RCC Door and Window Frame Technology – A New Chapter
 

Rajiv Kumar Jain         sara_sampark@yahoo.co.in

Reinforced Cement Concrete, as an alternative base material for producing door and window frames, has been around for some time now. Its technical and economic benefits have been extensively documented and the technology in its present form is being promoted by the government, through various government and semi government agencies.

In an effort to restrict the extensive use of wood, the government has banned its use in all government controlled construction activity, replacing it with Steel and Aluminum, which are produced through energy intensive production procedures. The private sector still continues to use wood extensively.

In this background Reinforced Cement Concrete was introduced as an alternative material to produce door and window frames. Very soon the benefits of the technology were realized i.e. – low cost, sturdy product, termite and moisture resistant, structurally sound and easily available material and manpower.

To take the benefits to the public at large a technology package was put together for setting up a commercial unit for production of RCC Door and Window frames.  

Present scenario

Although it has been present for some time in the market and in spite of its obvious benefits, the technology could achieve very limited success in some parts of the country, like parts of Maharashtra, Orissa, Gujarat and Rajasthan.  

Our response

STEP – 1 - Identification and definition of the problem.

To identify the weaknesses of the technology in its present form the following three aspects of the technology were studied–

1.                   The product design

2.                   The production equipment design

3.                   Potential for livelihood generation 

Step – 2 – To find the solution

The above issues were summarized as –

a.                   Product issues

a.       To modify the design so that all kinds of hardware available in the market can be used and installed, post production at the users end and by their choice.

b.       To create a design which is producible in any size desired without increasing the number of moulds.

b.                   Equipment issues

a.       In first phase - to produce equipment which lends itself to onsite and offsite production with cost of moulds off loadable on the client and the entrepreneurs investment limitable to a hand vibrator at the minimum and the cost of the vibrator plus the cost of wood/metal moulds at the maximum. 

The Solution

1.                   The Issue of the product was solved by –

a.       By introducing a wooden/plastic member in the rebate portion of the vertical members to take the hinges, locks, latches etc. post installation.

This member was installed at the time of casting of RCC itself.

b.       The size of the frame to meet various opening sizes was solved by designing a variable mould for the top member, which determines the opening size for which the frame is suited. 

2.                   The issue of the equipment was solved by –

a.       Creating a wood/metal mould - wood to decrease weight and cost and metal to increase life of surfaces in contact with wet RCC.

b.       Removable sides of the mould help in demoulding and achieving better finish.

c.       These moulds are light and economic and easily carried by 2-3 men after casting.

d.       Moreover one mason team can cast up to door 20 frames in a day with almost 1/3 the investment in equipment cost. 

Step – III – Fund the R&D and prototype

SARA - Sustainable Action for Rural Advancement an NGO working in the field of efficient habitat technologies for higher performance and commercial benefit to the entrepreneur.

SARA proposed the above project to Department of Science and Technology , Science and Society Division under the scheme STAWS for project funding for conducting applied R&D and producing prototype product and equipment. We got funding in February 2004 and successfully completed the project on 31^st December 2004. 

Way forward

During the project the SARA team undertook an exercise to get feedback from users and masons from the rural areas in the suburbs of Delhi. The effort resulted in getting the first commercial order for 150 improved RCC frames for doors and windows.

The successful completion of this project was noted by professionals from The Society for Development Alternatives. As a result a common program was evolved by SARA and SDA for joint implementation of the technology in their upcoming habitat programs in Bundelkhand, U.P., to be implemented through TARA Nirman Kendra, Orcha.

As a first step a training program was conducted by SARA at the Delhi and Orcha facilities of TARA Nirman Kendra for professional and masons, in the production of improved RCC door and window frames. This is to be the foundation for the future plans for introducing the technology in the larger region as a viable technology and livelihood package. 

We believe that the way forward for this or any other rural technology is through such strategic alliances between NGO’s engaged in strategic technical R&D and those with significant reach and presence in the rural areas. We welcome suggestion, queries, critiques and alliances with all those who are interested in ensuring that the fruits of technology reach all fellow Indians.  

The plantation drive by CLEAN-Delhi was thus a perfect example of how grass-root level NGOs, school students and the various government line departments can work in tandem towards a cleaner, greener city. It is hoped that in the coming years, the children not just plant more and more trees but also take care of them, watch them grow and be able bask in their glorious beauty.  q 

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