made capable of obtaining the highest strength in structure.

4. Cost-effective
The much simplified methods forms and also the process reduces the required period,
cost reduction is possible due to the increased the productivity and quality.

5. Durability
Life span of the Precast Concrete is much longer than the usual concrete structure with
maintenance at a lower span. It has a high density and is much more durable. The
concrete structures are more durable to acid effects, corrosion impact, reduce surface
irregularities and avoid dust accumulation.

6. Aesthetics:
The structures are completely fabricated as per requirements and its production is
regulated under strict supervision, several mixtures of colours and textures can be
used. There would be different shapes, sizes and materials for better finishing hence
aesthetically valued it.

7. Safe Construction Platform:

Not much raw materials are required to be stocked in site where there the Precast
Concrete structures are used and it much reduces the prerequisite of customary
methods.

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3.8 .ii. LIMITATIONS

The use of precast concrete structures in Indian construction industry is limited considering
the growth rate of the industry. The major factor for the non-acceptance by the stake
holders is that proper ascertainment of benefits of this technology is not published. Most of
the users are just viewed as a costlier technology without having proper study of it.
Another observation is that the use of precast technology is largely based on the
circumstances and not working on any data base.

Production of precast requires high capital investment, as it requires concrete mixing

plants, molds of different structural designs, casting and curing spaces, enough storage and
transporting facilities equipped with forklifts and cranes. Furthermore, structural changes
are difficult as every time different molds are required as per the demands of the projects.
Repairs and modification of the pre-casted structures are difficult.

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 CHAPTER 4: WIENERBERGER BRICK TECHNOLOGY

4.1 HISTORY

Founded in 1819 by Mr. Alois Miesbach in Vienna (Austria), Wienerberger Brick

introduced in the construction industry as an innovative product. During the period of last
two centuries, the use of wienerberger technology products has been used for construction
in many buildings and also has brought up a great tradition in Austria. Expansion and
diversification of this technology took place during the late eighties of the 20th century. It
was transformed to a leading producer of clay-based building materials by growing itself as
a multinational.

Since 2006, in India the first plant “Kunigal” was established, 70kms apart from
Bangalore, The ownership of the Company incorporated in producing high quality clay
building materials for local market. This was the first plant in the continent and
commenced production in the Kunigal (KIADB) Industrial Area in 2009.

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4.2 BACKGROUND STUDY

Architecture contributes shelter and beauty to human abode and design for a sustainable
planet. The Wienerberger Brick is the latest building trend, offering a faster and drier
construction process than traditional masonry work.

Wienerberger Brick sustain its traditional values along with the modern method of
construction; it is a precision clay block walling system. It’s revolutionizing the
construction industry fast and with high strength and heat efficiency. It is dry, safe and
simple to use as well as capable for holding stocks and its storage.

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There is interlocking device it’s a unique one which helps to remove the mortar in all the
vertical joints, and also consisted in manufacturing quality which allows for a true bed
joints. It has been a successful for many decades and it has been well established as an
ideal building solution in India. This type of bricks are used and it can be used in load
bearing and also for non- load bearing applications. It is ideal:

 Inner leaf of brick-faced hollow walls

 Inner and outer leaves of render hollow walls
 Infill panels within framed structures
 Partition walls and separating wall
 Single leaf internal and external walls

With its lean laying process and rapid daily output, Wienerberger brick brings cost and
time saving benefits throughout the construction, while its thermal and aural efficiencies
bring further advantages for decades to follow the anticipated lifespan for a Porotherm wall
is over 150 years.

4.3 TECHNICAL STUDY

4.3 .i. MANUFACTURING PROCESS

The mainly collected is clay from different stockpiles and also shoveled it into different
box. Along with Water, sand and other mixtures are mixed with the clay and uniformly
mixed well in mixer. It is later fed into grinding machine and is ground at last stage.

Then the ground clay transport through conveyor to the clay stock and finally the mixed
clay is dropped into the extruder. Later, in this process brick mass is being extruded
through a die and then further, it gets automatically cut down into small individual blocks.
For certain brick it requires only one die for up to 10mm.

The wet bricks are put on pallets transferred to the dryer. The next process is drying, it
almost take up to 1-2 days, after it gets dried up its moisture content of bricks can be

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 dropped about 20% to 2%. After the process of drying the bricks are grouped and set on
kiln cars and transferred to the furnace

Once it gets dried up, the bricks are collected and then are fired for about 6- 36 hours in the
furnace, it is usually heated using natural gas or by coal at 900°C. Strengthen the clay by
firing and additives create small holes inside the bricks which increases the thermal
insulation.

Thermal energy will be used again for the same purpose to save the energy, after the bricks
are fired. After firing bricks remove it from kiln cars, pack and make ready shipping. Later
the bricks are packed and they are been taken outside by forklifts and also placed for
further storage and delivery.

4.4. DESIGN STRATERGY

1. LIGHT WEIGHT & FASTER CONSTRUCTION

Porotherm Bricks are much lighter than conventional wall material. Use of porotherm
bricks reduces cost reduction in dead load and less handing charges. The benefit of this is
faster construction and for easy handling.

2. HEALTHY AND COMFORTABLE LIVING

Better thermal insulation ie; 45% better than the conventional wall material make possible
saving of energy consumption. Low absorption rate makes possible moderate temperature
in the interior.

3. ENVIRONMENT FRIENDLY
The clay using for its production is derived from de-silting of dead water tanks. Natural
additives like coal ash, rice husk and saw dust are added to it to make the mix for casting
brick. It also has been given good credit rating by Indian Green Building Council.

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4. STRENGTH & USE
High compressive strength ease handling of it and masonry productivity improves due to
the web design interlocking.

Easy fixing of fixture, chisel and chase for electrical and pumping installations such as
cabinets, air conditioners, closets, geysers etc.

5. UNLIMITED LIFE AND MAXIMUM FIRE PROTECTION

Wienerberger bricks have an exceptionally long life; it doesn't easily burn as it is already
fired at about 1000 degrees and has a fire rating of F240 - 240 minutes.

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4.5 SOLUTIONS FOR POROTHERM, WIENERBERGER BRICK

1. SPEED OF LAYING

There is a simple way of measure, productivity highlighting the stark contrast between
Porotherm and other methods; they are our precision clay blocks which have always been
laid significantly faster. There was no mortar that is required in vertical joints, and further
with each block precision the ground for easy on-site uses, Porotherm bricks are efficiently
designed for maximum build requirements.

2. OPTIMUM STOCK

In this the main factor that has to look up to is the structural performance of the Porotherm
system, it helps in reducing the variance of many block types and its strengths are mainly
required on-site. Hence hereafter, the next day delivered from stockiest also reduces
storage requirements on-site.

4.6 EFFICIENCY IN THE BUILD PROGRAMME

Although the price per square meter of block-work cannot be comparable to any other
masonry materials, it mainly matters not only the speed and its efficiency but also how the
porotherm system works on site and is capable in creating the savings virtually in every
area. It mainly starts with a clear reduction in preliminary costs, and also consolidated in
reducing the labour and mortar costs (due to the virtual and dry nature of the system).

The benefits has began with the foundations used in site, since our blocks are considerably
lighter than concrete, the foundation loads are lighter, compared to the other foundations in
this site it also makes us understand that the structural, labour and also the machinery costs
can be reduced at a desirable rate.

36 | P a g e
There is an increased laying speed built programme in which it achieves a water-tight shell
significantly more quickly, and also allow finishing the trades to start up the work sooner.
With Porotherm brick, in this project it can be built to 2nd storey height and without the
normal need to back up, so the external skin can be taken off the critical path. The Actual
height of the building is always dependent on exposure conditions and design is the major
factor that allows support during temporary conditions.

There will be an ultimate result, walling system required to save both the time and also
money along with the built process, it is without a compromising built quality or a main
sustainability criteria.

4.7 USES AND LIMITATIONS

4.7.i USES

Some of the advantages of Wienerberger Technology are:

Light weight in handling - 60% less weight than conventional wall material.

 High Compressed strength that last very long and strong.

 Excellent Sound and Thermal Insulation
 Water absorption rate is just 15% , cause minimal chances of dampness, cracks or
shrinkage of walls
 Non-susceptible to carbonation thus providing greater durability
 Technical support provided by Wienerberger at construction sites

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4.7 .ii. LIMITATIONS

 The compressive strength of Porotherm Thermo bricks is slightly above 3.5 N/mm²
 The water absorption is about 15% in case of Porotherm Thermo bricks
 The density of these bricks are less that comes about 694 to 783 kg/m^3.
 Uses of Porotherm bricks are not advisable for foundation and base slabs. It won’t
be resisting the negative pressures in areas of high ground water level.

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 CHAPTER 5. LIVE CASE STUDY

TECHNOLOGIES AND ITS COMPARATIVE ANALYSIS

5.1 GFRG TECHNOLOGY

PLACE: KARAMOLIPEDIKA, KOLENCHERRY

AREA: 133sq mtrs
PROJECT TYPE: VILLA PROJECT
ARCHITECT: SEBASTIAN JOSE

This villa project is situated near road side on high raised area. This project completely
evolves into landscape as well as type of construction used in this site.

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SITE LAYOUT

GROUND FLOOR

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FIRST FLOOR

This area is situated near to town place kolencherry. The essential facilities like shops
hospital church etc are situated near 5km radius.

SECTION

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The building is completely used with GFRG technology and for its aesthetics purpose
louvers have been used for the outer of the building. Traditional roofing is been used in this
building. In this villa project all the builds have common outer factors.

ELEVATION

5.2 PRECAST TECHNOLOGY

PLACE: PALARIVATTOM
AREA: 120 SQ MTRS
PROJECT TYPE: RESIDENCE
ARCHITECT: SEBASTIAN JOSE

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This residence is situated away from road side on high raised area. This project completely
evolves into landscape as well as type of construction used in this site.This area is situated far
way from town place. The essential facilities like shops hospital church etc are situated near
5km radius. The precast structures are harder for many longer years; it doesn’t burn, melt, or
rot. It has a High quality of precast structures and does not breed any of the harmful micro-
organisms.

It seems that cost of using this technology is little high compared to the conventional casting
at the work site. But in practical, considering the other factors it is much beneficial than the
onsite casting. Wastage free and time saving are the two major merits of this product.
Superior quality is the unmatched benefit to the clients together with no repair or maintenance
cost compared to conventional construction. This technology is considered investment-
friendly as the quality of the products will be enhanced without affecting the margin of the
investors.

5.3 WIENERBERGER BRICK

PLACE: THAMMANAM
AREA: 110 sq mtrs
PROJECT TYPE: RESISDENCE
ARCHITECT: SEBASTIAN JOSE

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This residence is situated away from road side on high raised area. This project completely
evolves into landscape as well as type of construction used in this site.This area is situated far
way from town place. The essential facilities like shops hospital church etc are situated near
5km radius. The benefits has began with the foundations used in site, since our blocks are
considerably lighter than concrete. The foundation loads are lighter, compared to the other
foundations in this site it also makes us understand that the structural, labour and also the
machinery costs can be reduced at a desirable rate.

Walls with Wienerberger are about 60% less weight than the conventional materials used for
making walls. This technology gains significant cost reduction basic structure due to reduced
dead load. Reduced handling charges and gains speed in construction ultimately favour the
project cost. It saves energy consumption least by 40%-45% better than the conventional
methods of constructing walls. It is fire resistant to the extent of F240-240 minutes as the
bricks are fired at about 1000 degrees.

5.4 FACTORS RELATED TO SITE SPECIFICATIONS

SL. PARAMETER PRECAST GFRG WIENERBERGER

NOS TECHNOLOGY TECHNOLOGY BRICK

1. Product Density 650 to 750 2000 kg/m3 700 - 800 Kg/m3

Kg/m3

Water Absorption
Standard does As per standards - ≤
not make any 10% As per IS 3952 - ≤
mention on For 8" thick - 2.0 20%, Actual for
water absorption W/m2K. POROTHERM
2.
when tested 12 to

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 properties of the 14% by weight
block - when (declared is ≤ 15%)
tested it is as for 8" thick - 1.0
high as 35 to W/m2K
3. U Value` 40% Requires more energy

for 8" thick - 0.7 for cooling of the

Better thermal
W/m2K environment within
insulation -
the enclosure.
comfortable

The values are atmosphere inside

applicable when the house

completely dry -
would deteriorate
very fast on
excessive water
absorption

Mason can be 50 As the block is Mason can be 50 %

Speed of
4. masonry/Construction % faster than heavy masons need faster than concrete
concrete block more helpers & the block while
while productivity of job constructing a wall
constructing a is as well slow. with POROTHERM
wall with due to its light
PRECAST due to weight
its light weight

Savings in Structural Optimization in Heavy structures need Optimization in

5. costs thickness of to be designed for thickness of plaster

Plaster Thickness plaster can be concrete walls. can be achieved due

achieved due to Due to porous nature to perfect shape &

perfect shape & of the surface & size and even

size and even uneven faces plaster surface finish,

surface finish, thickness of the

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 thickness of the thickness plaster can be as low
plaster can be as optimization is as 10 to 12mm
low as 10-12mm difficult

6. Transport cost PRECAST being Less quantity of

POROTHERM
60% lighter, the walling material can
being 60% lighter,
quantity of be transported due to
the quantity of
material which its heavy weight.
material which can
can be
be transported in a
transported in a
truck is more by
truck is more by
60%, as transport
60%, as transport
limits are specified
limits are
in weight (tons)
specified in
weight (tons).

7. Chasing & Conducting Faster & easier Takes more time as Faster & easier with
with less effort, one needs to scoop less effort, as one
as one needs to out the concrete needs to break the
break the outer material to create a outer shell & no
shell & no conduit or groove. scooping out of
scooping out of material.
material.

8. Shrinkage & Creep Extremely High There is shrinkage There is no

in PRECAST and creep which shrinkage or creep
would happen in in POROTHERM
concrete blocks over a clay bricks.
period of time.

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 9. Dimensional Stability
at site - under Highly UN-
Sufficiently stable Highly stable
construction. STABLE

10. Tampering at site Difficult Difficult Difficult

5.5 ANALYSIS OF FACTORS RELATED TO MATERIAL

SL. PARAMETER PRECAST GFRG WIENERBERGER

NOS TECHNOLOGY TECHNOLOGY BRICK

1. 30-40% of 20-30% of 25-35% of

Cost construction cost can construction cost construction cost can
be saved
be saved can be saved

2. (Ground floor + first (Ground floor +first (Ground floor +first

Time
floor) - 40 days floor) – 30 days floor )
-35 days

3.
Eco-friendly
It is ecofriendly It is ecofriendly Its is ecofriendly

Fire resistance
5. Conventional 100 Conventional 100 Conventional 100
degree for 3 hours degree for 4 hours degree for 4 hours.

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 Sometimes cause
6.
Earthquake resistance Can resist earthquake disturbances due to
Can resist
(panels itself act as a its structure or soil
earthquake
shear wall) type

7.
Life span
60years 80 years 65 years

8.
Water resistance waterproof waterproof Waterproof

4” wall thickness, 4” wall thickness,

3” wall thickness,
9. hence more carpet hence more carpet
Carpet area hence more carpet
area. area.
area.

10. 4 times stronger than 5 times stronger than 4 times stronger than
strength
other technologies other technologies other technologies

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 CHAPTER 6. COMPARATIVE ANALYSIS OF LIVE AND
LITERATURE

6.1. LIVE ANALYSIS

6.1 .i. GFRG TECHNOLOGY

It’s a new method of building construction using GFRG Panels to run the construction in
fast pace. The technology is to use the prefabricated light weight large panels to complete
the project in time. This technology replaces or reduces the conventional cast-in situ
constructional use of steel reinforced concrete in the construction.

Natural resources such as river sand, trees and water are become scarce along with good
agricultural land which have great impact on the construction and act as the thermal
regulators. Rapid wall panels have reduced embodied energy and act as thermo regulators
of interiors. Reduce the effect of Global warming by the use of Rapid wall buildings that
balances the environmental impact on new constructions.

Major human causalities occur in natural disasters such as fire, earth quakes, cyclones etc.
Severities of the causalities of these disasters are from the structural damages of the
buildings and other constructions by using the stone bricks and reinforced concrete. These
causalities can be reduced by the use of Rapid wall as these buildings will be resistant to
natural disasters.

Besides the above all, it is much affordable to the socially marginalized segments of the
society. Fulfill the housing needs of the low income segments will contribute to the overall
social development of the state. Fast delivery dwelling units is possible and can reduce the
scarcity of the housing shortages. Use of the Rapid wall panel can achieve all the above
goals to the overall growth of the society.

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6.1 .ii. PRECAST TECHNOLOGY

Precast industry has a lengthy history since the Roman Empire; precast technology was in
use from the Ancient Roman Era. Over ages, the technology undergoes many innovations
and design upgradation. The present day prevailing precast is the structurally sound and
strongest in the construction world, providing better scope for architectural growth and
innovations.

Precast concrete has the greater flexibility in molding limitless design options to build
variety structural designs. It is one of the fastest technologies to accomplish the timely
project completion. The reason for its continued use and growth is due to the benefits
aforementioned.

6.1 .iii. WIENERBERGER BRICK

Operational excellence has obtained by the Wienerberger India following a specialized

production methodology through:

 Plant automation.
 Material handling by machines and robots.
 Make use of the locally available raw materials

The factory was running throughout the year without lapsing any single day with a
production capacity unparalleled by any other brick industry in South East Asia. The
factory is fully automated and environment friendly manufacturing unit for clay hollow
bricks in India with the brand name Wienerberger Smart Bricks.

6.2 LITERATURE ANALYSIS

6.2 .i. GFRG TECHNOLOGY

Glass fiber reinforced concrete is fiber-reinforced concrete that uses glass fibers for
reinforcement instead of steel. It is termed as GRC in United Kingdom and Rapid wall in
Kerala.

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Increasing demand for construction materials to meet the shortages of houses in India urges
alternate and fast substitutes for the bricks and concrete blocks. Shortage of traditional
materials forced the people to source best alternative and GFRG panels hold the place of
the traditional materials. This cause the large scale production of panels in India and it has
also been developed in Kerala. The cost of construction can be reduced using cost
reduction methods such as management tools of cost control, use of low cost conventional
style of construction materials or using new techniques of construction.

Cost reduction by 20-30 percentiles will be examined to justify the selection of study and
test of time saving will be conducted to prove the duration of construction reduced to a
minimum 50% of the project period. The raw material for glass fiber is a waste material of
fertilizer industry named as Phosphogypsum. GFRG boards are usually made of 124 mm
thick with diameter of 3mx12m using natural gypsum or from the waste product of
chemical industry.

6.2 .ii. PRECAST TECHNOLOGY

The precast concrete products industry focuses on utility underground and other non-pre-
stressed products and is represented primarily by the National Precast Concrete
Association (NPCA). In precast technology the concrete structures in industry are mainly
focused on pre-stressed concrete elements and other precast concrete elements are been
used in the above ground structures such as buildings, parking structures, and bridges.

Precast industry is represented primarily by the Precast Pre-stressed Concrete Institute

(PPCI). Precast industry has shown an annual growth rate of 3.2% from 2016, leaving a
slow down during the recessions from 2017.

Precast technology is one such emerging construction process to reduce the time limitation
for the faster completion of the projects. Even though precast technology is widely
accepted especially in the Western and Middle East, India is not penetrated the
convenience of it.

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Low public awareness of the precast technology is the main cause of it’s seldom use in the
construction industry. More study and research of the challenges faced by the technology
and publish journals can enhance the public awareness of the use of this technology.

6.2 .iii. WIENERBERGER BRICK

The Wienerberger Brick is the newest technology, offering a faster and clean construction
process than traditional stone and brick work. Wienerberger Brick sustain its traditional
values along with the modern method of construction; it is a precision clay block walling
system. It’s revolutionizing the construction industry fast and with high strength and heat
efficiency. The product is simple to handle, safe in fixing and capable of holding air
storage to resist heat. The interlocking system developed is unique and eliminate mortar in
vertical joints. Its quality is consistent and bed joints are perfect.

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 REFERENCES

1. International Journal of Engineering Development & Research, www.ijedr.org

2. PAC No. 1009-S/2012, Issue No. 01, Date of Issue: 31-05-2012
3. Sk. Subhan Alisha, Sajja Neeraja, Sk. Akber, G. SaiManoj (2016) “Low Cost
Housing by Using GFRG Panels” International Journal of Scientific Research in
Science, Engineering and Technology.
4. Maganti Janardhana, A. Meher Prasad and Devadas Menon (2004) Indian Institute
of Technology Madras, “Studies on the Behavior of Glass Fiber Reinforced
Gypsum Wall Panels”.
5. Kadam Sagar P., Darade Milind M. (2016), “Comparing Rapid Wall Panel
Construction over Conventional Construction with Respect to Cost and Time of
Construction”.
6. Aiswrya Shukla Mohd. Afaque Khan, Abhishek Kumar (2016) “A Review of
Research on Building System using Glass Fiber Reinforced Gypsum Wall Panels”
International Research Journal of Engineering & Technology.
7. Eldhose M. Manjumekudiyil, Basil P. Alias, Biji K. Eldhose, Sarath Rajan,
Thasneem Hussain 2015) “ Stydy of GFRG Panels and Its Strengthening”
International Journal of Civil and Structural Engineering Research.
8. Mohammed Said Meselhy Elsaeed (2016) “ Cost Model for using Glass Fibre
Reinforced Gypsum System (GFRG)” International Journal of Development and
Economic Sustainability.
9. K. Kalaipriya, R. Jayanthi (2015) “Comparative study on estimation of wall panel
system with conventional building works in construction Industry”. International
Journal of Science and Engineering Research.
10. Devadas Menon, A. Meher Prasad (2013) “Development of Building system Using
Glass Fiber Reinforced Gypsum (GFRG) Panels” The master Builder.
11. Nithya Nandan A., Renjith R. (2016) “Experimental Study of Glass Fiber
Reinforced Gypsum (GFRG) Panels filled with Alternate Concrete Mix Using
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13. https://wienerberger.in/facts/wall-solutions-porotherm-smart-bricks
14. https://wienerberger.in/facts/porotherm-concrete-blocks-clay-solid-bricks
15. https://en.wikipedia.org/wiki/Precast_concrete
16. https://theconstructor.org/concrete/precast-concrete
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18. https://www.researchgate.net/publication
19. https://www.slideshare.net/SagarShah118/precast-building-system
20. http://conf.ncree.org.tw/proceedings/i0951012/data/pdf
21. https://www.unido.org/sites/default/files/2009-
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22. http://www.irbnet.de/daten/iconda/CIB8959.pdf

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