Precast
buildings in
India
by
Sthaladipti Saha
Chief Engineering Manager
Larsen & Toubro
Larsen & Toubro Limited,
ECC Division,
Chennai, India
Introduction…
Precast concrete construction in India
With the advent of precast concrete construction in India
post independence, L&T has used this method of
construction to gain a stronghold in the construction sector.
The methodology followed was the
setting up of a site prefabrication
yard close to the project site for ease
of transportation and use.
Gantry Casting yard
Introduction…
L&T‟s foray into precast construction . . .
• Roof elements
• Folded plate
• Truss
• Shell
• Silo
• Waffle slab
• Pipe rack
• Special structures
• Wall panels
• Miscellaneous
Tilting mould
Roof elements…
Folded plate
Structural steel arrangement
Side shutter reinforcement Curing
Mould
Roof elements…
Folded plate
Folded plates stacked in yard Loaded on trailer
Demoulding Temporary ties
Roof elements…
Folded plate
Erected using cranes
Sl.N
o Description Unit Qty
Qty /
Sq.m #
1 Concrete M40 Cum 6.20 0.103
2 Mould assembly
& demould Sq.m 130 2.17
3 Reinforcement Kg 1300 21.7
# Quantity per Sqm of Roof (plan) area
Techno-economic indices
Roof elements . . .
Folded plate
• Used as large span roofing
elements
• Efficient from viewpoint of
material consumption
24m span precast concrete folded plate
with north light glazing on one side for
MICO , Bengaluru
24m span precast concrete folded plate at
Pearl distilleries, Ongole
“V” shaped folded plate - 36m long, 6.5m
wide & 2.35m height at Ocean Engineering
Centre – IIT Chennai
Roof elements . . .
Folded plate
Gabriel India Limited at Pune
Perfect Circle Victor at Pune
Roof elements . . .
40m span precast concrete A-frame
supporting trussed purlins – Silo for SPIC at
Tuticorin
38m span precast trough slab A-
frame silo – State fertiliser
manufacturing Corporation,
Colombo
Truss
Truss Roof elements . . .
30m span precast concrete roof truss in
single piece as roof element for Food grain
godown at Madras port trust
20m span precast concrete arch shaped
truss and slabs as roofing system for
Tamilnadu minerals at Chennai
Truss Roof elements . . .
48m span precast
concrete truss – L&T
cements, Awarpur
Truss Roof elements . . .
27.7m precast concrete roof truss –
Foundry for Grindwell Norton at
Renigunta
Truss
Roof elements . . .
18m span diamond shaped precast concrete
truss with rafters and purlins as north light roof
system at EWL, Chennai
16m span precast concrete truss
supporting 13m span precast prestressed
concrete slabs as roofing systems for
indoor switchyard at Tuticorin
13.5m span north light precast
concrete portal during erection
– L&T McNeil at Chennai
22m precast concrete portals
with 8m span precast purlin –
Heavy Engineering Workshop
at L&T Hazira
Truss
Roof elements . . .
Shell Roof elements . . .
Erection of HP shell – Finishing shop
at L&T Bengaluru works
HP shell roof – L&T Bengaluru works
Silo
43.5m precast
prestressed concrete
truss (in 3 pieces)
and slabs as roof for
silo at Kakinada
Roof elements . . .
Silo
Roof elements . . .
55m span urea silo at IGFL Jagdishpur
Cyber park, Hyderabad
Waffle slab Roof elements . . .
Convention center, ECC
HQ campus
Columns & Beams. . .
• 15m precast columns
• Weight of column – 25MT
• Precast beams at gable end
ITC Badrachalam
Erection sequence
Pipe rack. . .
Erection sequence
Pipe rack. . .
Erection sequence
Pipe rack. . .
Erection sequence
Pipe rack. . .
Pipe rack. . .
Curing
Casting
Pipe rack. . .
Erection
Pipe rack. . .
Pipe rack. . .
Precast concrete trestles used for pipe rack structure at
Kothari caustic soda project at Manali
Panipat Naphtha cracker project
Special structures . . .
• Size – 24 x 6 x 3m
• 160mm to 250mm c/s
• Weight – 120MT
• No. of elements - 234
Bengaluru International Airport
Wall panels. . .
Bengaluru International Airport
Wall panels. . .
Mumbai International Airport
Wall panels. . .
Cognizant at MEPZ, Chennai
Beer bottle finish on the outside surface of
precast wall panel at L&T Bengaluru works
14m high 2.5m wide precast concrete
grooved wall panel with precast concrete
gutter for the assembly shop of L&T Poclain
– Bengaluru
Wall panels. . .
School rooms at Gujarat
In stacking yard
In transit
• 6000 school rooms
• Each of 54 sq.m. BUA
Assembled school room
Wall panels. . .
Curing tank
Compound wall. . .
Bengaluru International Airport Delhi International Airport
Miscellaneous. . .
Precast concrete water tower with
beer bottle finish on the outside
surface at L&T Bengaluru works
15m span conveyor galleries in
precast concrete at Awarpur
cement works
TISCO housing, Jamshedpur South city, Bengaluru
Miscellaneous. . . Stadiums
Precast bleachers and raker
beams in Qatar football stadiums
Precast roof element
and gallery units in
Jawaharlal Nehru
Stadium at Chennai
– built in 260 days
Elliptical roof made of 120 V-type folded plates of 40m span –
Kanteerava indoor stadium in Bengaluru
Miscellaneous. . .
EDRC building, ECC HQ campus
Precast „L‟
shaped duct
units in staking
yard
Delhi International Airport
• Precast element size – 2.0m X 1.5m
• No of Pieces – 1200 Pieces of 1.2m length
• 2.4 Kms completed in 4 months
Miscellaneous. . .
Box culvert under
pavements
Delhi International Airport
Precast pipes
Delhi International Airport
Precast drains
Miscellaneous. . .
Delhi International Airport
Precast baggage handling tunnel
Miscellaneous. . .
• Precast Tunnel Element size
• 4.43m X 2.8m of 1.2m length
• Precast tunnel length – 700m
Conclusion…
Precast concrete construction in India – the future . . .
Increase in urbanization and consequent shortage of skilled
labor and better infrastructure will require construction to
focus more on industrialized methods of construction like
prefabrication.
Move from site Prefabrication to Plant prefabrication . This
will lead to speed, economy and reduce the need for skilled
manpower.
L&T is setting up a Hollow core factory inline with the
changing scenario.
Thank you