1.

Filler Slab
1.1 What is filler slab
Filler slab is an alternate slab construction technology where part of concrete in the bottom of slab is
replaced by filler material, which may be terracotta pots, Mangalore tiles, Broken pieces of cement
blocks, coconut shells, glass bottles etc. in a filler slab, part of concrete in the bottom of the slab (in the
tension zone to be specific) is replaced by filler materials. The reinforcements are laid in a grid pattern
and the filler material is arranged in between. Provision for electrical points is provided wherever
required followed by concreting. Proper curing is required for a period of 21 days before removing the
shuttering. It should be noted that 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.

1.2 Advantages of Filler Slabs

● Due to the replacement of non-functional cement concrete with lighter filler materials, dead
load of the slab is reduced considerably. And this helps in reducing the foundation size, steel
required in structural members. The reduction in weight as much as 20 to 30%. Many fail to
note a very important point that reduction of dead weight has a very compounding positive
effect. When the dead weight is reduced the seismic demand is also reduced. Note that seismic
force is nothing but inertia.
● It is cost effective at least by 20% compared to the conventional RCC slab due to the usage of
less costly filler materials and decreased amount of steel and concrete.
● Filler slabs does not compromise on the strength or durability if designed and constructed with
stringent quality control.
● Filler slabs creates comfortable temperature conditions inside the living rooms as the air
pockets between the filler materials has heat resistant property. The thermal comfort provided
by filler slabs makes it an excellent option in humid hot climatic conditions.
● When materials like cyber wastes like key boards, waste plastic substances especially bottles
are used as fillers, this method by default does a waste management as the otherwise harmful
substances to the soil and earth are being reused.
● Filler slab reduces the carbon footprint of a building by around 20%.
● Correctly chosen patterns in the filler slabs increases the aesthetics of the ceiling.
1.3 Disadvantages of Filler slabs
 ● The filler slab technology needs some experience. Unless we have people, who have built a few
similar homes, there are chances that you mess up in its construction
● The rebars can corrode if it comes in contact with clay products that are used as fillers. Enough
care should be taken to ensure sufficient cover to reinforcement.
● For the same reasons above, the slopes at the terrace have to be meticulously planned and all
the rain water down pipes has to be clog free. Enough care to be taken to ensure maintenance
of terrace.
1.4 Selection 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.
● Lightweight 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 dining room. However, a keyboard as
filler perfectly suits a media room
1.5 Filler materials used
● Mangalore tiles
● Clay pans
● Bricks
● Waste bottles
● Coconut shells
● Thermocol
● Cyber wastes like keyboard
● Stabilized mud Blocks
● Terracotta tiles
2. Composite beam and panel roof

1. Composite beam and panel roof

The cost of a roof/flooring system is significant in the total cost of a building. Developing an
alternative roofing system which is cost effective and energy efficient is always a challenging
task.
Composite beam and panel roof is a system the beams and panels can be prefabricated, and
assembled into a roofing system with minimal formwork without the use of heavy equipment.
Such roofs are lighter and structurally more efficient when compared to solid reinforced
concrete slab roofs/floors.
2. Concept and Details of Composite Beam and Panel Roofs
The roofing system consists of panels and beams cast separately and assembled such that the system
behaves like a T-beam.
Based on the shape/geometry of the panel these types of roofing systems can be broadly grouped into
two categories viz.:
  Flat panel roof
 Curved panel or jack-arch roof

Since the panels and beams are cast separately and then assembled, there should be proper shear
connection between them to achieve composite action for the system to behave as an integral structural
unit.
The flexibility of composite beam and panel roofs arises out of the fact that the materials for the beams
and the panels could be of two different materials, and the composite action between them could be
achieved by proper shear connectors.
In the absence of shear connection the panels will simply sit on the beam and the roofing system will
be structurally inefficient.
Table below gives the typical list of materials/ technologies for the beams and panels. Various
combinations of beams and panels could lead to different types of composite beam and panel roofing
systems.

3. Construction Details and Roof Assembly

Composite beam and panel roof consists of partially cast beams over which the panels are assembled
and then shear connectors are grouted before spreading the screed concrete on top. Thus, the beam
becomes complete after the completion of in-situ concreting/mortaring to bring in the shear connectors
into action. Typical construction sequence involves:
1. Casting of beams and panels and curing
2. Positioning the beams into required spacing and providing temporary props
3. Placing the panels on the beams and mortaring the joints between the panels
4. Grouting the shear connectors jetting out of beams as well as panels
5. Tying nominal shrinkage reinforcement bars and spreading screed concrete
6. Removal of temporary props after curing and finishing
3. Pre-engineered and ready to use building elements.
Pre-engineered buildings are modern adapted systems where the building’s structural members are
manufactured at the factory and assembled at the site. When these buildings are built with great
efficiency, they can be 30% lighter than conventional steel buildings.
Generally, Pre-engineered buildings are steel structures; these are built according to the structure’s exact
requirement, such as its size, height, and width.
Then these built-up sections are transported to the site and assembled with bolted connections. This
type of construction method is widely adopted in industrial buildings, warehouses, Metro Station.
3.1 Components of Pre-engineered buildings

3.2 Basic components

1. Primary Frame
Primary frames consist of trusses, column or castellated beams, etc. these are built up of I-shaped steel
members. All the load of structure members passes to the base and consists of end wall frames.
These end wall frames are either designed with rigid frames or with economic bearing frames. These
frames are reinforced with wind bracing and connecting bolts. Sometimes with anchor bolts.
2. Secondary Elements
Secondary elements are cold-formed structural members, available in different shapes like C, Z, etc.—
commonly known as “Purlins.” For overall structure stability, these purlins transfer force from one
frame to another.
These purlins are resistant to corrosion, robust, lightweight, and they are easy to mount. Purlins come
in various lengths and thicknesses.
3. Roof and Wall Panels
Some of the pre-engineered building components like roof and wall panels come in Tin shades and
curtain walls made of glass and roll-formed steel sheets. Some special roofing sheets are used to
minimize energy usage.
4. Sandwich Panels
These panels are made in three-layer, where one non-aluminum layer is placed in between two
aluminum sheets.

3.3 Details of components

Main Framing or Vertical Columns – The mainframes include steel rigid frames of the building. The
PEB steel rigid frames include tapered columns and tapered rafters. These tapered sections are
fabricated using the state of the art technology while the flanges are welded. The frame is then erected
by bolting the splice plate of the connecting section together.
End Wall Framing – The end wall frame of the prefabricated building is designed as a main rigid
frame. The beam end wall system of framing consists of columns with pinned ends, supporting
horizontal beams as known as end wall rafters.
Purlins, Girts, and Eave Struts – Purlins, girts and eave struts are the secondary cold-formed
members. No welding is involved in this preparation. They are prepared by just bending the steel coil
in order to give it the desired shape.
Sheeting and Insulation – The steel sheets are normally galvanized profile sheets permanently colour
coated, plain or sheets can be coated with special paints for better anti-corrosion properties. These
buildings are properly insulated through insulation slab/rolls and then the roofing steel sheet is fixed
over it.
Crane System – Crane system in industrial buildings is used to improve material handling productivity
allowing more utilisation of space by reducing or eliminating traffic due to forklifts etc. These crane
runway beams are supported by built-up sections with cap channels.
Canopy – The standard PEB Steel canopy consists of built-up tapered canopy rafters that are
cantilevered from the mainframe columns or from the end wall columns, Wall Canopies over Doors,
Shutters and Windows at sidewall or ends walls.
Mezzanine System – The standard mezzanine framing system consists of a steel deck supported by
joists framed into main mezzanine beams. The economy of the mezzanine system s affected by the
applied loads and mezzanine column spacing.
Ventilator – Ventilation is the process of replacing contaminated indoor air with fresh air from outside
the building.
Paints and Finishing – Pre-painted steel is produced on modern, high-speed coil painting lines where
surface preparation prior to painting, paint application & paint curing is done on a highly automated
line under optimum condition.

3.4 Advantages of Pre-Engineered buildings

1. Quality Control
The quality of pre-engineered building materials is easy to manage as they are manufactured in a factory
under controlled conditions.
2. Low Maintenance
The maintenance cost of pre-engineered buildings is significantly less, as they are manufactured with
high-quality paint for steel and cladding.
3. Flexibility Of Expansion
The pre-engineered building has flexible expansion options, which means we can extend a building’s
length, height, and width in the future.
4. Energy Efficient
These buildings can be customized with polyurethane insulated panels or fiberglass blankets to make
them energy efficient.
6. Versatility
The pre-engineered building systems come in various types of fasciae, canopies, and metal wall panels,
designed according to the requirement.
7. Require Less Time to Construct
Construction of a structure using a pre-engineered building method consumes less time than the
conventional method.
3.5 Disadvantages of Pre-engineered Building
1. Insulation Cost
Insulating the whole pre-engineered building can cost you much.
2. Appearance
These buildings are steel structures that are not much attractive as they are left exposed.
3. Prone to Corrosion
As we know, these are steel structures, and they are prone to corrosion if the material or paint used is
not of good quality, which may reduce the life span of the steel structures.
3.6 Application
Pre-engineered buildings can be adapted in different construction.
● Labour Camps
● Office Buildings
● Workshops
● Schools
● Community Centre
● Factories
● House andLiving shelters
● Aircraft Hangers
● Supermarket
● Sports Halls
● Petrol Pumps
● Service Buildings
● Warehouses
3.7 Difference Between Pre-Engineered Building & Conventional Steel Building
4. Wood products
Engineered wood products are considered as best building materials due to environmentally friendly.
Huge change to the way in which wood has been utilized in primary application of construction in the
course of the most recent 25 years are in light of decreased admittance to high strength timber from
growth forests, and the turn of events and creation of various new design of manufactured wood
products. Engineered wood products are available in different variety of sizes and measurements like
laminated veneer lumber, glued laminated timber, finger jointed lumber, oriental strand board etc. It is
utilized for rooftop and floor sheathing, solid structure, beams and the hull of boats.
Engineered wood products (EWPs) are among the most excellent and harmless to the ecosystem
building materials. In manufacture, they are produced efficiently from a renewable resource. In
development, the way that engineered wood products is accessible in wide assortment of sizes and
measurements.
EWPs are chiefly laminated veneer lumber, wood I Beam, glued laminated lumber, cross laminated
timber, finger jointed lumber, oriented strand lumber, oriented stranded board, medium density fiber
board (MDF) and Particle Board (PB).
These EWPs are regularly created from the adhesive bonding of wood chips, pieces or veneers, as well
as the mechanical securing of timber segments to frame bigger segments, beams, boards or other
structural components.
The advantages of EWPs incorporate
● upgraded dimensional stability,
● the development of bigger and more complex structural segments
● decreased impact of common imperfections (for example knots)
● more noteworthy toughness
● more homogenous mechanical properties.
● Engineered wood products are making it conceivable to build taller and bigger wood structures
These properties of wood can be improved through controlled changes, and this is the establishment of
designed wood items. This builds the overall performance of structural wood composites, prompting a
more viable structure material, accordingly growing potential end uses. Engineered wood products have
permitted wood to be utilized in circumstances where solid timber is incapable, prompting specific
items to help a more different exhibit of uses.
4.1 Types of engineered wood product
Glued-laminated lumber (glulam)

Glulam, or glued laminated lumber, is the oldest member of the engineered wood products family and
has revolutionized the structural use of wood. Glulam eliminates the limitations of using solid sawn
timber, including size and deformities like knots and checking. Glulam consists of multiple wood
laminates that are bonded together with glue and pressed with hydraulic equipment for tight bonds.
Softwood lumber is typically used for lamination, and care is taken to ensure that the grain runs parallel
to the longitudinal axis of the glulam member. Glulam can span long distances without intermediate
support and can be curved and shaped to form unique designs. It is often used as straight beams,
columns, curved beams, and roofs. Recently, fiber-reinforced polymers have been included in some
glulam production, enhancing tensile performance and offering economic benefits in certain
applications. Glulam is a sustainable building material made from renewable resources and is sourced
from sustainably managed forests.
Cross laminated timber (CLT)

Mass lumber products, particularly cross-laminated timber (CLT), are gaining popularity in the
construction industry due to their potential to significantly increase the use of wood in construction.
CLT is made by gluing multiple layers of structural grade softwood boards perpendicular to each other,
creating large boards that are being used as floor slabs, load bearing and shear walls. This eco-friendly
product offers high strength and structural simplicity at a lower environmental cost than concrete or
steel. Its versatility is demonstrated by the range of board sizes and thicknesses available, and it can be
tailored to precise measurements to minimize waste. Architects are increasingly using CLT as a load-
bearing component in construction projects such as floors, roofs and walls, and its high strength and
substantial nature make it suitable for use in multistory buildings. CLT offers a green alternative to steel
and cement and provides a cost-effective building material for heavy framework.
Laminated veneer lumber (LVL)

While glulam and CLT boards are contained wooden boards, various engineered wood products are
made with wood veneer. LVL is perhaps the most generally utilized engineered wood products for
constructional applications. It is a composite board made from various thin layers of veneers that are
lined up with the length of the finished lumber. The product was invented in the last part of the 1960’s
and has gotten grounded as a high strength pillar and header segment in both residential con commercial
constructions. Since it is made from veneers, LVL makes up to 35% more powerful utilization of logs
than is conceivable with solid lumber. At fabricate, veneers are dried to 8% moisture content, and
reviewed for uniform strength and width before lay-up. Adhesive is applied and the board is pressed
under heat and consistent pressure until cure (Figure 3). Laminated veneer lumber is planned for use as
high strength, load carrying beams to help the heaviness of development over window and entryway,
and in floor and rooftop frameworks of residential and light commercial wood frame development. It
can give the both boards and beam/column components.
Laminated strand lumber (LSL)

LSL is usually realized Timber strand. As of now, LSL is being made from excess, over develop aspen
trees that normally are not huge, solid, or sufficiently straight to develop conventionally wood products.
In this cycle, the debarked logs are utilized to give the material to chipped strands, which can be up to
300 mm long. These strands are then dried, coated with adhesive, and pressed into huge billets by a
process which incorporates steam injection. The billet might be up to 140 mm thick, 2.4 m wide and
10metres long. Subsequent to sanding, countless sizes are sliced to suit applications like headers, edge
joists for floor frameworks, columns, joists and studs. It is utilized for a wide scope of millwork, like
doors, windows, and practically any item that require high grade lumber. It is additionally utilized for
truck decks, fabricated housing, and some structural lumber such as window and door headers.
Parallel strand lumber (PSL)
PSL, ordinarily known Parallam, is intended to supplant huge dimension lumber (beams, planks, and
posts). Parallel strand lumber was developed in Canada, advanced onto the market in the last part of the
1980’s. PSL comes in numerous thicknesses and widths and is fabricated up to 66 feet in length (Figure
5). The strands are for the most part taken from veneers peeled from the outermost part of the logs,
where more grain is found. Veneers e are dried to 11% moisture content and reviewed for strength prior
to chopping into strands. They are then adjusted parallel to each other, coated with waterproof glue,
then pressed and cured. It is utilized for enormous individuals in residential construction and as middle
and huge individuals in commercial building construction.

Structural plywood
One of the most important well-known building materials constructed with veneer is plywood. It is
handily sourced from everywhere the world and has exhibited fruitful. Plywood is utilized for some
light duty building materials. It is likewise utilized for rooftop and floor sheathing, concrete formwork,
webs of wood beams, and surprisingly the frames of boats. It very well may be utilized to oppose gravity
loads or to oppose horizontal burdens as in plywood diaphragms and shear walls. Plywood is fabricated
from stacked veneers which are organized in an odd number of layers, the grain of the face layers
arranged to the long dimension of the board. The cross-overlaid lay-up of the veneers gives strength,
stiffness and dimensional strength.

Oriented strand board (OSB)

OSB was first produced in Canada in 1964. Since the mid-1980s, OSB has been one of the most
commonly used engineered wood-based panels for structural construction in residential sectors due to
excellent properties, especially due to the increasingly competitive price. OSB is an engineered
structural panel made from strands of wood sliced from small diameter timber logs and bonded together
with an exterior grade adhesive, under heat and pressure. OSB is manufactured in various grades with
improving resistance to the effects of moisture. OSB is extensively used for wall sheathing, floor
underlayment, roof cover and I-joist in both commercial and residential building. OSB also is used in
furniture, reels, trailer liners and recreational vehicle floors.

Wood I beam

Wood I beam are engineered wood products which have great strength in respect to its size and weight.
Wood I beam is a light beam support assembled by gluing together wooden flanges and fiber board and
plywood beams. The flanges of beam made of laminated veneer lumber or finger jointed solid wood
lumber. The web of beam made of plywood, laminated veneer lumber or oriented strand board. Wood
I beam are available up to 80 feet long. It has been used in residential and commercial construction as
floor, rood structure of structure and external wall frames. I beam are best for the structure which
required rigidity, heat insulation and economy. Nowadays, wood based I beams are becoming popular.
Beams allow easy execution of installation penetration. Their ‘I’ configuration provides high strength
and stiffness.
5. Steel and Plastic for sustainable construction

5.1 Steel
Steel is one of the most widely used construction materials, due to its versatility and excellent
mechanical properties. It provides strength and a high loading capacity, while also having flexibility
and ductility. Steel can bend without cracking and can also handle great force without sudden failure,
providing more time to react during emergencies.
In addition to its beneficial properties as a construction material, steel also reduces construction waste.
Once the steel manufacturing process has been completed, it can be recycled continuously without
losing quality. Even when steel production consumes plenty of resources and energy, its durability
minimizes the environmental impact in the long run.
5.2 The Sustainability Benefits of Steel
● Steel is 100% recyclable, and can be recycled multiple times.
● Steel conserves its physical and chemical properties, regardless of how many times it has been
recycled.
● Manufacturing technology in the steel industry is very advanced, allowing a high usage of
recycled content.
● Steel manufacturing consumes less energy when it uses recycled steel.
● Steel has magnetic properties, which simplifies separation from waste with magnetic cranes.
5.3 Making Steel Production More Sustainable
● Steel produced nowadays is 40% stronger than steel from 25 years ago.
● Steel production uses 67% less energy than 35 years ago.
● Greenhouse emissions from steel manufacturing are 45% lower than 40 years ago.
● Water consumption for steel production has been lowered to 70 gallons per ton.
● Water loss has decreased to only 10%, mainly due to evaporation. Wastewater is treated and
returned to the source.
● Steel by-product gases from furnaces can be reused as fuel substitute for electricity generation,
of sold for power generation.
● Electric arc furnaces allow steel production from 100% scrap metal, reducing energy
consumption.
● The steel industry is continuously investing in manufacturing technologies that use greener
fuels, resulting in a greater reduction of CO2 emissions.
5.4 Using Steel for Sustainable Construction
By itself, steel framing provides greater strength than any other construction material. It is also durable,
flexible, ductile, and non-combustible. Therefore, structures made of steel have a very long lifespan,
making them cost-effective and sustainable. Another benefit of steel is having the highest strength-to-
weight ratio of any construction material - steel elements of a given strength will always be smaller and
lighter equivalent elements of other materials. Therefore, steel reduces dead loads and the amount of
material used.
In construction, steel provides other benefits such as the following:
● Steel elements are usually produced offsite, improving waste control.
● In construction and demolition sites, all steel waste can be collected and sold to recycling
facilities.
● Prefabricated steel buildings can be completed very quickly, reducing labor costs.
● Less disruption for the surrounding community.
● Less pollution from heavy machinery and equipment onsite.
● Endless Recyclability
Steel is the most widely recycled material, surpassing paper, aluminum, glass, and plastic
combined. It can be recycled multiple times without compromising strength or durability, and
it can be recycled at any point of its service life, even in small scraps. The magnetic properties
of steel simplify recycling, since it can be easily separated from waste. Steel by-products can
also be recycled and used in concrete, fertilizers, plastics, and paints.
More than 65 million tons of steel scrap are recycled each year, saving landfill space and natural
resources. One ton of recycled steel conserves 2500 pounds or iron ore, 1400 pounds of coal
and 120 pounds of limestone.
● Steel manufacturing brings economic benefits to surrounding communities, which include job
creation and increased tax revenue.
● Job creation for manufacturing personnel, researchers, recyclers, etc.
● The steel industry generates tax revenue for municipalities
● Steel structures can withstand natural disasters with less damage than other buildings
5.5 Plastic
Plastics have become increasingly popular in construction due to many factors, such as their
performance, durability and their ability to be weathering resistant, low maintenance, cost-effective,
lightweight and design flexible. These qualities make plastics ideal products for construction and an
essential component for a sustainable built environment.
Recycling of plastics that have been recycled not only saves energy, but it also saves space in landfills
and reduces costs to an even lower level.
When recycled plastic is blended with virgin plastic, costs can be lowered because there is a lower
amount of brand-new plastic being used and produced. Using recycled plastic can also help save on the
costs of other materials, such as wood and slate.As a low-cost alternative to other materials, this type
of plastic being salvaged has brought new life to many industries and companies around the world.
Examples of how using recycled plastics has changed the way a number of materials are being produced.
Roofing Tiles
A roof is an essential part of a house, so when it comes to home building, there have been many
innovations in roofing methodologies over the years. Using recycled plastics to build roofing tiles is a
great way to resemble other more expensive materials, while providing the same high-quality you can
expect with materials such as slate.
Other undeniable benefits from recycled plastic roofs include:
● Lighter material
● Easier, quicker installation
● Lower carbon footprint
Concrete
Recycled plastics can be used to make stronger concrete structures in the form of sidewalks, driveways
and more. Students at MIT have recently conducted experiments with recycled plastic by exposing
small amounts of it to gamma radiation, mixing it into a powder and then mixing that into cement paste.
Doing so can produce concrete that is up to 15% stronger than regular concrete, allowing this form of
construction to be both longer-lasting and more eco-friendly.
Indoor Insulation
Insulation is another essential factor in homebuilding and buying because it keeps your home’s
temperature regulated all year-round.
Various insulation companies have begun developing insulation with recycled plastic inside of it
because only a minimum amount of plastic will maximize your home’s energy efficiency levels.
Additional benefits for insulation from recycled plastics include:
● Easy installation
● Durability
● Long-term energy savings
Structural Lumber

Using recycled plastic as the main ingredient in structural lumber as an alternative to other
materials such as steel, comes with indisputable advantages.
By using plastic to make lumber instead of wood, you no longer have to spray wood with toxic
preservatives to protect it from aspects such as insects and weather. Rather, the polyethylene
from recycled plastics does not necessitate such requirements, and have now been used to make
materials like picnic tables and benches.
PVC Windows

PVC windows have grown in popularity because they are easy to design and can adapt to many
varying styles. A bonus is that because they are made primarily from plastics, the frames are
100% recyclable. Other benefits include:
● Longer lifetime (up to 40 years)
● Surplus of production material
● Same insulation quality as regular plastic
Bricks

Bricks are a stable material to build a home with, and more and more companies are embracing
the idea of building bricks with recycled plastic.
Recycled bricks can be put together in a LEGO-like way, making a home’s building time much
quicker than it would be with traditional brick. This plastic product can also be fire-resistant,
is cheaper, and, of course, is more eco-friendly.
Fences

Fences can be manufactured using fences. Homeowners can prioritize sustainability

by designing fences from recycled plastic.
Additional advantages of building fences with recycled plastic are:
● Longevity (can be exposed to many weather elements without rotting)
● Durability
● No need for paint (color can be added in during recycling process)
Floor Tiles

The floor covering of a house is one of the most essential part of a building and it has become
more common to utilize floor tiles that contain recycled plastics.
Some of their benefits include:
● Easy installation process
● Easy to clean
● Quiet and warm
● Affordable
Ceiling Tiles

Utilizing recycled plastic ceiling tiles is easy to work with, the installation process is quite
simple.
Some other pros include:
● Low maintenance (no painting, varnishing, or additional coats required once installed)
● Long lasting
● Affordable
● Great insulation material
6. Mivan Technique
Mivan shuttering is a fast-paced construction technique which offers strength and durability to a
building by use of aluminium formworks. It is much quicker than the traditional beam, column, and
brick construction. This technology does not use column and beam but involves walls and slabs cast in
easy to handle, light weight, pre-engineered aluminium forms.
Historically, the Mivan Technology, or the aluminium formwork system, was developed by a European
company. Later in 1990, the Mivan Company Ltd started manufacturing these formworks, hence giving
the name ‘Mivan Technology’.
6.1 Use in India
So far, the technology has not been used extensively in India. The concept is popular in Gulf countries,
Europe and some parts of Asia. However, its use is being promoted in India to realise the most ambitious
government scheme – Housing for All by 2022.
6.2 Mivan Shuttering: Components and parts
The following components and parts are used in Mivan Shuttering technology:
● Wall components: This includes a wall panel, stub pin, rocker and kickers.
● Beam components: This has beam side panel, prop head and panel for Soffit beam.
● Deck components: This has deck panels, deck prop, prop length, Soffit length.
● Other components: External and internal soffit corner and wall panel corners.
Detailed explanation of parts: https://qualityandconstruction.com/2021/05/26/mivan-shuttering/

6.3 Mivan Construction technique steps:

 1. Setting up the wall reinforcing steel -

The wall reinforcing steel is used to give a structure to the building and support the concrete until they
gain half of the required strength. The aluminium formworks are cast around the steel mesh, which is
factory made and directly erected on the construction site.
2. Placement of aluminium formwork
Along the wall reinforcing steel, prefabricated room sized walls and floor slabs are erected. These
aluminium alloy slabs are accurately made and are easy to handle. Spaces for windows, ducts, doors
and other features such as staircases, façade panels and chajjas are also integrated in these structures.
The forms are joint together using the pin and wedge system, which can be dismantled quickly after the
concrete structure is made.

3. Pouring concrete
After casting the forms, high-quality concrete is poured. This concrete takes the form and shape of the
cast, which is later removed to make way for a structure made entirely of cement concrete supported by
wall reinforcing steel. The aluminium forms can be reused at least 250 times, resulting in minimum
waste from the construction site.

6.4 What are the advantages of Mivan Shuttering Technology?

● Mivan Technology reduces the construction time by almost half in comparison to conventional
practices.
● Since it has a set procedure to follow, it minimises the need for skilled labour and completely
eliminates labour intensive activities such as masonry and rendering.”
● On the structural front, the technology makes the buildings more seismic-resistant and durable.
● Since there is a lesser number of joints, the building faces reduced leakages, hence requiring
negligible maintenance.
● There is uniformity in Mivan construction and the walls and slabs have a smooth finish.
● Moreover, the technology gives the scope to take out more carpet area in comparison to
conventional techniques.
6.5 Merits and Demerits
7. Contribution of agencies
7.1 COSTFORD
Centre of Science and Technology for Rural Development (COSTFORD) is a Thrissur city-based
organisation that gives technological assistance to people in alternative building technology. The
organization strives to change the social, economic and political position of the poor by providing low-
cost and eco-friendly housing technology using participatory, transparent and gender-sensitive
processes.
COSTFORD's headquarters are in Thrissur, and it operates from another 15 sub-centers, 14 in Kerala
and 1 in Gurgaon. The organisation was founded Laurie Baker, British-born Indian architect ; C.
Achutha Menon, the former Chief Minister of Kerala; Dr K. N. Raj, an economist and Dr T. R.
Chandradutt.
COSTFORD was registered as a non-profit voluntary organization in 1984 and started its construction
activities in 1986.
Contributions
After their formation, COSTFORD undertook a socio-economic survey in 3 different panchayats in
Kerala and realized that there was a need for cost-effective housing. Hence, in 1987, they took up the
housing scheme that was launched by the then district collector, which was a full subsidy scheme for
the construction of core houses within a budget of 9200 rupees per house for beneficiaries who were
below the poverty line. This scheme was completed entirely using the alternative technologies promoted
by Laurie baker and paved the way for COSTFORD for acquiring further such projects. Since then,
COSTFORD has come a long way with numerous buildings of all types including institutional
buildings, housing schemes, private residences etc. to their credit.
In 1996, the state government launched the decentralized planning scheme under the name of the
People's Planning Campaign. COSTFORD was selected to implement the total housing scheme in the
district of Thrissur, along with the Nirmiti Kendra and in Trivandrum along with Habitat Technology
group and the Nirmiti Kendra.
Till date COSTFORD has been able to construct 15,000 building through this project. Some of the
project areas include the tribal hills of Attapady where they are in charge of 5 hamlets, the Thankasheri
fishing village with 158 houses, all constructed with different plans and the rehabilitation of Chengal
Chulah slums, the biggest slum in Trivandrum.
Sustainable building techniques used by COSTFORD
COSTFORD uses a variety of techniques that were pioneered by Laurie Baker, namely
● Rat trap bond walls
● Filler slab roofing
● Brick jalli
● Patch-pointing, and exposed brickwork
● Promote the use of energy-efficient materials and which minimize the use of energy-intensive
materials such as cement, steel, and glass.
● Use fired bricks or mud blocks stabilized with lime and rice husks for masonry.
● Experiment with renewable building materials such as bamboo, which they use as
reinforcement for the foundations with lime concrete or for slabs where they use bamboo as an
exposed form with concrete on top.
Additional material: https://www.onmanorama.com/lifestyle/decor/2022/10/26/costford-technology-
gains-popularity-being-cost-effective-durable.html
7.2 Nirmithi kendra
The Government of India had launched a National Network of Building Centers ( Nirmithi Kendras or
Nirman Kendras) which are one of the most effective grass root level technology transfer centres for
disseminating and propagating appropriate skills to the cutting edge level for transforming the
technological know-how through hands-on show-how skill formation systems. The programme started
in 1988 in continuation of the work done by Laurie Baker, one of the doyens and eminent master builder
in the field of cost-effective construction. Government and with a broad-based participation of all stake
holder agencies has grown into a very powerful network with building centres all over the country.
Contributions of Nirmithi Kendra.
These centres take care of the following features:
● Technology transfer from ‘lab’ to ‘land’
● Skill Upgradation and training centre for the construction artisans on cost effective and disaster
resistant technologies.
● Building materials and component production centre using cost effective and disaster resistant
technologies.
● Construction centre using the trained work force and building material products manufactured
at the local level for various building construction like houses, schools, health centres,
community centres, etc.
● Housing guidance, information and counseling centre for the local population on all aspects of
cost effective and disaster resistant technologies.
The building centres all over the country have played a major role in all the above areas in the direction
of providing housing at minimum cost as compared to conventional technology using purely steel,
cement, wood, etc. Many projects were implemented with cost reduction ranging from 30% to 50% as
compared to conventional methods.
Impacts and achievements of Nirmithi kendra
 ● The movement which was an outcome of a local initiative to tranfer technology from lab to
land has made a perceptible dent in the housing scenario of the Kerala state by reducing the
cost by 30%. The Kerala model set an example of cost-effective housing for other states in
India. In 1988, the Nirmithi approach was included in the National Housing Policy.
● The Nirmithi style of cost-effectiveness and eco-friendliness was based on utilising locally
available and innovative materials; use of appropriate technology (solar energy, bio-gas and
minor water supply); beneficiary participation in construction activities; and blending modern
and conventional construction styles.
● The work force trained in the Nirmithi Kendras spread the message and thereby created a new
entrepreneurial culture. Participation of women and other under priviledged sections of the
society in the enterpreneurship training have improved their socio-economic conditions.
● Nirmithi earthquake resistant design used to construct housing colony for survivors of the quake
that hit Latur district in Maharashtra.
● The success of Nirmithi buildings led to waiving of building and excise taxes by the state and
the central governments of the country; accredition and incentives provided to those industries
producing cost-effective building materials.

● Incorporation of the Nirmithi style technology in the curricula of different technical institutions.
The Council of Scientific and Industrial Research of the country took upon the task of transfer
of technology.
Cost Effective Construction Technologies and Building Materials Promoted by the Nirmithi
kendra
Foundation
1. Arch foundation
2. Pile foundation
3. Random rubble stone masonry foundation
4. Block concreting to foundation
5. Size stone masonry foundation

Walling
1. Soil cement blocks or stabilized mud blocks for masonry by using regular or interlocking blocks
2. Hollow concrete blocks for brick masonry
3. Solid concrete blocks for brick masonry
4. Rat trap bond masonry
5. Boulder block or ruble filler blocks for brick masonry

Roofing
1. Filler slab roofing by using Mangalore tiles, bricks, cavity clay tiles, coconut shells or filler materials
2. Jack arch roofing by using cavity clay tiles or wire cut bricks
3. Brick panel roofing over RCC joists
4. Cadapah slabs roofing over RCC joists
5. Mangalore tiled roofing over steel angle purlins and trusses
6. Ferro cement channel roofing
7. Brick vaults and domes
8. Micro concrete tiles (MCR) roofing over steel purlins and trusses

Flooring
1. Clay tiles flooring
2. Cadapah slab flooring
3. Combination of tandoor and cadapah flooring
4. Ceramic tile flooring

Joineries
1. RCC door and window frames
2. Pressed or angle iron frames
3. Tyfac shutters
4. Coir board shutters
5. Cement particle board shutters
6. Corrugate steel shutters
7. MS and GI sheet shutters

Training programmes in 16 to 20 trades in the following areas are organized:

1. Manufacture of soil cement blocks, boulder blocks, cement concrete blocks,
2. Production of cement door & window frames
3. Production of ferro cement furniture
4. Welding, domestic electrical wiring training
5. Painting, bar bending, plumbing,
6. Production of pre-cast elements, lintels etc
7. Production of U shape Drainage slabs, Different Designer Paving Blocks, Kerbstone, fencing
poles etc.
7.3 Habitat
 ● Habitat technology group is a non-profit organisation under the leadership of Padma Shri
recipient Gopal Shankar which has been at the forefront of sustainable architecture in not just
India, but around the world.
● Habitat Technology Group is the largest non-profit in the shelter sector in India committed to
sustainable building solutions, cost-efficient, community-driven and eco-friendly architecture.
● Today the non-profit has a core group of 400 architects, engineers and social workers with a
support base of 35,000 trained workers and 34 regional offices spread all over India with project
offices in Nigeria, Bangladesh and SriLanka, among others.
● It has been at forefront of constructing nearly 1 million mass housing units (and over 100,000
green buildings) in more than five countries.
● Habitat Technology Group constructed the first township built with green building technology
in India, which contains 600 houses, a community centre and temple, in Sirumugai, Coimbatore
in 1995
● It has constructed the largest earth building in the world measuring over 600,000 square feet in
Bangladesh in 2006.
Key features of buildings built by habitat
 ⮚ The habitat technology group empowers poor people to build quality homes with their meagre
resources.
⮚ Habitat uses designs that are people-centric and based on parameter such as eco sensitivity, cost
efficiency, energy efficiency and disaster mitigant.
⮚ Local materials and resources are used and use of locals are encouraged.
⮚ Another key factor is eco-sensitivity. Any material that does not fit this mould is unacceptable.
The material needs to be both energy and cost efficient are used eg. Mud, Bamboo, lime etc.
Rehabilitation projects
For over three decades, the Habitat Technology Group has worked with State agencies, other non-
profits, corporations and local volunteers across multiple disaster-affected zones. Some of the
rehabilitation housing projects are related to
⮚ Rehabilitating hundreds of families following the Bhopal Gas Tragedy
⮚ Rebuilding homes following the Super Cyclone in Odisha in 1999
⮚ Sri Lanka after the devastating Tsunami
⮚ Rebuilding after Kerala floods of 2018
⮚ Rehabilitation housing colonies for tribals, dalits and fishermen in Kerala, Tamil Nadu, Andhra
Pradesh and Odisha