PROJECT

REPORT
December 2008

A project of housing shelters to the

teaching fraternity in Tanzania

Submitted By

National Social Security Fund

(NSSF) Tanzania.

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 TABLE OF CONTENTS

• EXECUTIVE SUMMARY………………………………………03

• THE TECHNOLOGY………………………………………………04

• PROJECT IMPLEMENTATION…………………………04

• SELECTION OF TECHNOLOGY………………………05

• TECHNOLOGY IN DETAIL………………………………09

• MIXING GUIDE……………………………………………………11

• APPLICATION&ADVANTAGES…………………………12

• DESCRIPTION OF HOUSE………………………………19

• METHODOLOGY………………………………………………………20

• BILL OF MATERIALS,EQUIPMENT……………38

• COST…………………………………………………………………………41

• COMPLETION…………………………………………………………42

• REPAYMENT……………………………………………………………43

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EXECUTIVE SUMMARY:
This report is being submitted to the Government of India by National
Social Security Fund-Tanzania for the further approval of the housing
project for housing shelters to the teaching fraternity in Tanzania.

This project will be executed with New Construction Technology by name

Light weight Concrete. This technology gives benefit of tremendous time
saving and cost benefits comparing with regular civil construction.

The project involves providing housing shelters to the teaching

fraternity. There are 300,000 such shelters planned to be constructed
and sold by NSSF to the teachers which shall be done in phased manner,
depending up on availability of fund.

The NSSF plans in the fist phase plan to construct 2800 houses.

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NSSF BACKGROUND
At 937,062 square kilometres, the United Republic of Tanzania is the largest
country in East Africa. Long considered an oasis of stability in the region,
it hosts the most refugees in Africa as an outcome of conflicts in
neighbouring Burundi, the Democratic Republic of the Congo and Rwanda.

The past decade has been marked by successful reforms and steady economic
growth. Tanzania’s challenge for the future is to control the spread of AIDS
and create better living conditions for the rural poor.

The United Republic of Tanzania was one of the ‘25 by 2005’ acceleration
countries, a UNICEF initiative designed to intensify efforts in 25 countries
in danger of missing the 2005 Millennium Development Goal of gender parity in
primary education. Today, the country has roughly equal numbers of girls and
boys enrolled in and attending primary school. The abolition of school fees in
2000 was an important initiative for getting children – both boys and girls –
into school.

The 2002-2006 Primary Education Development Plan, supported through a sector-

wide approach to planning, incorporates such measures as the construction of
new schools and teachers’ housing, teacher recruitment drives and quality
improvement.

In an effort to support these development initiatives NSSF has embarked on a

mission to provide solutions in the area of teachers housing. The retention
and recruitment of teaching personnel in Tanzania is key to the drive in
promoting education throughout the nation. One of the fundamental problems
encountered in this area is the lack of adequate housing for the teaching
staff.

It is our vision therefore to participate in facilitating the construction of

homes for these professionals, whereby creating employment, promoting a better
quality education in areas where access to basic education is scarce, and
providing sustainability by providing ownership through participation. NSSF
envisages allocation of a portion of the teachers Social Security
contributions towards loan repayments ---- a very simple but beneficial

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ownership scheme.

An average single family home of approximately 90 sq mtrs could be provided to

each participating teacher through a qualified home loan scheme of
approximately 20 years. Considering a home value of approximately 15,000 usd
with loan payments amortized over 20 years, effectively a monthly deduction /
contribution from a teacher’s salary of 70 USD would be sufficient to service
the loan. As a comparison an average rental property for a single family can
fetch approximately 80 – 200 USD depending on the area of allocation.

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THE TECHNOLOGY:
The following low cost housing technology available in India shall be
used:

• The technology which is being used for this construction is

called as “light weight concrete technology”. This has been
developed for residential, industrial and commercial building
applications. With strength to density ratios approximately
double existing products in the market; the new innovative
lightweight concrete technology can potentially be used in both
non-load bearing as well as load-bearing applications.

• Bulk densities approximately half that of conventional concrete /

1200 kg +/- 50 % ( 600 kg/m3 to 1800kg/m3)

• Compressive strengths up to 30 MPa ( up to 4 times stronger then

traditional autoclaved aerated concrete )

• Excellent thermal and sound insulation properties

• Non-combustible, good fire rating

• Cost saving through fast speed of construction and ease of

handling

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PROJECT IMPLEMENTATION
• The project will be implemented in phases.

• The first phase shall be of 1800 houses

• The total material shipment will be from India.

• The Design, Development& Plan will be India.

• Supervisory staff shall be from India

• All labor shall be arranged in Tanzania.

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SELECTION OF TECHNOLOGY:
We have lots of options for construction. This technology has been selected
for this project because of the following benefits:

 Reduces the dead weight of a structure.

 Can be manufactured to precise specifications of strength and densities.
 Possess excellent workability.
 Can be nailed, planed, drilled and sawn.
 Provides excellent heat and sound insulation.
 Can be applied with all traditional surface finishes - paint, tiles, carpets etc.
;
 Moisture resistant and Fire resistant.

Weight Reduction

Foam concrete density ranges from 250 to 1800 kg/m3, as compare to 2400 kg/m3 for
conventional concrete. Therefore, the weight of a structure built of foam concrete
would undoubtedly be reduced significantly.

Thermal insulation

Foam concrete with a density of 1200 kg/m3, for instance, can produce a monolithic wall
5 times thinner and require 10 times lesser raw material (by weight) and possesses 5
times superior insulation properties compared to that of conventional concrete. The
amplitude-ratio and phase-displacement of a 15 cm thick wall with a density of 1100
kg/m3 causes the outside temperature of a building to take between 10-12 hours to reach
inside. Such a duration, which is much longer than that of conventional concrete wall,
results in the foam concrete being naturally air-conditioning.

Fire rating

In 1100 kg/m3 density concrete, a 13 to 14 cm thick wall has a fire endurance of 5

hours. The same degree of endurance is achievable with a 400 kg/m3 density concrete of
only l0 cm thick. This concrete is non-combustible and the air-embedded in this
concrete attributes to the high fire-rating.

Sound insulation

This is a perfect impact and air-borne sound absorbing concrete and hence, highly
suitable for party walls and floor screeds / foundations.

Savings in material

Reduction in dead weights contributes substantially to savings in reinforcing steels in

foundations. The dimensions and therefore, the overall quantity of steel reinforcement
in this concrete can be reduced by as much as 50%. Savings are also substantial in
transportation, crane-and man-handling related activities as well as in raw materials,
as no gravel is required to produce concrete but only sand, cement, water and air, with
the resulting mortar/paste subsequently embedded in the foam. Casting very slender
walls can optimize the amount of concrete used, and some of our consumers had produced
walls as thin as 50 mm thick. The high flow ability of this concrete makes vibration

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unnecessary, and thus requires no prescription of vibrating equipment/accessories.

Savings in manpower

only a few semi-skilled workers are needed to produce this concrete for casting /
pouring of panels, blocks or even complete walls for houses. In producing this concrete
, steelworks, formworks, brick laying and cement renderings do not constitute major
site activities, and therefore the related workers are not required. Workers are only
needed to set up cost saving and reusable formworks, and for removal of formworks for
next erection / casting.

Glass and Steel Fiber addition

mixing randomly distributed short fibers in this concrete results in a three-

dimensionally reinforced matrix. The fibers have the effect of increasing the static
and impact strength, reducing early-age cracking and also reducing water absorption.

Compressive Strength

An average compressive strength of 2.86 MPa has been achieved on a 650 kg/m3 density
concrete cubes following 28 days of standard water-cure. Tests done to date on other
densities revealed that 28-day strength exceeding 18 MPa is achievable depending on the
density of the mix. Studies also show that compressive strength of above 20 MPa is
obtainable with the addition of short fibers and steel mesh reinforcements.

Life span of Foam concrete

Foam concrete has a life span of above 100 years. Previous investigation has shown that
sectioned blocks of foam concrete cast 10 years ago indicated only 75 percent of the
cement hydrated. It is expected that the strength would continue to increase with
continuing hydration. The use of this concrete in many cases makes additional man-made
products like clay bricks and other insulation materials out-dated.

Easy application

No special skill is required in applying the system. It is fully adoptable or at least

adaptable into existing concrete or prefabrication plants, adding only the Foam
Generator to produce and discharge foam of a precise dose into the mixer. The concrete
may later be pumped using conventional concrete pumps. Due to the absence of gravel and
the ball-bearing effect of the foam, This concrete possesses a high degree of flow
ability. No vibration is thus required and it completely fills all gaps and voids in
the concrete or mould, fully embedding any hoses, tubes, frames for windows and doors.

Fast completion

The rapid mixing and high fluidity of this concrete facilitates speedy casting of
building elements. With the application of vertical molds to cast complete houses in
place, omission of vibrating equipment results in the entire walls and ceiling/roof of
a building being filled in one step. Openings (or the actual frames) for doors and
windows, and ducting and conduits for sanitary and electrical services can be cast in
place and firmly embedded in the foam concrete.

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Foaming agent

The foaming agent is based on a protein-hydrolisation and is bio-degradable. It causes

no chemical reaction with the surrounding matrix but serves solely as wrapping material
for the air to be encapsulated in the concrete (mortar).

Production procedures

only sand, cement and water are mixed in accordance with the design-mix charts
recommended by this technology that take into consideration suitable property-enhancing
materials like fibers and other pozzolan and/or cementitious products. The water-to-
cement ratio must be strictly followed since too little water might cause the cement to
draw its requirement from the foam, causing the latter to collapse partly or in total.
The extremely high stability and stiffness of the foam allows any density of the
concrete from as low as 250 kg/m3 to 1800 kg/m3 to be produced with an optimum ratio of
strength-to-density. The possible wide range of densities achievable thus offers
multiple and diversified applications, such as site mixing, off-site mixing,
prefabrication, pre-cast or cast in place.

Curing

This concrete requires curing means and period identical to that of conventional
concrete. It is essential as in conventional concrete, that cement-based elements need
moisture for hydration at an early age. This is particularly true in the presence of
direct sunlight that is known to cause rapid dehydration of concrete surfaces and that
curing compound can be applied as an alternative barrier.

Skim coating

This technology requires no plaster (as in sporex-type cellular concrete), and a usual
water-repellent paint suffices. However, where desired, this concrete can hold plaster
very well, offering superb adhesive properties. It is also possible to apply wallpapers
directly onto the surface. Nevertheless skim coating is highly recommended with this.

Popular applications

The density 300 kg/m3 offers the only system worldwide to produce a solely mineral-
based insulation board with the same insulating properties as man-made polystyrene,
polyurethane or mineral wool, with no hazardous elements to health, environment or
fire.

The density between 250 - 550 kg/m3 is primarily used for thermal insulation or fire
protection. It uses only cement (or with a small proportion of sand), water and foam
and can easily be pumped into moulds of varying orientations.

The density between 600 - 800 kg/m3 is used for void-filling, such as in landscaping
(above/underground construction), filling voids behind archways and refurbishing
damaged sewerage systems, as well as producing masonry units.

The density ranging from 800 to 900 kg/m3 is primarily used in the production of blocks
and other non-load bearing building elements such as balcony railings, partitions,
parapets, etc.

The density ranging from 1100 - 1400 kg/m3 are commonly used in prefabricated and cast
in place walls, either load-bearing or non-load bearing. It can also be successfully

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used for floor screeds.

The density between 1600 - 1800 kg / m3 would be recommended for slabs and other load-
bearing building elements where higher strength is obligatory.

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TECHNOLOGY IN DETAIL:
The product:

It is Mortar + Foam: It can be produced at the project site like ordinary concrete. The
only difference is that it does not use coarse aggregate, but instead, uses pre-formed
foam. This foam has no chemical action in concrete. It only serves as a temporary
wrapping material for the air bubbles till cement mortar develops its own final set and
strength. Hydrolysated protein base is mix and mash into a concentrated liquid Foaming
agent is used to make the foam.

Free flowing & self compacting:

This lightweight concrete has higher consistency due to absence of coarse aggregate
(gravel) and a ball bearing effect on the concrete. This higher consistency is of great
advantage for it flows by itself into the moulds and shuttering and any cavities,
thereby doing away with the necessity of compaction or vibration.

The high stability of this foam prevents a loss of volume during mixing, conveying
(even pumping), pouring or during hardening process. The use of appropriate mould
release agent has substantial influence on the surface finish of face cast against the
mould. The curing of this concrete is as normal as it can be.

Wider density range:

The entrained air with help of foam reduces density of concrete. The density would
naturally depend on the extent of foam injected in the slurry. Foaming Generator
enables accurate dozing of foam, thereby enabling production of wide range of
controlled densities from 300 kg/cu.m to 1,800 kg/cu.m. The water absorption of this
construction is also very low. It is in the range of 6.5% to 14% depending on the
density.

Light and Flowing, A material for a wide range of purposes:

All you need to obtain foam concrete are a foam generator and a foaming agent, as
foamed concrete is simply a mixture of a cement mortar slurry with foam, which can be
prepared in an ordinary concrete mixer, or even without it, if only a small quantity of
the material is necessary.

Thanks to that minor investment, you will have the opportunity to produce by yourself
the material that can be used for the following purposes:

• ROOFING INSULATION - Low-density lightweight concrete has great thermal

insulation properties
• TRENCH REINSTATEMENT - Lightweight concrete doesn't settle, requires no
compaction and has excellent load spreading.
• BUILDING CONSTRUCTION (panels, blocks, partitions, etc.) - Lightweight concrete
density and therefore strength is adjustable during production and can be
adjusted to the customer's choice of form and size.
• VOID FILLING - Lightweight concrete is very fluid and will fill every void, even
in the most inaccessible areas. Can be applied through a very small opening.

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 • ROAD SUB-BASE - Lightweight concrete used in such purposes, prevents the road
from subsiding into the soft earth it was built on.
• FLOOR CONSTRUCTION - Lightweight concrete levels, raises, isolates, speeds up and
reduces the cost of making floors.
• FIRE BREAKS - Lightweight concrete is inflammable and therefore prevents fire
from spreading when used to fill spaces between floors and ceilings.

Lightweight foam concrete's biggest advantage is the fact that it can be produced right
on the spot of construction, which is possible thanks to the foam generator, a compact
tool which ensures constant foam production and quality control. The produced FLcT can
be used for casting into the necessary shapes, or can be pumped straight to where it is
required

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MIXING GUIDE:
Normal concrete will weight 2.4 kg per liter. ( 2400 kg /m3)

To know how to get the Density of lightweight concrete, it is usual to take 1 liter of
the mix and weight it, cement, sand and water mix weights between 2 kg to 2.2 kg per
liter. The trick is the combinations.

This is the density of cement and sand we call slurry. By adding the foam which is
prepare with the foaming generator. Shoot in the foam during mixing, this way you are
actually aerating the slurry, so that the air entrapped by the foam is added into the
cement mix to make it porous and this way you are making lightweight concrete.

To know exactly the design mix after adding the foam, you take 1 liter of the foamed
concrete and weight it, if the mix weight 1.8 kg per liter, you have the 1800 kg /m3
density, if you want a lighter concrete, you add more foam into the mix. Note : Only 2
or 3 mix is justified by the same combinations.

Totally there are more then 48 types of design mix, the aeration with foam determine
the density of the concrete. The amount of cement content in each mix will determine
the compressive strength of each mix.

Compressive strength of 20 mpa at 28 days text has been achieved with a 1600 kg /m3
density. This high strength design mix is achieved with a 700 kg of cement content per
meter cube with a 1 part cement and 2 part sand mix. Strength of this concrete
increases in time.

Using the same design mix above, you can still add extra foam to make a lower density
mix. Density can be reduced to 1200 kg /m3. Note = Strength is reduced accordingly.

The above mix is base on a medium strength design mix (Ratio 1:2), every density mix
can have 3 types of design mix depending on the cement content as well as strength
requirement.

If using a low cement mix of 350 kg/m3, the cost of per m3 is reduced, the above mix is
a 500 kg/m3. A 700 kg/m3 (Ratio 1-1) cement content mix has a very high compressive
strength.

Medium and high mix are for the casting of load bearing walls, foundation as well
others high strength requirement projects.

Design Mix for a non-loading bearing wall or partition. Blocks and panels. Foundation
bases. This depending on the cement content adjustment will result in a concrete
strength of between 2 to 7 Mpa.

The above mix's a very low cost mix which strength increases in time but has a lower
compressive strength reports.

This technology has a total of 48 Design mix. (from 300 kg/m3 to 1800 kg /m3 @ x 3)

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 • Density 300 to 600 kg/m cubed = Thermal insulation for flat roofing with required
gradient. Floor sub surfaces. Block in fills for sub-floor slabs. Cavity walls
filling. General thermal and acoustic insulation. Heat insulating roof slabs.
• Density 600 to 900 kg/m cubed = Internal partition wall blocks and panels.
Roofing slabs. Floor. Sub-surface for stables, pig sties and poultry farms.
Walls, roof and floor sub-surface of large cool rooms. Facade panels. Trench
reinstatement.
• Density 900 to 1200 kg/m cubed = External wall blocks and panels, both structural
and non-structural. General sound proofing in industrial areas.
• Density 1200 to 1800 kg/m cubed = Medium weight blocks and slabs. Large
reinforced slabs and panels. Walls, either pre cast or poured in situ. Garden
ornaments.

Only sand, cement and water are mixed in accordance to the mix-chart recommended,
taking into consideration the most suitable raw materials or those which are available.

The water/cement ratio should not be less than 0,35 before adding foam, too little
water might cause the cement to draw its requirement from the foam, causing the latter
to collapse partly or in total.

Different from conventional concrete, possible too much water does not necessarily
influence this concrete generally. Too much water would also create a void in the
concrete. But then this is full of voids/bubbles.

The mix (mortar) before adding foam should not "break" apart but remain a homogeneous
mass. It should not be watery unless in densities below 1.000kg/m3

If fiber (coconut fiber, palm oil fiber, glass fiber or others fibers) is used, it has
to be added to the dry mix, after sand (1) and cement (2) have been added and firmly
mixed, but before adding water, allowing the fibrillated fiber to "open up". All
containments such as mixer, buckets, molds etc., should be reasonably tight, preventing
this concrete from leaking. Most traditional molds (vertical) are tight enough to hold
this concrete. Small leakages are normally plugged with a wet piece of paper from a
cement bag soaked before. When casting walls/houses in-situ it is recommended to first
cast a "kicker" for the mold to be firmly mounted against and preventing possible
leakage and consequent lifting of the entire mold. Steel pieces are stuck into the
still soft "kicker" to form the connection to the wall to be cast.

This technology requires no plaster (as in siporex-type cellular concrete). A usual

water-repellent paint will do. Where desired, this concrete holds plaster very well
however. It offers superb adhesive properties, of great benefit when using tiles. It is
also possible to apply wall-papers directly onto the surface.

Under floor Thermal Insulation is now available for new and existing timber floored
houses, to help reduce heat loss and keep homes dry and comfortable. Dampness in houses
with wooden floors that have little or no under floor insulation can be a difficult
problem to treat. If it is allowed to continue long term it can lead to expensive
repairs.

A very good answer is foam concrete. This is free flowing and easy to pump into
confined areas such as the cavity beneath a wooden floor where poor ventilation and
lack of sub-floor insulation, combined with damp ground create excessive water vapor

15
transmission, or rising damp. Foam concrete readily flows to surround the piles and out
to the foundations where it provides resistance to water vapors transmission. Access to
the sub-floor area can be provided by removing vents from around the foundation, the
manhole opening in the floor or through predrilled holes in places such as the bottom
of wardrobes.

Half Slab System and Fire Resistant Party Walls:

This methods of casting slab is not new but using this technology to do it at 600
density as stay in place to replace styrofoam is.

As can be seen from this sequence construction images, they is no need for any formwork
except some stand alone bracings, it's faster and cheaper.

The reinforce pre-cast half slab is pre-cast and laid on top of this concrete load
bearing cast in-place wall, 600 density blocks are place, and normal concrete is pour
(the conventional way) on top.

Also the cast in place walls are with this technology formwork and can withstand 2 to 7
hours fire ratings depending on mix and density of this concrete mix you decide.

It is at least 30% cheaper then brickworks and faster to construct and better heat
insulation (save on air conditioning with this 2 combine system) and sound proofing as
well as acoustics.

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APPLICATIONS & ADVANTAGES:
 cast in-place for a unit of low cost terrace houses and bungalows.
 in lightweight bricks or blocks for high-rise buildings.
 in panels and partition walls of various dimensions either pre-cast or poured in
place.
 in all types of insulation works, including cavity walls.
 in roofing and ceiling panels. in sound proofing application.
 in pre-cast / in-place exterior wall facades for all sizes of buildings.
 in foundations for roads and sidewalks.
 in sub-surface for sport arenas, e.g. tennis courts.
 in infill sections between beams of suspended floors.
 aircraft arresting beds. road crash barriers.
 explosion-resistant structure. highway sound barriers.
 floating barge, jetties, floating homes, and slope protection.

Strength:

Strength is a relative term. Concrete mixes should be designed based on end use. High
compressive strength is useful where dead load or abrasion are factors, but unnecessary
for roofs and non-structural partitions. All concrete is deficient in tensile and shear
strengths; however these are supplemented through structural reinforcement. Compressive
strength in concrete can be made up to 24 Mpa, far exceeding most structural
requirements. Concrete is in common use in many third world countries lacking
preconceived notions of how things ought to be. Unfortunately, like most good things in
life, you have to seek them out.

Advantages of pre-formed foam:

The pre-formed foam process offers excellent quality control and assurance of specified
density. Preformed foam, unlike gas-forming chemicals, assures a consistent three-
dimensional distribution of the engineered air cell system. Pre-formed foam produces a
consistent matrix of relatively small air cells which are more desirable than a
disorganized matrix of different size bubbles often created with the gas off method of
reactive admixtures.

Segregation:

Unlike plain concrete there is little to segregate in lightweight concrete rendering

segregation a moot point. The lightweight concrete equivalent to segregation would be a
collapse of the air cell system and a volume reduction in material. To prevent this one
should use the most stable liquid foam concentrates and treat the mixed lightweight
concrete with some care in placing. Fresh lightweight concrete is not fragile and can
be pumped for long distances but conversely neither is it indestructible.

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Chemical compatibility:

Lightweight concrete is compatible with common concrete construction admixtures;

however, most common admixtures are added to plain concrete to effect a change in the
characteristics of the concrete that are not applicable to lightweight concrete
application performance. As an example, lightweight concrete needs no air entrainment
or finishing aids; however, color admixtures and strength enhancing admixtures work
well if they are applicable to the project.

Common additives:

Fiber reinforcement Heat-of-hydration reducers (iced water or chemicals) Compressive

strength enhancers Coloring pigments or color enhancing admixtures

water to cement ratio:

Typically, water to cement ratio slurry consisting of two parts cement to one part
water is typically used as a base mixture for lightweight concrete. The water cement
ratio is varied according to specific project requirements. We should note that
lightweight concrete obtains it's natural fluidity from the air bubble structure, not
from excess water content.

Designs fine or course aggregate:

Lightweight concrete may also contain normal or lightweight, fine and/or coarse
aggregates. The rigid foam air cell system differs from conventional aggregate concrete
in the methods of production and in the more extensive range of end uses. Lightweight
concrete may be either cast-in-place or pre-cast. Lightweight concrete mix designs in
general are designed to create a product with a low density and resultant relatively
lower compressive strength (when compared to plain concrete). When higher compressive
strengths are required, the addition of fine and/or course aggregate will result in a
stronger lightweight concrete with resultant higher densities. We should note that most
lightweight concrete applications call for a lightweight material. When considering the
addition of course aggregate, one must consider how appropriate this heavy aggregate
will be to a project, which typically calls for lightweight material. The inclusion of
aggregate, particularly course aggregate may be counter productive to the materials
intended performance.

Type of cement:

Lightweight concrete may be produce with any type of Portland cement or Portland cement
& fly ash mixture. The performance characteristics of type II, type III and specialty
cements carry forward into the performance of the lightweight concrete.

Addition of fly ash:

Fly ash added to the cement does not adversely affect the basic hardened state of
lightweight concrete. Infusing and supporting the lightweight concrete with the air
cell system is a mechanical action and is not problematic with fly ash or admixture
concrete chemistry. Note that some fly ash mixes may take longer to set than pure
Portland cement applications. Mixes with large percentages of fly ash may take an very
extended time to set up. High carbon content fly ash such as typical "bottom ash"

18
should be generally avoided in most cellular or plain concrete mixes. With synthetic :

With synthetic fibers:

Synthetic fiber reinforcement is a mechanical process and does not have any effect on
the chemistry of concrete. It is therefore perfectly acceptable to design fiber
reinforced lightweight concrete. Fiber reinforced cellular concrete is becoming a
standard material for roof decks and Insulated Concrete Form (ICF) construction. Oil
palm fibers are also successfully being added to this technology and it produces a very
good design mix of 900 kg density per meter cube most suitable for high rise buildings
wall panels.

Steel fibers:

There is no chemical or mechanical reason not to reinforce lightweight concrete with

steel fibers. However, most lightweight concrete applications require a lightweight
material. Most steel fiber concrete applications require heavy, high compressive
strength steel fiber reinforced concrete. It would seem somewhat unlikely that an
application would require steel fiber reinforce lightweight concrete, but there is no
technical reason not to design a steel fiber reinforced lightweight concrete.

Bubbles in lightweight concrete:

The pre-formed foam lightweight concrete products made from top quality liquid foam
concentrates do not collapse. Air cell stability is the mark of a superior foam
concentrate and foam generator combination. Which is not to say that all lightweight
concrete products are stable. Particular care should be taken to test foams from water
pressure type foam generators, and gas-off chemical products. The proposed pre-formed
foam for an application should be tested for stability or certified for stability
before actual project placement.

Densities and Strengths:

One of the most useful features of a lightweight concrete system is the system's
ability to be manufactured in a wide range of low densities and strengths. Application
requirements for lightweight concrete range from very light density low strength fill
dirt replacement to higher strength structural lightweight concrete. To accommodate
this wide range of performance properties lightweight concrete has developed a mix
design chart, which will illustrate the basics of making this wide range of materials
from just one lightweight concrete concentrate. With a lightweight concrete foam
generator and a single liquid foam concentrate the contractor now has available to them
a wide variety of cost effective, high performance, lighter lightweight concrete
products.

Available densities and strengths:

Lightweight concrete exhibits a much lighter density than typical aggregate concrete.
Typical plain concrete has a density of 2400 kg/m3, lightweight concrete densities
range from 300 kg/m3 to 1800 kg / m3. Lightweight concrete is an insulator and can be
used in a variety of applications which require an insulating material that can also
exhibit some integrity and strength. Lightweight concrete at its lightest density is
still more stable and strong that well compacted soil. When replacing soils,

19
lightweight concrete can be designed to provide whatever strengths and characteristics
needed for the soil stabilization project. Some soils engineers lightheartedly refer to
lightweight concrete used in Geotechnical stabilization projects as "designer dirt."
They know that lightweight concrete can be specified to easily exceed whatever
compacted soil requirements are needed.

Floating properties:At the lower densities, lightweight concrete will float, and in
many cases float indefinitely. Because of its limited impact and abrasion resistance,
lightweight concrete used for marine flotation should be encased and used for the fill
of a float. For example, a superior marine float could be made with sealed 55-gallon
drums full of low-density lightweight concrete.

Concrete canoe:

Lightweight concrete could be used for the fill in a concrete canoe but should probably
be encased in a waterproof membrane

Lightweight concrete placement:

The pre-formed foam is added to the cement slurry and mixed in the concrete mixer or in
a continuous process. >From that point, lightweight concrete is placed in any way that
a fluid mix can be transported. Pumping is the most common method of placement.
Tailgate ready mix truck delivery, bucket cranes, wheelbarrows, hand carried buckets
and any other acceptable method of delivering a fluid mix works well.

Pumping of lightweight concrete:

Lightweight concrete is a very easily pumped, highly fluid mixture. The bulk of
lightweight concrete is placed by pumping. Lightweight concrete typically will move
through the pump lines using less pressure than typical heavier grout mixes

Finishing of lightweight concrete:

Most lightweight concrete is left to self-seek a level and not surface "finished" in
the traditional sense. Much lightweight concrete is covered by another material. A
floor over payment type smoother tool can be used simply to break the surface air cells
and create a more uniform and polished look to the surface in the rare case when a more
uniform surface appearance is desired.

Testing of lightweight concrete:

Test procedures for lightweight concrete are beyond the scope of this short document;
however, we will be happy to assist you in the actual testing or furnishing
descriptions of common tests.

Properties commonly tested are for its compressive strength The majority of regular
concrete produced is in the density range of 2400 kg perimeter cube. The last decade
has seen great strides in the realm of dense concrete and fantastic compressive
strengths which mix designers have achieved. Yet regular concrete has some drawbacks.

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It is heavy, hard to work with, and after it sets, one cannot cut or nail into it
without some difficulty or use of special tools. Some complaints about it include the
perception that it is cold and damp. Still, it is a remarkable building material -
fluid, strong, relatively cheap, and environmentally innocuous. And, it is available in
almost every part of the world.

Regular concrete with microscopic air bubbles added up to 7% is called air entrained
concrete. It is generally used for increasing the workability of wet concrete and
reducing the freeze-thaw damage by making it less permeable to water absorption.
Conventional air entrainment admixtures, while providing relatively stable air in small
quantities, have a limited range of application and aren't well suited for specialty
lightweight mix designs.

Light concrete begins in the density range of less than 300 kg/m3 to 1800 kg per/m3. It
has traditionally been made using such aggregates as expanded shale, clay, vermiculite,
pumice, and scoria among others. Each one has their peculiarities in handling,
especially the volcanic aggregates which need careful moisture monitoring and are
difficult to pump. Decreasing the weight and density produces significant changes which
improves many properties of concrete, both in placement and application. Although this
has been accomplished primarily through the use of lightweight aggregates, since 1960
various preformed foams have been added to mixes, further reducing weight. The very
lightest mixes (from 300 kg /m3 to 800 kg / m3) are often made using only foam as the
sand and aggregate are eliminated, and are referred to as floating lightweight
concrete. The entrapped air takes the form of small, macroscopic, spherically shaped
bubbles uniformly dispersed in the concrete mix. Today foams are available which have a
high degree of compatibility with many of the admixtures currently used in modern
concrete mix designs. Foam used with either lightweight aggregates and/or admixtures
such as fly ash, silica fume, synthetic fiber reinforcement, and high range water
reducers (aka super plasticizers), has produced a new hybrid of concrete called
lightweight concrete materials. For the most part, implementation of Lightweight
Composite design and construction utilizes existing technology. Its uniqueness,
however, is the novel combination drawing from several fields at once: architecture,
mix design chemistry, structural engineering, and concrete placement.

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DESCRIPTION OF HOUSES:
• Each House shall be 90 Sqr Mtrs buildup area
• There will be 3 bed rooms kitchen &living room

Each House shall be complete with the following

1.ANCILLARIES:

Bib tap
Stop tap
Low level water closer
Flushing System
Wash basin with tap

2.WALL FINISHERS, PAVING AND TILING

Plastering finished internal walls

Semi rough in external wall
Mosaic for main rooms
Non-slip Ceramic Floor Tiling /Mosaic /Pressed Cement tile Flooring for
Toilet and Bath rooms
Primary Painting

3.ELECTRICAL INSTALLATION

Wall bracket with wiring

Lamp points
Fan points
Switch boards & socket outlets
G.I. Earth pipe

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HOUSE CASTING METHODOLOGY:
WORK SUMMARY:
• Excavation and Earth Work
• Foundation Work
• Foam Work
• Roof covering Roof Plumbing
• Carpentry and Joinery
• Plumbing and Drainage Work
• Wall Finishers, Paving and Tiling
• Painting
• Electrical Installations
• Sanitary and toilet Fittings

23
Evacuvation:
Day-1

24
Formwork and BRC reinforcement in
place

25
Finished Basement – Starters for
Form Work

26
Day-2
Assembly of Panels

27
Foam Work

28
29
Erection – Doors & Windows

30
Assembly of Walls

31
Electrical Conduits Installed

32
Plumbing in Place

33
Form Work

34
Assembly of Roof

35
Assembled Walls & Roof

36
Finished Form Work

37
38
Mixing Foam Agent

39
Pouring Concrete

40
Day-3
Dismantling Form Work

41
Finished House

42
BILL OF MATERIALS,EQUIPMENT
1.Bill of materials:

• Cement
• Sand
• Steel
• Foam work
• Foaming agent
• Electrical fittings and accessories
• Plumbing pipes and accessories
• Flooring tiles
• Sanitary items
• Windows
• Doors

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2.Equipments

• Foam generator
• Concrete mixer
• Tools and accessories
• Water storage tanks with motors
• Compressors
• Cranes
• Lifters
• Earth Movers

44
45
COST
The cost per house is worked out based on above scope of work
and amenities:

USD 15,000.00 per House.

The entire house will cast at site (C2)

46
COMPLETION:
The entire material shall be shipped from India. The material shall be
shipped in parts- in lots of 500 houses each shipment

The entire shipment shall be completed in 6 months.

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Month 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1st Shipment Dispatch
1st Shipment Sailing
1st Shipment
Installation
2nd Shipment Dispatch
2nd Shipment Sailing
2nd Shipment
Installation
3rd Shipment Dispatch
3rd Shipment Sailing
3rd Shipment
Installation
4th Shipment Dispatch
4th Shipment Sailing
4th Shipment
Installation
5th Shipment Dispatch
5th Shipment Sailing
5th Shipment
Installation
6th Shipment Dispatch
6th Shipment Sailing
6th Shipment
Installation

Survey & Site

Preparation
Construction

REPAYMENT:
This has to be filled by Tanzania Government:

1.How they will sell this Houses

2.To Whom they will sell this Houses

3.At what installment they will sell this Houses

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To justify the repayment.

49