K.L.N.

COLLEGE OF INFORMATION
TECHNOLOGY

INNOVATIVE MATERIALS IN CIVIL

ENGINEERING

SUBMITTED BY:

FINAL YEAR CIVIL

CONTACTS:
MAIL ID...
Veerakumar07@gmail.com

PHONE NO.
9659402133

ADVANCED CONSTRUCTION TECHNIQUES

INTRODUCTION:
For the use of advanced construction techniques we must use innovative building
materials. Thus we come to know that new construction materials are the key to advanced
construction techniques, thus it will be correct to discuss about the new building materials
and the technique adopted for the usage of it. Thus in this topic we have dealt about the
new building materials which is currently becoming popular and is being used in every
construction. As very the future engineers, who are related to this we must make use of
such innovative building materials so as to reduce the cost of building and as well as to
improve the comforts of a building. This has what provoked us to select this topic, so that
it would be useful for our future life. The acceptance of such innovative materials is very
slow in India and it comparatively very much slower in the south. This is a great barrier
for our development in civil engineering trends, which are recent.
A high housing deficit of about 120 million houses is one of the major problems
in India, a country of 1000 million inhabitants. The high cost of the building process for
domestic housing is a major burden for those people who want to have access to this
basic need in developing countries, such as India. This housing deficit problem is more
evident in areas where people live under the line of extreme poverty conditions, which in
terms of population represents more than 50 percentages of inhabitants, that is half of the
total population in the whole country. One alternative to this situation is the use of new
building materials aimed at reducing construction costs whilst providing suitable indoor
thermal comfort conditions for occupants. This work presents the application of
innovative building materials for achieving these objectives. These materials are basically
made of recycling, local and low cost components and have been applied under a new
construction system approach. Results have shown that the use of these building
materials can effectively reduce construction costs both for labor and materials, whilst
improving the thermal comfort conditions in domestic buildings. These techniques are a
promising alternative and can also be applied to promote a beneficial multiple effects in
the country, and if they are applied at massive levels, they can contribute to reduce the
high housing deficit in the country.
EXAMPLES OF INNOVATIVE BUILDING MARERIALS:
 There are many innovative building materials used currently in world wide and in
India. All these cannot be described, so we have dealt with some of them. They are as
follows;
• AGRO BASED BUILDING MATERIALS: These are materials used from
agricultural waste such as dried banana leaves, coconut fiber as an insulator for
damp proof course and as well as sound proof course, etc;
• WOOD/PLASTC COMPOSITE: Now a days the has been mixed with plastic t
get the desired quality and this type of material is resistant to dampness as well as
the rate is not also very high, when compared to its uses.
• CPVC PIPES: These pipes don’t allow the salt content of the water to get
deposited on their walls. Thus they prevent the corrosion of the pipes and there by
reduce the frequent replacement of the pipes. They are even resistant to fire and
also to acids to some extent. Though their initial cost higher than that of
conventional pipes, their maintenance cost is very low.
• FLY ASH CEMENT: This consists of a small proportion of fly ash instead of
the usual components present in it. This will not only reduce the cost of cement
but also it reduces the effect of pollution by removing the concentration of carbon
di oxide in air.
• PVC DOORS: These are the purely plastic doors, which has easy workability
and it is much more durable than wooden doors. It is resistant to water corrosion
and it can be mainly used for bathroom and toilet doors where safety is not much
needed.

TOPICS DEALT:
The topics which are dealt in this are as follows;
• FLY ASH BRICKS
• THERMO MECHANICALLY TREATED (TMT) STEEL RODS
• INHIBITORS ADMIXED CONCRETE

FLY ASH BRICKS

INTRODUCTION:
A Clay brick, which was the primary wall material, is now being replaced by
FLY ASH BRICKS, which are hi-tech well-improved quality products. They are
competitive in comparison to the conventional clay bricks and provide enormous indirect
benefits. The country can gain a lot by gainful utilization of fly ash bricks resulting in
conservation of natural resources as well as protection of environment.
COMPOSITION:
The important compositions of fly ash bricks are as follows;
 FLY ASH
 CEMENT
 SAND
 WATER
SOURCES OF FLY ASH:

72% of India's power plants are coal based. These power stations
generate nearly 40 million tones of fly ash annually. Fly ash contains Co2
emitted from Thermal power plants, industries using coal as a fuel emits
unwanted ash and smoke from which fly ash is produced. In all the power
plants and industries, they separate the fly ash by using the cyclone
converter. This fly ash is then used as a raw material for manufacture of
bricks.

NATURE OF POLLUTION CAUSED BY FLY ASH:

Fly ash causes severe pollution of air and water, and its disposal gobbles up large
tracts of land. Well-planned programs for proper management of fly ash are therefore
being undertaken to enhance the use of fly ash in various applications, so that our already
perilously imbalanced environment can be protected

MANUFACTURE:
 The fly
ash brick is
nothing but a slow setting pozzalona cement mix. The process is same as making cement
in cement factories whereas the clay and limestone are burnt with coal and gypsum. And
it is mixed and ground to cement.
In fly ash mix also the fly ash, which is burnt clay particles (oxides of clay)
obtained from burning coal, which contains clay from the mines. When hydrated lime
powder, gypsum are mixed and ground in a pan, the mixture gives a slow setting
pozzalona cement.
While the mix is pressed at low pressure at low moisture content in hydraulic
machine, which is specially designed to give high pressure load at a slow rate, in the
order of 350kg/square inch.
At this of rate of pressure and with holding the pressure for a desired time gives
ultimate strength to fly ash bricks.

FLOWCHART SHOWING THE MANUFACTURE:

 MIXING OF FLY ASH WITH CEMENT, SAND &
WATER

POURING OF MORTAR INTO THE MOULDS

DRYING IN ATMOSPHERIC TEMPERATURE & PRESSURE

CURING FOR A PERIOD OF 28 DAYS

REMOVING FROM THE MOULDS

FLY ASH BRICKS

FLY ASH TO LESSEN GLOBAL WARMING:

The increase in green house gases, out of which CO2 is one of the major
constituents, increases the global warming year after year, causing drought and floods.
The total CO2 Emissions globally account for 24,960 million tons at 1990 levels. Cement
and building materials industry is one of the major contributors.

The CO2 emission is about ninety million tons out of cement and forty nine
million tons out of clay bricks production in India. As per the ongoing practices in India,
each million clay bricks consume about 200 tons of coal (or any other fuel with equal
quantity of thermal values) and emit around 270 tons of CO2.
Fly ash bricks production in energy-free route saves the emissions totally,
befitting the project to qualify under Clean Development Mechanism (CDM), as
envisaged by Kyoto Protocol towards the welfare of Mother Earth.

COMPARISON OF CLAY BRICKS AND FLY ASH BRICKS:

PROPERTIES RED BRICKS FLY ASH BRICKS REMARK

1. Density 1600-1750 kg/m3 1700-1850 kg/m3 Higher load
bearing
2 2
2. Compressive 30-35 kg/cm 90-100 kg/cm Higher load
strength bearing
3. Absorption 15-25% 10-14% Less
dampness
4. Dimensional Very low tolerance High tolerance Saving in
stability mortar up to
25%
5. Wastage during Up to 10% Less than 2% Saving in cost
transit up to 8%
6. Plastering Thickness vary on the Even on both sides Saving in
both sides of wall plaster up to
15%.

TMT STEEL RODS:

INTRODUCTION:
 For year’s, Bamboo has been used by man for construction activities, later it has been
replaced by CTD (Cold Twisted Deformed steel rods) or TOR steel rods. The
manufacturers adopted the “Cold Twisting Process” in which the naturally cooled
rods were twisted by means of motors. Thus the molecular structure of the core steel
is weakened. Thus it should not be used for construction activities.
Now, the TMT (THERMO MECHANICALLY TREATED) steel rods have emerged.
This rod is not twisted; instead it is treated with the WATER JACKETING
PROCESS and allowed to cool in the ambient condition.

COMPOSITION:
The TMT chemistry
BIS (BUREAU OF INDIAN
ROSUN TMT
STANDARDS)
Carbon (Max%) 0.30 0.25 to 0.30
Manganese (%) 0.5 to 1.2 SCRAP MELTING
0.5 to 0.8

Sulphur & Phosphorous as per IS:1786/85 as per IS:1786/85

INGOT MOULDING

ROLLING &
MANUFACTURE: FURNACE HEATING
(Temperature – 1200 to 1500 Degree Celsius)

WATER JACKETING – TMT BOX

TMT STEEL BARS

WATER JACKETING:

The steel rebar are at high temperature when they leave the last rolling stand.
They are immediately passed through a pre-determined quantity of a high-pressure water-
cooling system. These instant cooling tempers the outer surface and it becomes very hard.
The next phase involves cooling at an ambient temperature that allows the hot core to
temper the surface through thermal exchange. This result in a unique tempered structure
 of MARTENSITE (outer) and a fine-grained BAINITE-FERRITE / PEARLITE
(core) that is stronger, more flexible and far better suited for construction.

TEMP (CELSIUS)
100 CORE

0-
800 - EQULISATION TEMP

500 -

400 -

200 -
QUENCHING TEMP

FINE TIME
STRENGTHENED
GRAINED OUTER LAYER
CORE

BAINITE + TEMPERED
FERRITE / MARTENSITE
PEARLITE MIXED

MARTENSITE
+ BAINITE
COMPARISON OF TMT & CTD:

Properties CTD Bars TMT Bars

Very High as grades of Fe-500 & 550 are easily

Strength High (Normally up to Grade Fe-415)
achievable

Very High in all grades and over- achieves the

elongation requirement in the recent
Elongation As per IS: 1786/ '85
amendment to IS: 1786 for earthquake
resistance
 Preferably avoided as welded joints are
Weld-ability Better and no loss of strength
weak

Formability Bend 3D - 5D, Re-bend 5D - 8D Excellent due to uniform elongation

Ductility &
Very High, Most suited for earthquake resistant
Fatigue High
structures
Strength

Fire Hazards Loss of Strength on temperature rise Negligible loss in strength up to 500 deg. C

Corrosion
Scale fall down during cold twisting Pre-welded meshes can be used
Resistance

Availability of Grade Fe-500 & 550 results in

Workability Easy working at site
steel saving

Availability of Grades Fe-500 & 550 results in

Overall Economy
steel Saving

Advantages of TMT: Special Features of TMT Bars:

1. Savings of 14 - 19% steel 1. Higher strength with better elongation

2. Reduction in Costs 2. Excellent Weld-ability
3. Better safety of structures 3. Resistance to fire hazards
4. Easy working at site 4. Excellent Ductility
5. Better ductility & bend-ability 5. Higher Fatigue Strength
6. Better Corrosion Resistance 6. Easy work - ability at site
7. Good Weld-ability 7. Better Bonding Strength
8. Better Corrosion Resistance
8. Resistant to fire hazards
9. Achieves better results than BIS Standards

INHIBITORS ADMIXED CEMENT:

INTRODUCTION:
New concrete buildings are built for long life. Inhibitors added concrete structures
have still longer life.
The crack formation in concrete structure occurs due to the corrosion of rebar
inside the concrete. This occurs because of the surface oxidization of iron rod into iron
oxide due to diffused oxygen and moisture in the concrete.
 The places, where the chloride content in the ground water is more, carbonation
reaction occurs which leads to the decrease in alkalinity. Because of this, the rate of
corrosion of steel rebar increases and eventually the cracks are formed. By adding the
inhibitors admixture to the concrete mix, the corrosion of steel rebar can be prevented.
TWO MAJOR CAUSES OF CORROSION IN CONCRETE:
Concrete is highly alkaline material when first produced (pH range 12-13). The
embedded steel is protected by a passive oxide layer which is maintained by high
alkalinity at the surface of steel.
Under certain exposures and conditions the natural passivating protection of steel
breaks down. In the presence of moisture and oxygen, the corrosion then occurs.
The two major causes are,
1. CARBONATION OF CONCRETE:
The most common cause of loss of passivating alkalinity is carbonation-a process
where by atmospheric carbon-di-oxide and sulphur-di-oxide present in lime reacts with
the soluble alkaline calcium hydroxide in concrete and it is converted into soluble
calcium carbonate and calcium sulphate.
Ca (OH) 2 + Co2  CaCo3 + H2O
Ca (OH) 2 + So2  CaSo3 + H2O
Ca (OH) 2 + So3  CaSo4 + H2O
(High alkalinity) (Lower Alkalinity)
The alkalinity of the cement matrix is reduced and its passivating ability is lost
progressively from the surface inward.
Once the concrete in contact with reinforced steel was carbonated the steel is no
longer protected. In the presence of moisture and oxygen corrosion is inevitable.
2. CHLORIDES IN CONCRETE:
The concentration of chlorides require to promote corrosion of embedded
reinforcement is affected by the pH of the concrete. In alkaline fresh concrete higher
chloride concentration is needed to promote corrosion. When the alkalinity is reduced
due to carbonation process even small chloride concentration may induce the corrosion of
rebar in concrete.
PROCESS OF CORROSION:
 The corrosion product of steel (iron oxides or hydroxides) occupies a much
greater volume than the steel (4-12 times the volume). This increase in volume exerts a
great expansive pressure within the concrete, leading to cracking.
Being an electrochemical process, corrosion of steel in concrete requires an
electrolyte. Concrete is full of small pores which contains moisture, and so, is an
effective electrolyte. A small, electrical current flows between the anode and the cathode
with corrosion activity (rust formation) taking place at the anode. When INHIBITORS
reaches reinforcing steel, it forms a protective layer that protects the steel in both anode
and cathode areas.

CORROSION RATE OF STEEL:

CEMENT +
PROPERTY CEMENT
INHIBITOR
Corrosion
0.0191 0.0029
rate (mmpy)
CORROSION RATE

0.025
0.0191
0.02
(mmpy)

CORROSION PREVENTION ACTION BY INHIBITORS:

0.015
0.01
When inhibitor approaches the steel rebar surface, it forms a protective layer
which prevents the corrosion of iron by moisture and other ions such as chloride. The

0.005
steel rebar’s life is increased by five times, which is proved by the weight loss
experiment. The inhibitor doesn’t alter the properties of concrete such as strength and

0
CEMENT
setting time but increases the life of the concrete. The chemical nature of the inhibitor
doesn’t change with time. This property helps in increasing the life of the concrete.

APPERANCE OF STEEL REBARS AFTER

IMMERSION IN CHLORIDE SOLUTION FOR 365
DAYS

STEEL REBAR IN STEEL REBAR IN

CHLORIDE SOLUTION CHLORIDE SOLUTION
WITH INHIBITORS WITHOUT INHIBITORS

COMPARISON OF PHYSICAL CHARACTERISTICS:

 CEMENT +
S.No. CHARACTERISTICS CEMENT
INHIBITORS
2
1. Compressive Strength (N/mm )
On mortar cubes as per
IS 1489 (Part I):1991
3 days 16.000 16.500
7 days 17.750 19.830
2. 28 days compressive strength
on concrete cubes (N/mm2) 38.70 38.70
3. Tensile strength (N/mm2}
(As per IS 269: 195) 1.240 1.260
4. Consistency for 33 mm penetration
(As per IS269:1952) .328 .290
5. Setting time (minutes)
[As per IS 1489 (Part I): 1991]
Initial setting time (mts) 149 135
Final setting time (mts) 345 330

CORROSION RESISTANT PROPERTY OF CONCRETE (AFTER 3 YEARS):

ADDED
CORROSION CEMENT +
TECHNIQUE CHLORIDE CEMENT DURABILITY
PARAMETER INHIBITOR
IN PPM

Charge transfer
Impedance resistance (Rct) 10,000 5.2 37 7
(K-ohm)

We infer from the tabular column, that the concrete’s corrosion resistant property
is very much less when compared to that of INHIBITOR ADMIXED CONCRETE.
The same is shown in the graphical representation as below;

COMPARISON OF CORROSION RESISTANT PROPERTY:

 CHARGE TRANSFER
37

RESISTANCE (K ohm
40

30

cm^2)
20

10 5.2

0
CEMENT CEMENT + INHIBITOR
CEMENT TYPE

6. CONCLUSIONS:
The application of innovative building systems using low cost materials can be a
key factor to promote an increase of house construction in India. Furthermore, the uses of
these types of materials have also some other benefits:
• Reduction of environmental damage,
• A promising platform for creating jobs and
• Productive projects in poor rural regions, as well as
• Forms the basis of examples for new building techniques.
The results of this demonstrative example can eventually be used in some
other regions of country and this can also lead to energy savings and the
improvement of the natural environment and the quality of living of people. All
these can be aimed at achieving a new culture in the use of energy and natural
resources for the current and new generations of the new millennium.

”the good should be accepted as that of the advanced construction techniques and the
bad should be denied as that of the bribe.”
- Sir Henry Ibsen Bacon

ABSTRACT
For the use of advanced construction techniques we must use innovative building
materials. Thus we come to know that new construction materials are the key to advanced
construction techniques, thus it will be correct to discuss about the new building materials
and the technique adopted for the usage of it. Thus in this topic we have dealt about the
new building materials which is currently becoming popular and is being used in every
construction. As very the future engineers, who are related to this we must make use of
such innovative building materials so as to reduce the cost of building and as well as to
improve the comforts of a building. These materials are basically made of recycling, local
and low cost components and have been applied under a new construction system
approach. Results have shown that the use of these building materials can effectively
reduce construction costs both for labor and materials. Agro based building materials,
wood/plastic composite, CPVC pipes, fly ash cement and PVC doors are some of the
innovative building materials. The topics dealt in this paper are fly ash bricks, thermo
mechanically treated (TMT) steel rods and inhibitors admixed concrete. A study of the
composition, manufacture and the properties of the above materials are conducted. The
advantages of these innovative materials over the conventional materials are discussed.
Some of the vital properties such as the corrosion prevention are attained by using these
materials which shows the importance of these materials. As a result, the application of
innovative building systems using low cost materials can be a key factor to energy
savings and the improvement of the natural environment and the quality of living of
people.