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An In – Built Trial Mechanism of Providing Permanent

‘Sound Proofing and Thermal Insulation’ In Buildings
Using Steel Shear Bolsters In Sandwiched Reinforced
Cement Concrete Slabs and Beams
V. Akshay,
Senior Engineer, Larsen & Toubro – Construction Division, Rajashree Cement Works, Unit – IV, Malkhed Road, Karnataka,
India
Email: [email protected], [email protected]

Abstract – This paper proposes to provide a permanent ‘combo’ A. Concept of Reinforced Cement Concrete Sandwiched
in-built solution to two major problems in buildings without Beams and Slabs
maintenance issues – Sound proofing and Thermal Insulation.
While conventional eco – hating techniques of sound proofing
The proposed sandwiched beam section (composite
in buildings utilize porous saw dust boards, coir mats and Reinforced concrete section) is detailed as shown in figure 1.
carpets, thermal insulation is done by coatings of toxic external In the following pages, Reinforced cement concrete shall be
paints, This paper proposes a eco – friendly theory in which denoted by RCC. (NA in figure indicates Neutral Axis)
sand is used for sound proofing and aluminium sheets as heat
sinks sandwiched between two layers of Reinforced Cement
Concrete in roof slabs and beams. This paper also evolves
with the idea of modifying brick manufacture to counter the
above mentioned issues with a positive approach. The theory
proves to be of better efficiency as is it is in-built and
permanent. The concept of Reinforced Cement Concrete
design is coupled with the concept of steel sections to achieve
structural stability of the ‘sandwiched’ slabs and beams. Details
involving design procedures of such sandwiched Reinforced
Cement Concrete slabs and beams with shear bolsters using
steel plates forms the essence of this paper. A case study
comparing the economies of sound proofing and thermal
insulation using traditional Limit state design of RCC and Figure.1. Proposed Sandwich Beam Section
that of the proposed sandwich theory is also enumerated.
The design of such Sandwiched beams out rightly defies
Index Terms – Limit State Design, RCC, Sandwich Theory, basic assumptions in the Limit state design of RCC members
Shear Bolsters, Sound and Heat Insulation, Cost Calculator as mentioned in the code [1]. For a sandwiched section,
1. Plane sections do not remain plane after bending.
I. INTRODUCTION 2. Sections are not homogenous.
3. The portions of the section above and below the Neutral
It has become an immense necessity in this noisy world Axis do not stay in fixed position in space with respect to
to provide sound proofing and thermal insulation in homes, each other defying transfer of stresses from the top fiber
schools, hospitals and office buildings at economical rates concrete to bottom fiber steel.
offering the same or better efficiency without causing any 4. Section may slip and separate as the sand bath in between
damage to the environment by artificial means of cooling can be assumed to possesses neither bending or shear
and/or non – eco friendly sound proofing techniques. strength.
Utilizing traditional sound proofing solutions such as To counter these effects, the Limit state design of collapse
wooden coir mats and foams adds additional problems in needs to be considered as mentioned below.
terms of maintenance and dims lighting in interiors resulting a. Limit state of Flexure in which the concrete above neutral
in negative contribution to Global Warming. If roof slabs, axis takes care of bending compressive stresses while Steel
beams and walls could be sealed completely from sound and below the neutral axis resists bending tensile stresses (As
heat with an in – built solution, interiors would be cooler and per initial assumption)1
more peaceful. For achieving this, it is proposed to utilize the The steel stirrups/ plate bolsters in beams/ slabs serve
‘Sandwiching’ Theory inspired from a Sandwich itself. The the purpose of preventing section slip between the
designs and details are enumerated in the first portion of the compression and tensile zones and allow for transfer of
paper followed by its functioning and a case study in the flexural forces from the top fiber to the bottom fiber.
second portion.
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b. Limit state of Shear in which the section is assumed to

have zero shear capacity. 2 – Legged or 4 – Legged Steel
stirrups in beams (and steel plate bolsters in slabs which
shall be enumerated later) should be able to completely resist
shear stresses without contribution from concrete.
c. Side face reinforcement of nominal amount has to be
provided in beams to ensure that plane sections remain plane
after bending. The sand bed should not extend to the ends of
the member and should leave side covers.
All other assumptions for flexural design can be applied
in the design. The relationship between compressive stress
distribution in concrete and the strain in concrete, stress and
strain curves as well as stress block parameters can be
adopted in the same manner as mentioned in the code[1]. A
revision of partial safety factor may be done to a greater
value on the basis of experimental results.

II. INCORPORATION OF THEORY IN SLABS

In general, a one – way slab is designed for a beam of
width 1000 mm and depth equal to the thickness of the slab
[2]. In most cases, slabs are designed only for Limit State of
Flexure while it is found that owing to the large width
considered for design, it is safe in shear. Yet, in the proposed
Sandwiched slabs, it has been assumed that the shear capacity Figure. 2. Plan Of Bottom Reinforcement Of Proposed One – Way
of the section is zero. Similar to the utilization of vertical Slab

stirrups in beams, there is a need for provision of additional For instance, if ‘x’ is the spacing between two shear bolsters,
accessories in the section in order to completely resist shear. forces arising due to live load and dead load on a width ‘x’
Two – Legged and Four – Legged stirrups cannot be used per metre length on either side of the bolster would be the
successfully in slabs owing to large spans in both directions. governing shear force for designing the dimensions of the
In such cases, the concept of steel I – sections can be steel plate/ bolster.
incorporated into RCC slab design. I – sections with long
webs have substantial success in resisting shear [3]. The
RCC slab is designed purely to resist only flexural stresses
whereas steel I – sections incorporated into the slab shall be
designed to resist only shear and torsion. Local Buckling is
not an issue with I – sections in slabs and hence steel sections
can be made thinner and longer into optimum size so as to
provide greatest shear resistance.
Instead of I - sections, vertical steel plates at all cross –
sections are positioned where shear failure is likely to occur.
These vertical steel plates can be labeled ‘Steel Shear Bolsters’
owing to their function. They need to be ‘roughed up’ on
their surface to provide a strong bond between the plates
and concrete. Utilization of vertical plates instead of Rolled I
- sections reduces cost of fabrication and self – weight.
An instance of Steel Shear Bolsters incorporated in the
one – way slab is shown in figure 2.The end supports are L –
Figure. 3. Left Portion (Section) Of Proposed One – Way Sandwich
beams in this case, whose shear is resisted by vertical stirrups Slab
alone while steel shear bolsters are used for the same in the
above one – way slab. Each shear bolster would be designed III. THEORY INCORPORATION IN TWO – WAY SLABS
to support shear arising due to live and dead load on the slab
adjacent to the bolster on either side. The steel shear bolsters would form a grid system in case
of a two – way slab is as shown in figure 4.The grids form

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larger panels at the centre of the slab where shear is low and
bending moments are high.The shear bolsters need to be
designed in each direction separately and the grid – set of
bolsters can be pre – fabricated and brought to the site on
the day of construction. This facilitates quicker construction.
It can be incorporated even in continuous one – way, two
– way slabs and beams but the designer has to ensure that
the sand bed and Aluminium sheet is always present in the
tensile zone. The shift of position of sand bed from the bottom
zone to the top zone in case of continuous slabs has to be
gradual from the point of contra flexure. Figure. 5. 3 – D Sectional View Of Proposed Stuffed Brick
This however, involves a risk factor and more research in larger strength.A compromise needs to be reached in the
into the same has to be carried out before ascertaining its ratio of matrix to surrounding in order to get optimum effect
structural safety. in terms of strength, sound proofing and thermal insulation.
20x10x10 cm is the standard size of a brick [4].
Hence the total load coming on a standard first class brick
at failure adopting the load per sq mm at failure as 10 N = 10
x 200 x 100 = 200 kN
Considering the equilibrium of the brick system neglecting
Aluminium, we have
p1A1 + p2A2 = P ————————— (1)[5]
p1 = Maximum stress resisted by the cement portion
A1 = Area of cement portion of brick
p2 = Maximum stress resisted by Sand portion
A2 = Area of sand portion of brick
P = Total load resisted by brick
Assume that the strength exhibited by the cement portion
of the brick manufactured by 43 grade cement with fly ash is
35 MPa. Hence, by trial and error, if 30% of the sectional area
of the brick is occupied by the cement portion, then
p1A1 = 35 x (30/100) x200 x100 = 180 kN
Sand within the hollow portion is purposely kept porous
to facilitate sound proofing. Yet, with optimum compaction, a
small amount of compressive resistance is exhibited by the
portion of sand in brick to achieve total load resisted by the
brick, P H” 200 kN which is almost equivalent to that of a first
class brick. The grade of cement, the amount of fly ash, the
overall size of brick and proportioning of matrix and
surrounding can be varied to achieve better strength and
Figure. 4. Plan Of Bottom Reinforcement Of A Proposed Two – greater sound proofing.Aluminium plates are on the expensive
Way Sandwiched Slab side; hence utilization of these on the outer face of the brick
would be sufficient for optimum thermal insulation. The
IV. SOUND AND HEAT INSULATION INCORPORATED IN WALLS thickness of the plates can be kept as small as possible, as
THROUGH STUFFED CEMENT/FLY ASH BRICKS they do not contribute towards strength of the brick and
A similar strategy can be applied to bricks in walls, only are present for thermal insulation. Two or three layers
however, without compromising on compressive ofAluminium foils on the hollow inner of the brick also serves
strength.Since bricks used for sound proof walls would the same purpose in an economical way.
generally be First class bricks with an average compressive Therefore, any apprehensions regarding the brittleness of
strength of 10 MPa, proposed ‘Sandwich’ bricks or ‘Stuffed’ hollow bricks can be cleared by introducing the concept of
bricks also need to exhibit same or better strength ‘Stuffing’ in bricks to produce multiple advantages.
characteristics.The 3-D sectional view of the proposed
stuffed brick is shown in figure 5. Greater the hollow portion, V. MECHANISM OF SOUND PROOFING AND T HERMAL INSULATION
IN BUILDINGS USING SANDWICH THEORY
greater would be the sand content allowed, larger would the
length of Aluminium plates and greater would be effect of Sand is one of the best sound proofing mediums which
sound proofing and thermal insulation. On the contrary, larger can be used in construction at highly economical rates in
space of the section occupied by cement/ fly ash would result comparison to traditional techniques. Transfer of sound

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waves from one medium to another takes place when there is VI. CASE STUDY
a continuous medium in between them. When the continuous
The following case presents a comparative study between
medium is interrupted at regular intervals by a porous medium,
economies of construction of a 7m x 3m simply supported
Sound waves fail to flow and sound insulation is achieved.
one – way slab present in a single long room atop the terrace
An experiment was conducted to test sound absorption.Two
of a one – storey residential home in Secunderabad designed
tuning forks were inserted into a sand bed at close intervals
by the conventional limit state design of RCC members (as
(15 cm) and one of them was strongly disturbed. There was
per IS 456:2000) and by the proposed sandwich theory. The
no transfer of vibrations into the adjacent fork. However, on
rates used for comparison are based on construction materials
fixing two tuning forks to a concrete floor at the same distance
in Hyderabad.
apart, the second tuning fork vibrated 10 seconds after the
first tuning fork vibrated. A. Design of Basic RCC slab 7m x 3m by Limit State method
(as per IS 456:2000) using Fe415 steel and M15 concrete
Since L/ b > 2, it is a one – way slab and load will be
transferred to the supports along the shorter span.
Considering a 1 m strip parallel to its shorter span.
Minimum depth of slab D =L/ (α x β x γ x δ x λ)
Let α = 20, β = 1, γ = 1, δ = 1 and λ = 1
Therefore, on substitution,
D = 3000/ 20 = 150 mm
Adopt overall depth of slab D = 175 mm and
effective depth d = 150 mm.
Dead load of slab = 0.175 x 1 x 25 = 4.375 kN/m
Superimposed load = 4 kN/m (Assumed value)
Total load = 8.375 kN/m
Factored load for load factor as 1.5,
wu= 8.375 x 1.5 = 12.56 kN/m
Maximum Bending Moment (BM) at centre of shorter span
= (wul2) / 8
Effective span of slab, l = 3 + d = 3 +.15 = 3.15 m
Therefore, BM = 12.56 x 3.152/8 = 15.58 kN-m
Maximum Shear Force = (wulc)/ 2 = 12.56 x 3/2 = 18.84 kN
Where lcis the clear span between supports.
Checking Depth of Slab:
Figure. 6. Mechanism Of Thermal Insulation And Sound Dissipation As per IS 456:2000, to check for minimum depth of the
Through Roofs And Walls Of An Interior Room (One – Way Slab) slab, we use the equation,
Aluminium is known as one of the best thermal insulators. BM = 0.138 σckbd2
Aluminium foils are known worldwide to keep food hot for σck= 15 MPa (for M15 concrete)
long durations, disallowing temperature to escape into Substituting values of BM, σ ck and b in the above
surroundings. If outside heat is disallowed from entering equation, we get
interiors by placing Aluminium barriers, interiors would remain d = 87 mm
cool for longer periods reducing need for artificial cooling Adopt new values of slab depths as D = 150 mm and
requirements. Even if Air conditioners were used in such d = 125 mm.
rooms, the thermostat would ensure lower usage of power Area of tension steel is determined by the equation
by retaining cool temperatures in the interior for longer periods. BM = 0.87σyAt [d – (σyAt)/ (σckb)]
The mechanism of sound proofing and thermal insulation Substituting all values in the above equation, we
works as shown in Figure 6 on application of the ‘Sandwich’ determine the area of tensile steel for the under – reinforced
Theory. To avoid complexities, columns have been assumed section as
inert in transferring both sound and heat. At = 377 mm2
Sand is also a heat dissipating agent, though in a smaller Provide 10 mm bars @ 200 mm c/c giving actual area of tensile
magnitude when compared to Aluminium. For instance, steel = 392.5 mm2
villagers use sand beds on top of their flooring to separate Bend alternate bars at L/7 from the face of support where
their stoves from the floor to prevent heat transfer. Thus, by moment reduces to half of its maximum value.
using the ‘Sandwich’ Theory, the interiors are virtually sealed Temperature reinforcement at 0.15% of the gross concrete
from noise and external heat. area will be provided in the longitudinal direction
= 0.0015 x 1000 x 150 = 225 mm2
Use 6 mm MS bars @ 100 mm c/c giving total area = 28 x 1000/
100 = 280 mm2> 225 mm2
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Check for Shear Let d1 = 95 mm (providing cover at the top to prevent corrosion)
The slab is safe in shear as nominal shear stress Let us adopt structural steel of Grade St 52 giving a Yield
developed is less than shear strength of concrete for the stress of 360 MPa for steel shear bolsters each extending for
percentage tensile steel provided. a length 6.8 m providing 100 mm side covers at the ends[7].
Development Length Adopt 4 mm thickness of steel shear bolsters.
Since development length is not a major criterion for Therefore, Vp = (95 x 4 x 360) / = 79 kN
comparison between the two theories, we shall not delve > 70.65 kN OK!
into details. The code requires that bars must be carried into Thus, provide 5mm thick, 95 mm depth steel plates as
the supports by at least Ld /3 [1]. steel shear bolsters for a length of 6.75m at a spacingof 125
The design is complete with respect to collapse. mm near supports. Increase the spacing to 200 mm near mid
span for a distance of 1.5 m.
B. Design of Basic RCC slab 7m x 3m by Sandwich theory
The design is complete with respect to collapse.
using Fe415 steel and M15 concrete
Design for flexure shall be carried out in the same manner VII. A COMPARISON OF MATERIALS OF THE DESIGNED SLAB (FOR
as it has been in the previous case. Amount of tensile CLEAR SPAN) BY UTILIZING BOTH T HEORIES
reinforcement is provided in same amount with same effective
TABLE I. MATERIAL REQUIREMENTS AS PER I S: 456 AND AS PER SANDWICH
depth. Do not provide any temperature reinforcement as steel
T HEORY
shear bolsters take care of the same.
Determination of Neutral Axis
Force of compression = 0.36 σckbx = 0.36 x 15 x 1000 x
= 5400x N
Force of tension = 0.87 σy At
= 0.87 x 415 x 392.5
= 141712.125 N
Therefore, on equating the above forces, we get depth of
neutral axis as x = 26.24 mm < 0.48d
OK!
Provide 4 mm thickness Aluminium sheet and 20 mm
thickness sand bed at a depth of 30 mm from top. Thus the
distance of top compression fiber from the bottom of sand
bed = 54 mm.
Design for Shear
It is assumed that shear capacity of the section is nil.
Design of shear bolsters and its spacing is done by adopting
guidelines from the code[6].
Maximum Factored Shear Force = 18.84 kN
The nominal plastic shear resistance under pure shear is
given by Vp = Av fyw/
Where Av = shear area, and
fyw= yield strength of the material of plate
For plates, shear area = A = d1 x t
Where d1 is the depth of steel shear bolster and t is its
thickness.
The factored design shear force, V, in a beam due to external
actions shall satisfy
V Vd
Where Vd= design strength = Vp/ γmo(for pure shear)
The partial safety factor against shear failure resistance,
governed by ultimate stress is 1.25.
Thus, Vpshould exceed the product of factored shear force
and 1.25
Therefore, Vp 23.55 kN for critical section. Yet, the steel
shear bolster is required to resist shear from all sections at a
distance ‘(spacing)/2’ on either side of the bolster. Assume
that the total shear resisted by the shear bolster for a spacing
of 125 mm near supports is thrice Vp i.e. 70.65 kN. 3Vp is also
taken in consideration for transfer of stress from top to bottom.
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Summary: (Difference In Quantities Between Sandwich of maintenance = 40,472

Theory Of Design And IS 456: 2000 Method)Difference In Replacement for above mentioned traditional technique is
Concrete Requirement = -0.504 cu.mDifference in Steel required approximately in 12 years which adds to maintenance
requirement (Fe415 bars) = - 0.0061 cu.mDifference in Steel costs. Thus, by adopting Sandwiching technique the costs
requirement (Grade St 52) = 0.0646 cu.mDifference in Sand are recovered in a maximum of 5 years even if cheapest
requirement (apart from that required for concrete) = 0.42 traditional sound proofing techniques are used. Utilizing
cu.mDifference in Aluminium requirement = 0.084 ‘Stuffed Bricks’ shall further reduce maintenance costs
cu.m(Negative sign indicates lesser material required in incurred by sound proofing and thermal insulation using
Sandwich technique) traditional ways. Further, the client is morally right as he
disallows use of eco – hating materials.
VIII. COST CALCULATOR (AS PER RATES OF CONSTRUCTION Advantages of the proposed ‘Sandwich’ Theory:
MATERIALS IN HYDERABAD) a. It is in – built and permanent. Hence there is no issue of
TABLE III. COST D IFFERENCE TABLE BETWEEN IS: 456 AND SANDWICH
maintenance and heavy costs accompanying it.
T HEORY b. It is eco – friendly. It prevents felling of millions of trees for
sound – proofing, usage of toxic heat insulating paints.
c. Assures long – term economy. No compromise made on
strength.
d. No compromise made on head room space – Slabs and
beams are of the same size as they would be without
sandwiching.
e. Stuffed bricks may be manufactured thinner than ordinary
bricks, thus increasing room space.

IX. FUTURE PROSPECTS OF RESEARCH ON ‘SANDWICH’ THEORY

The following points form the basis of future research on
the proposed sandwich theory.
a. It does not account for reversal of stresses
b. Aluminium has a higher coefficient of linear expansion
when compared to steel and concrete.
c. The inertness of sand to resist loads is a cause for concern,
a factor which may be considered risky for application as a
Theory.
d. Even though Steel Shear Bolsters will ensure sufficient
resistance to deflection, Shrinkage and creep of concrete have
not been accounted for in the design.
e. Effect of lateral loads not considered

CONCLUSION
The need for new techniques in building construction is
Approximate cost difference between Sandwich theory and essential as traditional methods are more prone to eco –
IS 456:2000 method (excluding maintenance) = 36,317.681.1. hazards. Yet, a new theory like the sandwich theory does
A. Sound and Heat insulation costs using traditional pose technical challenges to a researcher, as mentioned in
methods (for slab designed as per IS 456:2000): the previous item. The challenges that the theory poses shall
be worked upon in the next portion of this research.
Cost of 3 coats vinyl painting atop 7 x 3 m roof slab for heat
insulation = 4320 (approximate)
REFERENCES
Cost of sound proofing using an industrial grade composite
of two pound mass loaded vinyl and one inch polyether foam [1] Indian Standard code of practice for Plain and Reinforced
underneath 7 x 3 m roof using 3 sheets of the product = Concrete (Fourth Revision), IS 456: 2000, Bureau of Indian
11,408x 3 = 34,224 Standards, New Delhi.
[2] Ashok Jain K., Reinforced Concrete Limit State Design (6th
Total cost incurred = 34,224 + 4320 = 38,544
Edition), Nem Chand & Bros, Roorkee, 2002, pp.287 – 295
Adding 10% maintenance cost for 5 years, Total cost inclusive

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[3] Duggal S.K., Design of Steel Structures (3 rd Edition), Tata Mechanics of Materials, Laxmi Publications Ltd., New Delhi,
McGraw Hill Education Private Limited, New Delhi, 2009, 2006, pp.38 – 39
pp. 350, 354 – 357 [6] Indian Standard Code of Practice for General Construction in
[4] Arora S.P. and Bindra S.P., The Text Book of Building Steel (Third Revision), IS 800: 2007, Bureau of Indian
Construction (4th Reprint), DhanpatRai Publications Ltd., New Standards, New Delhi.
Delhi, 2007, pp.5.6 – 5.8 [7] Subramanian N., Design Of Steel Structures (Fifth impression),
[5] Dr. Punmia B.C., Ashok Kumar Jain and Arun Kumar Jain, Oxford University Press, New Delhi, 2010

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