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Emerging construction technologies

C A PRASAD

DIRECTOR METEY ENGINEERING CONSULTANTS, HYD/VJA

Different types of construction technologies for high rise structures for speedy delivery

• Shear wall / Monolithic construction using aluminum shuttering

• Insulated wall panel construction using shotcreteing of concrete

• Light gauge steel or cold formed steel construction

• Precast/Prefabricated construction using concrete/steel

• Composite construction1/20/2018 METEY ENGINEERING AND CONSULTANCY PVT LTD 2

SHEAR WALL / MONOLITHIC CONSTRUCTION USING ALUMINUM SHUTTERING

Methodology:The elements like walls, beams and slabs made of RCC are cast together at one go by using aluminum form work. Panels of 2’(0.6m) wide X 10’(3m), floor height are connected together with connectors.

Merits:Construction speeds can be achieved faster due to light weight of forms and less labor required for carrying the form work.

Quality of finish achieved is very good to receive painting directly without plaster.

Formwork components are durable and can be used for 100 repetitions.

5 to 7 days cycle is easily achieved in most of the constructions and construction for overall project is dramatically reduced.

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Demerits:Initial investment on formwork is higher at the rate of Rs.10,000/sqmAbout 50 repetitions are easy to achieve and there after maintenance is required to be done for correctness of shape such that another 50 repetitions could be completedNo. of sets of formwork to be decided based on time of construction and the repetitions to be achieved.

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Insulated wall panel construction using shotcreteing of concrete.Methodology:System is conceived with insulated wall and roof panels of corrugated extruded polystyrene(EPS), which consists of zinc coated square mesh on either sides of it connected by a shear connectors

The panels are coated with concrete through shotcreting machines

Merits:Light weight, seismic resistant, sound and thermal resistant

EPS will reduce the Air conditioning loads too and there will be a difference of 4 deg C in these buildings

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Demerits:Shotcreting means insitu work and needs to be closely monitored and inspected

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Light gauge steel or cold formed steel construction.Methodology:Light weight cold formed steel sections for speedy low rise building construction.

Gauge thickness from 0.7-2.0mm.

These could be used in industrial townships, residential and commercial buildings, hospitals and schools etc.,

External and internal walls are to be covered with plaster boards duly putting the rock wool in between them, which will give the thermal insulation.

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Demerits:Spacing of studs and joists will have an effect on internal and external planning of structurePlaster boards are required to be fire resistant and should be durable against the external environment, thereby, its cost is prohibitive compared to conventional systems

Merits:Light weight, Seismic resistance, Thermal and acoustic insulation. With rock wool insulation inside, Air conditioning loads will be lesser

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Composite construction.

Methodology:Structural Steel columns and beams with Deck slab + Concrete or Insitu concrete with shuttering is a method of construction

Steel columns could be encased to get additional strength in addition to steel.

Merits:Very faster construction

Concrete encasement makes the steel fire resistant and protects from corrosion/ durability

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Demerits:Cost is higher by about 20 to 30% compared to RCC type of constructionFire resistant paint to be applied to structural steel elements is very prohibitive

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PRECAST DEVELOPMENT SO FAR IN INDIAIMPLEMENTATION CHALLENGES

PLANNING FOR PRECASTAwareness of precast

Future of precast

Development of Precast in India so far

• Number of precast manufacturing units have been set up and are being set up in India.

• The demand for precast systems is rising day by day

• The developers and Govt. Institutions have felt the necessity of completion of projects faster and thus pass on benefits to the customers early as well as for themselves

• Spirol from UK have set up a facility in south India to supply the steel plates required for beds duly tying up with a local firm

• Bianchi from Italy have set up the facility near to Mumbai and are supplying the tilting moulds required for making walls, as well as for forms for columns, beams and have already supplied to number of precast manufacturers in India.

S.N

o

Client Equipment supplied from Unit

I Hyderabad

1 Janapriya Developers, Elematic, FINLAND Battery Mould

2 PRECA Prensoland, Spain

3 Skill promoter Nordimpianti, Italy

II COIMBATORE

TEEMAGE PRECAST ECHO, from

NETHERLANDS, &

WECKENMANN, Germany

5 bed HCSplant

Battery Mould

III CALICUT Weckenmann, Germany Battery Mould

IV Chennai

VME PRECAST Elematic, Finland HCS & Tilting

Table wall unit

Precast construction is fast catching up and is establishing itself as the construction technology for the future

The different precast projects so far came up in India and are built by the different precast companies are a testimony of the same which are indicated below:

Brigade Orchards

Brigade Orchards

Precast Multi-Level Car Park, Terminal 1B, Domestic Airport Mumbai

Multi-level Car Park (MLCP)was a unique project thathas been successfullycompleted by L&T despitethe challenges of beingsituated at busy junction ofDomestic Airport andWestern Express highwaysurrounded with many liveline underground services.

Precast Multi-Level Car Park, Terminal 1B, Domestic Airport Mumbai

Built up area – 30,497sqm

8 Levels car parking

Comprising 2B + G+ 4

Bharat Forge Research and Development Centre (BFRD)

Total Area: 1.1 lakh sq.ft

Total No. of Floors:

G+L1+L2+L3+Terrace

Delivered in 7.5 months

Schmersal India

Built up area – 8880 sq m

PRODUCTION FACILITY FOR SCHMERSAL India Pvt. Ltd, PUNE

TRANSPORTATION OF COLUMNS

ERECTION OF COLUMNS /STAIRS

COLUMNS AND BEAMS

BOUNDARY WALLS

Infosys Multi Level Car Parking

Total Area = 4.5 Lakh Sq.Ft

Total No of Floors Basement+10 Floors

Infosys multi level car park pune

FACADE

INFOSYS MLCP

INFOSYS MLCP

INFOSYS MLCP

INFOSYS MLCP

INFOSYS MLCP

INFOSYS MLCP

INFOSYS MLCP

INFOSYS MLCP

WTC-WORLD TRADE CENTRE, PUNE

Built up area :16.5 Lakh Sq.FtTotal No of Floors: Basement+Podium+10 Floor

BDA Project

Bangalore DevelopmentAuthority (BDA) B+S+18 floorhousing projectDoddabanahalli Bangalore

B+S+18 FLOOR HOUSINGPROJECT, DODDABANAHALLI,BANGALORE

M/s. B.G.Shirke ConstructionTechnology Pvt Limited, Punebuilt the structure usingPrefab technology

Office Building in Hyderabad:

• Stilts- 2no’s + G +4 ; 1,65,000 sft

• Delivered in 4.5 months

Hospital Building:

G+4 – 1,20,000 sft : Built in 4months

Precast elements used are, viz.,

Precast Prestressed Hollowcore slabs,

Prestressed beams,

Precast Retaining walls, PrecastStairs,

Precast Lift walls,

Precast Architectural elements,

Precast ducts

Industrial Building in Hyderabad

• Cadbury’s project-2,20,000 sft

• CompositeConstruction:Steel columns andBeams + PrecastHollow core slabs

• Delivered in 5months

Few of the projects carried out byVME Group, Chennai

D.R.D.O, CABS HANGER & OFFICES BUILDINGS, BANGALORE.

NOVOTEL IBIS COMBO HOTEL, CHENNAI.

KHIVRAJ MOTORS – CAR SHOWROOM, CHENNAI

CHENNAI SILKS SHOWROOM, TIRUNELVELI

OFFICE BUILDING – GUINDY, CHENNAI

LAKESIDE, CHENNAI

Few of the projects carried out by TEEMAGE, Coimbatore

M/s TSM Canteen Block

• Built-up Area : 13,500 Sq.Ft

• Scope : Beams, Columns,Hollow core slabs, Wallpanels, Solid Slabs andStaircase

• Time: 38 days

M/s. Rotary School, Tirupur, Tamilnadu

• Duration : 28 Days

• Built-up Area : 19,000 Sq.Ft

• Scope : Beams, Columns, Hollow core slabs, Wall panels, Solid Slabs and Staircase

M/s. SCM Silks (P) Ltd : Tirupur, Tamil Nadu

• Duration : 30 Days

• Built-up Area : 52,300 Sq.Ft

• Scope : Beams, columns, Hollow core slabs, Wall panels and staircase

M/s.Christian Medical College Vellore, Tamil Nadu

• Duration : 27 Days

• Built-up Area : 49,500 Sq.Ft

• Scope : Beams, Columns,Hollow core slabs, Wallpanels and Staircase

• Supertech, from Noida,Shobha Developers aremeeting their in Houserequirements, while, KEFInfra, and other companieshave also done differentstructures across India.

THANK YOU