PRECAST ELEMENTS

REPORT

PRADNYA V CHAVAN 5TH YEAR ARCHITECTURE BUILDING CONSTUCTION 9/6/2011

A precast concrete structure is an assemblage of precast elements, which when suitably connected together, form a 3D framework capable of resisting gravitation and wind (or even earthquakes) loads. The framework is ideally suited to buildings such as Apartments, Shopping Malls, Offices, Schools, Studio, etc. each precast panel is independently supported to the building structure using an assemblage of metal components and anchors. Joints around each of the precast panels are usually filled with sealant. The connections for precast concrete panels are an important component of the envelope system. Precast manufacturers utilize numerous different types of anchors but they are often characterized as gravity and lateral types of connections. The primary purposes of the connection are to transfer load to the supporting structure and provide stability. The criteria used to design precast connections including but not limited to: Strength Ductility Volume change accommodations Durability Fire resistance Constructability BENEFITS OF PRECAST CONSTRUCTION The use of precast concrete in construction is widely regarded as an economic, durable, structurally and architecturally versatile form of construction. 1. Compared with traditional construction methods and other building materials, precast as a construction method, has a number of positive features. It is an industrialized way of construction with inherent advantages: 2. Factory-made products meaning rational and efficient manufacturing processes, skilled workers, repetition of actions, quality surveillance, etc. Reduced traffic handling costs 3. Reduced accident exposure risks 4. Shorter construction time - less than half of conventional cast in-situ construction. 5. Contractors benefit from reduced exposure to traffic hazards. More work can be accomplished in less time, with fewer weather delays. 6. Costs are lower for forms, skilled field labor, scaffolding and shoring, and cranes.After foundations have been completed, scheduling can be controlled by a single contractor working with a familiar material 7. High capacity enabling the realization of massive projects. 8. Factory made products means consistent high quality. 9. Structural efficiency with longer spans and shallower construction depths offering both flexibility and extended lifetime of buildings. 10.Opportunities for good architecture as almost every building can be adapted to the requirement of the Architect or the Builder. 11.Fire resistant construction of 60 to 120 minutes and more. 12.Healthy Buildings. 13. Energy conservation .Environment friendly buildings, with optimum use of materials, less noise, less dust, etc., 14.Precast concrete wall systems offer a wide variety of shapes, colors, textures, and finishes to the designer. As a result, the assessment of samples is a key component in the use of precast concrete. The majority of the review and approval process is conducted at the precast plant prior to precast panel production. This assessment is in addition to the quality control and field testing that takes place during the production phase. 15.Speed of construction 16.Attractive appearance 17.Low noise transmission 18.Flexibility for expansion 19.Durability Precast 20.High load capacity 21.Low depth-span ratios MATERIALS USED IN PRECAST STRUCTURE

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Types of Precast Products Hollow Core Slabs Beams Columns Outer Wall Panels Hollow core Inner Wall Inner Panels Applications of Precast Products The developments in products, materials and techniques have made precast / prestressed concrete competitive in a variety of residential, commercial, industrial, transportation and many other types of structures. A few examples of applications to different types of structures are: Building Structures - Residential Buildings, Office Buildings, Warehouses and Industrial Buildings and Other Building Structures Parking Structures Precast Concrete Cladding Stadiums/Arenas Bridges Precast concrete piles They come in different sizes and shapes, ranging from 10-inch square piles to 66-inch diameter hollow cylinder piles. Pile caps also can be precast concrete, reducing exposure, forming and curing in the field. The concept of precast (also known as prefabricated) construction includes those buildings where the majority of structural components are standardized and produced in plants in a location away from the building, and then transported to the site for assembly. These components are manufactured by industrial methods based on mass production in order to build a large number of buildings in a short time at low cost. The main features of this construction process are as follows: The division and specialization of the human workforce The use of tools, machinery, and other equipment, usually automated, in the production of standard, interchangeable parts and products This type of construction requires a restructuring of the entire conventional construction process to enable interaction between the design phase and production planning in order to improve and speed up the construction. One of the key premises for achieving that objective is to design buildings with a regular configuration in plan and elevation.

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CONCRETE: Precast concrete is of the highest possible quality, both in terms of strength and durability. Concrete is accurately delivered to every part of the mould, ensuring zero segregation, honeycombing and minimal vibration. Using materials that have passed strict quality control procedures, rapid hardening cement is mixed with excellent quality aggregates of known source and purity, in computer controlled Batching and Mixing Plant, to produce concrete of specified workability and strength. STEEL RE-INFORCEMENT: Precast concrete elements are normally heavily reinforced because they are cast horizontally. NON-CEMENTITIOUS MATERIAL: Epoxy resins and hardeners are occasionally used for tensile strength. The product - precast/prestressed concrete building systems In conventional method, concrete is mixed on-site or ready mix is placed into forms on-site. Precast is a high quality concrete prepared in a specialized factory, formed using automated machinery into predesigned forms. Components are assembled on site, with connections being made on site. In the conventional method, steel reinforcement is used to counteract tensile (pulling apart) forces that can damage/destroy concrete. In the prestressed method, high quality steel is first pulled apart, placed in concrete, and the stress thereafter is released once the concrete is set. This procedure is carried out in a factory, automated for higher productivity, with specialized machinery.

Depending on the load-bearing structure, precast systems described in the WHE can be divided into the following categories: Large-panel systems Frame systems Slab-column systems with walls Mixed systems The designation large-panel system refers to multistory structures composed of large wall and floor concrete panels connected in the vertical and horizontal directions so that the wall panels enclose appropriate spaces for the rooms within a building. These panels form a box-like structure. Both vertical and horizontal panels resist gravity load. Wall panels are usually one story high. Horizontal floor and roof panels span either as one-way or two-way slabs. When properly joined together, these horizontal elements act as diaphragms that transfer the lateral loads to the walls.

A large-panel concrete building under construction Depending on the wall layout, there are three basic configurations of large-panel buildings: Cross-wall system. The main walls that resist gravity and lateral loads are placed in the short direction of the building. Longitudinal-wall system. The walls resisting gravity and lateral loads are placed in the longitudinal direction Panel connections represent the key structural components in these systems. Based on their location within a building, these connections can be classified into vertical and horizontal joints. Vertical joints connect the vertical faces of adjoining wall panels and primarily resist vertical seismic shear forces. Horizontal joints connect the horizontal faces of the adjoining wall and floor panels and resist both gravity and seismic loads. Depending on the construction method, these joints can be classified as wet and dry. Wet joints are constructed with cast-in-place concrete poured between the precast panels. To ensure structural continuity, protruding reinforcing bars from the panels(dowels) are welded, looped, or otherwise connected in the joint region before the concrete is placed. Dry joints are constructed by bolting or welding together steel plates or other steel inserts cast into the ends of the precast panels for this purpose. Wet joints more closely approximate cast-inplace construction, whereas the force transfer instructures with dry joints is accomplished at discrete points. Figure 5 shows a plan of a large-panel building with the connection details. In this system, vertical wall panel connections are accomplished by means of groove joints, which consist of a continuous void between the panels with lapping horizontal steel and vertical tiebars. Horizontal joint reinforcement consists of dowels projected from the panels and the hairpin hooks site-welded to the dowels; the welded length of the lapped bars depends on the bar

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diameter and the steel grade. Vertical tie bars are designed for tension forces developed at the panel intersections. bars placed in vertical and horizontal joints provide an increase in bearing area for the transfer of tension across the connections

Plan of a large-panel building showing vertical connection details Frame Systems Precast frames can be constructed using either linear elements or spatial beam-column sub assemblages. Precast beam-column sub assemblages have the advantage that the connecting faces between the sub assemblages can be placed away from the critical frame regions; however, linear elements are generally preferred because of the difficulties associated with forming, handling, and erecting spatial elements. The use of linear elements generally means placing the connecting faces at the beam-column junctions. The beams can be seated on corbels at the columns, for ease of construction and to and to aid the shear transfer from the beam to the column. The beam-column joints accomplished in this way are hinged. However, rigid beamcolumn connections are used in some cases, when the continuity of longitudinal reinforcement through the beam-column joint needs to be ensured. The components of a precast reinforced concrete frame are shown in Figure

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Slab-Column Systems with Shear Walls These systems rely on shear walls to sustain lateral load effects, whereas the slab-column structure resists mainly gravity loads. There are two main systems in this category: Lift-slab system with walls Prestressed slab-column system Precast columns are usually two stories high. All precast structural elements are assembled by means of special joints. Reinforced concrete slabs are poured on the ground in forms, one on top of the other, as shown in Figure Precast concrete floor slabs are lifted from the ground up to the final height by lifting cranes.The slab panels are lifted to the top of the column and then moved downwards to the final position. Temporary supports are used to keep the slabs in the position until the connection with the columns has been achieved. In the connections, the steel bars (dowels) that project from the edges of the slabs are welded to the dowels of the adjacent components and transverse reinforcement bars are installed in place. The connections are then filled with concrete that is poured at the site. Most buildings of this type have some kind of lateral load-resisting elements, mainly consisting of cast-in-place or precast shear walls, etc. In case lateral load-resisting elements (shear walls, etc.) are not present, the lateral load path depends on the ability of the slab-column connections to transfer bending moments. When the connections have been poorly constructed, this is not possible, and the lateral load path may be incomplete.

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Another type of precast system is a slab-column system that uses horizontal prestressing in two orthogonal directions to achieve continuity. The precast concrete column elements are 1 to 3

stories high. The reinforced concrete floor slabs fit the clear span between columns. Hollow-core precast slab After erecting the slabs and columns of a story, the columns and floor slabs are prestressed by means of prestressing tendons that pass through ducts in the columns at the floor level and along the gaps left between adjacent slabs After prestressing, the gaps between the slabs are filled with in situ concrete and the tendons then become bonded with the spans. Seismic loads are resisted mainly by the shear walls (precast or cast-in-place) positioned between the columns at appropriate locations. A typical building under construction is shown in Figure

Post-tensioned slab-column connection Precast Panel Types for Building Envelopes There are generally four types of precast panels used as part of building envelopes: Cladding or curtain walls Load-bearing wall units Shear walls Formwork for cast-in-place concrete Precast cladding or curtain walls Precast cladding or curtain walls are the most common use of precast concrete for building envelopes. These types of precast concrete panels do not transfer vertical loads but simply enclose the space. They are only designed to resist wind, seismic forces generated by their own weight, and forces required to transfer the weight of the panel to the support. Common cladding units include wall panels, window wall units, spandrels, mullions, and column covers. These units can usually be removed individually if necessary. Load-bearing wall units resist and transfer loads from other elements and cannot be removed without affecting the strength or stability of the building. Typical load-bearing wall units include solid wall panels, and window wall and spandrel panels. Precast concrete shear wall panels are used to provide lateral load resisting system when combined with diaphragm action of the floor construction. The effectiveness of precast shear walls is largely dependent upon the panel-to-panel connections. Precast panels are used as formwork for cast-in-place concrete. The precast panels act as a form, providing the visible

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aesthetics of the system, while the cast-in-place portion provides the structural component of the system.

CENTRAL BUILDING RESEACH BUILDING

Construction Technologies Pre cast stone-blocks and solid concrete blocks for masonry. Pre cast concrete cored units and channel units for flooring and roofing

Products Brick Extrusion machine for clay bricks. (Indian Patent no 118570) Energy efficient gypsum calcinator for making plaster of paris. (NRDC REPUBLIC DAY AWARD 1989) Mini climbing crane for material handling for construction of muli-tistoreyed buildings (Indian Patent no. 172047, NRDC Republic Day Award-1994) Concrete block making machines (Indian Patent No. 2266/DEL/97) Automatic free fall hammer for sub soil investigations (Indian Patent no. 172108) CBRICK machine for production of flyash bricks. Boring and skirting machine for making bored piles and skirted granular pile foundation. (Indian Patent no. 159540) Plant for production of coir-cement board as wood substitute Accelerated electrical curing for precast RCC and prestressed concrete components. Underground Horizontal Boring Machine for making bores under the ground.

Gypsum Calcinator MACHINE

CONCRETE BLOCK MAKING MACHINE

CBRICK

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BRICK MAKING MACHINE

Rural Buildings & Environment Division has been conducting studies on rural housing and is engaged in the development of appropriate construction technologies, to improve traditional houses, new technologies for low cost houses and other buildings and environmental improvements. Disaster mitigation for housing in cyclone affected areas including relief and rehabilitation and training to various organisations involved in rural development are some other areas of work. Major Areas of R&D Activities Technologies for improvement in the performance of traditional houses made of locally available materials like mud and thatch New technologies for constructing houses using durable materials like brick, cement concrete, steel , stone and timber Construction technologies for disaster (cyclone/flood) mitigation and relief and rehabilitation work

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MAJOR AREAS OF R&D ACTIVITY Utilisation of agro-industrial by-product wastes in making burnt clay bricks & tiles Improved brick production and commercialization of process technologies Technical appraisal, characterisation of raw material resources and suitability assessment for brick & tile production Manual and mechanised production of bricks and tiles Conversation of natural raw material resources and energy through innovative techniques Design and development of thermally efficient fixed chimney brick kiln Utilization of low grade bio-mass in burning of bricks and tiles Lime based building bricks / blocks through pressing and autoclaving/ atmospheric steam curing/ moist curing Pre-design cost estimate, plant lay out, productivity and maintenance for brick and tile units. Durability appraisal of building products RURAL BUILDINGS & ENVIRONMENT

Low cost sanitation and waste water disposal systems Development and design of houses for economically weaker section for different regions Houses for hilly areas Highlights of R & D Improvement on Traditional Materials Soil stabilized bricks using cement, bitumen, molasses, lime Non-erodable mud plaster Plinth protection of mud walls Improved method of making fire-retardent thatch roof Ferro cement plaster for mud walls Ferro-cement plaster for fire-retardant thatch roof Frameless doors and window fixtures New Construction Techniques Pedestal piles for foundation Precast concrete panel Precast concrete joists Ferro concrete arched panels for roofs Pyramidal roof with triangular precast concrete panels & beams Unreinforced pyramidal brick roof Houses for cyclone prone areas Instant shelter for disaster relief Manually pressed thatch panels Ultra low cost house Doubly curved tiles Houses for rural poor in different regions Houses for hilly areas Houses for economically weaker section

Demonstration house using rural technologies

Fire retardent thatch roof

Highlights of R & D Improvement on Traditional Materials Soil stabilized bricks using cement, bitumen, molasses, lime Non-erodable mud plaster Plinth protection of mud walls Improved method of making fire-retardent thatch roof Ferro cement plaster for mud walls Ferro-cement plaster for fire-retardant thatch roof Frameless doors and window fixtures New Construction Techniques Pedestal piles for foundation

Demonstration house using rural technologies

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Precast concrete panel Precast concrete joists Ferro concrete arched panels for roofs Pyramidal roof with triangular precast concrete panels & beams Unreinforced pyramidal brick roof Houses for cyclone prone areas Instant shelter for disaster relief Manually pressed thatch panels Ultra low cost house Doubly curved tiles Houses for rural poor in different regions Houses for hilly areas Houses for economically weaker section

Fire retardent thatch roof

Lowcost latrine

Waste water disposal

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Building Systems Prefab brick panel system Prefab concrete panel system Prefab jack-arch panel system Integrated thin wall and column system Disaster relief ultra low Brick skeleton system cost house Concrete skeleton system Timber skeleton system Brick panels & concrete joists systems Precast concrete system for cyclone resistant houses Heat reflective & water proofing treatment for roofs. Sanitation & Environmental Improvement Low cost latrines Low cost latrines for high water table area Prefab brick panel system Waste water disposal system Ferro Cement unit for waste water disposal system

system

TECHNOLOGY SHOWCASE C BRICK A technological approach for employment generation in areas near flyash ponds. Quality bricks from flyash. Compressive strength 40 to 80 kg/sq. cm. Water absorption less than 20%. Efflorescence free product 3000 Bricks per day production requires: Manpower: 10 persons Land: 700 Sq.m. Power requirement: 10 KW Suited to small scale industry Value addition to flyash 30% saving in fuel in firing as compared to traditional clay brick technology. Suitable for manual and semi-mechanised production Raw materials : Moderately plastic clay mass, flyash and fuel. Plant requirements : Conventional CLAY FLYASH BRICKS Value addition to flyash 30% saving in fuel in firing as compared to traditional clay brick technology. Suitable for manual and semi-mechanised production Raw materials : Moderately plastic clay mass, flyash and fuel. Plant requirements : Conventional POLYTILES High mechanical strength Excellent chemical and wear resistance Very low porosity Decorative and durable Suitable for floors and walls to residential, commercial and industrial buildings.

COIP CNSL BOARD Single layer flat pressed medium density fiber board. Low water absorption Workable with normal wood working tools Paint-able, nail-able and screw-able Physico-mechanical properties as per IS: 3087 100% wood replacement Lab scale technology ready for transfer

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55-60% of 28-days strength attained within 24 hours. Especially useful in low temperature regions. Suitable for PCC poles, PSC railway sleepers and PCC rafters. ENVIRONMENT FRIENDLY MATERIALS AND TECHNIQUES By and large, conventional building technologies like burnt bricks, steel and cement are high in cost, utilise large amount of nonrenewable natural resources like energy, minerals, top-soil, forest cover etc. These increase dependence on external materials and manpower, harm the local economy and are generally polluting in nature. The materials and technologies chosen for construction must, in addition to functional efficiency, fulfil some or more of the following criterion, for the cause of sustainability and a better quality environment: non endanger bio-reserves and be non-polluting; be self-sustaining and promote self-reliance. recycle polluting waste into usable materials utilise locally available materials utilise local skills, manpower and management systems benefit local economy by being income generating utilise renewable energy sources be accessible to the people be low in monetary cost Environment-Friendly, Energy Efficient, Cost-Effective Composite Materials/Products for Low Cost Housing

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SISLANA PANELS Raw materials: Sisal fiber and polyester resin. Alternative to single walled press boards. Light weight, rigid and weather resistant. Screw-able and nail-able. Adequate thermal insulation and sound absorption. Panel meets IS: 12406-88 requirements. Suitable for walling, door paneling and roofing applications GYPSUM BINDER Water resistant gypsum binder. Properties : Color: Grayish white Bulk density:1000-1200 kg/m3 Compressive strength:20-30 MPa (28 days) Water absorption: 5-10% (28 days) Performance in water:No leaching Suitable for exterior applications for blocks and masonry mortars, low and high density glass fiber reinforced gypsum boards and for commercial gypsum plasters. ELECTRIC CURING OF CONCRETE Consistent quality product. Low voltage (around 60V) to reduce electrical hazards. Power consumption: 70 Kwh/m3 of concrete.

Product : Raw Material Source : Materials for production : Applications : Product : Raw Material Source : Materials for production : Applications :

BAMBOO MAT BOARD Bamboo grass (Plant), species (Meleannca baccifera) Bamboo, polymeric resin, chlorinated hydrocarbons and boron and cashew n shell liquid Flooring, walling, structural membrane, false ceiling, door/window

BAMBOO MAT VENEER COMPOSITE Plantation wood, bamboo plant, Plantation wood veneer, bamboo mat, polymeric resin, chlorinated hydrocar boron, cashew nut shell liquid, Door skin in flush doors, structural use as roofing, web construction, prefab a shelters, packing, modular partitions, furniture.

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BAMBOO CORRUGATED ROOFING SHEET Bamboo grass (Plant), Species (Meleannca baccifera) Bamboo, polymeric resin, chlorinated hydrocarbons, boron, cashew nut shell coating for UV protection and to improve impermeability to water. Roofing sheets as substitute to corrugated Asbestos Cement sheets, Galvani Iron sheets, Aluminum sheets and Fibre-reinforced Plastic (FRP) sheets.

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BAGASSE COMPOSITE PANEL/BOARD Sugar industry General purpose, polyester resin, methyl ethyl ketone and cobalt napthenate For variety of building and furniture applications. Properties closely resemble with the wood but lighter in weight. Stackable and can be easily chiselled and sawed.

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JUTE POLYESTER COMPOSITE Jute industry (Jute plant is grown in several developing countries) Woven jute fibres, and polyester amide polyol as interfacing agent Chip boards, roofing sheets, door shutters, partition panels and door/window

COIR COMPOSITE BOARD Coconut Plantation in Coastal Regions Core fibres, mineralized water, cashew nut shell liquid, para formaldehyde Medium Density Fibre boards, can be used as wood substitute for paneling, c surfacing and partitioning and door/window shutters.

BAMBOO-RICE HUSK COMPOSITE Rice mills, bamboo plants (grass) Rice husk, bamboo mat, cashew nut shell liquid and phenolic resin Temporary shelters, warehouses, false ceilings, Insulation, partition and stag industrial and domestic floorings. RED-MUD POLYMER JUTE COMPOSITE Aluminium extraction plant and Jute Industry Red-mud, jute fabric, polymeric binder

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PHOSPHOGYPSUM PANEL Hydrofluoric and phosphoric acid industry and fertilizer industries. By-product phosphogypsum/flouro-gypsum, water, hot aqueous ammonium sulphate and sulphuric acid silica mixture etc. Gypsum plaster and plaster products: Plaster boards, blocks, bricks, tiles, roo and walling panels, false ceiling tiles.

Applications :

Partitions, door shutters, roofing sheets.

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RED-MUD-JUTE DOOR SHUTTER Aluminium extraction plant and Jute Industry Red-mud, jute fabric, polymeric binder Door shutters.

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FLY ASH POLYMER COMPOSITE Ash from coal-based power generating plants Fly ash, polymeric material Partitions, door shutters, roofing sheets. COTTON STALK COMPOSITE Waste from cotton plants Cotton plant waste, cashew nut shell liquid, para formaldehyde Medium Density Fibre boards, partitions, door shutters and furniture. BLAST FURNACE SLAG COMPOSITE Waste from steel plants Blast furnace slag, polymeric resin, laminating material Partitions and interior finishing on walls. BAMBOO LAMINATED COMPOSITE Bamboo plant, wood Bamboo mat, waste wood chips, polymeric resin Flooring, walling and partitions. FIBRE REINFORCED BAMBOO COMPOSITE Synthetic fibre, bamboo Synthetic fibre, polymeric resin, bamboo Partitions, false ceilings and interior finishing on walls. JUTE LAMINATED COMPOSITE Jute plants, wood Jute fibres and wood chips Flooring, walling and partitions. CEMENT BONDED PARTICLE BOARD Cement and wood Cement, waste wood chips Roofing, flooring, walling and door shutters.

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CELLULAR LIGHT WEIGHT CONCRETE BLOCK Fly Ash from coal based power generating plants Fly Ash, cement, sand, water and foaming agent Concrete blocks, densities ranging from 400 kg/m3 to 1800 kg/m3. Filler wal In-situ cellular walls & partitions. Very good insulation at roof tops for reduction of heat load in buildings.

Product : Raw Material Source : Materials for production : Applications : Product : Raw Material Source : Materials for production : Applications : Product : Raw Material Source : Materials for production : Applications : Product : Raw Material Source : Materials for production : Applications : Product : Raw Material Source : Materials for production : Applications : Product : Raw Material Source : Materials for production : Applications :

BANANA COMPOSITE BOARD Banana plant Banana plant sheath, methyl ethyl ketone and cobalt napthenate Partition panels and panels for door shutters. SANDWITCHED FLY ASH PANEL Ash from coal-based power generating plants Fly Ash, cement, sand, foaming agent. Partitions and walling panels.

JUTE/COIR COMPOSITES Jute plant, coconut tree Jute fibres, coir fibres, polyester amide polyol as interfacing agent. For making chip boards, roofing sheets, door shutters, partitions and window

PINE NEEDLES BOARD Pine tree Needles from pine tree, polymeric resin, methyl ethyl ketone Flooring, walling, structural membrane, boxes and interior finishing on walls. WHEAT STRAW BOARD Waste from wheat crop Wheat straw/husk, cashew nut shell liquid, polymeric resin Partitions, false ceilings, insulation and interior finishing on walls.

PLANTATION TIMBER DOORS/WINDOWS Quick growing plant-wood from rubber wood plants, poplar wood and other s Rubber wood and poplar wood plants. Thermoplastic and thermosetting resin Doors and window frames, flush and panelled door shutters.

OPEN PREFAB SYSTEMS & SMALL BUILDING COMPONENTS

Partial Prefabrication Open prefab systems based on an appropriate production level and small, easily to handle elements with rationalised production methods have attracted the attention of housing experts as an important option for arresting the rapidly rising escalation in the costs of material and labour. Building Centers in different regions of India have been instrumental in propagating several of these prefab systems at the grass-root level. Partial prefabrication can be usefully employed for practically every part of a building - foundations, walling systems, doors and windows, roofing systems, lintels and staircase elements. Costs of a roof being one of the major components of the construction outlay in any building project, one of the thrust areas has been the prefabrication of roofing elements

CELLULAR LIGHTWEIGHT CONCRETE

Cellular Lightweight Concrete (CLC) has been used in over 40 countries over the past 25 years to produce over hundred thousand houses and apartments, apart from schools, hospitals, industrial and commercial buildings. CLC is an air-cured lightweight concrete with flyash as a major ingredient, that can be produced at large project sites just like traditional concrete, utilising equipment and moulds normally used for traditional concreting. It is especially suitable in India for low-rise loadbearing constructions and for partitioning work in multistorey blocks. Benefits of CLC Blocks/Panels: Tremendous weight reduction

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High thermal insulation Optimal fire rating Substantial material saving: No gravel used Little cement Less steel in structure and foundation Easy and fast production No primary energy and reduced transportation costs Boon for remote areas with only sand availability. In view the use of flyash (33%) in CLC and this being a good substitute of ordinary clay bricks ( which use high energy and precious agricultural topsoil) the Govt. of India has given special import duty concessions for specialised equipment.

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