“Filler-slab construction using coconut shell ”

Thesis submitted to

Chhattisgarh Swami Vivekanand Technical University

Bhilai (India)

For partial fulfillment of award of the degree of

BACHELOR OF TECHNOLOGY
(Civil Engineering )

by

Sameer Ranjan Sahu 301402020054

Pritesh Kumar Chouhan 301402020091
Harsh Kumar Sahu 301402020021
Moksh Dewangan 301402020069

Under the Guidance of

Ms. Nupur Dewangan
( Assistant professor)

Nov-dec 2022

Department of civil engineering

Shri Shankaracharya Technical Campus
(An Autonomous Institute)
Junwani, Bhilai (C.G.) Pin- 490020
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 CERTIFICATE FROM THE EXTERNAL

This is to certify that “Name of Student”, student of B. Tech (Civil Engineering ), has
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under the Guidance of “Ms. Nupur Dewangan”.

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3
iv
 ABSTRACT

In experimental study of bubble deck slab by inserting coconut shell, A filler slab is where we
replace a portion of concrete in the 'tension' zone of the slab with inexpensive lightweight filler
materials such as coconut shells, glass bottles or any other creative material we can think of. In a
simply supported RCC slab, the upper part of the slab is in compression while the lower portion
of the slab experiences tensile forces. The steel reinforcement in such a slab is in the lower part
to counter the tensile forces but the concrete (which is weak in tension) in that zone is mostly
redundant except for a small portion required to hold and protect the steel rods. This redundant
concrete can be replaced with a cheaper filler material. By choosing the filler material Coconut
Shell, we could save about 30-35% of concrete compared to a traditional RCC slab. A light
weight filler material also reduces the dead load hence less steel reinforcement is required. In all
we may expect to save about 25% of the cost,and also redcing the weight as much as 20to 30%.
A filler slab with two stacked clay tiles as shown in the sketch above also increases the thermal
insulation of the slab. A filler slab can be used to Reduce use of energy intensive materials,. Save
on construction cost, Increase thermal comfort, and create an interesting look. Coconut Shell
roofs are made to meet functional and architectural requirements.According to the bubble deck
company, the reduction in weight of passive concrete may save up to 40% on embodied carbon
which can help in reducing global warming and useful for carbon credits. Generally, for every
5000 m2 of bubble deck slab area, one can save up to 1000 m2 of on-site concrete. The benefits
in the form of 166 concrete truck trips, 1798 tons of foundation load, 1745 GJ of energy used in
concrete production & transportation and 278 tons
of CO2 emissions respectively.

5
 List of Tables

Table Captions Page

No. No.

6
 List of Figures

Figure Captions Page

No. No.

7
List of Abbreviations /Symbols

viii
 Table of Contents

S. Page
Title
No. No.

1. List of Tables

2. List of Figures

3. List to abbreviations/Symbols

4. Chapter1 Introduction

5. Chapter2 Review of Literature

6. Chapter3 Materials and Methods

7. Chapter4 Results and Discussion

8. Chapter5 Summary and Conclusions
References

Annexure: Publication Details

 CHAPTER 1
INTRODUCTION
 Introduction

Chapter1

Introduction- In the world, low-cost housings are major leftovers, a big challenge for
Civil Engineers and many governments, particularly in the emergent countries of the world
like India. The crisis is aggravated by fast escalating population, migration of rural masses
into the urban and industrial centres, which demands for the better eminence of existence.
Due to this insufficiency of conventional building construction systems, new building
systems appeared at the beginning of the 20th century. During 1999 the government has
conducted government-sponsored contest on the topic of new habits of constructing
buildings. In this contest, the bubble deck technology was accepted and become popular in
Europe and around the world as large scale profit-making construction.In bubble deck slab
construction, in addition to HDPE (High-Density Poly Ethylene) hollow spheres, all other
materials are the same as the conventional solid slab. The reinforced steel which is
fabricated in two layers for lateral support and diagonal girders for vertical support of the
bubbles which are made from recycled high-density HDPE. In this process, the bubbles are
placed firmly in between the top and bottom reinforcement.
Bubble deck slab is the slab in which some amount of the concrete is replaced by the
plastic hollow bubbles which are made by the waste plastic material, which reduces the self-
weight of the structure. The main effect of the plastic sphere is to reduce the dead load of
the deck by in compare to solid slab having same thickness without effecting its deflection
behavior & bending strength. The slab is cast with the same capabilities as a solid slab, but
with considerably lesser weight due to elimination of excessive concrete. The spheres
could be recycled even after the building is demolished or renovated in the future. The
dead air space in the hollow spheres provides insulating value and can be introduced with
foam for additional energy efficiency, this also increases fire resistance as well as sound
insulation.

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 Introduction

History of Filler slab in India

Filler slab technology has been used across India from a long time in different forms.Indo –
British architect Ar. Laurie Baker has popularized this filler slab technique in India
especially in South India and particularly in Kerala. It was so popular in Kerala some time
back that there was a period when everyone wanted to build a ‘’Baker model home’’His
style was unique and revolutionary.He was an outstanding Architect in sustainable
architecture and green buildings, incorporating these design principles even as early as in
1960s.Concepts of rain-water harvesting, minimizing use of energy consuming materials
and building homes suiting the site and environment were his primary focus. Filler slab
technology is another cost efficient and sustainable technology introduced by “Gandhiji of
Architecture”- Ar. Laurie Baker

The amount of the concrete used in bubble deck slab is 35-50% less than the conventional
solid slab. The amount of non effective reduced concrete is replaced by HDPE hollow
spheres leads to the usage of less reinforcement because of the reduction in the dead load
from the slab which is more useful for low-cost housing . Load bearing walls are not
necessary because of the reduced dead load from the slab and its two-way spanning action .
Support beams and girder members can also be eliminated if the bubble deck is designed as
a flat slab bubble deck which results in the reduction in some of the structural requirements
of the columns and foundations Out of all types of bubble deckthe finished planks
technology is more time-saving process when compared to filigree elements and
reinforcement modules. Because this is a type of construction like a precast can be cast in
the workshop which leads to the fast erection of column. Bubble deck slab is not only time-
saving construction, but it also has a very good impact on cost saving due to a reduction in
self-weight. Further, it would be easier to lift the panels thereby it reduces the labour costs.
Slight rise in the cost for HDPE hollow spheres can be overcome by saving in
transportation, materials, time and labour.

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 Introduction

Concrete Floor Systems

Reinforced concrete slabs are components commonly used in floors, ceilings, garages,
and outdoor wearing surfaces. There are several types of concrete floor systems in use today,
and are shown in Figure 2-1:
- Two-way flat plate (biaxial slab)- There are no beams supporting the floor between
the columns. Instead, the slab is heavily reinforced with steel in both directions and
connected to the columns in order to transfer the loads.
- Two-wayflat slab with drop panels- This system differs from the two-way flat plate
system by the drop panel used to provide extra thickness around the columns. This
strengthens the column to floor connection in consideration of punching shear.
- One-way beam and slab- This is the most typical floor system used in construction.
The slab loads are transferred to the beams, which are then transferred to the columns.
- One-way joist slab- The joists act like small beams to support the slab. This floor
system is economical since the formwork is readily available and less reinforcement
is required.
- One-way wide module joist slab- This system is a variation on the one-way joist slab
with wider spaces between the joists.
- Two-way joist slab (waffle slab)- This floor system is the stiffest and has the least
deflection of those mentioned since the joists run in two directions (Concrete
Reinforcing Steel Institute).

Figure 2-1: Types of Reinforced Concrete Floor Systems (Concrete Reinforcing Steel Institute)
Reinforced concrete has many advantages for floor systems- it provides resistance to high
compressive stresses and to bending stresses; it is relatively cheap to produce and construct; and
it can be molded into virtually any shape and size. Disadvantages include a high weight-to-
strength ratio and difficulty in structural health monitoring (Reinforced Cement Concrete
Design).

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 Introduction

2.1.1. Hollow-Core Slabs

In the mid-20th Century, the voided or hollow core floor system was created to reduce the
high weight-to-strength ratio of typical concrete systems. This concept removes and/or replaces
concrete from the center of the slab, where it is less useful, with a lighter material in order to
decrease the dead weight of the concrete floor. However, these hollow cavities significantly
decrease the slabs resistance to shear and fire, thus reducing its structural integrity.
This floor system typically comes in the form of precast planks that run from 4 ft to 12 ft
wide and consist of strips of hollow coring with pre-stressed steel strands in between. Figure 2-2
illustrates several types of hollow-core planks used in the industry. They are combined on site to
form a one-way spanning slab and topped with a thin layer of surfacing (PCI).

Problem Statement
In the 1990's, Jorgen Breuning invented a way to link the air space and steel within a
voided biaxial concrete slab. The BubbleDeck* technology uses spheres made of recycled
industrial plastic to create air voids while providing strength through arch action. See Figure 2-3
for a section cut of a BubbleDeck. As a result, this allows the hollow slab to act as a normal
monolithic two-way spanning concrete slab. These bubbles can decrease the dead weight up to
35% and can increase the capacity by almost 100% with the same thickness. As a result,
BubbleDeck* slabs can be lighter, stronger, and thinner than regular reinforced concrete slabs
(BubbleDeck*-UK).

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 CHAPTER 2

REVIEW OF LITERATURE
 Chapter2

Review of Literature-

1 Deepika Dinesh1 Akhil P.A(2018)

The whole weight of the building is very much influenced by the self- weight of the reinforced
concrete. Cost reductions in roofs/ floors are achieved through the adoption of filling a part of
concrete in tension zone with cheaper substitutes. Roof tiles are better substitutes; here the
concrete consumption as well as reinforcement could be significantly controlled. In this paper a
hollow roofing tile is used as a filler material so that portion of concrete below the neutral axis
can be replaced by these materials. The diameters of the steel reinforcement used are 8mm and
6mmdeformed bars. The slab thickness was 13 cm. The results showed that hollow core slab
can reduce theweight as compared to the solid slab. The value of ultimate loading capacity of
solid slab is greater than the hollow concrete slabs. However, the hollow slab satisfies the
design criteria.
Experimental investigations on control specimen and slab with different arrangement of the
hollow roofing tiles were carried out. Load carrying capacity, maximum deflection and failure
patterns were analysed.The maximum load carrying capacity found on the control specimen is
94.3 kN and the central deflection corresponding to that load is 16.46mm. By reducing the self-
weight of slab SB – 1 of about 33.52 %, compared to that of normal slab SB – C, the maximum
loadcarrying capacity is 42.6 kN and the central deflection corresponding to the maximum load
is 10.55mm.
By reducing the self-weight of slab SB – 2 of about 27.93 %, compared to that of normal slab
SB – C, the maximum load carrying capacity is 47.3 kN and the central deflection
corresponding to the maximum load is 8.43mm.

In comparison with the two test specimens SB- 1 and SB- 2, the slab with hollow roofing tiles
only on the edges is having a higher load carrying capacity of about 9.93 % compared to the
other one.
2. MR. AMIT D CHOUGULE, 2 MR.MANOJ H. MOTA, 3 DR. MRS. USHADEVI S
PATIL (2015)

In the context, with the utilization of waste material in building construction and solving its
disposal problem, a technology has been developed at the Central Building Research Institute
(CBRI), Roorkee, India, to construct reinforced floor/roof slab with various materials as filler
material. The paper describes the literature review studies and various results with context to
embedded energy, Design and durability, Cost effective, Designoptimization for filler slab.
Compared to conventional in situ RC slab, this technique is economical and will result in
saving of cement and steel and is an ideal step towards generation of affordable housing, for
developing countries.
A slab is a flat two dimensional planar structural element having thickness small compared to
its other two dimensions. It provides a working flat surface or a covering shelter in buildings. It
primarily transfers the load by bending in one or two directions. Reinforced concrete slabs are
used in floors, roofs and walls of buildings and as the decks of bridges. Concrete slab behave
primarily as flexural members and the design is similar to that of beams. A concrete slab is a
common structural element of modern buildings. Horizontal slabs of steel reinforced concrete,
typically between 100 and 500 millimetres thick, are most often used to construct floors and
ceilings, while thinner slabs are also used for exterior paving.

3. A.Arun, V. Sreevidya, T.P.A.Aravind (2016)

Concrete is most frequently used composite material. Concrete is the combination of M-
Sand, coarse aggregate and binding medium of concrete paste. Next to the water demand
which is increased in concrete day by day, in this project we incorporate Activated
carbon in Filler slabs. Filler slab is the sustainable concept which reduces unwanted
concrete in the tension zone. The main perspective of this project is to study the characteristic

behaviour of concrete with activated carbon. Also, to maximize the rate of Compressive
strength of the concrete and to Filter air pollutants and to investigate the flexural behaviour of
filler slab with activated carbon. Filler slab with Activated carbon in cement greatly increases
the sustainability.
Compression test and Flexural test were carried out by three different proportion of Activated
carbon in cement from these mixes results are obtained. Further morphological arrangements
are to be carried out.
Filler slab is other stand-in slab establishment technology where a part of concrete in base of
slab is supplanted by filler substance. the following results were obtained from the
Compression test Flexural load test of cube and prism. From the above test results, it ensured
that 3% of activated carbon is the exact proportion that is to be replaced from cement.
Cement is replaced with Activated carbon from 3% is the proportion. Also, from the above
investigation the result proves that the Compressive strength and Flexural strength of the filer
slab in tension zone is increased. This gives scope for further investigation of testing this
project by casting the filler.

4 M.Ranjitham, N.V.Manjunath2 and S.Dhivyabharathi3(2016)

ompare to other load bearing structures, Slab is one of the prevalent intense concrete members
to carrying a dead load. The essential part of the building is a slab and it should be profitably
anticipated and utilized. While constructing the slabrequires additional concrete. During the
constructing of slab the co2 emission is elevated and its leads to global warming. The average
minimum cost per square foot of a concrete slab is Rs -140, While transferring the load from
slab to beam and then column load mechanism is purely based on type of slab and the load can
be transfer to beam either in one or two direction .The entire construction weight and cost
saving is also elevated by reducing the dead weight of the slab. Nowadays in many engineering
projects around the world bubble deck slab is one of the recently developed prefabricated for
construction technology. Steel balls or hollow balls can be used in normal slab can be called as
bubble deck slab willreduced the dead weight of the slab and also removed the concrete part
where the shear will be minimum or zero.
0.750m x 0.750m x 0.2mm. size of the slab is casted. Four different type of specimens were
casted, first two one was a conventional one-way R.C slab and other two one was one-way
Bubble deck slab. The size of both slabs is the slab was simply supported at two sides which
had a hinge support at one end and roller support at other end of slab.Specimens were tested in
Test Frame by applying uniformly distributed load over the top portion of slab. The maximum
capacity of hydraulic jack is 500KN. In both the Conventional slab and Bubble deck slab
deflections were measured at mid span and strain was measured using strain gauge. The load
was increased regularly at increments of 10KN to confirmation the deflection up to failure.
By reducing the weight of the bubble deck technology called asEnvironmentally green and
sustainable.5% Weight reduction is analysed in bubble deck slab.Flexural strength of the
bubble deck slab has been analysed.The elastic property of the bubble deck slab has
increased.By using bubbles in slab concrete volume indirectly reduced on the beamand walls
also decreased in the building foundations is designed for smaller dead loads.It is concluded
that Load, deflection and weight parameters gives betterresult for bubble deck slab as
compared to conventional slab.Both in numerical and experimental results bubble deck slab
shows a high load bearing capacity.

5 Mr. Muhammad sshafiq mushfiq,(2016)

Bubble deck, which is another name for slabswhose core is embedded with spherical balls that
can be of various shapes and sizes is a technology that is currently gaining awareness around
the world as a result of its tremendous positive effects on an entire structure; this include its
light weight, economy and flexibility in terms of slab span. This research work focused on the
use of bubble deck in construction. M30 Grade of concrete was used. Three slabs were casted,
two with spherical bubbles and the other without bubbles. The slab without bubbles
(conventional slab) was casted with (183.35 kg) of concrete. In The slabs with bubbles, one has
spherical balls of size 90 mm in which (164 kg) of concrete was used and the other has
spherical balls of size 120mm in which (151.54 kg) of concrete was used and B/H ratios of
0.60 & 0.80 having 35 and 16 spherical balls respectively. Experimental tests results indicate
that the conventional slab carried a load of 424.95KN and cause 12.1 mm deflection with crack
occurring after a load of 164KN. The bubble deck slab with B/H ratio 0.60, carried load of 350
KN and cause 12.64 mm deflection with crack occurring after a load of 168 KN. The last
Bubble Deck slab with B/H ratio 0.80, carried a load of 398.2KN and causes 13.3mm
deflection with crack occurring after a load of 300KN. A total of 10.55% of concrete was
saved in the first Bubble Deck slab and 17% of concrete saved in the second one.

6 .Rittik Bhowmik, Sourish Mukherjee, Aparna Das(2017)

The aim of this paper is to discuss about various significance of Bubble Deck Slab against
Conventional Slab based on the various studies. Reinforced concrete slabs are one of the most
common components in modern building construction consuming most of the concrete. Due to
the sheer amount of concrete required to produce these slabs, the dead weight of them tend to
be very large.Concrete usage is significantly reduced; 1kg of recycled plastic replaces 100kg of
concrete. It is, therefore, environmentally friendly. The overall result is a significant cost
saving of usingconventional slabs. te construction time can be shortened since Bubble Deck
slabs can be precast. Quicker casting time as there is much lesser concrete content in the
According to Bubble Deck Company, 1 kg of recycled plasticreplaces 100 kg of concrete.
By using less concrete, designers can save up to 40% on embodied carbon in the slab.
Additionally, the HDPE bubbles can be reused for other projects, or can be recycled.

7. By Ayush Srivastav(2014)
As a whole, the housing shortage of the country can be overcome within lesser funds, without
compromising with the quality control and structural stability of the structure In my work I
have used filler-slab technology. Filler-slab technology is nothing but an alternative of R.C.C.
slab. On comparison of data in the above two table (cost approximation of walls only), it can
be calculated that about 24% of the cost is lesser in Rat-trap bond masonry work as compared
to that of solid English bond masonry work whereas when all other technologies are also
combined, the overall saving increases upto 30-35%.
about 30-35% of the total cost of construction of a single or two storied building can be saved
without compromising its quality control and structural stability. Although, there is reduction in
the use of costly building materials, the used materials are compiled in such a way that the
structural strength and its durability increase as compared to the conventional building
construction technologies. We have converted the tension members to the compression
members which themselves are highly stable. The total cost of construction of a building can be
broken into two parts, i.e., material cost which is 70% of the total cost and labour cost which
comprises the remaining 30% of the total cost. By effective use of all the above mentioned
technologies, we make a huge savings in the material cost. Even though the labour component
increases slightly but then too about 25-30% of the total cost is saved, keeping in concern the
structural stability and quality control of the structure.

8. A. churakov(2016)
The invention of a new type of hollow core slabs was a breakthrough at the turn of 20th and
21" centuries. During the first decade there have been many studies on the feasibility of using
the new technology- This article presents the different types of hollow core slabs technology
that have appeared over the last 15 years. As a result of the review the advantages of a new
kind of hollow slab over a solid slab were summed up. In this article the most famous of
present examples of the new technology are also demonstrated. All the experiments and studies
carried out, mainly by manufacturer companies, are supported by regulations and
local/international codes. Use of recycled plastics and filler materials can reduces the amount
of concrete used. Reducing material consumption made it possible to make the construction
time faster, to reduce the overall costs
According to the analysis such conclusion can be drawn:
1. Due to the fact, that the structural behavior of this new kind of monolithic flat slab is the
same as for solid slab, excluding slab-edge column connection, we surely can talk about
appropriateness of use and advantages of the new technology.
 2. Concrete usage is reduced - 1 kg of recycled plastic replaces 100 kg of concrete. Reducing
material consumption made it possible to make the construction time faster, to reduce the
overall costs. Besides that, it has led to reduce dead weight up to 50%, which allow creating
foundation sizes smaller.
3. The technology is environmentally green and sustainable. Avoiding the cement production
allows toreduce global CO, emissions. The use of the BubbleDeck system qualifies for LEED
points in North America.
4. This technology is very prospective in modern construction and perhaps future of civil
engineering belongs to this new kind of hollow slab.

9.Harshit Varshney1, Nitish Jauhari2, Himanshu Bhatt3 (2017)

Concrete slab is the most important component of any building structure. Slab provides great
thermal comfort and great lifestyle for human beings. Concrete slab consumes more concrete
in the casting for providing flooring and roofing. Concrete is heavy in weight and more than
5% of CO2 is created during the manufacturing of cement that goes into it. In this paper we
studied that reduction of concrete in slab may be suitable and useful for making
lightweight and most effective concrete slab after using High density polyethylene hollow
spheres.Bubble deck reduces up to 35% of the structural concrete in slab and upto 20%
reduction in other structural members due to this. This method is effective in time saving, use
of Bubble deck means floor cycles up to 20% faster than traditional construction methods.
Bubble deck system makes the slab lighter in weight, this reduction in weight reduces some
column and beam ie. equal to the time saving. There are also a number of green attributes
including; use of recycled materials, lower energy consumption, reduction in total
construction materials, reduced CO2 emissions, less transportation and crane lifts that make
Bubble deck more environmentally friendly than other concrete construction techniques. This
study firstly invented by Jorgen Bruenig in 90’s who developed the first biaxial slab in
Denmark. The bubble deck is also known as voided slab. It is a new technique of construction
using recycled spherical balls in slab to reduce the self- weight of the structure. Use of
spherical balls to fill the voids in the middle of a slab eliminates 35% of a slab self-weight
compared
10. Ali Haider Jasvi1 , D.K. Bera(2015)
Basic need of man in today’s world is food, clothing and shelter. House construction is a dream
for low income people in our India. Whether he is a farmer, labour or private employee. Cost
of construction is at high because of high wages andhigh material cost. A poor man has to
spend his entire life in construction a house [1]. Low cost housing is reasonable for low income
owners, if they can invest 30% of their household income. India as a developing country, has
20% of high income population that can afford a house [2]. High and middle income people
takeover most of the low income housing [3]. There is a need of cost effective construction
technology and materials. A low cost housing doesn’t mean to sacrifice with strength or build
with operational materials but it means effective use of local materials and techniques that
aredurable and require less maintenance. Low cost material reduce the cost by using alternative
techniques [2].India’s urban population is the second largest in the world. The country needs a
plan for land acquision and rapid construction. 40–45% is slum population which is growing
day by day [4]. Current shortage of 17.6 million houses is being faced by India [5]. Mumbai is
the largest populated city of India having a population of 16 million according to 2011 census
which has seen an increment of 15.98% from 2001 census [6].India’s population grows by
1.3% per annum which is amain problem as 37% of population is below poverty line [7]. A
need of using low cost and easily available materials and technology. Shortage of 17.6 million
houses generates the usage of local available and natural materials in rural and urban India.
According to World Bank the rural and urban population of India in 2013 is 67.97% and
32.02% respectively.

11. Jaisingh(2014)

In this context, utilisation of this waste material in building construction will go a long way in
solving developed at the Central Building Research its disposal problem.Towards this end, a

technology has been Institute (CBRI), Roorkee, India, to construct reinforced floor/roof slab
with nonautoclaved cellular concrete filler blocks cast with flyash, lime, cement and a foaming
agent Room size filler slabs were tested for their structural and functional performance at
CBRI.
Flyash is a major industrial waste which pollutes the atmosphere. The thermal plants inIndia
will generate about 100 million tonnes of flyash per year by the turn of the century.Acres of
usable land are wasted for dumping of ash. Transportation poses handlingproblems; besides,
the proposition is uneconomical. In this context, utilisation of this waste material in building
construction will go a long way in solving its disposal problem.Towards this end, a technology
has been developed at the Central Building ResearchInstitute (CBRI), Roorkee, India, to
construct reinforced floor/roof slab with nonautoclaved cellular concrete filler blocks cast with
flyash, lime,cement and a foamingagent. Autoclaved cellular concrete blocks are being used in
the building industry to someextent in India. But as they require autoclaving for the production,
they are costly. Hence non-autoclaved units have been developed with a suitable proportion of
the constituents.The blocks are of size 260 x 560 mm, tapering down to 250 x 550 mm and are
110 mm thick.The floor/roof slab is cast with cement concrete of grade Ml 5 with these blocks
as fillers.Reinforcement bars are provided in two perpendicular directions in the space between
theblocks.

12 Nilanjan Sengupta;(2018)
Concentration of greenhouse gases play major role in raising the earth’s temperature. Carbon
dioxide, produced from burning of fossil fuels, is the principle greenhouse gas and efforts are
being made at international level to reduce its emission through adoption of energy-efficient
technologies. The UN Conference on Environment and Development, 1992 made a significant
development in this field by initiating the discussion on sustainable development under the
Agenda 21. Cost-effective construction technologies can bring down the embodied energy
level associated with production of building materials by lowering use of energy-consuming
materials. This embodied energy is a crucial factor for sustainable construction practices and
effective reduction of the same would contribute in mitigating global warming. The cost-
effective construction technologies would emerge as the most acceptable case of sustainable

technologies in India both in terms of cost and environment.

Now it is the task of scientists, engineers and policy mak-ers of our country to popularize the
technology, so that aaemission from its huge and rapidly growing construction sector. Most
Government Bodies and Municipalities in India are reluctant to accept this technology and give
permission to people to build their house with cost effective technology (CET). The following
steps may be taken to ensure proper and extensive use of CET in the light of sustainable
develop-ment and protection of the environment.

13. Neeraj Tiwari, Sana Zafer (2016)

The Bubble Deck slab is a newly designed biaxial concrete floor slab system. High density
polythene (HDPE) hollow spheres are placed in the center of slab by replacing the ineffective
concrete its decreases the dead weight so increases the efficiency of floor. It have many
advantages over normal solid conventional concrete slabs it decreases the cost and reduces
material used and also enhances the structural efficiency of the slab it decreases the time of
concentration and is a green technology. Through the test performed on models, Bubble deck
was proved as better slab in comparison to solid concrete slab. The reduced dead load gives
better response and more economical for the structure while offsetting the slight increase in
deflection of slab. The punching shear & shear resistance of bubble deck floor is low in
comparison to conventional solid slab since it is directly related to depth of concrete. for
reduction of these differences in strength, the reduction factors have been suggested.
BubbleDeck performs better than normal conventional solid slabs. The internal forces &
maximum stresses in the voided deck were upto 40% lesser than solid slab due to reduced
dead weight by use of HDPE spheres. The deflection was little greater by 10% since the
stiffness reduces from presence of bubbles. These results says that this type of slab will
provide better long durable floor slab with better long term result under a dominant gravity
and uniform load.

14. Saifee bhagataar(2010,2016)

In this paper various parameters of the voided and solid flat plate slabs is calculated to
comparethe both systems.The use of flat plate slab is gaining much popularity amongst
architects, because the flat plate slab system provides a way for the architect to achieve the
concept of high and completely flat ceiling with no beam.
As we know that, slab is one of the largest members consuming concrete, when the load acting
on the slab is large or clear span between columns is more, the slab thickness is on increasing.
It leads to consume more material such as concrete and steel, due to that self-weight of slab is
increase. To avoid these disadvantages various studies carried out and researchers suggest
voided flat plate slab system to reduce the self-weight of the slab. In this paper various
parameters of the voided and solid flat plate slabs is calculated to compare the both systems.
To evaluate the performance of the R.C.C voided and solid flat plate slabs, modelling of slabs
is carried out using SAP 2000 having span ranging from 6x6 m to 14x14 m of 4x4 bay in both
direction with thickness of the slabs 280 to 600 mm. The results drawn from the SAP 2000 are
Reaction, Deflection, Moment and Reinforcement required for the voided and solid flat plate
slabs.

15. hagyashri G. Bhade1 and S.M Barelikar2(2016)

Bubble deck slab is a method of virtually eliminating all concrete from the middle of a floor
slab, which is not performing any structural function, thereby dramatically reducing structural
dead weight. High density polyethylene hollow spheres replace the in-effective concrete in the
centre of the slab, thus decreasing the dead weight and increasing the efficiency of the floor.
The advantages are less energy consumption - both in production, transport and carrying out,
less emission - exhaust gases from production and transport, especially CO2 and reduce the
material, the load, lower the cost and it is also a green technology.In the bubble deck
technology reduce the concrete volume by replacing the spherical bubbles, these are locally
available which is called as PEPSI balls, these balls are made up of HDPE (High Density
polyethylene). In this experimental program conventional slab and bubble deck slab are cast
with various bubbles arrangement which is continuousarrangement of bubbles within whole
slab and two types of alternative bubbles arrangement in the slab. And trying to enhance the
increasing strength of that slab. In building constructions, the slab is a very important structural
member to make a space and it is one of the largest member consuming concrete. A slab being
 Review of Literature

the essential part of the structure has to be effectively designed and utilized. It tends to use
more concrete than requirement, hence has to be optimized. When the load acting on the slab
is large or clear span between columns is more, the deflection of the slab is also more.
Therefore the slab thickness is on increasing. Increasing the slab thickness makes the slabs
heavier because of self-weight of slab also increase, and will increase column and
foundations size. Thus, it makes buildings consuming more materials such as concrete and
steel reinforcement.The new prefabricated construction technology using Bubble Deck slab is
recently applied in many industrial projects in the world. Bubble Deck slab uses hollow balls
made by recycled plastic and therefore it is an innovatory method of eliminating the concrete
part in the middle of conventional slab which doesnot contribute to the structural
performance. Bubble Deck is a two-way spanning hollow deck in which recycled plastic
bubbles serve the purpose of eliminating non-structural concrete, thereby reducing structural
dead weight, void formers in the middle of a flat slab eliminates 25% of a slabs selfweight.

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 CHAPTER 3

MATERIAL AND METHOD

 Material and Method

Chapter3

Material and Method

As we all know, for simply supported RCC slab or any flexural member for
that matter, lower part of the neutral axis experiences tensile forces and we have
compression on top of the neutral axis. We also know that concrete is not great
in tension and rebars take the entire tensional forces. In fact, we could have
removed the concrete while placing had it been not fluid. However, concrete is
fluid in nature and we cannot replace it with out an effective means. Filler
material act as a means that help us to remove this concrete from the bottom face
of the slab where only rebar is needed. Please note that we will need adequate
cover to the rebars and stringent quality control needs to be adopted during the
design and construction stage to ensure proper binding of bars, holding of bars
thereby ensuring that strength, serviceability and durability is not compromised
in any manner.
Even the sleeve provision in beams are based on the same priciple of avoiding
compressive zones for its provision.election criteria of filler materials and
generally used filler materials Filler materials should be non-reactive to cement
and water and other materials used like rebars.The filler dimensions, size and
shape have to suit with the reinforcement spacing. This shall be well coordinated
between all stake holders like client, Architect and Structural Engineer. Any
last-minute realization can in fact encourage a compromise and you end up with
corroded rebars and leaks after a few years. Its mandatory to ensure the water
absorbed by the filler is minimal and better to check this before construction.
• Local materials to be chosen to keep the costs in control.
• Light weigh materials to be preferred
Ceiling patterns and the functional use of the room also decides the material
selection. For example, we cannot propose a computer keyboard in a dinning
room. However a keyboard as filler perfectly suits a media room.

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 Material and Method

Filler materials that’s are use in filler sab

 Mangalore tiles
 Clay pans
 Bricks
 Waste bottles
 Coconut shells
 Thermocol
 Cyber wastes like keyboard
 Stabilized mud Blocks
 Terracotta tiles

Here we use coconut shell as a filler material

Coconut Shell –
Coconut shells were collected from Palakkad, Kerala, India. Some of the
coconutshells have a small hole at its crown part, and some are without a hole.
The thicknessof shells varies from 2 to 4 mm, height 50 to 70 mm, and diameter
70 to 110 mm.Shells were dried in the sunlight to remove moisture from it.

Coconut Shell
Coconut shells were collected from
Palakkad, Kerala, India. Some of the coconut
shells have a small hole at its crown part,
and some are without a hole. The thickness
of shells varies from 2 to 4 mm, height 50 to
70 mm, and diameter 70 to 110 mm.
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 Material and Method

Shells were dried in the sunlight to remove

moisture from
Coconut Shell
Coconut shells were collected from
Palakkad, Kerala, India. Some of the coconut
shells have a small hole at its crown part,
and some are without a hole. The thickness
of shells varies from 2 to 4 mm, height 50 to
70 mm, and diameter 70 to 110 mm.
Shells were dried in the sunlight to remove
moisture from
S..No. Property Value(%) References
1 Impact value 9.01 IS: 5640–
1970[14]
2 Crusing value 2.76 IS: 2386 PartIV–
1963 [15]
3 Abration value 1.50 IS: 2386 PartIV–
1963 [15]

Physical and Mechanical Properties - Important properties like moisture

content and water absorption tests were conductedto know the physical
properties of the coconut shell. As there are no separate testprocedures for
coconut shells to find the

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 Material and Method

above properties, the shells were crushed into small pieces of size 2–10 mm.
Then the standard procedures available to testcoarse aggregate were used. The
moisture content came out to be 3.92% as per IS:2386 Part III–1963 [13] and
water absorption was 19.87%.The mechanical properties of coconut shells, like
impact, crushing, and abrasionvalues, were found to measure the resistance of
shell toward impact loads, graduallyapplied load and wear, respectively. The
values are tabulated in the following Table 1.

Compressive strength properties-

the shell is tested under the universal testing machine (UTM) with different
orien-tations to know the maximum load taken by the shell and to study the
failure patternof the shell. The different orientations of the shell are shown in
Fig. 1.After a number of trials, it is observed that the coconut shell (with hole-
crown up),i.e., CSHU will take a load of about 7 kN. The load taken by shells in
their differentorientations is shown in Table 2. The failure of a coconut shell
with a hole (Fig. 2)issafe as the crack will extend up to the hole and it stops. As
there is no material at thehole the load will not pass through the other half shell.

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 Material and Method
The failure of coconut shellwithout a hole occurs at the crown part and the
failure will be sudden

Plain Concrete- Anormal M25 mix has been used to cast all concrete cubes.
Based on specific gravity,water absorption, the total moisture content of coarse
and fine aggregates, and byconsidering mild exposure conditions, the proportion
of mix was 1:1.821:2.766 asper IS: 10262–2009 [16]. Ordinary Portland Cement
of 43 grade, river sand, andmined quarry coarse aggregates were used in casting
cubes. The concrete cubes of 150 mm ×150 mm ×150 mm were cast with a
nominal cover of 25 mm for concrete infilled shells and no cover for hollow
shells.

Schematic Design
BubbleDeck is intended to be a flat, two-way spanning slab supported directly
by columns. The design of this system is generally regulated by the allowed
maximum deflection during service loading. The dimensions are controlled by
the span (L) to effective depth (d) ratio (L/d) as stated by BS8 110 or EC2. This
criterion can be modified by applying a factor of 1.5 that takes into account the
significantly decreased dead weight of the BubbleDeck slab as compared to a
solid concrete slab. In addition, larger spans can be achieved with the use of
post- tensioning as the L/d ratio can be increased up to 30%. (BubbleDeck*-UK)
L/d < 30 for simply supported, single spans
L/d < 41 for continuously supported, multiple spans
L/d < 10.5 for cantilevers
There are five standard thicknesses for BubbleDeck, which vary from 230 mm
to 450
mm, and up to 510 mm and 600 mm for specific designs pending KOMO
certification.
varieties of BubbleDeck can be found in Table 3-1.
Table 3-1: Versions of BubbleDeck* (The Biaxial Hollow deck- The way to
new solutions)

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 Material and Method
Version C
Diameter (fm). Th %im u Cee pacing mm)
BD230 180 230 200
BD280 225 280 250
BD340 270 340 300
BD390 315 390 350
BD450 360 450 400
BD510 405 510 450
BD600 450 600 500

Types of BubbleDeck

All of the BubbleDeck versions come in three forms- filigree elements, reinforcement
modules, and finished planks. They are depicted in Figure 3-2. For all types of
BubbleDeck, the maximum element size for transportation reasons is 3 m. Once the
sections are connected on site however, there is no difference in the capacity.
Type A- Filigree Elements
BubbleDeck Type A is a combination of constructed and unconstructed elements. A 60
mm thick concrete layer that acts as both the formwork and part of the finished depth
is precast and brought on site with the bubbles and steel reinforcement unattached. The
bubbles are then supported by temporary stands on top of the precast layer and held in
place by a honeycomb of interconnected steel mesh. Additional steel may be inserted
according to the reinforcement requirements of the design. The full depth of the slab is
reached by common concreting techniques and finished as necessary. This type of
BubbleDeck is optimal for new construction projects where the designer can determine
the bubble positions and steel mesh layout.
Type B- Reinforcement Modules
BubbleDeck Type B is a reinforcement module that consists of a pre-assembled
sandwich of steel mesh and plastic bubbles, or "bubble lattice". These components are
brought to the site, laid on traditional formwork, connected with any additional
reinforcement, and then concreted in place by traditional methods. This category of
BubbleDeck is optimal for construction areas with tight spaces since these modules can

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 Material and Method
be stacked on top of one another for storage until needed.

Type C- Finished Planks

BubbleDeck Type C is a shop-fabricated module that includes the plastic spheres,
reinforcement mesh and concrete in its finished form. The module is manufactured to
the final
depth in the form of a plank and is delivered on site. Unlike Type A and B, it is a one-way
spanning design that requires the use of support beams or load bearing walls. This
class of
BubbleDeck is best for shorter spans and limited construction schedules (BubbleDeck*-UK).

Figure 3-2: Three Types of BubbleDeck- Type A, B, & C (BjOrnson)

Advantages of BubbleDeck

Material and Weight Reduction

The dominant advantage of a BubbleDeck slab is that it uses 30-50% less concrete
than
normal solid slabs. The HDPE bubbles replace the non-effective concrete in the center
of the
section, thus reducing the dead load of the structure by removing unused, heavy
material.
Decreased concrete material and weight also leads to less structural steel since the
need for
reinforcement diminishes. The building foundations can be designed for smaller dead
loads as
well. Overall, due to the lighter floor slabs, the several downstream components can be
engineered for lower loads and thus save additional material (Wrap).
Structural Properties
Due to the lower dead weight of the slab and its two-way spanning action, load-bearing
walls become unnecessary. BubbleDeck is also designed as a flat slab, which eliminates the
need for support beams and girder members. As a result, these features decrease some of the

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 Material and Method
structural requirements for the columns and foundations.
Additionally, BubbleDeck slabs can be designed and analyzed as a standard concrete flat
slab according to research performed on its strength and ductility, which will be discussed in
depth later in the report. As summarized by Table 3-2, the dead load-to-carrying capacity of a
solid slab is 3:1 while a BubbleDeck of the same thickness has a 1:1 dead load-to-carrying
capacity ratio (Wrap).
Construction and Time Savings
On site construction time can be shortened since BubbleDeck slabs can be precast. Type
A includes a 60 mm precast concrete plate as the base and formwork for the slab. This type of
slab would eliminate the need for on site erection of formwork, thus significantly cutting
down construction time. Similar to modem precast concrete flooring modules, BubbleDeck
can be fully shop fabricated and transported on site for installation as well. Figure 3-3 is an
example of how BubbleDeck* sections can be lifted into place at the construction site.
Time savings can also be achieved through the faster erection of walls, columns and
MEPs due to the lack of support beams and load bearing walls for this innovative flat slab.
Addition time may be saved from the quicker curing time since there is less concrete in the
slab.
Cost Savings
In relation to the savings in material and time, cost reductions are also typical with the
BubbleDeck system. The decreased weight and materials mean lower transportation costs, and
would by more economical to lift the components. With less on-site construction from the full
and semi-precast modules, labor costs will decrease as well. In addition, money can be saved
downstream in the design and construction of the building frame elements (columns and
walls)

for lower loads. There is a slight rise in production costs for the BubbleDeck slab due to the
manufacturing and assembly of the HDPE spheres. However, the other savings in material,
time, transportation and labor will offset this manufacturing price increase (Stubbs).

Green Design
The number of owners, designers and engineers who desire green alternatives is growing
exponentially. BubbleDeck is a fitting solution for lowering the embodied carbon in new

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 Material and Method
buildings. According to the BubbleDeck* company, 1 kg of recycled plastic replaces 100 kg
of
concrete. By using less concrete, designers can save up to 40% on embodied carbon in the
slab,
resulting in significant savings downstream in the design of other structural members. Carbon
emissions from transportation and equipment usage will also decrease with the use of fewer
materials. Additionally, the HDPE bubbles can be salvaged and reused for other projects, or
can
be recycled.
[00:12, 13/01/2023] Sameer Sahu: Generally, for every 5,000 m2 of BubbleDeck floor slab,
the owner can save:
- 1,000 m2 of on-site concrete
e 166 concrete truck trips
e 1,798 tonnes of foundation load, or 19 less piles
e 1,745 GJ of energy used in concrete production and transportation
- 278 tonnes of CO2 emissions (BubbleDeck*-UK)

Filler Slab planning and Casting

Filler slabs are as normal slabs, cast in site. Formwork is laid and the rebars that are
designed are laid. Generally, a max allowable spacing of 3d or 300 is adopted.
Minimum needed steel is also needed to be provided as per codes. If a better-
quality control can be provided and if crack widths can be checked by design, we
can adopt wider spacings than 3d or 300. This may be needed if the size of the
material demands more spacing than 300.

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 Material and Method

Note that if the filler material is some thing that absorbs water, it should be soaked
in water to ensure that while construction, it don’t absorb water from the concrete.

MATERIALS USED

MATERIALS SPECIFICATION

Cement ppc of grade 43

Sand M sand
Coaese Gravel 20mm
aggregâte Technical Campus nominal size
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Fe 415 of 10mm@
Coconut Sell 70mm dia (avg.)
 CHAPTER 4

RESULTSAND DISCUSSION
 Result and Discussion

Chapter4

4. Results and Discussion

Rebound Hammer -Test -Rebound hammer test, a non-destructive test was done as per the
standard procedurespecified in IS: 13311 (Part 2)–1992. The compressive strength of
concrete cubes wasmeasured from the rebound number. The calibration chart given by the
equipmentmanufacturer was used to measure the compressive strength.

Fig. 3 a CS crown down in bottom portion of cube (DB) (CS infilled with concrete). bCS crowndown in top
portion of cube (DT) (CS infilled with concrete or hollow CS). cCScrownupinbottomportion of cube (UB) (CS
infilled with concrete or hollow CS). dCS crown up in top portion ofcube (UT) (CS infilled with concrete

From the above results, it can be seen that the cubes in which shell was in thebottom portion
shown high compressive strength. The hollow shells and shells infilledwith concrete gave
almost the same strength. But, the failure pattern of differentconcrete cubes was not known
with a rebound hammer test. To observe this and tofind the reason behind the strength,
compression tests were performed.

Compressive Strength Tests - Figure 4shows the 7-day compressive strength and Fig.
5shows the 28-day compres-sive strength of different specimens as specified in Table 3.
From the above compar-ison charts, it can be clearly seen that the specimen with crown up
shell at. Its bottem.

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 Result and Discussion

Fig.4 Compressive strength of different specimens (7 days cured)

Fig 5-Compressive strength of different specimens (28 days cured)

portion provided higher compressive strength. The infilled shell concrete cubes didnot show
much good results than the hollow shell concrete cube. While testing,different failure
patterns were observed.While performing the compressive strength test of concrete cubes
having CS, itwas observed that the shell took the load which was transferred from concrete
to CSafter the formation of the first crack. As discussed earlier in Sect. 2.1.2, the
concreteshell can withstand up to a load of around 7 kN. It can be observed clearly that
dueto the presence of CS, the crack took a path as seen in Fig. 6. This indicates that
theconcrete cubes with CS are satisfying the serviceability criteria.

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 Result and Discussion

Fig. Failure pattern of Slab

Work to be done
➡ Test for cube
➡ Test for cylinder
➡ Experimental investigation for slab
• Flexural test
• Crack Pattern
➡ Comparison between filler slab and conventional slab

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 CHAPTER 5

SUMMARY AND
CONCLUSION
 Summary and Conclusion

Chapter 5

Summary-The BubbleDeck slab is a revolutionary biaxial concrete floor system developed in

Europe. High-density polyethylene hollow spheres replace the ineffective concrete in the center
of the slab, thus decreasing the dead weight and increasing the efficiency of the floor. These
biaxial slabs have many advantages over a conventional solid concrete slab: lower total cost,
reduced material use, enhanced structural efficiency, decreased construction time, and is a
green technology.
Through tests, models and analysis from a variety of institutions, BubbleDeck® was
proven to be superior to the traditional solid concrete slab. The reduced dead load makes the
long-term response more economical for the building while offsetting the slightly increased
deflection of the slab. However, the shear and punching shear resistance of the BubbleDeck
floor is significantly less than a solid deck since resistance is directly related to the depth of
concrete. Design reduction factors have been suggested to compensate for these differences in
strength. This system is certified in the Netherlands, the United Kingdom, Denmark and
Germany.
In this investigation, after verifying the validity of the prior research through a finite
element analysis of an office floor in SAP2000, the BubbleDeck® slab was tested for a
pedestrian bridge deck. Bridge design is dominated by the dead weight of the structure and by
concentrated stresses from vehicular traffic. This new slab can solve both of these problems by
reducing weight with the plastic spheres and by applying it to a pedestrian bridge to limit the
high stresses.A set of bridge decks were modeled and analyzed in SAP2000 for this study.

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Conclusion-
This investigation has proven that the BubbleDeck* technology is more efficient than a
traditional biaxial concrete slab in an office floor system. The finite element models of the
office
slabs created for this study in SAP2000 verify the prior analysis and experiments. However, the
performance of the voided slab is not as successful in a pedestrian bridge deck. The non-
continuous, simply supported bay layout of this test bridge was not optimal for this system
since
it generated a one-way slab response rather than a biaxial one. This does not discount the use of
BubbleDeck in a bridge deck, but requires further studies on a variety of bridge layouts to fully
determine the feasibility of this slab in a bridge.

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REFERENCES
 References

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 References

1. Deepika Dinesh, Akhil P.A (2018) "Study on Flexural Behaviour of RCC Slab

Filled with Hollow Roofing Tiles" International Journal of Engineering and

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4. M ranjitham (2014) "numerical and experimental on bubble deck slab with M-

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5. Mr. Muhammad Shafiq Mushfiq, Shikha Saini, Nishant (2016) "Experimental

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andTechnology (IRJET), 4(5),1000-1004

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Volume 2, Issue 6

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 References

Harshit varshneyl,nitish jauhari,himanshu bhatt (2017). Review of bubble deck slab

9. Intertional journal of civil engineering and technology(IJRASET)5(10),2136-2139

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india”,Intertional journal of civil engineering and technology,04(13),534-544

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Journal of Civil Engineering and Technology 9(7), 1000-1011

13. .Neeraj tiwari ,sana zafer(2016)structural behavior of bubble deck slab and its

applications.IJSRD Intertional journal of scientific research and development.

Vol.4,issue 2

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bubble deck slab with spherical hollow balls. Intertional journal of recent

scientific research vol.7,issue 6

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ANNEXURE
 Annexure

Publication Details: