CSIR SERC

CONSTRUCTION TECHNOLOGY
CSIR-Structural Engineering Research Centre (CSIR-SERC),
Chennai, India is one of the national laboratories under the
Council of Scientific & Industrial Research (CSIR), India.
CSIR-SERC has built-up excellent facilities and expertise for
the analysis, design and testing of structures and structural
components. Services of CSIR-SERC are being extensively
used by the Central and State Governments and public and
private sector undertakings. Scientists of CSIR-SERC serve on
many national and international committees and the Centre is
recognized at the national and international levels as a leading
research institution in the field of structural engineering. CSIR-
SERC has been certified as ISO 9001:2008 quality institution.

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Charter of THEResearch Centre:

CSIR-SERC acts as a clearing house for the latest available knowledge and develops know-how on
design and construction of all types of structures.

It undertakes application-oriented research in all aspects of structural engineering both design and
construction, including rehabilitation of structures.

It provides design consultancy services, including proof checking, to organizations in the public and
private sectors for developing a variety of structural designs.

CSIR-SERC also organizes specialized courses on structural engineering for the benefit of practicing
engineers to familiarize them with the latest developments in analysis, design and construction.

Vision of CSIR-SERC

The vision of CSIR-SERC envisages that it shall continuously strive to excel on its expertise, facilities
and performance in order to be a globally competitive R&D organization in Structural Engineering.

Towards this CSIR has initiated

* Innovative programmes of R&D for technology / expertise development leading to reliable and safe
designs and construction practices

* Action to establish advanced / state-of-the-art facilities for testing and advanced analysis / software
development

* Action to publish high quality papers in international journals, to enhance IPR content in R&D
activities and to attract external financial support to R&D programmes

* Transfer of technology and expertise for industrial/societal benefit.

R&D Areas

Research and Development efforts at CSIR-SERC deal with development of improved analysis,
design and construction techniques for different types of complex structures such as shell roofs,
transmission line and microwave towers and other tower-like structures, ships, offshore structures and
machine foundations. A number of time and cost saving precast construction techniques and products
have been developed by the Centre. High strength deformed bars, funicular shells, fibre reinforced
concrete manhole covers, ferro cement water tanks, service core units, etc., developed by the Centre
have been extensively used in many organizations in the country. Over the years, several general
purpose computer software packages have been developed for computer-aided analysis, design and
drafting of various structures and structural components. CSIR-Structural Engineering Research
Centre has been focusing its research & development programmes in the following broad thrust areas:

Structural Concrete Engineering & Technology

Sustainable Materials and Composites & retrofitting/Rehabilitation of Structures
Computational Structural Mechanics for Analysis and Design, Modeling Simulation &
Software Development
Transmission line towers, Metal Structure Behavior and Fatigue and Fracture
Structural Health Monitoring and Evaluation & Forensic Analysis
Wind Engineering and Earthquake Engineering

Major Services

~ Knowledge Resource Division

~ RPBD

~ HRG & RTI

~ Engineering works & Services Section

~ Knowledge Network Unit

~ Knowledge Management Division

~ Electronics, Instrumentation

~ Network Services Division

 FERRO CEMENT

Ferrocement or ferro-cement (also called thin-shell concrete or ferro-concrete) is a system of

reinforced mortar or plaster (lime or cement, sand and water) applied over layer of
metal mesh, woven expanded-metal or metal-fibers and closely spaced thin steel rods such
as rebar, metal commonly used is iron or some type of steel. It is used to construct relatively
thin, hard, strong surfaces and structures in many shapes such as hulls for boats, shell roofs,
and water tanks. Ferrocement originated in the 1840s in France and is the origin of reinforced
concrete. It has a wide range of other uses including sculpture and prefabricated building
components. The term "ferrocement" has been applied by extension to other composite
materials, including some containing no cement and no ferrous material.

Properties of Ferrocement:

Highly versatile form of reinforced concrete.

Its a type of thin reinforced concrete construction, in which large amount of small diameter
wire meshes uniformly throughout the cross section.
Mesh may be metal or suitable material.
Instead of concrete Portland cement mortar is used.
Strength depends on two factors quality of sand/cement mortar mix and quantity of
reinforcing materials used.
 Constituent Materials for Ferrocement:
1. Cement
2. Fine Aggregate
3. Water
4. Admixture
5. Mortar Mix
6. Reinforcing mesh
7. Skeletal Steel
8. Coating

Advantages and Disadvantages of Ferrocement

Advantages:

Basic raw materials are readily available in most countries.

Fabricated into any desired shape.
Low labour skill required.
Ease of construction, low weight and long lifetime.
Low construction material cost.
Better resistance against earthquake.

Disadvantages:

Structures made of it can be punctured by collision with pointed objects.

Corrosion of the reinforcing materials due to the incomplete coverage of metal by mortar.
It is difficult to fasten to Ferrocement with bolts, screws, welding and nail etc.
Large no of labours required.
Cost of semi-skilled and unskilled labours is high.
Tying rods and mesh together is especially tedious and time consuming.
Ferrocement bathroom in CSIR SERC
FLY ASH BRICKS
Fly ash brick (FAB) is a building material, specifically masonry units, containing class C fly ash and
water. Compressed at 28 MPa (272 atm) and cured for 24 hours in a 66 C steam bath, then toughened
with an air entrainment agent, the bricks last for more than 100 freeze-thaw cycles. Owing to the high
concentration of calcium oxide in class C fly ash, the brick is described as "self-cementing". The
manufacturing method saves energy, reduces mercury pollution, and costs 20% less than traditional
clay brick manufacturing.

Fly ash bricks

 COMPARISON BETWEEN FLY ASH BRICK AND CLAY BRICK

Fly ash bricks Clay bricks

The colour of fly ash brick is Not in uniform colour as the
same as the manufacturing is colour of brick depends upon
carried out using machinery in type of soil and quality control
controlled condition. during production.
Uniform in shape and smooth in
finish as the COMPARISON
BETWEEN FLY ASH BRICK AND
CLAY BRICK

Clay bricks are uneven in shape

manufacturing is carried out as mostly clay bricks are made
using machinery. manually.
As the surface is even and joints
are thinner, no plastering As the surface finish is not even,
required in normal cases. plastering is necessary.
Fly ash bricks are lighter as the Clay bricks are heavier as
main composition is fly ash. compared to fly ash bricks.
Fly ash bricks are less porous. Clay bricks are more porous.
The cost of fly ash brick is
approximate 30% lower than The cost of clay brick is higher
clay brick. than fly ash brick.
Continuing use of clay bricks in
This is made by using by- construction industry will lead to
product of Thermal Power Plant, extensive loss of fertile top soil.
which save environment from This could be a devastating
being polluted. environmental hazard.
PRECAST FUNICULAR SHELL

Funicular shell, a special type of shell doubly-curved in shape distributes the load in all
directions equally to withstand loading purely in compression in most parts of the shell. This
property of the shell has been taken advantageously to distribute the load.
It is generally used for floors and roofing
The usage of steel is reduced
Partial or complete elimination of shuttering
Precast RCC leads to 20% cost saving.
Due to arch action the loads are evenly distributed to the two support hence it is stable
structure.

FUNICULAR SHELL ROOFING IN CSIR SERC

FIBRE REINFORCED CONCRETE (FRC) MANHOLE COVERS AND FRAMES

IPR Status Patent/copyright/trademark Secured in India

Application-uses Replacement for iron manhole covers.
Salient technical features including competing features FRC manhole covers for light,
medium and heavy-duty applications having a circular shape. If the requirement pertains to
covers of other shapes, specific designs can be worked out and made available. Pilfer-
proof, durable and long-lasting
Possess greater impact and wear resistance
Ductility and energy absorption is far superior
Suitable for mass production at site or in a factory
with less capital investment Upto 40% savings in cost compared to cast-iron
man-hole covers 5 Level/Scale of Development Prototype available with various vendors
Environmental considerations Fibre reinforced concrete products are environmental
friendly
Status of commercialization Technology released through NRDC 8 Major raw materials to
be utilized Concrete and steel fibers 9 Major plant equipment and machinery required
Concrete mixer and moulds 10 Techno-economics The fibre reinforced concrete manhole
covers and frames will generally work out cheaper by about 30 to 45% compared to their
counterparts in cast iron.
LARGE PANEL PREFABRICATED SYSTEM

Prefabricated elements of buildings and structures made from large factory-

produced slab elements (panels) that areassembled on-site. Large-
panel structures are one of the most progressive industrial types of structural elements. In moderncons
truction they are used in building apartment houses, public and industrial buildings, roads, air-
fields, dams, and canals.They have become most widespread in large-
scale housing and civil construction, where the erection of buildings from largepanels manufactured at
housing construction combines and plants makes possible a reduction in construction time by a
factor of 1.5 to
2.0 in comparison with erection of the buildings from brick or other traditional materials, as well as a
decreaseof 30
40 percent in labor expenditures at the construction site. The estimated cost of a square meter of housi
ng space is1215 percent lower than in brick buildings.
Below are the features of this

All the elements are cast at site

Room sized composite panels for external and internal walls, and
roof/floor slab with funicular shell elements
Industrialized construction
Hollow clay blocks and concrete for external walls to enhance
thermal comfort
Sandwich panels for internal walls
Maximum weight of panel is 4 tonnes
A flat of 90 square meters can be erected in two days
Disciplined use of cement and steel
Saving in time upto 40%
Quality control effected in construction
Industrialization proves continuous employment to skilled labour
Offers scope for standardization and modular co-ordination
Faster construction enables earlier return of rentals
LIGHT WEIGHT WALL PANEL SYSTEM

IPR Status Patent/Copyright / Trademark Secured in India /Abroad IPR Details Patent filed
No.2441 DEL 2013 For mass housing and affordable buildings
Application -For quality and speedy constructions
Constructions in earthquake prone areas
Lightweight buildings in poor soil conditions
For all types of single and multistoried buildings
Salient Technical Features including Competing Features The panels are sandwich type
comprising of two high strength concrete withes separated by an inner lightweight core.
The panels are one of the most structurally efficient system in terms of low material
consumption.
The panels are extremely light in weight and are easy to handle, transport and erect.
The panels are assembled on the site edge to edge to form an enclosure and the joints
between the wall to wall and roof to wall is connected.
The system provides satisfactory thermal and acoustic insulation for the constructed facility.
use of waste material in large quantities is also involved which adds to the reduction in cost
and eco-friendliness of the system.
resistant to forces caused by disaster such as earthquake. Thus, the panels are a unique
combination of strength, lightweight, ductility and durability.
A (G+1) building constructed using these panels when tested performed excellently in
seismic zone -5 loadings. 5. Level / Scale of Development and test result summary
Lightweight large wall under roof panel has been developed at CSIR-SERC. The flexural and
axial behavior of these panels have been evaluated.
A proto-type G+1 storey has been constructed and 2 studied for seismic behavior on shake
table and also for pushover study. Experimental demonstration of construction of four
classrooms for Kendriya Vidyalaya, CLRI, has been taken up using innovative technology
developed at CSIR-SERC particularly the lightweight large wall panels.
Environmental Considerations, if applicable Sustainable and green construction through
savings in energy costs for cooling or heating

HOUSE BUILT OF LIGHT WEIGHT PANELS IN CSIR SERC

 HYPERBOLIS PARABOLOID SHELL

A hyperbolic paraboloid (sometimes referred to as h/p) is a doubly-curved surface that

resembles the shape of a saddle, that is, it has a convex form along one axis, and a concave
form on along the other. It is also a doubly-ruled surface, that is, every point on its surface
lies on two straight lines across the surface. Horizontal sections taken through the surface
are hyperbolic in format and vertical sections are parabolic.
CATENARY ARCH

A catenary arch is a type of arch that keeps its members in compression when bearing no load
but its own weight.
A catenary arch, which is the ideal arch shape if the only weight you are to bear is the weight
of the arch itself. A catenary is that shape formed by a chain, hanging down in the middle
when supported on both ends.