ALTERNATIVE WALLING MATERIAL

Mud has been the most basic building material since the beginning of human existence. Moreover, is still
being used by almost 1/3rd of our world’s population for housing purposes. Even after being used so
extensively, mud is often regarded with detriment. Mud has numerous inherent properties that give the
material its potential importance throughout the world.

AVAILABILITY
Mud is found in abundance in almost every part of the world. This attribute makes it cheaper than any
other conventional building material. There are certain circumstances when it is difficult to transport
construction materials from one place to another. In such cases, mud, because of its easy availability
could be used as an alternative eco-friendly material for construction.
ENERGY CONSUMPTION
An enormous amount of fossil energy is consumed in the manufacturing and transporting of modern
construction materials. However, due to the abundance and easy availability and lesser use of energy-
consuming construction equipment, mud directly reduces the consumption of energy.
RECYCLING
Recycling of modern materials for building construction is expensive, and does even not apply for most
of the materials. However, the recycling of soil does not even require the input of any external source.
Therefore, saving a lot of time and money. Another important benet of using earth is that the
characteristics of recycled soil post-construction remain the same. Whereas, in the case of modern
building materials, it acquires sub-standard characters after recycling. This characteristic makes mud a
perfectly reusable resource for construction.
INSULATION
It is extremely malleable and offers a way better insulation than steel and concrete structures. It
decentralizes the construction process as it utilizes local materials and construction technology. Mud as an
insulation material prevents external heat from entering inside the building while maintaining a cool
environment inside.
WHAT TYPE OF MUD SHOULD BE USED FOR CONSTRUCTION?
Mud doesn’t have to be transported from far off places. It can be dug directly from the construction site
itself for use. As soon as we start digging, we see different layers of soil coming out of the earth. All of
these soil types cannot be used for construction. Some of these earth types, when combined with different
material, can act as a better material for construction. But how do we know which layer is the most
suitable for construction?
Materials such as Gravel, sand, silt, clay and organic soils cannot be used separately. However, clay,
when mixed with other binders and aggregates, acts as one of the main ingredients which are used
throughout the building. The use of Binders, aggregates and stabilizers vary according to the technique
that we are using. Soils like gravel, sand and silt are often mixed with stabilizers such as cement, slaked
and unslaked lime for stability purposes.

MUD CONSTRUCTION PROCESS

FOUNDATION Foundation is an integral part of any building. If the foundation is strong and can transfer
load effectively then the building can stand still for even 1000’s of years. When considering Mud
construction, the foundation has to be constructed out of some other stronger material rather than
mud. There are various alternatives that can be used for the foundation in mud construction:

 Stone can be used in the foundation if locally available. I

 n some cases, the topsoil might be loose and useless. However, the subsoil can be strong
enough to carry the weight of a single-story house. In such a case, we can excavate the topsoil
just like we would do for a stone or brick foundation. Then slightly dampen the excavated soil
and put it back into the trench. Ram it to achieve the required proctor density. Repeat this until
the trench is full.
 If bamboo is readily available, we can split it into halves for narrow rafts to be used in the
foundation. A
 local alternative is, laying broken Matka (earthen pots) followed by ramming of the earth to
achieve the required Proctor density

MUD WALL CONSTRUCTION TECHNIQUES

The type and process of mud construction differ from place to place. It varies as per the climate and
the type of soil availability. As for every different type of mud we use a different construction
method. Mud construction techniques can broadly be divided into 5 types:

1. Wattle and Daub

2. Rammed earth

3. Adobe construction

4. Cob wall construction

5. Earthbag construction

Cob wall construction

: Cob is easy to learn and the most inexpensive mud construction technique. This vernacular
technique has no contribution towards deforestation, pollution, and nor does it depend upon
manufactured materials and power tools. Cob doesn’t require skilled laborers and is completely
recyclable.

The word cob means “a lump of the soil “in old English Latin origins. Cob is formed by mixing 25-30%
clay along with 70-75% sand and straw. The properties of this material are very similar to lean
concrete. As the water from cob dries out, it hardens and takes its shape just like concrete. All the
cobs are simply piled one above the other layer by layer in the desired shape that we want. When
creating window openings, regular operable windows or xed glass windows can be placed at the
preferred location and height while the layers are building up.

2. Adobe

Adobe or sun-dried bricks is one of the most popular mud construction techniques used throughout
the world. Even today various workshops are being conducted to spread awareness and use of this
particular technique. This natural building material is created using 25-30 % clay, 70-75 % sand,
water, and other organic material like straw, manure, or sticks. The Masson mixes all of these
ingredients and pours them into a wood-framed container to shape this mixture into bricks. The
rectangular bricks are then kept under the sun for a few days. After drying for a few days, bricks are
moved into a shaded area for air drying up to 4 weeks. During this process, the bricks are sprinkled
with water to keep them from drying completely. Adobe bricks are more benecial in hot climates
due to their greater thermal mass. It provides insulation from external heat waves. Sun-dried bricks
are most commonly used in West Asia, West Africa, Spain, Eastern Europe, and South America.

Rammed earth

Another commonly used mud construction technique. Rammed earth walls are derived from the cob
wall which had ununiformed widths. However, due to the framework used in this process, a
standard width can be maintained throughout the building.
The raw materials used in this technique are clay (minimum 15% and maximum up to 30%) and the
rest is sand, chalk, lime, and gravel. The compressive strength of concrete of similar thickness is
better than rammed earth. However, carefully built rammed earth houses and domestic buildings
can survive for years. Two parallel planks are held at a xed distance with the help of metal rods or
small cross pieces of wood while creating a cavity in between. The material mix is then tossed into
the cavity between the two planks. It is further rammed with the help of wooden or metal ramrod.
When one section is completed and is hard enough to stand still, the two boards are moved along.
This entire process gets repeated again. For the second course, the two planks are moved up and
the entire process is repeated over the rst course. These rammed earth walls, when constructed
without reinforcements cannot withstand earthquakes. However, if we use reinforcement bars,
wood, or bamboo reinforcement, it can prevent the failures caused by earthquakes and storms.

4. Wattle and Daub

Wattle- a woven lattice of wooden strips, and Daub- mud mixed with other binders’, aggregates and
reinforcements, is used. The daub is either mixed by hand or with the help of livestock.

Binders are those substances that hold the soil together, these include Clay, lime, chalk dust, and
limestone dust.

Aggregates provide the mix with its dimensional stability and strength. The materials include earth,
sand, crushed stone, and crushed chalk. The size of these aggregates depends upon the wattle
design that we are using.

Reinforcements materials such as straw hair, hay, or some other brous materials hold the mud mix
together. It preventing shrinkage and allows exibility.

This method is one of the most sustainable and eco friendly construction types due to its better
stability and quick construction:

First, a mesh of bamboo cane and straws is created and hung in between the gaps of the timber-
framed structure. Mud mix is then plastered over this bamboo mesh Further, it is whitewashed to
increase resistance to rain.

. Earthbag construction
This construction method was inspired by the bunkers built by the military. As the name suggests
the process includes earth (mud) and gravel-lled bags as a construction material. The bags are either
articial or organic. The most used bag is made of woven propylene which is an articial material.
Other organic materials include hemp, gunny sacks, burlap or other natural ber bags. Earthbag
construction begins by rst digging a trench. Multiple rows of these bags are lled with readily
available inorganic material. Each layer above the foundation will have one or more strand of
barbed wire on top. The heavyweight of these earth-lled bags pushes down on the barbed wire
strands while locking the bag in place. This process is then repeated layer by layer in the desired
shape and height of the structure.

MUD MORTAR:

Mortar is a material mixture used for lling in between the gaps for holding the bricks and blocks in
place. The clay that we use for construction can also be used as mortar. There are few factors that
we need to keep in mind before using clay as a mortar:

Mortar is a material mixture used for lling in between the gaps for holding the bricks and blocks in
place. The clay that we use for construction can also be used as mortar. There are few factors that
we need to keep in mind before using clay as a mortar:

PLASTER The cob, rammed earth and adobe walls often have a rough nish so to smoothen it out, we
need to apply a nishing layer of plaster on it. It is often recommended to leave the mortar between
the mud blocks a little rough and not scrape the extra part out. This extra mortar would act as a key
to hold the plaster. Plaster could be of just mud or mud with some other stabilizer such as cow
dung, lime, or cement.

bamboo

The Basic Unit

The proposed low cost housing unit illustrated in Figure 4.1 would serve an individual’s basic shelter
needs as a sleeping quarter and storage space for personal items. The unit could be expanded
horizontally and stacked up vertically as the need for more space arises. In order to eliminate the
requirement to outfit each unit with plumbing and drainage systems, a group of units would be
supported by communal kitchens, bathrooms and gathering areas as illustrated in Figure 4.2. The
housing units could be used to upgrade inner-city slums or start new communities. The essential
infrastructure for new communities would need to be provided by local government.

Types of bamboo
The type of bamboo poles used range from 2 to 4 inches in diameter with up to
1/4 inch wall thickness. The 2 inch diameter poles are ideal for building single story
structures and non structural components. The 4 inch diameter poles could be used to
build long columns and beams ideal for multistory structures. Widely available 3/4 and 1
inch diameter poles are used for floor and ceiling coverings. Depending on the original
length of bamboo culms, 10 to 20 feet long poles with even diameter can be produced.
Results from laboratory tests performed on 2 inch single poles and prefabricated
structural components will be illustrated in subsection 5.1.4 of chapter five discussing
testing and construction.
Cracked and damaged poles can be used to build non structural components and
coverings. Poles can also be split and woven to produce different sizes of bamboo mats
used for covering floors, walls and ceilings.
2 Woven Bamboo
Woven bamboo mats are commonly used to build fences, sheds, and floors
throughout Ethiopia. If protected from direct exposure to sunlight and rain, woven
bamboo mats can last up to fifty years. This can be seen on traditional huts throughout
the country built over half a century ago. Although used as an interior covering in the
proposed low cost housing design, woven bamboo mat can also be used as an exterior
covering in warmer regions of Ethiopia with low annual moisture. In this situation it
would be necessary to incorporate a roof design with a larger overhang or a patio to
minimize direct exposure to sunlight.
Corrugated Iron
Locally manufactured in large quantities, corrugated iron is the cheapest and most
prevalent roofing material for urban housing in Ethiopia. Its application as an exterior
envelope for the proposed low cost housing unit helps protect bamboo structural
components from being exposed to direct sunlight and rain. The sheet could easily be
attached to bamboo poles using self-taping∗
screws illustrated in chapter five Figure 5.16,
which prevents poles from cracking while being drilled in. As images of the prototype in
Figure 4.4 show the unit is designed to take advantage of commonly available 4 foot by 8
foot sheets of corrugated iron.
Structural System
The proposed bamboo post and beam structural system, illustrated in Figure 4.5 consists
of prefabricated bamboo columns and beams. The structural components are assembled
from 2 inch or 4 inch diameter poles suitable for single units or multistory structures
respectively. In order to minimize damages from insects and ground moisture, the
structure is designed to sit on precast concrete piers above ground. The prefabrication of
components as well as assembly of the structure can be accomplished using simple hand
tools and workers with minimal training.
Column
A column illustrated in Figure 4.6 is an assembly of four bamboo poles and
bamboo spacers of similar diameter. Locally manufactured threaded rods are used to bolt
the assembly. Columns for the basic unit use 10 foot poles, but longer columns up to 20
feet long can be constructed from quality bamboo culms with consistent diameter. The 10
foot columns are designed to be stacked up in order to create multistory units. Detailed
specifications and test results are discussed in chapter five, subsection 5.1.4
Beams
The structural system utilizes two types of beams. Beam A, shown in Figure 4.7
supports the roof load and creates a rigid post and beam framing. The component is
prefabricated in 10 or 20 foot long pieces for a single 10 foot by 10 foot unit or a wider
10 foot by 20 foot unit suitable for staking up to four stories. Beam B is designed to
support the floor system and to span 10 feet. Detailed specifications and test results for
each beam are discussed in chapter five, subsection 5.1.1.

Wall System
A typical unit would have a wall type constructed from corrugated iron exterior
and woven bamboo mat interior (Figure 4.8). Depending on the diameter of bamboo
poles used in the structural framing there will be a 2 or 4 inch gap between the envelopes.
In cooler environments the gap could be used to install wall insulation, and in warmer
environments the opening could be used for air circulation

Floor system
The basic floor system is composed of one inch diameter bamboo decking
supported by a series of bamboo joists referred to as beam B in section 4.4.2. Woven
bamboo mat over the decking provides a comfortable and even surface for walking and
installing furniture. Depending on the environment additional coverings and insulation may
be incorporated in the system. The floor load is directly transferred to the ground through
precast concrete piers supporting the structure. The floor system sits above ground to
minimize damage from insects and ground moisture. Details regarding feasibility of the
system and construction will be discussed in sections 5.1 and 5.2 of chapter five.
Roof System
The basic unit has a flat roof system that utilizes corrugated iron sheet covering
and sheet metal flashing (Figure 4.10). The roof is inclined to drain water to the rear side
of the unit. The flashing surrounding three sides of the unit prevent the passage of water
in to the structural system.
A ceiling system similar to the floor decking (one inch bamboo layer covered
with woven bamboo mat) can be incorporated in the roof system. Details of the roof
system and construction will be discussed in subsection 5.2 of chapter five.