Building Materials in India: 50 Years

A COMMEMORATIVE VOLUME

Edited by
T .N. Gupta
Executive Director,
Building Materials & Technology Promotion Council
and Advisor (Technology),
Ministry of Urban Affairs & Employment
Government of India, New Delhi

Associate Editors

Mohan Rai S.P.Ghosh

Former Head Former Director General
Building Materials Division National Council for Cement and
Central Building Research Institute, Building Materials,
Roorkee New Delhi

V.S. Parmeswaran P.B. Vijay

President and Chief Executive Former Director General
Design Technology Consultants, Central Public Works Department
Chennai New Delhi

Building Materials and Technology Promotion Council

Ministry of Urban Affairs & Employment,Governmentof India
G-Wing,Nirman Bhawan,New Delhi - 110 011 (INDIA)
A CommemorativeVolume
TN Gupta

Copyright@ExecutiveDirector,Building Materials and TechnologyPromotionCouncil, Ministry of

Urban Affairs & Employment,Governmentof India, Nirman Bhawan,New Delhi 110 Oil (India).
-

All rights reserved.This book, or parts there of, may not be reproduced,storedin a retrieval system,
or transmitted in any form without the prior written permission of the publishers.

Published by
Building Materials and Technology Promotion Council
Ministry of Urban Affairs & Employment, Government of India
G-Wing, Nirman Bhawan
New Delhi - 110011 (India)

Design and print production

WordSmithy, New Delhi

First edition, 1998

ISBN 81-86930-01-9

Notice to the readers

Theinformation in this book has beenderived and extractedfrom a multitude of sourcesincluding
standard specifications, manufacturer's literature, engineeringand materials encyclopediasand
referencebooksand personal experienceof eminent professionals.It is presentedin goodfaith but
the authors and publishers do not assumeany liability for lack of accuracy of the information
included in this book.It is primarily intended as an infonnation disseminationexercise,and not as
a sourcefor the actual designand manufacturing techniques.It is the responsibility of the usersto
apply their professionalknowledgewhile utilising the infonnation presentedin this book for any
specific task.
 Minister of Urban Affairs & Employment
Government of India
FOREWORD

Soon after independence in 1947, India launched a massive programme of

economic development and adopted consciously a path of mixed economy with
huge investments in public sector enterprises. The successive Five Year Plans laid
progressively increasing 'emphasis on development planning involving large
construction programmes and projects in various social and economic sectors. The
Ninth Plan of the country has been drawn in the backdrop of widespread economic
changes that permit rolling back the public sector investment from those sectors of
economy where private sector can increasingly play more significant role
While country has become self.,sufficient in food and clothing and can boast of
achievements on several fronts, most public efforts in housing and infrastructure
development got frustrated largely due to uncontrolled growth of population, and
lack of policy emphasis on integration of public and private sectors in the shelter
process. It is a matter of great satisfaction that now the Government has taken several
initiatives to ensure that 'housing for all' becomes a reality. Foremost of these
initiatives is the formulation of the National Housing and Habitat Policy laid in the
Parliament recently. Besides addressing a spectrum of areas, the Policy, i~ter alia,
recognises the need for massive participation of private sector and strengthening of
the building materials and technology delivery mechanisms that provide crucial
inputs to the housing and infrastructure development.
I understand that there has been remarkable progress in the area of building
materials resulting from the excellent contributions made by our scientists,
technologists and the progressive' corporate sector. It is remarkable that the country
today not only produces almost all materials like steel, aluminium, cement, glass,
ceramics, alloys, sanitary wares, paints, plastics and composites but many of them of
world-class quality, conforming to the ISO standards. Today India produces 70
million tonnes of cement and 22 million tonnes of steel and globally ranks fourth in
cement production. The new technologies based on recycling of industrial wastes
now increasingly utilised by the materials industry should help in achieving a
sustaInable consumption of natural resources thereby leading to environmental
protection and reduction in energy demand.
In the fiftieth year of our independence, it is heartening that BMTPC, with active
participation of CSIR, DST, BIS and other public and private organisations has
nucleated this study and produced this document which meticulously records
techno-industrial progress achieved by the building materials sector. I like to
congratulate Shri T.N.Gupta, Executive Director, Building Materials & Technology
Promotion Council, for bringing out this Commemorative Volume. I hope it would
provide an opportunity for introspection and catapult the efforts of researchers,
professionals and industry to meet the future challenges in the construction sector.

~ (~;~~'"I-1._~.Q
,
(Ram jethmalani)
 Minister of State
Ministry of Urban Affairs & Employment
Government of India

MESSAGE

With the rising industrialisation and population, problems of shortage of housing

and infrastructure, increasing poverty and unemployment and vulnerability to
natural hazards are the foremost challenges which need to be addressed in the
national development process. Recognising that urbanisation and increase in
population is inevitable, the government has formulated several policies and
programmes for socio-economic betterment of the deprived sectors of population by
ameliorating poverty and unemployment.
The urban population which was about 14 per cent at the time of
independence, is likely to rise to 33 per cent by the turn of the century and is
expected to rise to 50 per cent by 2025. While we are on the threshold of the next
millennium, maintaining quality of life, particularly in urban centres, is going to be
a big challenge for our construction sector. Besides issues related to land and
finance, one of the critical issuesthat require to be tackled is the access to building
materials and technologies, which is a crucial input for the planned growth of
housing.
Soon after independence the national planners recognised the need to integrate
science and technology with the social and economic development process. The
advancements in science and technology during pastfive decades have resulted in
a number of innovative build)ng materials and technologies which are environment
friendly, energy efficient and cost effective. Since the transfer of technology from lab
to land has been a complex process, the present Government has formulated the
National Housing and Habitat Policy, which lays emphasis on improving the access
of common man to crucial inputs to housing. I am sure the Policy will provide much
needed reorientation and help in bringing about the attitudinal change among
various players of the construction sector. The emphasis on public private
partnerships would encourage and expedite technology transfer and entrepreneurial
initiatives.
The Building Materials and Technology Promotion Council has been actively
engaged in enhancing the technology climate for efficient and effective
implementation of housing programmes. In the 50th year of our independence it is
heartening that BMTPC is bringing out a Commemorative Volume on 'Building
Materials in India: 50 Years' which documents the progress achieved by the building
materials sector during last five decades. I hope this publication will encourage all
those involved in the housing and building activity to take advantage of the cost-
effective technologies for improving productivity and affordability in the housing
sector. (j ~ ~

I wish the BMTPC all success in their efforts. C"l.£:O \\ /::!j)"))~~

(Bandaru Dattatrava)
 Secretary
Ministry of Urban Affairs & Employment
Government of India

MESSAGE

In India art and science of construction are as old as its civilisation. However, in the
modern context construction is an activity that provides crucial inputs for
development in all sectors of economy. Implicit in the attainment of goals of
economic development is, provision of physical infrastructure like roads, railways,
bridges, canals power stations, industrial and institutional buildings and housing,
along with other civil engineering works. All these are the output of the construction
sector and important components in developmental process. Soon after
Independence, when the country launched various programmes of social and
economic development, the need to strengthen the construction and building
materials sector was realised. The successive governments, therefore, laid emphasis
on the integration of scientific and technological advancements in the construction
activities.
Recognising the gap between laboratory development and large scale field
application of innovative building materials and construction technologies
developed by our R&D institutions, this Ministry established Building Materials and
Technology Promotion Council in 1990 to strengthen the technology transfer and
delivery systems in the building sector. The Council has been actively engaged in the
evaluation, validation and dissemination of new technologies particularly those
based on agro-industrial wastes and bye-products. These new technologies have
been found to be more energy efficient and environment friendly compared to their
traditional counterparts which were both material and energy intensive.
I am happy to note that the BMTPC is bringing out this Commemorative Volume
to document the progress achieved in the building materials sector during the last
five decades. The publication reflects on the phenomenal proliferation of large
variety and volume of building materials that has taken place in the post-
independence era. Though India has attained an internationally competitive status
in several areas of technology development, yet its impact is still to be felt in the
housing sector. I am sure this Commemorative Volume will help all those concerned
with housing and building in identifying and introducing the appropriate building
material options to achieve the goals of sustainable housing development.

~Ir-- ~
(Kiran Aggarwal)
Acknowledgements The author is highly grateful to Shri RamJethmalani, the Honourable Minister of Urban Affairs
and Employment, for his continued encouragement and very kindly agreeing to write the
Foreword for this Commemorative Volume.
Grateful thanks are conveyed to Shri Bandaru Dattatraya, Hon 'ble Minister of State,
Ministry of Urban Affairs & Employment, and Smt. Kiran Aggarwal, Secretary, Ministry of
Urban Affairs & Employment for their kind messageson the completion of this volume.
Special thanks to Shri G.C. Bhandari, Addl. Secretary (Finance), Shri J.P. Murty, Jt.
Secretary (Housing) Ministry of Urban Affairs and Employment and Shri V. Suresh, CMD
HUDCO for their continued encouragementin bringing out this special publication.
The thirtY one topics, which constitute this book, have been possible through the excellent
contributions received in response to my request to the eminent scholars, experts and
professionals. Special recognition is due to the following for contributing inputs relating to
their fields of expertise:
Dr. S.P.Ghosh,Director General,National Council of Cementand Building Materials, New
Delhi, Dr. V.S. Ramachandran, Distinguished Scientist, Former Head Building Materials,
National ResearchCouncil of Canada,Ottawa, Shri DilipBiswas, Chairman, Central Pollution
Control Board,Dr. P.S.Das,Director General,Bureau of Indian Standards,Dr. S.K.Chopra,former
Additional Director General,NCB, New Delhi, ProfessorR.N. Iyengar, Director Central Building
ResearchInstitute, Roorkee, (Late) Dr. A.K.Gupta, Director, Central Road ResearchInstitute,
ProfessorPrem Krishna, University of Roorkee,ProfessorT .R. Ramachandran,Director, Jawahar
Lal Nehru Aluminium Researchand Training Centre, Nagpur, Dr. Mohammed Yaseen,Deputy
Director Indian Institute of Chemical Technology, Hyderabad, Shri S.A. Reddi, Director,
Gammons India Pvt. Ltd., Dr. V.S. Parmeswaran, Director, Design Technology Consultants,
Chennai, Shri P.B. Vijay, Former Director-General, CPWD, New Delhi, Shri Jose Kurien,
Suprintending Engineer,CPWD,New Delhi, Dr. JosephGeorge,former Director, Indian Plywood
Industries Research& Training Institute, Bangalore,Prof. K.N.Vaid, Director General,NICMAR,
Bombay, Dr.R.S.Bisht, Director, Archeological Survey of India, New Delhi, Dr. T.P. Sharma,
Deputy Director, CBRI, Roorkee,Shri Arun Shrivastava,Consultant, New Delhi, ProfessorT.C.
Rao,Director, RRL, Bhopal, Dr. Mohan Rai, former Deputy Director and Head,Building Materials,
CBRI,Shri N.C. Majumdar, former Senior Scientist, CBRI,Shri S.C.Gupta, Former Chief Engineer,
CPWD, Shri K.S.Pruthi, Scientist, Forest ResearchInstitute, Dehradun, Shri J.Sengupta,Chief
Building Materials, BMTPC; Shri R.K.Celly, Chief Technology Marketing, BMTPC, A.C.
Khazanchi, Deputy Director, RRL, Bhopal, Dr. Mohini Saxena,Scientist, RRL, Bhopal and Shri
O.P. Ratra, former Deputy Chief, BMTPC.
The untiring efforts made by my colleagues in the BMTPt:::in the compilation, checking
and verifying the entire text helped in successfully completing this book. Special efforts made
by Sarvashri H.C.Matai, S.K.Gupta, V.K.Sethi, D.P.Singh, M.Ramesh Kumar, Dalip Kumar,
M.M.Arora, Praveen Suri, Anita, Sukhpal Pundir, merit my personal appreciation for their
patience, perseveranceand dedicated support in the preparation of this publication.
The compilation of various chaptershas beenpossible by taking someliberty in modifying
the original contributions received, with the additions of relevant information from books,
journals, directories, and encyclopedias which have been mentioned as sources,referencesand /
bibliographies. I am also thankful to the Archaeological Survey of India for facilitating copies
of the p~otographs of someancient buildings, reflecting the glorious culture of Indian buildings
architecture and heritage. Permission accorded the PergamonPress,Oxford is acknowledged
for utilising selected excerpts from the Concise Encyclopedia of Building & Construction
Materials, first edition 1990.
The efforts of Shri Anurag Gupta and colleaguesShri RaneshRay and Km. Urmi Goswami
of Wordsmithy are acknowledged for design and printing of the volume.

T.N.Gupta,
Executive Director. BMTPC
 XI

Preface Post independence situation posed several challenges due to widening gap in
demand and supply of building materials which were crucial inputs to the
national development programmes and projects. This necessitated a close study
of the existing base of the building materials industry with a view to imbibe new
thinking and encourage innovation. A strong construction sector was imperative
to cope with the desired level of economic growth and the resulting demand for
building materials. Perhaps this marked the beginning of intensive search and
rapid strides for enlarging the range and production of building materials far
beyond that existed in 1947 at the time of independence.
Recognising the role of research and development in various sectors, the
Government of India had established in 1942, the Council of Scientific and
Industrial Research, an umbrella organisation which enabled R&D to flourish as a
nationally recognised activity. Besides research and development, the emphasis
on rapid industrialisation catalysed the need for standardisation and regulatory
mechanisms to assist in the systematic growth of the industry and also to deal with
the emerging concerns for environmental protection and energy conservation.
These concerns are reflected in the establishment of Indian Standards Institution
in 1947, the Department of Environment and Forests, and the subsequent
enactments to tackle environmental problems. Since building and construction is
the largest consumer of natural material resources, it is worthwhile to mention
that, India is the first country which has made provisions for the protection and
improvement of environment in its constitution through 42nd amendment in
1976.
In this volume, attempt has been made to present a holistic picture of the
successive stages of growth and development in building materials sector,
reflecting on the technology inputs, promotional efforts, policy level supports
created in the country along with standardisation and regulatory instruments
established during past five decades.
The Editor is personally responsible for the selection of topics and the experts
who contributed in various areas covered and the Associate Editors for helping in
completing this book. In both these tasks he had the benefit of advice of the senior
professionals, eminent experts and the decision makers associated with this
Council.
During past one and half years that I have been engaged in bringing out this
volume, it was a great pleasure to interact closely with several eminent scholars
and professionals who have willingly contributed their time and efforts to realise
this undertaking which I, consider an obligatory task for the Council particularly
in the Golden Jubilee year of the country's independence.
It is with great pleasure that I convey my deepest gratitude to the contributors.
The task would not have been completed without the guidance and inputs from
them and the Associate Editors.
I like to record my special thanks and deepest appreciation to Dr. Mohan Rai
for his valuable contribution, unwavering attention and dedicated effort in
helping me to complete this task.
T .N.Gupta
Editor
XIV

Indian Standards Organisation (ISI) (now Bureau of Indian Standards) was also set up
in 1947. TheBIS was basically instrumental in the drafting and publication of Indian
Standards on Building Materials and Codes of Practices in line with standardisation
work on other materials. An intensive exercise is already being undertaken for
harmonisation of Indian standards with those brought out by ISO. Sometime ago a
Quality Control Certification System has also been launched by BIS for some
important factory-made building materials, such as cement, steel bars, paints, sanitary
wares and items of glass and aluminium alloys. The standardisation processreceived
its inputs from experts representing various interest gro~ps of technology developers,
consumers and manufacturers. \
Construction industry being the largest consumer of material resources, of both
the natural ones (like stone, sand, clay, lime) and the processed and synthetic ones.
During the last 50 years there has been some unplanned, unchecked and haphazard
exploitation of the mineral resources-limestone, clay, iron ore, bauxite and coal. The
intense mining activities of the minerals produced a variety of mining wastes, ore
benefication tailings, coal preparation/washing rejects. The growth in industrial and
agricultural activities continued to throwaway huge quantities of wastes and by-
products such as fly ash from power generation by burning pulverised coal, blast
furnace and other slagsfrom iron steel, non ferrous metal smelters, alumina red mud,
slate and marble wastes etc. These coupled with calcareousand suIphi tic wastes from
chemical industries - sugar, paper acetylene, tannery, phosphatic fertilisers,' soda ash
etc. amount today to nearly 250 million tonnes annually. Greatemphasis has been laid
in this publication on describing the results of R&D in waste utilisation. Research
efforts in this area have now established that (a) there could be ways and means to
dispose off the wastes and relieve pressure on land and environment (b) the waste
could form secondary resource materials for the production of alternative building
materials, and thus make effective savings in primary grade raw materials, energy,
labour and capital investment in plant and machinery, and (c) it is possible to make the
wastes free from the hazardous constituents and make them environment friendly.
There is an increasing awareness that the manufacture of building materials from
wastes and by-products would reduce pollution and energy consumption levels
compared to traditional processesusing the basic raw materials.
The Ministry of Environment and Forests,the Central and StatePollution Control
Boards, and the National Environmental Engineering ResearchInstitute, have been
making vigorous attempts for establishing regulatory regimes to monitor and control
pollution levels. As a result of promotional efforts by organisations like BMTPC
awarenessfor utilisation of industrial and mining-mineral wastes in the manufacture
of building materials has increased and several waste based building material
technologies stand proven and amply demonstrated.
The range of materials produced in the country today, include, steel, aluminium,
cement, glass, ceramics, alloys, sanitarywares, paints, plastics and a large variety of
building chemicals, admixtures and composites. It is not only the range of materials
which is impressive but most of these indigenously produced materials compare well
with world-class quality and conform to the ISO standards.
Fly ash (70/75 million tonnes per year) and blast furnace slag (10 million tonnes
per year) are the two most important wastes which are finding good application in
construction sector. Concrete products, bricks and blocks and ready mixed concrete
are being produced with fly ash or slag content up to 65 per cent. This is one of the
 xv
1

various emerging technologies being practised in the country. Lime sludges,

phosphogypsum, red mud and mine tailings are the next category of the wastes
available in substantial quantities on which a good level of research work has already
been undertaken, though commercialisation of these technologies has yet to happen.
There is growing awarenessabout their utilisation in cement, concrete, lime-gypsum-
pozzolana and blended masonry cements. The one of the important trends currently
being pursued is to use ordinary Portland Cement to the minimum and make best
exploitation of potential benefits of the mineralogical constituents of the wastes in
cement and cement concretes for specific applications.
4 Modern concepts of material science evolves around basic understanding of the
structure-property relationships of materials. Several advanced composite materials,
now being produced are light-weight but structurally very strong, fracture resistant
and highly impermeable. They are being produced using polymer as well as cement
matrix, with both the manmade and the natural fibres. Many types of composites,
using jute, sisal, coir, bagasse,mixed with steel and glass fibres, have been used in the
manufacture of door and window shutters and frames, panelling and partitioning
systems. The concepts of composites have been extended to the amorphons <-->
crystalline phases of materials for the development of glass-ceramicsand refractories
of outstanding structural properties and long durability.
Severalvarieties of new materials have now found well established recognition as
partial substitutes of timber, aluminium, steel and cement. The Building Materials and
Technology Promotion Council, during the last eight years have been responsible for
the upgradation and development of many of the new materials listed here, through
technical collaboration, developmental and consultancy efforts.
New materials, during the development stageshave successfully crossedhurdles
and stand proven through standardisation, validation and are displaying increasingly
wider acceptability. These are the well accepted teething troubles faced by any new
industry. Such problems, could not be settled in the meetings of the technical
committees or deliberations at the conferencesand therefore required vigorous efforts
for technology transfer, demonstration, fiscal incentives to attract investment and
wider dissemination of the range of innovative options. With the efforts of the BMTPC
and the support of the Ministry of Urban Affairs and Employment, many well-meaning
fiscal incentives for the promotion of new building materials based on industrial,
mining, mineral and agro-wasteswere provided by Government of India in terms of
excise duty and lowering or exemption of import duties on the plant and machinery
essentially required to be imported. These incentives not only helped in displaying a
policy support for waste based building materials but created a confidence amongst
entrepreneurs and users thereby attracting greater investments in the building
materials sector.
This book, covering 31 well established topics related to building materials, is
intended to present the current status about the various aspectsof research,technology
development, standardisation, commercialisation and field applications and
acceptability. Care has been taken, wherever possible to deal with comparative
information on developments in the world and India - during the past 50 years. The
material presented in the book is based on the inputs provided by the recognised
professionals and eminent experts in their specific areasof specialisation.
XVI

TABLE OF CONTENTS Foreword v

Message vi
Message vii
Contributors viii
Acknowledgements x
Preface xi
Introduction xii

1. Evolutionof building materials 2

1. Introduction. 2. Theancientperiod. 3. Themedievalperiod .4. TheSultanate. 5. TheMughalPeriod
. 6. Thecolonialperiod. 7. Unprocessed
materialsof commonuse. 8.Concludingremarks. 9. Bibliography

2. Burnt clay brick and tile 14

1. Introduction;Progressin the colonial period. 2. Focusof researchand development;Studyof soils.
3. Standardisation;Compressivestrengthand water absorption;Efflorescence;Bulk density; Fireresistance;Other
properties. 4. Utilisation of waste in brick making; Redmud; Flyash;Stonedust;Coal washeryrejects;Granulated
slag; Siliceous river sediments;Cinder; Rice-husk ash. 5. Processimprovement; Improved hand-moulding;
Semi-mechanisedbrick plant; High draught kiln; Fully mechanised brick plant. 6. Product range upgrading
and expansion; Improved bricks from inferior soils; Product range expansion. 7. Environmental concerns;
Energyaudit; Environmentalpollution. 8. Clay tiles; Mangalore patter!)roofing tiles; Prefabbrick panel system;
Burnt clay canal lining tiles; Standardson tiles. 9. Concluding remarks. 10. Standard specifications. 11.
Bibliography

3. Stone 40
1. Introduction. 2. Classification of building stones. 3. Uses of stones in building. 4. General properties
. 5. Stone slab frames for doors/windows. 6. Occurrence of decorative stones in India. 7. Export of Indian
stones. 8. Quarrying. 9. Finishing and polishing. 10. Stone as aggregate in concrete. 11. Effect of heat
.12. Durability; Physical weathering; Effectsof pollutants; Protection of stones. 13. Concluding remarks.
14. Standard specifications 49 . 15. Bibliography 50

4. Building Lime 52
1. Introduction. 2. Limein constructionindustry. 3. Limeproductiontechnology. 4. Focusof research
anddevelopment;Processimprovement;New processfor makinghydratedlime; New products;Pollution
in lime industry; Utilisation of waste. 5. Stagnationand continuedbackwardness
of the lime industry. 6.
Concludingremarks. 7. Standardspecifications. 8. Bibliography

5. Gypsum 64
1. Introduction. 2. Gypsum products. Plasterof Paris. Gypsum plaster. 3. Fibrous gypsum plaster board
. 4. Gypsum blocks. 5. Acoustic tiles. 6. Processimprovement. 7. Utilisation of by-product gypsum. 8.
Concludingremarks. 9. Standardspecifications. 10. Bibliography

6. Glass 74
1. Introduction; History of glass-makingtechnology. 2. The Indian glass industry. 3. Composition of glass
. 4. Typesof glass. 5. Glass as building material; Glass for door and window shutters; Glass tiles; Mirrors;
Glassfibre; Glasswool; Glassblocks. 6. Researchand development in India; Waste utilisation; New products
. 7. Concluding remarks. 8. Standard specifications. 9. Bibliography

7.Ceramics 84
1. Introduction. 2. Indianceramicindustry. 3. Classificationof ceramics;Whitewaretiles;Structuralclay
products;Refractories;Vitreousenamels. 4. Kiln for ceramic production. 5. Focusof researchand
development; Indigenous processes developed by CG&CRI; Advanced ceramics. 6. Employment and education
in ceramics. 7. Concludingremarks. 8. Standardspecifications. 9. Bibliography

8. Steel 96
1. Introduction;Indiansteelindustry. 2. Determinantsof the growth of steelindustry;Domesticdemand
projection;Projectionof demandfor steelalloys. 3. Globalsteelscenario;Exportopportunitiesfor Indian
steel. 4. New technologiesin steelproduction;Energyconsumption. 5. Infrastructureaspects;Coastal
transport;Power. 6. Research and development. 7. Structuralsteel;Universalbeams(UB);Taperflange
beams (TFB); Parallel flange channels (PFC); Taper flange channels (TFC) . 8. Steel in buildings; Major structural
applications; Non-structural applications; Steel bars/rods for reinforcement; Prestressing steel; Steel sections;
Steel doors, windows, ventilators and frames; Galvanised steel sheets; Rolling shutters and grills; Steel gates
and welded grills; Weld mesh and expanded metal sheets. 9. Concluding remarks. 10. Standard specifications
.11. Bibliography

9. Aluminium 112
1. Introduction. 2. Technology. 3. Aluminiumproductionand consumption;Consumptionpattern. 4.
User industries; Automobile industry; Packaging; Construction; Electrical. 5. Wastes of the aluminium industry;
Red mud; Fluoride emissions; Spent pot lining (SPL) . 6. Indian scenario and efforts needed to achieve
international standards. 7. Copper, zinc and their alloys; Copper; Zinc. 8. Recycling of aluminium and
copper scrap. 9. Concluding remarks. 10. Standard specifi<:ations . 11. Bibliography
 XVII

10. Cement
1. Introduction. 2. The Indian cement industry; Production and consumption; Mini cement plants; GDP
growth, demand and forecast; Levies on cement; Exports. 3. Properties of cement; Grades of cement;
Additional requirements; Initial and final setting times; Functional requirement; Chemical properties;
Fineness of cement. 4. Types of cement; Ordinary Portland cement (OPC); Blended cement. 5. Cements
to meet specific service conditions; Rapid hardening cement (RHC); Low heat cement (LHC); Oil well
cement (OWC); White cement (WC); Masonry cement (MSC); Expansive cement. 6: Research and
development; Specific R&D in scientific institutions. 7. Energy conservation in cement; Quality control in
cement manufacture . 8. Efforts at environmental protection; Conservation of mineral resources; Recycling
of wastes. 9. Concluding remarks; Future planning in cement industry; Mining; Process. 10. Standard
specifications. 11. Bibliography

11. Concrete
1. Introduction. 2. Types of cement. 3. Cements other than OPC; Portland pozzolana cement (PPC);
Portland blast furnace slag cement (PBFSC); Sulphate resisting cement (SRC); Low alkali cement; Low heat
cement. 4. Concrete as a structural material; Concrete mix design. 5. Aggregates; Coarse aggregate; Fine
aggregate. 6. Ready mixed concrete (RMC) . 7. Precast concrete elements (PC) . 8. Prestressed concrete
(PSC); Reinforcement steel; Reinforcement coyer blocks; Prestressing tendons. 9. Cement replacement
materials; Pulverised flyash concrete; High volume flyash concrete; Condensed silica fume concrete; Rice-husk
ash concrete; Ground granulated blast furnace slag (GGBS) . 10. Lightweight concretes; No-fines concrete;
Aerated concrete. 11. Low density concretes; Low density lightweight aggregate concrete; Moderate strength
lightweight aggregate concrete; Structural lightweight concretes; Whisper concrete. 12. Concluding remarks
. 13. Standard specifications. 14. Bibliography

12. Recent advances in concrete technology

1. Introduction. 2. Types of concrete; Polymer concrete; Sulphur concrete; Fibre reinforced concrete; High
performance fibre reinforced concrete; Ferrocement; Roller compacted concrete; Very high strength concrete;
Superplasticised concrete. 3. Concluding remarks. 4. Standard Specifications.5. Bibliography

13. Admixtures
1. Introduction. 2. Classification
of admixtures by source/origin; Natural and mineral admixtures; By-
products and wastes; Chemical 3. Classification of admixtures by end-use; Air-entraining agents;
admixtures.
Accelerators; Retarders; Gas-forming agents; Alkali-aggregate expansion inhibitors; Damp-proofing and
permeability-reducing agents; Water reducing and workability agents; Superplasticisers; Cement-
superplasticiser compatibility; Grouting agents; Corrosion inhibiting agents; Bonding admixtures; Fungicidal
admixtures; Colouring admixtures; Miscellaneous admixtures. 4. Codes of practice. 5. Future directions.
6. Standard specifications. 7. Bibliography

14. Utilisation of industrial wastes 202

1. Introduction. 2. Development in the utilisation of wastes. 3. Waste as concrete aggregate; Slags, By-
products from power plants; Recycling of concrete. 4. Mining and quarrying waste; Miscellaneous wastes as
aggregates .5. Utilisation of waste in cement manufacture; As fuel; As raw material; Blended cement; Flyash;
Slag. 6. Gypsum substitution; Waste gypsum and limestone dust additive in cement; Waste chemical
admixtures; Utilisation of ore dressing tailings wastes. 7. Bricks and blocks using flyash; Flyash-clay bricks.
8. Concluding remarks .9. Standard specifications .10. Bibliography

15. Materialsfor roads

1. Introduction. 2. The R&D scenario. 3. Road construction materials; Surkhi as a pozzolana; Steel fibre
reinforced concrete (SFRC); Synthetic resins; Magnesium phosphate cement (MPC);Roller compacted concrete
pavement (RCCP);Magnesium oxychloride cement (MOC); Improved surface finish for cement concrete roads;
Low quality aggregates in pavement quality concrete; Durability of concrete; Agro/industrial waste
materials;Municipal waste; Mining and quarrying wastes. 4. New construction techniques for pavements;
Prestressed ~oncrete pavements; Continuously reinforced concrete pavement; Fibre reinforced concrete
pavement; Precast concrete block pavement. 5. Concluding remarks. 6. Standard specifications. 7.
Bibliography

16. Bitumen
1. Introduction. 2. Kinds of bitumen and products; Solid bitumen and bitumen mastic; Liquid or cut-back
bitumen; Bitumen emulsion ;Bitumen felts and fabrics; Oxidised or air-blown bitumen; Bitumen-polymer
composites; Bitumen mortar and concrete; Bitumen-paper board roofing sheets. 3. Bitumen for roads;
Additives to asphalt concrete. 4. Antioxidants for bitumen. 5. Rubbers and polymers in road construction-
related R&D at CRRI; Limestonedust powder; Natural rubber and bitumen mixture. 6. Blown grade bitumen
in roads. 7. Mastic asphalt. 8. Anti-stripping chemicals. 9. Waste thermoplastic in roads. 10. Concluding
remarks. 11. Standard specifications. 12. Bibliography

17. Geotextiles 242

1. Introduction. 2. Historical background. 3. Development in India. 4. Geotextile raw materials. 5. Types

Geocomposites .
of geotextiles; Geomembranes; Geogrids; Geotextile nets or geonets; Geotextile mats; Geotextile webs;
6. Functions of geotextiles; Hydraulic functions; Mechanical functions; Protection; 5upport
. 7. Geotextiles in road construction. 8. Present R&D activities in the area of geotextiles . 9. Concluding
remarks. 10. Standard specifications. 11. Bibliography

18. Wood and other lignocellulosic products

1. Introduction. 2. Researchand development in India (FRI & IPIRTI);Timber Engineering; Seasoningof
timber; Timber mechanics; Preservation of timber; Wood working. 3. Panelsand composites. 4. Plywood;
XVIII

Grades of plywood; General purpose plywood; Decorative plywood; Marine plywood; Shuttering plywood;

Properties and uses of plywood; Flushdoor .

Structural plywood; Preservative treated plywood; Fire retardant plywood; Other speciality plywood;
5. Particleboard; Particleboards from agricultural residue; Jute
stick; Rice husk; Portland cement bonded particleboard ;Properties and uses of particleboards. 6. Blockboard
. 7. Fibreboard; Medium density fibreboard (MDF). 8. Insulation board. 9. Standard hardboard; Tempered
hardboard; Prefinished hardboard. 10. laminated veneer lumber; laminated lumber panel board; Glued
laminated wood. 11. Bamboo mat board; Properties and uses. 12. Biomass as building materials. 13.
Durability of bamboo and thatch; Impact of treatment on cost; Empirical evidence of treated bamboo;
Treatment of bamboo; Technology used. 14. ~oncluding remarks. 15. Standard specifications. 16.
Bibliography

19. Polymers and plastics

1. Introduction. 2. Petroleum industry. 3. Natural gas. 4. Petrochemical industry. 5. Shellac-natural
resin .6. Plastics industry; Raw materials for plastics; Characterisation of polymers & plastics. 7.
Diversification and organised marketing. 8. Major applications in buildings; Water tanks and sanitaryware;
Plastics for waterproofing and damp-proofing;Plastics and rubber for damp-proofing ;Alternative to timber;
Moulded furniture; Temporary shelter; Plastics glass; Composite materials. 9. Recycled plastics waste .10.
Performance-in-use concept; Standard specifications .11. Export of plastics goods. 12. Concluding remarks
.13. Standard specifications .14. Bibliography

20. Composite materials 294

1. Introduction. 2. Components of composites. 3. Particulate composite. 4. Fibre reinforced composite;
Compatibility of fibre with matrix; Characteristics of fibre reinforced composites; Matrix properties. 5. Hybrid
fibre-resin composites. 6. Advanced ceramic composites. 7. Composites for common applications in
buildings. 8. Vegetable fibre reinforced composites in India. 9. Contribution of the BMTPC, India .10. IS
Specifications on composites. 11. Composites for special applications. 12. Mission on advanced
composites. 13. Advanced materials; Semiconducting materials; Non-crystalline materials; Superconducting
materials; Bioceramics; Optical fibre materials; Polymers; Aluminium alloys. 14. Concluding remarks. 15.
Standard specifications .16. Bibliography

21. Protective and decorative coatings

1. Introduction. 2. The past and present scenario. 3. Growth in market. 4. Architectural coatings. 5.
Coatings for buildings; Paint coatings for exterior use; Coatings for mineral substrates. 6. Coatings for
furniture and wooden structures. 7. Coatings on metallic structures in the building. 8. Coatings on
structures made of plastics. 9. Coatings on interior surfaces. 10. Coatings for concrete, wooden or steel
floors. 11. Fireretardantcoatings. 12. Paint/coatingsystemsfor the automotiveindustry. 13. Protection
of substrate by organic coatings; Prospective performance of paints in protection of a substrate. 14. Indian
R&D in protective and decorative coatings; Zinc rich paints; Phosphate treatments for mild steel; Corrosion in
fertiliser factories; Paint systems for wood and wood based materials; New formulations of cement paints;
Resins and paint coatings formulations; Curing aid for concrete; Polyurethane formulations; IPN coating. 15.
Modern progress; Quality; Breakthrough in paint and coatings industry. 16. The prospective consumption of
paints in different sectors. 17. Regulatory restrictions; Enactment of Rule 66 on the use of organic solvents;
Safety, health and environment; Environmental protection agency (EPA); Compliant or VOC exempt solvents;
The United Nations VOC Protocol; VOC in Indian paint industry. 18. Strategy of the paint industry; Eco-
friendly paint formulations. 19. Water-borne coatings. 20. Powder coatings. 21. High solids coatings
(HSC) . 22. Global scenario and concluding remarks. 23. Standard specifications. 24. Bibliography

22. Flooring materials

1. Introduction. 2. Modern requirements of flooring 3. Research and development. 4. Industrial progress
. 5. In situ floor finishes; Portland cement concrete; High alumina cement concrete; Rubber latex cement
concrete; Bitumen mastic; Polymer concrete. 6. Hardeners. 7. Jointed floor finishes. 8. Decorative marble
tiles. 9. Granite floor tiles. 10. Agglomerated marble. 11. Gypsum marble; Technical specifications. 12.
Cork floors. 13. Vinyl tiles and sheets;Technicalspecifications. 14. Glazedceramictiles; Technical
specifications. 15. Concluding remarks. 16. Standard specifications. 17. Bibliography

23. Energy in building materials

1. Introduction. 2. Energy and the environment. 3. Studies on energy in building materials; Cement industry;
Energy efficiency in cement industry in India; Energy content in burnt clay bricks and tiles; Energy consumption
in the manufacture of metals; Energy content in lime and gypsum; Energy requirement for production of sand,
aggregate and stone; Energy requirements of concrete and concrete blocks; Energy requirement in miscellaneous
building materials and components. 4. Energy in building. 5. Recycling of materials. 6. Energy supply; Coal
; Hydrocarbons; Liquified petroleum gas; Production of electric power; Renewable energy. 7. Concluding
remarksand recommendations;Fuel,energy and environment; Improvement in the mining of ores, minerals and
their beneficiation processes, transport and storage; Recycling of waste to save energy; Utilisation of waste for

construction .
energysaving;Realfuel value of organic wasteto be exploited; Need for clean processing of materials and cleaner
sites; 8. Standard specifications. 9. Bibliography

24. Fire and building materials

1. Introduction. 2. Causeof fire; Materials at high temperature; Reactions of some basic materials to fire. 3.
Data baseon fire and materials. 4. Modified building codesand standards. 5. Improvementin fire
protectionthroughmaterials. 6. Spreadof fire within the roomof origin. 7. Spreadof fire outsidethe room
of origin. 8. Fireretardantchemicals. 9. Mattresses and upholsteredfurniture fires. 10. Fireresistance;
Fire detection. 11. Containmentof fire. 12. Fire protection of structural elements. 13. Post-fire
investigations and repair of damages. 14. Fire modelling and CBRI work. 15. Concluding remarks. 16. Test
facilities at CBRI, Roorkee . 17. Standard specifications. 18. Bibliography
 xix

25. Building materials industry and pollution

1. Introduction; Pollution potential .2. Carbon dioxide emission; Improved technologies and reduction in
carbon dioxide emission; Carbon dioxide emission by other building materials. 3. Standardson emission.
4. legislation for prevention and control. 5. Pollution control standards. 6. Incentives. 7. Utilisation and
management of waste. 8. Concluding remarks. 9. Standard Specifications. 10. Bibliography

26. Building materials in central public works

1. Introduction. 2. History of public works in India. 3. Materials and construction practices in pre-
independence period. 4. Building materials and their standardisation during post-independenceperiod. 5.
New materials-development and applications. 6. Wood substitutes; Need for wood substitutes; Development
of wood substitutes; Wood substitutes approved by CPWD; Wood substitutes underfinalisation . 7. Use oftlyash
for different applications; Flyash-a national level problem; Utilisation of flyash in CPWD . 8. Construction
materials and technologies in highway sector; Roads--an important sector of public works; Roads in pre-
independence period; Developments in the highway sector; Developments in road construction; Developments
in bridge and flyover construction. 9. landmark events in the development of building materials and associated
technologies; Designed masonry for load bearing walls.Use of high strength deformed bars; Use of high strength
concrete; Use of prestressed concrete; Use of precast elements; Improvement in specifications of public buildings
to provide permanent and durable finishes; Repairs and rehabilitation. 10. Future scenario; Ready mixed
concrete (RMC); High performance concrete (HPC); Composite materials as replacement of reinforcing steel; Use
of polymers; Use of flyash; Energy efficiency and sustainable development

27. Standardisationin constructionmaterials

1. Introduction; Standardisation activities in India. 2. Standardisation of building materials; Cement and
aggregates;Pozzolanas;Building lime; Stone;Clay products for buildings; Gypsum building materials;Timber;
Wood products; Bitumen and tar products; Floor coverings and other finishes; Waterproofing and damp-
proofing material; Sanitary appliances and water fittings; Doors and windows; Aluminium and aluminium
alloys; Concrete reinforcement and other steel sections; Other building materials; 3. Development in design
and construction; Concrete and steel; Timber; Functional requirements in buildings; Measurement of civil
engineering works; Construction practicesand safety;Fire safetycodes and equipment; National Building Code
and Handbook. 4. Innovative building materials. 5. Quality control. 6. BIS Certification Marks Scheme
. 7. Role at international level . 8. Concluding remarks

1.lntroductiQn .
28. Performance and durability of building materials
2. Servicelife of materials. 3. Performancecriteria. 4. Suggestedmethodologyof performance
criteria. 5. Service stresses and working conditions of building materials; Surface hardening, fracture toughness
,

and fatigue; Fatigue strength; Creep. 6. Concrete; Chemical deterioration; Steel reinforcement; Aggregate. 7. Fibre
composites; Glass fibre reinforced plastics (GRP); Polymer fibre reinforced cement and concrete; Composite
materials and fire; Composites and water. 8. Timber. 9. Surface coatings. 10. Adhesives and plastics; Natural
outdoor weathering .11. Brick, tiles, stone and silicate cements; laterite; Deterioration of building stone; Stabilised
bricks. 12. Concluding remarks. 13. Standard specifications .14. Bibliography

29. Building materials in civil engineering education

1. Introduction. 2. New materials. 3. Civil engineering education at different levels. 4. Changing pattern
of education in materials. 5. Researchand continuing education programme; Impact of emerging research
areason engineering education. 7. Concluding remarks

30. Technologytransfer in building materialsindustry

1. Introduction; Strengths;Weaknesses;Threats and opportunities for the industry; Strategic position of the
industry. 2. Resource base; Manpower resources; Institutional resources; lack of co-ordination between
technology producers and users;Contribution of scientific studies in educational institutions; The need for co-
ordination: establishmentof DST; National ResearchDevelopment Corporation; Situation by the mid-1980s;
Housing and Urban Development Corporation (HUDCO); National Network of Building Centres. 3. The
genesis of technology transfer in building materials. 4. Formation of Building Materials and Technology
Promotion Council; Corporate strategy of BMTPC (1993-98); Implementation strategy; Joint technology
development programmes; IDNDR project on protection of non-engineered houses from natural hazards;
Achievements; Innovative technologies developed by BMTPC and licensed to enterprises for commercial
. .
production; Publications of the Council. 5. Concluding remarks. 6. Bibliography

31. Emerging trends in building materials 484

1. Introduction. 2. Nature of changing needs and effective materials utilisation. 3. Current status. 4.
Traditional materiars. 5. Burnt clay bricks. 6. Cement and concrete; Blended cement; Use of wastes in
concrete; Waste as aggregates. 7. Composites; Man-made and natural fibres based composites; Wood
substitutes; Composites from local materials; Use of bamboo for building components; Polymers, plastics and
surface coatings. 8. Metal matrix composites; Surface engineering. 9. Structure-property relationship;
Property of engineering materials. 10. Searchfor materials and emerging technologies 11. Valorisation and
recycling of industrial wastes. 12. Ceramic materials obtained by recycling wastes: some considerations
and examples. 13. Glass ceramic materials obtained by recycling hazardous industrial wastes: state of the
art. 14. Concludin2 remarks. 15. Biblio2raphv

Appendixes

landmarks 510
ForeignCollaborations 512
Abbreviation and Unit s 526