LOW COST CONSTRUCTION AND

COMPARATIVE STUDY OF THREE TECHNOLOGIES

Livya Roby#1, Ar. Minna Daniel#2
1, 2
SCMS School of Architecture,
Vidya Nagar, Palissery, Karukutty

Abstract 3. Porotherm Clay Bricks-Wienerberger Brick

Housing at low cost is a new concept which deals with
efficient budgeting by adopting the techniques that help in
reducing the cost of construction through the use of
materials available locally along with updated skills and
technology without compromising the strength,
performance and life of the structure, abide by the state
legislations towards environmental and inhabitant friendly
constructions.
1. Introduction
Low cost housing refers to those housing units that are
affordable to the lower income groups. ‘Affordability’ is
indexed based on the ability to own / build a home from
the average income of the society. Low income groups
spare their whole life to build a house and spend their
major part of earning to pay back the funds availed from
many sources.
Hence, own a house is a herculean task of the lower
income groups in the present economic situation. The
necessity of adopting cost- effective and modern
construction technology developed to support the low cost
housing for the society.
Technology is most popular among the various bricks
using for the construction. Its strength, cost and energy
savings, speed and cleanliness in work and easy
maintenance brings extensive use.
2. Literature Review
Cost effective housing is a relative concept and has to do
more with budgeting and economic planning, seeks to
reduce construction cost through applying management
techniques, apt use of indigenous materials and skills
without compromising the quality and life of the structure
(Tiwari et al.,). The concept, ‘low cost construction’ does
not mean that the materials used are cheap and substandard
to reduce the cost, but reduce the cost by its design and use
of locally available resources accepted by the industry
(Miles, 2000).
The identified two facts in the Indian context are- 1)
technology of production and erection be suitable to the
level of skills available and 2) the regional acceptance of the
technology, ie: to the metropolitan, urban and rural
conditions.

1. GFRG Technology- GFRG is concrete that uses Glass

fibers for reinforcement instead of steel. The technology
protects the lives and properties of people as these
buildings are resistant to natural disasters like
earthquakes, cyclone, fire etc.

2. Precast Technology- Precast concrete is the form of

construction that concrete is cast in molds that can be
reused, cured in a controlled environment in a precast
plant, transport to the project site and fix it in
appropriate place.
The study in this paper is heading mainly with three
technologies depict for foundation and walling of
structures. These are:

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 1. GFRG Technology
2. PRECAST Technology
3. WIENERBERGER BRCK Technology.

2.1. Glass Fiber Reinforced Gypsum (GFRG)

Glass fiber reinforced concrete or GFRC is fiber-

reinforced concrete that uses glass fibers to strengthen
instead of steel. It’s a panel made -up of calcined gypsum
plaster, reinforced with glass fibers. Glass fiber concretes
are mainly used in exterior building façade panels and
architectural precast concrete. Shortage of traditional
materials forced the people to source best alternative and
GFRG panels hold the place of the traditional materials. ‘Beat the heat’ is the global challenge and especially in the
context of Kerala as the region is experiencing such an
The cost of building or houses can be reduced using atmospheric temperature. Reinforced gypsum boards are
methods that can reduce the cost such as cost control tools less absorbent of heat and keeps interior cool. GFRG is
of management, use of low cost conventional style of good water, fire and corrosive resistant. It is advisable for
construction materials or using new techniques of the seismic zone IV & V areas for earthquakes as the
construction. weight is low compared to other alternative of GFRG.
Benefit more carpet area by bringing down the cost is
GFRG panels can have a life span of more than 60 years. highly preferable in urban region.
It is stronger and long life span than the traditional
building. Rapid wall was recognized by awarding “2009 Reduction of Mass of Tested % Weight
Global Gypsum Product of the Year” and was recognized GFRG panels weight reduction
by the United Nations with ‘Habitat Business Award’ for Weight of 1 Sq.M. 9" Brick 400 Kg -
sustainable urbanizations as ‘good practice’. The product wall with cement plaster
is internationally identified and recognized as a low cost in 2 sides
construction technology for the good living. Weight of 1 Sq.M. Rapid 40 Kg 90.0%
Wall panel
Efforts to identify an alternative of alkali-resistant macro Weight of 1 Sq.M. Panel 250 Kg 37.5%
glass fibers as concrete corroboration in structural with concrete refil
elements ends up in GFRG. Structural glass fibers
reinforced concrete provide a simple and attractive
(Comparison of weight of GFRG with Brick wall)
alternate to conventional steel bars and steel fibers
reinforced concrete.
2.1.1 Conditions Required
The foundation for construction done on site is
Cost reduction by 20-30 percentiles will be conventional and Stripped Footing is particularly designed
examined to justify the selection of study and test of on specific soil conditions. Fixing of wall panels are in the
time saving will be conducted to prove the duration foundation and therefore interaction with soil is not
of construction reduced to a minimum 50% of the subjected. The climatic conditions and soil do not affect the
project period. construction.

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Humid warm climate of the region is not affecting the
product. GFRG is less heat absorbent and less than 5%
water absorbent.
2.1.2 Design Strategy
Conventional construction method is using for the
foundation of the buildings that use GFRG. GFRG panels
can also be used for roofing, fixing by concrete and weld
mesh to build further floor on top of it.
Panels of GFRG are with only 124 mm thick which means
that the carpet area will be more for the same size of built
up area constructed in the conventional method. Walls of
the buildings can be finished within no time by using
GFRG considering the conventional methods. Overall
weight of the structure will be much less even though
some of the hollow spaces are filled with concrete.
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2.1.3 Benefits
Fast Construction, reduced material handling hassles,
savings in freight, savings in labour cost, environment
friendly construction, more built up area and less
weight are the major benefits of the Technology.
2.1.4 Limitations
 Not suitable for wall with circular or higher
curvature like arch.
 Clear span shall be limited as per the design
specifications.
 Not economical and cumbersome for
complicated design in structure.
 Skilled labors who are expertise only can
handle it fix it.
 Need specific vehicles are required for
transport handling of the panels.
 Handle carefully not to damage as it cannot be
repaired easily. Much space is required at site
as machineries are required to move and fix.
 Need specific machinery for cutting GFRG
panels at site.
 Need proper storage space at site to store the
panels.
2.2. Precast Technology
Present uses of precast technology comprise of variety of
architectural and structural designs which includes different
parts or even entire building structure. Now a day the
precast industry has been spread into many different regions
such as North America, Europe, Asia Pacific, and Latin
America & Middle East & Africa. The study facilitates a
detailed view of country-level aspects of the market on the
basis of application segments and estimates the market in
terms of revenue and volume during the forecast period.
2.2.1. Growth and Technical Study
Rapid growth of Indian cities marked high rise buildings
than the horizontal constructions to adjust with the
affordable land availability. These high-rise projects are
usually overrun for its costs due to slowdown of economic
growth and Government interventions that ultimately on the
shoulders of tenants or occupants. To cut short the project
time and cost hike, developers consider emerging means to
cover up the issues.
2.2.2. Conditions Required
Precast technology with the longer extent gives an architect
and other designers more viability to find out and get into
the scope of this technology. It can be used as the building
material, but it can also be obtained with the steel and is
utilized as composite structures. The utility of precast
structures as composite structures mainly depends on local
building traditions and restrictions.
2.2.3. Design Strategy
High standards are fixed for the production line and for the
product design. The Production process is in a controlled
environment and experts care is always available. Precast
get strength as per the standards as it cure appropriately in
the production table. The benefit of adequate curing of
concrete is its strength and durability.
Cost of using this technology is little high compared to the
conventional casting at the work site. But in practical,
considering the other factors it is much beneficial than the
onsite casting.
2.2.4. Challenges
Even though precast industry is best among the solution to
feed the increasing housing demands, it has not been given
attention to promote. Unlike developed countries, densely
populated countries like India is not make use of the
advantages of precast industry.
The challenges are grouped into 4 categories.
 The Standardization, Procurement and the
Technological aspects.
 The Documentation and Design aspects.
 The Skill Development and development of
technology and equipment.
 The End-user perspective, propaganda and promotion
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2.2.5. Benefits
Save project period, better product quality, high load
bearing capacity, cost effective, durability and aesthetic are
the benefits of precast products.
2.2.6 Limitations
The use of precast concrete structures in Indian construction
industry is limited considering the growth rate of the
industry. The major factor for the non-acceptance by the
stake holders is that proper ascertainment of benefits of this
technology is not published.
Production of precast requires high capital investment, as it
requires concrete mixing plants, molds of different
structural designs, casting and curing spaces, enough
storage and transporting facilities equipped with forklifts
and cranes. Furthermore, structural changes are difficult as
every time different molds are required as per the demands
of the projects. Repairs and modification of the pre-casted
structures are difficult.
2.3. Wienerberger Brick Technology
During the period of last two centuries, the use of
wienerberger technology products has been used for
construction in many buildings and also has brought up a
great tradition in Austria. The Wienerberger Brick is the
latest building trend, offering a faster and drier construction
process than traditional masonry work. It sustains its
traditional values along with the modern method of
construction; it is a precision clay block walling system. It’s
revolutionizing the construction industry fast and with high
strength and heat efficiency. It is dry, safe and simple to
use as well as capable for holding stocks and its storage.
2.3.1. Design Strategy
Porotherm Bricks are much lighter than conventional wall
material. Use of porotherm bricks reduces cost reduction in
dead load and less handing charges.
Better thermal insulation i.e.; 45% better than the
conventional wall material make possible saving of energy
consumption. Low absorption rate makes possible moderate
temperature in the interior.
High compressive strength, ease handling of it and masonry
productivity improves due to the web design interlocking.
There is an increased laying speed built programme in
which it achieves a water-tight shell significantly more
quickly, and also allow finishing the trades to start up the
work sooner.
2.1.3 Benefits
Light weight in handling - 60% less weight than
conventional wall material.
 High Compressed strength, last very long and strong.
 Excellent Sound and Thermal Insulation.
 Water absorption rate is just 15%, cause minimal
chances of dampness, cracks or shrinkage of walls.

2.1.4. Limitations

 The compressive strength of Porotherm Thermo bricks

2.3.2. Solutions
There is a simple way of measure, productivity highlighting
the stark contrast between Porotherm and other methods
There was no mortar that is required in vertical joints, and
further with each block precision the ground for easy on-
site uses, Porotherm bricks are efficiently designed for
maximum build requirements.
2.3.3. Better efficiency in the built programme.
is slightly above 3.5 N/mm²
 The water absorption is about 15% in case of
Porotherm Thermo bricks
 The density of these bricks are less that comes about
694 to 783 kg/m^3.
 Uses of Porotherm bricks are not advisable for
foundation and base slabs. It won’t be resisting the
negative pressures in areas of high ground water level.
3. Case studies
3.1. GFRG - Villa Project at Kolencherry
This villa project is situated near road side on high raised
area. This project completely evolves into landscape as well
as type of construction used in this site.

Although the price per square meter of block-work cannot

be comparable to any other masonry materials, it mainly
matters not only the speed and its efficiency but also how
the porotherm system works on site and is capable in
creating the savings virtually in every area.

The benefits has began with the foundations used in site,

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

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Site Layout
This area is situated near to town Kolencherry. The
essential facilities like shops hospital church etc are situated
near 1km radius. The building is completely used with
GFRG technology and for its aesthetics purpose louvers
have been used for the outer of the building. Traditional
roofing is been used in this building. In this villa project all
the builds have common outer factors.
3.2. Precast – Residence project at Palarivattom,
Ernakulam
This residence is situated away from road side on high
raised area. The essential facilities like shops hospital
church etc are situated near 5km radius.
The precast structures are harder for many longer years; it
doesn’t burn, melt, or rot. It has a High quality of precast
structures and does not breed any of the harmful micro-
organisms.
3.3. Wienerberger Brick – Residence project at
Thammanam, Ernakulam
This residence is situated away from road side on high
raised area.
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The essential facilities like shops hospital church etc are
situated near 5km radius.
The essential facilities like shops hospital church etc are
situated near 5km radius. The benefits has began with the
foundations used in site, since our blocks are considerably
lighter than concrete.
4. Comparative Analysis
4.1. Live
GFRG technology is to use the prefabricated light weight
large panels to complete the project in time. This
technology replaces or reduces the conventional cast-in situ
constructional use of steel reinforced concrete in the
construction. Natural resources such as river sand, trees
and water are become scarce along with good agricultural
land which have great impact on the construction and act as
the thermal regulators. Reduce the effect of Global
warming by the use of Rapid wall buildings that balances
the environmental impact on new constructions. Besides the
above all, it is much affordable to the socially marginalized
segments of the society.
Precast concrete has the greater flexibility in molding
limitless design options to build variety structural designs.
It is one of the fastest technologies to accomplish the timely
project completion. The present day prevailing precast is
the structurally sound and strongest in the construction
world, providing better scope for architectural growth and
innovations.
Operational excellence has obtained by the Wienerberger
India following a specialized production methodology
through:
 5.References
 Plant automation.
 Material handling by machines and robots.
 Make use of the locally available raw materials
The Wienerberger Brick offering a faster and clean
construction process than traditional stone and brick work.
4.1. Literature
Increasing demand for construction materials to meet the
shortages of houses in India urges alternate and fast
substitutes for the bricks and concrete blocks. Shortage of
traditional materials forced the people to source best
alternative and GFRG panels hold the place of the
traditional materials. Cost reduction by 20-30 percentiles
will be examined to justify the selection of study and test of
time saving will be conducted to prove the duration of
construction reduced to a minimum 50% of the project
period.
The precast concrete products industry focuses on utility
underground and other non-pre-stressed products and is
represented primarily by the National Precast Concrete
Association (NPCA). Precast technology is one such
emerging construction process to reduce the time limitation
for the faster completion of the projects. Even though
precast technology is widely accepted especially in the
Western and Middle East, India is not penetrated the
convenience of it. Low public awareness of the precast
technology is the main cause of it’s seldom use in the
construction industry. More study and research of the
challenges faced by the technology and publish journals can
enhance the public awareness of the use of this technology.
The Wienerberger Brick is the newest technology, offering
a faster and clean construction process than traditional stone
and brick work. Wienerberger Brick sustain its traditional
values along with the modern method of construction; it is a
precision clay block walling system. It’s revolutionizing the
construction industry fast and with high strength and heat
efficiency. The product is simple to handle, safe in fixing
and capable of holding air storage to resist heat. The
interlocking system developed is unique and eliminate
mortar in vertical joints. Its quality is consistent and bed
joints are perfect.
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