Precast

Cast Insitu

FLOW OF PRESENTATION
NEED FOR INNOVATION IN CONSTRUCTION COMPARISON OF CONVENTIONAL AND PRECAST TECHNOLOGY

PRECAST TECHNOLOGY CASE STUDIES

DESIGN ASPECTS OF PRECAST CONCRETE CONSTRUCTION SUSTAINABLE GOALS RISK MANAGEMENT

1.NEED FOR INNOVATION IN CONSTRUCTION

-Shortage of skill & Experts

Construction industry employs approx 49 million personnel.

Sharp decline in skilled workers and engineers. The table below shows statistics from Planning Commissions 11th five year plan (2007-2012).
SR NO. DESCRIPTION NOS. IN 1995 (IN 1000S) 687 % WITH TOTAL NOS. 4.71 NOS. IN 2005 (IN 1000S) 822 % WITH TOTAL NOS. 2.65

ENGINEERS

2
3 4 5

TECHNICIANS & FOREMAN

CLERICAL SKILLED WORKERS UNSKILLED WORKERS

359
646 2,241 10,670

2.46
4.4 15.34 73.08

573
738 3,267 25,600

1.85
2.38 10.57 82.45

TOTAL

14,600

100

31,000

100

1.NEED FOR INNOVATION IN CONSTRUCTION

-Demand & Supply Demand for affordable housing in top seven cities is likely to outstrip
supply by 2015, according to global consultant Cushman & Wakefield. Total demand of 3.94 million units of residential property in the next five years at CAGR of 11%.
600 61.0

HOUSING UNITS (IN THOUSANDS)

60.0
500 59.0 58.0 57.0 Supply 300 56.0 55.0 200 54.0 53.0 52.0 0 51.0 Demand Gap(%)

400

100

2011

2012

2013

2014

2015
Source: Cushman & Wakefield Research

YEAR

GAP (%)

1.NEED FOR INNOVATION IN CONSTRUCTION

-Demand & Supply
Estimated supply by the use of conventional methods is expected to be approximately around 1 million units from top 7 cities. Demand for the top 7 cities is forecasted as 2.3 million units indicating a shortfall of 1.3 million units.
Demand Supply Projections 2011-2015 Bangaluru Chennai NCR Kolkata Hyderabad Pune Supply Demand Gap

Mumbai
0 200 400 600 800
Source: Cushman & Wakefield Research

HOUSING UNITS (IN THOUSANDS)

1.NEED FOR INNOVATION IN CONSTRUCTION

PRINCIPLES IN AFFORDABLE HOUSING
Simple adaptation of western ideas for processes does not support housing solutions for low-income parts of society. Use of designs that are appropriate to the economic, social, cultural and natural conditions of each community are of vital importance. Outflow of currency to purchase machinery and raw material for local production should be stopped. Standards and rules from developed world make housing unavailable in third world and developing countries.

CONCLUSION: Technology

"When compared to any other discipline of building construction, civil construction is conventional in it's approach. We need to breakaway from the convention to meet the demand and de risk critical construction activities. One such technology proven elsewhere in building construction is Precast -Innovations in other discipline High speed lifts Automation Censors to control usage of electricity and water

1.NEED FOR INNOVATION IN CONSTRUCTION

-Cost Analysis
2% 2% 5% 28% 75% Margin 25%

63%

2%
7%

10%

9%

Project Costs

Land Construction Design Fees Marketing Admin

Project Cost 75%

Selling Rate

21% 51% 45%

Sub structure Architecture FPS super structure PHE Electrical

37%

4.5%
Yard 40% Erection 60%

Cost analysis for structure

Concrete

18% Cost analysis for Precast

Yard set up/Erection Rebar

1.NEED FOR INNOVATION IN CONSTRUCTION

- PROJECT MANAGEMENT

Project Life Cycle Plan Phase 1 Initiation High Phase 2 Planning Phase 3 Execution Act Phase 4 Close out

Low Time Cost of Making Change Curve

1.NEED FOR INNOVATION IN CONSTRUCTION

- PROJECT MANAGEMENT

Project Life Cycle Plan Phase 1 Initiation High Phase 2 Planning Phase 3 Execution Act Phase 4 Close out

Low Time

1.NEED FOR INNOVATION IN CONSTRUCTION

- PROJECT MANAGEMENT

Project Life Cycle Plan Phase 1 Initiation High Phase 2 Planning Phase 3 Execution Act Phase 4 Close out

Low Time Value Addition Curve

1.NEED FOR INNOVATION IN CONSTRUCTION

- PROJECT MANAGEMENT

Project Life Cycle Plan Phase 1 Initiation High Phase 2 Planning Phase 3 Execution Act Phase 4 Close out

Low Time Amount of Stake Curve

1.NEED FOR INNOVATION IN CONSTRUCTION

PRECAST SYSTEM - OPTIONS Precast Concrete construction a) Full Precast system All elements including faade are precast b) Precast column / walls with flat plate / flat slab c) Precast beam and precast slab Floor system could be Precast hollow core slab + cast-in-situ topping (this can be used for long span structure of 8.0m to 15.0m Spans) Precast plank with cast in situ topping

1.NEED FOR INNOVATION IN CONSTRUCTION

- BENEFITS OF PRECAST SYSTEM
Construction time can be reduced by 40%. - Layout should be suitable for mechanization Labour requirement can be reduced by 40%. High Quality Finishes. Design flexibility by maximizing repetition can reduce cost and aids speed of construction. Faster construction results in earlier cash flows and leads to reduced capital costs. - Central yard can be a strategy for huge developments Reduces Environmental impact. Enhances Energy Performance.

1.NEED FOR INNOVATION IN CONSTRUCTION

- BENEFITS OF PRECAST SYSTEM
Durable and require little or no maintenance to preserve their original look. Fireproofing material is not required as Precast concrete is noncombustible.

Acoustical isolation and vibration attenuation.

Improved air quality Various kinds of architectural finishes can be easily incorporated in design.

1.NEED FOR INNOVATION IN CONSTRUCTION

- LIMITATIONS OF PRECAST SYSTEM The system has certain limitations. Precast member sizes will be restricted by crane capacity Progress depends on hoisting facilities. If it breaks down progress of work will be affected Lack of planning will derail the schedule. Missing of any components will affect the progress of work seriously. Proper logistic planning and inventory checks are required Requires skilled labour for erection.

BACK

2.COMPARISON WITH CONVENTIONAL CONSTRUCTION

Sr No. Description Conventional technology Precast technology

For construction of 1 Million sq.ft. G+20 (6 bldgs).

1 2 3 Construction time Cost (considering labour and construction costs) Labour requirement 34 Months 100% 5 Lakh man days/year Quality control at site is difficult owing to variable parameters. 24 Months. 95% 2.5 Lakh man days/year Factory production ensures quality product.

Quality

Safety

Safety at site requires more attention and comparatively more expensive

Less safety measures needed when compared with conventional.

2.COMPARISON WITH CONVENTIONAL CONSTRUCTION

Conventional Construction

Precast Construction

Design Period Mobilization

Construction Time

Construction Payment Schedule

Accumulated costs/payments

2.COMPARISON WITH CONVENTIONAL CONSTRUCTION

Proposed Tentative Construction Schedule-Precast
Activity

Month
1 2 3 2M 3M 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Mobilization Design Precast Yard Set up Casting of Precast Elements Substructure Superstructure Finishing Handing Over

6M 10 M 6M 11 M 11M 1

Proposed Tentative Construction Schedule-Conventional

Activity Design Substructure Superstructure Finishing Handing Over

Month
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 3M 6M 25 M 20 M 1

BACK

3.PRECAST TECHNOLOGY
Following are the two widely accepted systems suitable for Residential building construction: 1. Large Panel System. 2. Framed System.

Panel System
Large Panel System Framed System Modular System Combination of Both

Precast Technology

3.PRECAST TECHNOLOGY -LARGE PANEL SYSTEM

Consists of large concrete walls and slab panels Horizontal slabs acts as a diaphragm in transferring load. Height of panels is one floor high. Gravity load is resisted by vertical panels. Panel connection are the key structural components. Seismic shear forces are resisted by horizontal and vertical joints. Horizontal panels can be hollow or solid. Vertical panels can be load bearing and non load bearing Vertical panels can be solid or sandwich panels.

3.PRECAST TECHNOLOGY -FRAMED SYSTEM

CONCEPT:
All elements including facade are precast. Precast column, precast beam and precast slab. Nonstructural Infill walls were also cast along with Precast column and beam. Foundation Cast in situ, Few non typical elements can be cast insitu.

Floor system consists of Precast plank with cast in situ topping.

3.PRECAST TECHNOLOGY -FRAMED SYSTEM

Columns, beams and slabs are factory made precast elements.

SCHEMATIC DIAGRAM OF FRAMED SYSTEMS.

3.PRECAST TECHNOLOGY -FRAMED SYSTEM

3.PRECAST TECHNOLOGY -FRAMED SYSTEM

BACK

5. DESIGN ASPECTS OF PRECAST CONCRETE CONSTRUCTION

Full advantage of precast concrete construction is achieved when the building has been designed for high construction speed and maximum repetition. In every precast concrete projects the following aspects are important for the design team: Architecture MEP services Structure Manufacturing

Erection

5. DESIGN ASPECTS OF PRECAST CONCRETE CONSTRUCTION ARCHITECTURAL ASPECTS

The architect should be considering the following points: Simple and symmetrical layout and elevations. Achieve standardization and repetition. Modular grids. Modular design has big impact on costing. Design with larger floor spans.
ELEVATION

Minimize joints.
Keep precast elements as large as possible, but maximum around 5 to 6 Tons.

HOLLOW CORE SLAB FINISHES

5. DESIGN ASPECTS OF PRECAST CONCRETE CONSTRUCTION ARCHITECTURAL ASPECTS

5. DESIGN ASPECTS OF PRECAST CONCRETE CONSTRUCTION ARCHITECTURAL ASPECTS

Integrate architecture services and structure . Avoid last minute changes. Modular Design modular principles can be strictly followed. A balance should be found between modular design and customized prefabrication. Flexibility Flexibility in precast concrete building projects can be achieved by creating larger floor spans with larger open spaces.
Precast Architectural Designs

HOLLOW CORE SLAB FINISHES

HOLLOW CORE SLAB FINISHES

5. DESIGN ASPECTS OF PRECAST CONCRETE CONSTRUCTION MEP SERVICES

In precast concrete building projects, it is important that the MEP service consultants and the MEP vendors are part of the design team. Services like air conditioning, electrical and plumbing have to be an integrated part of the precast design.

MEP SERVICES IN HOLLOW CORE SLABS

5. DESIGN ASPECTS OF PRECAST CONCRETE CONSTRUCTION MEP SERVICES

Wall panels can be provided with electricity conduits , electricity boxes and openings for ducts. Hollow core slabs (HCS) can be provided with electricity boxes and block outs. Precast planks with RCC toppings can be provided with electricity boxes and conduits.

MEP SERVICE IN HOLLOW CORE SLABS.

PLUMBING WORK IN HCS WITHOUT SUNK

5. DESIGN ASPECTS OF PRECAST CONCRETE CONSTRUCTION STRUCTURAL ASPECTS

India being an earthquake prone country the seismic resistant requirements are the most important criteria of the structural design. Looking at the requirements, the following design rules should be followed: Simple and symmetrical layout. Uniform distribution of mass and structural stiffness over the height. Avoid torsion. Ductile behaviour of the structure. Transfer of vertical loads between wall panels can be achieved by direct structural connection. The precast floor units should be properly joined together to act as a floor diaphragm that transfers the lateral load to the shear walls. The shear walls will transfer the lateral loads to the foundation by acting as cantilevered walls.

5. DESIGN ASPECTS OF PRECAST CONCRETE CONSTRUCTION MANUFACTURING ASPECTS

Customization according to the requirements of the project Capabilities of manufacturing unit to be considered in design stage Standardization of embedded parts, lifting anchor, reinforcement etc. Reduction of damage by chamfering the edges of the wall.

Tapering of block outs.

5. DESIGN ASPECTS OF PRECAST CONCRETE CONSTRUCTION MANUFACTURING ASPECTS

Mould Design. Suitable material including steel, timber/ plywood is selected on the basis of No of repetitions. Required surface finish. Complexity of Precast Element.
3 D Pod Mould

Cost competitiveness is enhanced by

using adjustable moulds. Adequate no of braces, ties and struts

should be provided for proper casting

of elements.
Adjustable Mould

5. DESIGN ASPECTS OF PRECAST CONCRETE CONSTRUCTION ERECTION ASPECTS

Crane position and lifting capabilities. Lifting speed and speed of erection. Space for mobile cranes / Crawler cranes. Easy access to connections. Tolerances (Ref:IS 15916:2010, PCI 117,Appen I). Erection Sequence. Easy and fast erection.

Filling of joints with grout / mortar.

Position of Props and supporting structures.

5. DESIGN ASPECTS OF PRECAST CONCRETE CONSTRUCTION DESIGN ASPECTS

Design of Precast elements. Involves understanding the method of fabrication. Involves aspects that facilitate the erection and assembly of elements on site. Integration of different elements, such as beam-wall system, multitier columns and three dimensional units.
3 - D Pod elements Parapet Beam

5. DESIGN ASPECTS OF PRECAST CONCRETE CONSTRUCTION CONNECTION DESIGN ASPECTS

Structural integrity - Diaphragm action lateral forces (seismic & wind)

Designed actions.

against

progressive accidental

collapse/Robustness/

Ref

Seismic

design

of

floor

diaphragms - Farzad Naeim & R.Rao Boppana

5. DESIGN ASPECTS OF PRECAST CONCRETE CONSTRUCTION CONNECTION DESIGN ASPECTS

The wall panels connections can be classified into horizontal joints and vertical joints.

The horizontal joints have to transfer vertical loads as well as lateral loads.
The vertical joint can either be structural joints which have to transfer shear forces or non structural joints which dont have to transfer any forces. For fully monolithic behaviour the protruding reinforcement connection in combination with drop in stirrups can be used. The connection in Hollow core slabs should transfer the internal diaphragm forces and it should be designed as structural integrity tie.

5. DESIGN ASPECTS OF PRECAST CONCRETE CONSTRUCTION CONNECTION DESIGN ASPECTS

Joints and Connections Joints are designed on the basis of Transfer of loads from a precast concrete element to the supporting structure to form the structure. Avoiding congestion at joints.
Column-Beam Joint.

Avoiding penetration of forms.

Allow for erection and production tolerances. Easy assembly and accessibility.

External wall joint.

5. DESIGN ASPECTS OF PRECAST CONCRETE CONSTRUCTION CONNECTION DESIGN CONCEPTS

Progressive collapse / Robustness
These effects may generally be prevented if the following precautions are taken. (Ref : IS 15916:2010)

o Notional horizontal load

o Design of ties Peripheral ties

Internal ties
Floor to wall ties Vertical wall ties. Ref : Precast concrete structures by Kim.S.Elliot.

5. DESIGN ASPECTS OF PRECAST CONCRETE CONSTRUCTION LOCATION OF TIES IN PRECAST SKELETAL STRUCTURES

1 Internal floor ties 2 Peripheral floor ties 3 Gable peripheral floor ties 4 Floor to wall ties 5 Internal Beam ties 6 Peripheral Beam ties 7 Gable Peripheral beam ties 8 Corner Column ties 9 Edge Column ties 10 Vertical Column ties 11 Vertical wall ties

Location of ties in Precast Skeletal Structures

5. DESIGN ASPECTS OF PRECAST CONCRETE CONSTRUCTION CONNECTION DETAILS : FLOOR TO FLOOR DIAPHRAGM

Reinforcement designed for chord forces (tension) Typical Cross section

BACK

Typical Plan view

6. Sustainable Goals
Resource Efficient
Concrete- made from water, sand, aggregates and cement(limestone) Abundantly available materials. Waste by products from power plants and manufacturing facilities can be used in concrete

Energy Efficient
Thermal mass of concrete saves energy by reducing temperature

swings in buildings. Concrete has low energy requirements for production. Concrete has low transportation energy costs as it is produced by materials available locally.

Light colored precast concrete roof pavers reduces Heat Island Effect.

6. Sustainable Goals
Highly Durable
Concrete gets stronger with age.

Strength gained by concrete for years and even decades.

Ecologically Preferable
compared to wood, iron ore mining, extraction for constituents of

concrete is less disruptive to land Concrete reduces construction waste and can be recycled.

Recyclable
Concrete- crushed and used as aggregate in new concrete mixtures for infrastructure projects. Steel reinforcement can be recycled again.

6. Sustainable Goals
Reduction of CO2 emissions.
Industrial wastes such as slag cement and silica fume reduces the amount of cement which in turn reduces CO2 emissions

Reduces the amount of materials used.

Precast concrete is designed to optimize the amount of concrete used. For ex: hollow core slabs.

80 60 40 20 0

Total self weight Gravel & Steel Cement Water

45% savings in hollow core slabs

6. Sustainable Goals
Reduces the toxicity of materials.
As a manufactured product under controlled conditions in the plant, precast concrete generates less waste and waste generated has low toxicity.

Indoor Air Quality.

Concrete contains low to negligible VOCs.

Also, concrete has resistance to moisture. No renders and plasters required for internal applications.

BACK

7. RISK MANAGEMENT
Risk Management is the process of planning, leading and controlling the resources and activities of the organization to To fulfill its objectives cost effectively To protect and grow corporate assets To enhance shareholder value. Risk Management Techniques in Construction: Structural design principles Codal standards against Progressive collapse Case study Effective Progressive collapse design

7. RISK MANAGEMENT
-RONAN POINT, LONDON
22 storey block of flats built in 1966-68 (one of nine identical blocks). Precast concrete walls and floors with in situ joints between units. No in situ core or

shear walls.
Collapse of south east corner over full height of building caused by a gas explosion in corner flat on the18th floor in May 1968. 5 people died. Emergency strengthening works carried out. South east corner of building rebuilt and occupation of building continued.

7. RISK MANAGEMENT -RONAN POINT, LONDON

Precast floor units 7in thick and reinforced. Wall panels 6in thick with little or no reinforcement. Diagram shows typical connection detail with emergency strengthening angles.

5th Amendment to the Building Regulations

in 1970 (includes requirements for the prevention of progressive collapse). Evacuation of Ronan Point and 8 sister blocks 1984. Detailed survey carried out 1984. Building dismantled 1986.

7. RISK MANAGEMENT
- KHOBAR TOWERS, SAUDI ARABIA
Overview
Damage due to bomb explosion on June 1996. Severe damage in facing facade wall in closest building and widespread glass damage.

Structural detail
Precast concrete structure with wall and floor components. Lateral load resisted by wall system. British code CP-110 was adopted. Heavily damaged building was 8 storey

tall and T shaped in plan.

7. RISK MANAGEMENT
- KHOBAR TOWERS, SAUDI ARABIA
Detailing
The code adopted addresses progressive collapse, ties and ductile detailing.

Protruding

reinforcement from

floor planks

overlap with the reinforcement in adjacent plank. After erection overlapping bars are threaded with 11mm steel strands effectively interlocking them and are grouted. Wall panels were casted with protruding loops which is threaded with steel bars and grouted

with adjacent wall panels.

Bars from one level to another were connected with nuts inside connecting bracket.

7. RISK MANAGEMENT
- KHOBAR TOWERS, SAUDI ARABIA
Performance
The code addresses progressive collapse, ties and ductile detailing. Collapse was limited to the external facade wall. Exterior shear wall was completely destroyed but no progressive collapse. Interior walls and slab panels had extensive damaged but did not collapse The precast elements had sufficient ductility detailing to with stand the impulse force. The interlocked ductile connections maintained integrity of the structure preventing progressive

collapse.
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