Pre-fab technology for buildings

WELCOME

PRESENTATION ON

CONSTRUCTION TECHNOLOGIES

(Pre-Fab Technologies)1

PREFACE• Govt., of A.P. invited EOI from the reputed, experienced,

technically and financially sound companies/ firms/ Contractors/ Institutions / Individuals/ Developers for Construction of Houses / Structures on Design and Built Basis using Alternate Technologies preferably Pre-cast concrete/ Pre-Fabricated (fully/ Partially) etc., other than conventional.

• 18 no. of bids were received in response to the EOI .

• Technical Committee meeting held on 10-3-15 and 11-3-15 under the Chairmanship of the ED, BMTPC for evaluation of Technologies.

• Of the (9) alternative technologies presented by the Agencies (7) Technologies were accepted by the Technical Committee.

Technology/Agencies participated• Glass Fibre Reinforced Gypsum Panels for Walls &

Roof slabs.1. M/s. Nanobright Solar Technologies Pvt., Ltd., Hyderabad2. M/s Belasia Engineers & Developers (P) Ltd, Kochi.3. M/s. R.P.P.Infra Projects Ltd., Erode• Expandable Polystyrene Panels for Walling and

Roofing1. M/s DSP Infra Pvt. Ltd – CTSPL - (JV), Hyderabad2. M/s. RMN-BKCHEM-PREVISE HOMES (JV), Hyderabad3. M/s Beardcell Ltd., Visakhapatnam

• Light gauge Steel structures1. M/s Everest Industries Ltd., New Delhi• Pre-cast Concrete System (3-S Pre-Fab Technology)1. M/s.B.G.SHIRKE Construction Technology Pvt Ltd., Pune

Technology/Agencies participated• Steel frame with Aerocon Panels/PUF panels

1. M/s. PANDHE INFRACONS PVT.LTD.,Solapur ( with aerocon panels)2. M/s. Jindal Mectec Pvt., Ltd.,Gurgaon ( with PUF panels)3. M/s. ENERTECH ENGINEERING PVT.LTD.,Hyderabad (with PUF

panels)4. M/s. Satec Envir Engineering (I) Pvt., Ltd., Mumbai

• Monolithic Concrete Walls (Shear Wall Technology) with Plastic/Aluminium frame work

1. M/s Sintex Infra Projects Ltd., Kalol (Plastic frame work)2. M/s M.V.Omni Projects (INDIA) Limited. Ahamadabad (with

Aluminum frame work)3. M/s NCC LIMITED, Hyderabad ( with Aluminum frame work) • Waffle Crete Pre-cast Concrete Panels1. M/s KCL-SRL Houses, Ahmedabad (Load bearing wall - Waffle

Crete concrete panels for walls and slabs with vertical and horizontal ribs)

Glass Fibre Reinforced Gypsum PANELS FOR WALLS AND ROOF SLABS

• Glass Fiber Reinforced Gypsum (GFRG) Panel, called RAPIDWALL …. is an alternative building material to replace bricks / concrete blocks which will also save river sand, water etc and protect the environment

• GFRG wall panels are 124 mm thick which are factory molded from fiber glass reinforced gypsum creating two 15+/-3 mm thick sheets spaced apart by web members at 250 mm centre

• Cavities may be filled with concrete for multistoried buildings• The cavities can be used to accommodate building services such as

plumbing, electrical conduits and insulation• GFRG Wall panels can be used for hybrid construction

Advantages of GFRG Panel system • Light weight and accurate• Load bearing • Flexible in all aspects of home plan designs• Reduces construction time and space saving• High quality finish• Good sound attenuation• Earth quake resistant, Termite resistant, Fire Resistant &

Water resistant • Environment friendly and Recyclable• Substantial reduction in the structural weight of the building• Escalation of project time schedule can be avoided Validation of Technology:• Validated by SERC Chennai, IIT Madras duly conducting

various Tests.

Hybrid Building in which RCC columns & beams are framed & walls & floor slab is with Rapidwall

APPLICATIONS OF GFRG PANELS

• Load Bearing walling and • Partition infill walls.

» Compound Wall and fencing

• Mass housing

• Horizantal roof slabs and• multi storied buildings

Name of Agency

Technology Proposed No of Houses Propos

ed

Cost Per Sft in Rs.

Foundations

Walling Roofing

M/S Nanobright Solar technologies Ltd., Hyderabad

Conventional

GFRG Panels GFRG Panel with Screed slab with Micro T-Beams

500 1738/- to 1994/-

Belasia Engineers & Developers Ltd., Kochie

Conventional

GFRG Panel with M20 Concrete as infilling

GFRG Panel with Screed slab with Micro T-Beams

… Not participated ion bids

RPP Infra Projects Ltd., Erode

Conventional

GFRG Panels GFRG Panel with Screed slab with Micro T-Beams

Not participated ion bids

Costing of the Dwelling Unit on Sq. ft. Plinth area Basis

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Panel being placed / seated on RCC plinth beam over a thin layer of cement mortar slurry.

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2 panels erected as corner walls. Angles are provided from two sides using nuts& bolts. After setting of concrete in-filled, these angles are removed.

For supporting panel in position, adjustable slanting prop is provided.

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First pouring of concrete into wall corner joint.

13All the walls of ground floor are erected in two days.

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For roof/floor, panel to be lifted horizontally / flat as seen in picture.

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RW roof panel placed on walls.

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100 mm x 100 mm, 10 gauge weld mesh provided for 50 mm thick RCC screed. Embedded RCC micro-beams act as micro “T” beams

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Simultaneous concreting of RCC horizontal tie beams, micro-beams and screed concrete

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Wall panel with window and ventilator opening is being placed in first floor

EPS PANELS for walling and Roofing Concept:• Expanded Polystrene Panel Systems• EPS Panel comprises of a layer of mesh on

either side of EPS core welded together by steel octogonal (trusses) which penetrates through EPS core.

• The panels are joined together on site and sprayed on both sides with shotcrete to form a sandwich type construction.

• The exterior of the panels finished with weather proof coating such as plaster

• Interior surfaces (walls) and ceilings can either be plastered.

Time required for completion• 6 months for 500 units

EPS PANELS for walling and Roofing

• The EPPS construction system is based on a series of polystyrene panels and galvanized steel wire meshes.

• The EPPS fulfils the required structural and load-bearing functions.

• Offering high thermal and sound resistance.

• After the panel assembly, structural plaster should be sprayed and/or poured on the panel, depending on panel type.

EPS Panels – ADVANTAGES OVER CONVENTIONAL BUILDING

Description Conventional EPPS Panels Remarks

Floor Area 612 670 58 Sq.Mtr of more usable area is obtained

Insulation POOR EXCELLENT. Average of 5 times more R value is obtained.

Seismic Resistance POOR EXCELLENTWith stood more than 7.6 ric scale in testing also meets Govt. of India's Earth quake disaster management recommendation.

Dead Weight High ( more than 2000 tons)

Low ( less than 700 tons)

Less dead weight requires less foundation and is more stable and has better life.

Life Of The Building Good Give better life by 1.5 times

Panels are made with G.I wire which is rust resistance and EPS is non Degradable material.

Name of Agency Technology Proposed No of Houses Propos

ed

Cost Per Sft in Rs.

Foundations Walling Roofing

M/S DSP Infra-CTSPL (JV), Hyderabad

Conventional RCC

EPS Panels insulated with concrete

EPS Panels covered with RCC

2000 1296/- to 1496/-

RMN-BKCHEM-Previse Homes (JV), Hyderabad

Micro foundations with Piling or Conventional RCC

EMMEDUEs EPS panels insulated with concrete

EMMEDUEs EPS panels Strengthenedwith concrete

… Not participated in bids

Beardsell Ltd., Visakhapatnam

Not Specified Quick build EPS Panels

Quick build EPS Panels

… Not participated in bids


FIXING OF DIFFERENT FIXTURES ON QUIKBUILD WALLS – SHOWING THE STRENGTH OF THE WALLS

Different Models of G+1 AND G+2 Construction.

Pre-Engineered Structures with Light Gauge Steel Frame Agency Presented: M/S Everest Industries Ltd.,

Light Gauge Steel Frame is lipped C steel sections. The sections are with Zinc coating of 275GSM and steel yield strength of 550 MPa custom designed and fabricated in factory through fully automated CNC controlled machines. The section sizes will be in required length as per structural design.

LIP = 11mm

WEB = 89mm

FLANGE = 41mm

SECTION PROFILE

SECTION DETAILS OF LIGHT GAUGE STEEL FRAME

SWAGEA section that fits into another is swaged. This gives a leveled outer surface.

NOTCHA section through which another section passes is notched (web is knocked-out) in that portion.

PUNCH& DIMPLEWherever a screw comes, the section is punched and dimpled. This helps in easy screwing and getting leveled surface after screwing.

Advantages of Building with Steel• A Durable and safe material• Consistent material quality• Superior seismic and wind performance• Non-combustible material • Dimensionally Stable• 100% recyclable• Insect and rodent resistant and does not root• High Strength to weight ratio• Ease of handling, transportation and

installation• Complete design flexibility

Name of Agency


ed

Cost Per Sft in Rs.

Foundations

Walling Roofing

M/S Everest Industries Ltd., New Delhi

Conventional

Light Gauge steel frame with Rockwool walling

Deck sheet of concreting

2250/- to 2750/-


Pre-cast Concrete System- 3 S Prefab Technology

• ‘3-S3-S’ is the brand name of Prefab Building Construction System fully developed and perfected by SHIRKE after years of strenuous R & D supplemented by extensive field trials.

• Structural components like Slabs, Walls, Columns and Beams are precast in casting yard having factory like condition.

• Manufactured precast components are erected, aligned and connected using Self-Compacting Concrete of appropriate grade along with embedded reinforcement.

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Pre-cast Concrete System- 3 S Prefab Technology

• Sustainable green Technology due to-Judicious use of construction materials-Reduction in wastage of materials -Using more durable materials-Use of energy efficient building materials-Use of products that contribute to a safe, healthy built environment-Use of construction system minimizing air, water and noise pollution during construction

• Tested and Evaluated by-IIT, Mumbai-CBRI, Roorkey-Stanford University-Civil AID Technoclinic, Bangalore

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Name of Agency


ed

Cost Per Sft in Rs.

Foundations

Walling Roofing

M/S BG Shirke construction technology Pvt. Ltd., Pune

Conventional

Precast Plinth Beams, Columns and Shear wall for exterior

Roof Panels Lattice girder slabs

Approx2000/-


Projects Executed

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HOUSING PROJECT FOR MHADA, MAZGAON, MUMBAI- EWSProject

HOUSING PROJECT FOR MHADA, GHATKOPAR, MUMBAI (G+7 EWS/LIG)

A VIEW OF PRECAST CONSTRUCTION SITE

SHEAR WALL TECHNOLOGYConcept In-situ RCC walls and Roof with modular

Shuttering made up of Aluminium / Fibre shuttering.

Monolithic Construction.

Experience in Actual Use

- Delhi Ind. Infra Board- construction of 6740 units.

- Delhi slum Development Board- construction of 7260 units.

- Tumkur – KSEB construction of 1200 units.- Boiser, Mumbai – TATA- construction of 1200

units.- 990 houses in Ahmadabad.Cost of construction:- Approximately from Rs. 1530 to Rs. 2800/- per

Sq.Ft.

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SHEAR WALL TECHNOLOGY

44Adopted in private projects and JnNURM projects at Delhi and

Bangalore

MONOLITHIC CONCRETE WALLS (SHEAR WALL TECHNOLOGY)

Monolithic Concrete Construction System using Aluminum Formwork

Eliminates Traditional Column & Beam Construction.

Walls and Slabs are cast in one operation at site.

Specially Designed, Light Weight Pre-Engineered Aluminum formwork used.

Entire operation essentially comprises fitting and erecting of Formwork.

Then carrying out concreting of the walls and slabs

ADVANTAGES OF SHEARWALL TECHNOLOGY Labour Requirements Minimal. No Requirement of Any Specialized Equipment's. Dimensional accuracy of the formwork is of high order, hence

errors are minimal. Rapid Construction of Repetitive Type Dwelling Units. Earthquake Resistant – Box Type Structure. Very High Life – 50 Yrs Plus. Structurally Superior as Very Few Construction Joints. Four day Casting Cycle Compared to 14-20 Days conventional Cycle. Completed RCC structure is available for subsequent finish trades

much faster.Limitations:• Prior and proper planning is in all aspects including services at

the Zero date of the project is very very essential. • Large volume of work is necessary to be cost effective i.e. at

least 200 repetitions of the forms should be possible at work.

COMPARISON BETWEEN CONVENTIONAL AND SHEARWALL TECHNOLOGY

S. No FACTOR CONVENTIONAL IN – SITU ALUMINIUM SYSTEM REMARKS

1 QualityIn – Situ casting of whole structure and transverse walls done in a continuous operation

Superior quality in “System housing”

2 Speed of construction

The pace of construction is slow due to step – by – step completion of different stages

In this system, the walls and floors are cast together in one continuous operation in matter of few hours.

System constructionismuch faster.

3 Aesthetics

In the case of RCC structural framework, the columns and beams show unsightly projections in room interiors.

The Room – Sized wall panels and the ceiling elements cast against steel plates have smooth finishing and the interiors have neat and clean lines without unsightly projections in various corners.

4 External finishes

Finishing needs painting every in three years.

This will need no frequent repainting.

Permanent facia finishes feasible with minor extra initial cost.

COMPARISON BETWEEN CONVENTIONAL AND SHEARWALL TECHNOLOGY

S. No FACTOR CONVENTIONAL IN – SITU ALUMINIUM SYSTEM REMARKS

5Useful carpet area as % of plinth area.

Efficiency around 83.5% Efficiency around 87.5%More efficient utilization of land for useful living space.

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Consumption of basic raw materials

Cement. Reinforcing Steel

Reinforcing steel required is less as compared to the in situ construction as RCC framework uses brick wall as alternative

Consumption somewhat more It may, however will be slightly more than corresponding load – bearing brick wall.

strength and durability is also more Steel requirement is more, as it is required for the shear wall construction. But shear wall construction increases safety against earthquake.

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Maintenance In maintenance cost, the major expenditure is involved due to

·Repairs and maintenance of plaster of walls/ ceiling etc.·Painting of outer and inner walls.Leakages due to plumbing and sanitation installation.

The walls and ceiling being smooth and high quality concrete repairs for plastering and leakage’s are not at all required frequently.

It can be concluded that maintenance cost is negligible.

Shear Wall Technology – Construction in progress

Shear Wall Technology

JnNURM, EWS Projects, JnNURM, EWS Projects, Vadodara(2928 DUs)Vadodara(2928 DUs)

JnNURM, EWS Projects, JnNURM, EWS Projects, Ahmedabad.(5952DUs)Ahmedabad.(5952DUs)

• Prefabricated steel building with aerocon panel partition walls

• Framing System:- Entire building frame will be of Prefabricated steel building of I, C and angle sections

• Partition Walls:- All the Partition walls will be of Aerocon Blocks and panels of having Male and Female connection system supplied by well known suppliers HIL

• Flooring :- All the Flooring system will be of Deck slab (sheet profiled) of min. thickness 125mm.

• Top Slab :- Galvalume Sheet with false ceiling

• Doors and Windows, Finishing, Sanitary and internal

• Electrification:- As per specification

PANDHE INFRACONS PVT. LTD., SolapurPANDHE INFRACONS PVT. LTD., Solapur

Steel Frame with Aerocon/PUF PanelsConcept• Building construction designed based on Steel structure

with different walling components.• Fabricated in a controlled factory environment and erected

at building site.• Once all the components are assembled and erected at

site, Walling is made with the factory made Aerocon Blocks/Panels or Poly Urethane Foam (PUF) Panel walls making it a monolithic structure.

Experience in actual use • Mass housing Projects in Solapur (10000 units),Andaman

Project (5000), RGK-APHB at Suraram (4324) & VAMBAY Yojana (Apna Ghar)

Time required for Completion• 6 Months period.

ABOUT – AEROCON PANELSABOUT – AEROCON PANELS

A sandwich panel of two fiber-reinforced cement sheets enclosing a light weight concrete core composed of Portland cement and Fly-ash

Fully cured at factory, they are ready for installation right away

Unique “Tongue and Groove” jointing system facilitates rapid construction with minimum effort

Applications – AEROCON PANELSApplications – AEROCON PANELS

Jindhal Project Accommodation unit

Residential Qtrs Commercial Building - Hyderabad

PUF INSULATED SANDWICH PANEL

MULTISTOREY STEEL BUILDING MULTISTOREY RCC BUILDING

Self Weight of the overall structure is less than RCC building.

Self Weight of the overall structure is Higher than steel building.

Base shear in steel building is lesser than RCC building.

Base shear in RCC building is higher than steel building

Time taken in the construction is less Time taken in the construction is more

Alteration and Strengthening of floor are relatively easy as compare to RCC Alteration and strengthening is complex

COMPARISON B/w INSULATED PEB & RCC BUILDING

Name of Agency Technology Proposed No of Houses Propos

ed

Cost Per Sft in Rs.Foundatio

nsWalling Roofing

M/S Pandhe Infracons Pvt.Ltd., Solapur

Conventional RCC

Aerocon Panels External 75mm Internal 50 mm thick

Galvonised sheet with Zipsum false ceiling

1500 1310/- to 1870/-

M/S Jindal Mectec Pvt Ltd., Gurgaon

Conventional

Insulated PUF Panels 50 mm thick

Deck sheet roofing

1826/- to 2066/-

M/S Enertec Engineering Pvt.Ltd., Hyderabad

Conventional

CLC Blocks for External walls and Insulated PUF sandwitch Panels

Steel Deck sheet with concrete for Roof slab

1957/- to 1990/-

M/S Satec Envir Engineering Pvt. Ltd., Mumbai

Not furnished

Not participated in the bids


LOW COST ACCOMODATIONS

MULTI-STORIED BUILDING, GUJRAT

ADVANTAGES & HIGHLIGHTS

WAFFLE CRETE PRE-CAST CONCRETE PANELS

• Also named as SRPL Technology suitable for low rise building construction.

• Wall and Slabs will be M30 grade concrete. Vertical ribs of Walls will act as columns and horizontal ribs of walls acts as beams.

• Architectural Design Consideration of the proposed technology

a Aesthetic Consideration- Excellentb Min/Max Size - As per requirementc Finishes Details- No plaster is required only paints as per requirement

WAFFLE CRETE PRE-CAST CONCRETE PANELSAdvantages • Reduce construction time• Reduction in the need for skilled labor• Low maintenance cost• 30-35% lighter compared to brick walls in weight• Options available with insulation system• Curing time is reduced by trapping the moisture generated from the

concrete.


Name of Agency Technology Proposed No of Houses

Proposed

Cost Per Sft in Rs.Foundations Walling Roofing

M/S KCL-SRL Houses, Ahmadabad

Conventional

Precast concrete Panels for walling

Precast concrete Panels for walling

Approx. 1200/-

MERITS AND DEMERITS Sl. No.

Prefab Technology

Merits Demerits

1 EPPS panels (with or without RCC frame)

Fast to construct .Thermal comfort - GoodStructurally sound.Low maintenance.

Higher costNo scope for alterationsValidation required.

2 GFRG Panels (with or without RCC frame)


Higher CostNo scope for alterationsValidation required.Prone for cracks during transportJoint handling Peeling / fading due to rain/ sunBeneficiary acceptance issues.

3 Steel Frame with Aerocon/PUF/EPS wall Panels


Moderate costNo scope for alterationsValidation required.Beneficiary acceptance issues.

4 Light Gauge Steel Frame with Rock wool wall Panels


Moderate costNo scope for alterationsValidation required.Beneficiary acceptance issues.

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MERITS AND DEMERITS Sl.No

Prefab Technology

Merits Demerits

5 Precast Concrete Systems (3-S prefab technology)

Fast to construct .Thermal comfort – Not Good.Structurally sound.Low maintenance.

No scope for alterationsDifficulty in ensuring quality of jointsScope for cracks/ breakages during

transport & handling.Designs are to be wetted.Higher cost

6 Shear Wall Technology

Superstructure and Roofcan be completed in7 -12 days.Structurally strong.Cost of repairs & maintenance is minimal.

No scope for alterations. Aluminum/ Plywood / Heavy Plastic s used in Form work.Limited Agencies having required shuttering material.Designs are to be wetted.Higher cost

7 Waffle Crete Pre-cast Concrete Panels

Fast to constructThermal comfort –Good if insulation is provided.

Maintenance required.Validation required.Windows sizes restricted.No scope for alterations.Moderate Cost

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THANK YOU THANK YOU

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Pre-fab technology for buildings

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