FILLER SLAB

Filler slab is alternate slab construction technology where part of concrete in bottom of slab is
replaced by filler material. The basic principal is that the concrete in bottom half of RCC slab
is structurally not required as concrete acts as compression material which is required in top
half portion of slab. So this portion concrete is replaced by low cost, light weight filler material
like Mangalore tile, clay pots etc.
Filler slab technology is a simple and a very innovative technology for a slab construction. The
reason why, concrete and steel are used together to construct RCC slab is in their individual
properties as separate building materials and their individual limitation. Concrete is good in
taking compression and steel is good in tension. Thus RCC slab is a product which resists both
compressions as well as tensile. Filler slab is a very cost effective roofing technology. It is not
easy to remove, the concrete from the tension zone, hence concrete can be replace (partially);
that part of concrete using light weight and low cost filler material. This method of construction
is called filler slab. Filler slab technology is being used across India, but substantial amount of
work on the successful promotion and mostly adopted in South India. These filler materials are
so placed as not to compromise the structural strength, stability and durability, resulting in
replacing unwanted and non-functional tension concrete, from below and thus resulting in
economy of high energy material consumption and respective cost savings and decreased dead
load of the slab and resulting in economy of high energy materials consumption and considerable
cost saving and decreased dead load of the slab. An internal cavity can be provided between the
filler material which adds an extra advantage; other than cost savings and energy savings;
improved thermal comfort for the interiors. Also an added advantage of lower dead weight
transferred to the supporting elements and finally onto the foundation to further adds up cost
saving in design of these elements.
Once the shuttering is done, the reinforcements are laid in grid form. The size of grid depends
on structural design and size of filler material. For example, grid of 35cm X 50cm is used for
Mangalore tile as filler material and grid of 45cm X 45cm is used for clay pots of 40cm
diameter filler. The filler material to be soaked in water before casting so that it does not
absorb water from concrete. Then the slab is cast with cement concrete similar to traditional
concrete slabs.
Filler slab roofs are solid reinforced concrete slabs with filler material in the tension zone. The
filler material could be cheaper and/or lighter. A number of alternative materials can be thought
of: (a) brick or brick panel, (b) Mangalore tile, (c) stabilized mud block, (d) Concrete Waste etc.
Figure 9.2 below shows ceiling of a typical filler slab roof using SMB filler. Depending on
thickness of slab the tension zone of the slab can be replaced by filler material
Advantages of using filler slab roof
Concrete required in this technology is about 20% less than conventional slab construction.

Due to reduced concrete, self-weight of the slab is reduced and thus about 30% less steel is

required, without compromising strength of the slab. This technology was used by Architect

Laurie Baker in Kerala extensively.

Things to consider about filler material

Filler material should be inert. It should not react with concrete or steel It should be light

weight, low cost and preferably locally available Size of filler material should be such that it

fits in bottom half of the slab and structural grid of reinforcement Using material with good

thermal insulation properties like clay will provide thermal comfort inside the room The filler

material will be seen as part of ceiling so shape and finish of the material should be as per

desired aesthetics

Design parameters
Filler slab can be designed like a conventional RCC slab, however the dead load reduction due to
the filler material and the spacing of reinforcement as per the size of the filler material should be
considered [111]. The thickness of filler material should not exceed the depth of the neutral axis.
e.g. for a slab thickness of 125mm, the filler material depth should not exceed 60mm.The size
and shape of the filler material selected should comply to the design requirements. Shape and
size of filler material governs the quantity of concrete to be replaced in tension zone. Form cost
consideration, effective compaction and ease in pouring concrete at least 25% of the concrete
should be replaced by filler material.
Construction of filler slabs
Important construction steps for filler slab are as discussed below.
1. The filler material to be used must be waste materials which are available locally and lighter
than concrete. Refer fig 9.3.
2. The shuttering for slab is erected as for a conventional RCC slab.
3. A minimum bottom cover of 15 mm is kept after erecting the shuttering which forms a grid
and filler material can be placed centrally in each space of the grid. No filler material is
provided in bands of concrete along the edge of the slab. The width of these concrete bands
is normally minimum 300 mm. The reinforcement spacing in these bands is smaller than
spacing around the filler materials.
4. After all the filler materials have been placed any concealed electrical work etc., should be
placed in the spaces between the filler material and then concrete is placed between the filler
materials and top of it to achieve slab thickness.
5. Concrete vibrators must be avoided in bottom portion of slab as they may disturb the
placement of the filler materials. Manual tamping is advised.
6. Reinforcement layout for a filler slab using compressed earth blocks as filler material of size 230mm
x 190mm x 50mm.(Refer fig. 9.4) [17-19].

MATERIALS SELECTION AS PER NEED AND DESIGN

Light weight, inert and inexpensive materials such as low grade Mangalore tiles, Thermopolis
Burnt Clay Bricks, Hollow Concrete blocks, Stabilized Mud blocks/ Hollow Mud blocks, Clay
pots, Coconut shells etc. can be used as filler materials. These materials are laid in the grids of
steel reinforcement rods and concreting/concrete topping is done over them.

The following points should be considered for filler material selection:

• Filler material should be inert in nature. It should not react with concrete or steel in RCC slab
constructed.
• Filler materials water absorption should be checked for as it will soak the hydration water from
concrete.
• Filler material should be light in weight, so that overall weight of the slab reduces and also the
dead load onto the foundations is reduced.
• Filler material should be low cost so that it cost is much lesser then the cost of the concrete it
replaces. This is very important to achieve economy.
• Filler material should be of a size and cross-section, which can be accommodated within the
spacing of the reinforcement and also thickness wise could be accommodated within the cross
section of the slab.
• Filler material texture should match with the desired ceiling finish requirements so as not to
provide an ugly ceiling pattern.

Design and durability

National Building Code of India 2005 specifies the filler slab is satisfactory and confirms to the
provisions of relevant parts regarding material, design and construction and the material, method
or work offered is for the purpose intended. The provisions of this part are not intended to
prevent use of any construction techniques including any alternative materials, nonspecifically
prescribed by the Code, provided any such alternative has been approved. The Authority may
approve any such alternative such as Ferro cement construction, row-lock (rat trap) bond in
masonry, stretcher bond in filler slab and filler slab provided it is found that the proposed
alternative is satisfactory and conforms to the provisions of relevant parts regarding material,
design and construction and that material, method, or work offered is, for the purpose intended,
at least equivalent to that prescribed in the Code in quality, strength, compatibility, effectiveness,
fire and water resistance, durability and safety.

CONCLUSION:
After carrying out the study and various papers it can be stated that this technology can be
proved to stand as cost effective and alternate technology for construction.
1. Strength of conventional slab filler slab instead of conventional slab.
2. Economic point of view, 30% of concrete is saving in filler slab cost is saving, which is
greatly effect on economy.
3. In manufacture of cement, filler slab technique saves 30% of carbon emission which proves
ecofriendly.
4. Aesthetic: There is no need of extra expenditure for interior decoration purpose