Prefabricated construction systems in India- Precast Status and needed Impetus

Prefabricated construction systems in India-

Precast Status and needed Impetus

Prof. S. K. Singh

Sr. Principal Scientist & Professor, AcSIR

CSIR-Central Building Research Institute

Roorkee-247 667, Uttarakhand, India

Outline

• Introduction

• Issues

• Affordable Housing

• Why Prefabrication?

• Worldwide Status

• Prefab Technologies

• Sustainable Approach

• Advantages &

Disadvantages

• Summary

CSIR-Central Building Research Institute, Roorkee-247 667, INDIA

Questions to be Answered

Is it

sustainable?What are the

benefits?

Why prefabricated

construction system?


Collapse

while

demolition

Conventional Reinforced Concrete System

Source: NDTVCSIR-Central Building Research Institute, Roorkee-247 667, INDIA

Problems in India

Affordable Housing system is the need of today

The Ministry of Housing

estimated a housing

shortage of 20 million

houses ,with 99 percent

in the economically

weaker and lower income

groups.

Source: Ministry of housing(July 2017)


Compromising

Quality Legal Issues

Improper

manwork

Time

consuming

High formwork

cost

Issues in conventional system


Prefabricated Construction System


Introduction

“The partly/fully assembled and erected building, of

which the structural parts consist of pre-fabricated

individual units or assemblies using ordinary or

controlled materials, including service facilities; and

in which the service equipment may be either

prefabricated or constructed in-situ”.

Source: IS 15916:2010


Need

fo

r Tech

no

log

y

Proper

strength

Better

quality

control

Sustainable

Time & cost

saving

Eco-friendly

Prefab

Technology


Worldwide Status


Prefabrication in India

Emergence of Hindustan Housing Factory in 1950s

Partially prefabricated system developed by CSIR-CBRI joist and plank system in Early 1980’s

Pradhan Mantri Awas Yojna (PMAY) launched on 25th June 2015

Rural housing which launched on 1st April, 2016

16 innovative pre-fabricated construction systems adopted /developed


Status in India

Innovative technologies for

affordable housing

Techniques adopted in ancient

time

Large scale adoption of

prefabrication reduces cost

• Prasher et al.

(2016)

• BMTPC 2017

• Palanichamy et al.

(2002)


Worldwide Status

Improving the performance of

company by identifying the gaps

Sustainable construction method

Management of prefabricated

construction (MPC)

• Steinhardt et al.

(2016)

• Li et al. (2014)

• Dave et al. (2017)


Pre-cast Roofing Solutions


Pre-fab Brick Panels

Brick Arch Panel

RCC Planks and Joists

Ferro-cement Channels

Baffle Unit

Ribbed Units

Pre-cast RC Planks & Joists System


Pre-cast Roofing Solutions


Technology Embodied Energy /10 sqm of roof in Mega Joules

Cement Steel Aggregate Total/sq.m saving

RCC Slab 2100 2400 600 5,100 0

RC Plank & Joist 1,617 2064 444 4,125 975

RC Ribbed Slab 1,113 2,064 318 3,595 1,505

RC Channel Unit 1,344 2,352 384 4,080 1,020

L-pan units 1,155 1,320 330 2,805 2,295

Brick panel & RC

JoistBricks: 1,220 MJ

1,800 1,984 140 5,144 - 44

Pre-cast RC Planks & Joist System The floor / roof is constructed with precast RC

joist and precast RC planks.

The size of precast RC plank is 300 mm wide x 30

to 60 mm thick x up to max. 1500 mm long;

precast RC joists 150x150 mm in cross-section

and up to 4.2 m long.

The components are produced on casting

platform at construction site.

As soon as the walls reach the floor/roof level, the

components are created, and partly filled with

concrete to form the floor\ roof.

This results 20% saving in overall cost, 25% in

cement and 10% in steel as compared to

conventional R.C. slab floor/roof.

SK Singh, CSIR-CBRI, Roorkee

Pre-cast RC Planks & Joist System

Suitable For Single/Multi Storied

Houses

Economical to RCC slab

Saves shuttering, construction

time & materials

Manual handling of components

Amenable to entrepreneurship

development

Widely accepted in cost effective

housing

Conventional water proofing

methods

Standards used

Country Codes

New Zealand Standards New Zealand 1995 covers many

aspects of seismic designs,

Precast R.C. structures

U.S.A. Design Guides and Manuals by Precast/Pre-

stressed concrete Institute

Canada CPCI (Canadian Pre-stressed Research

Institute) Design Handbook;

NBCC (National Building Code of Canada)

Japan Design and construction of precast R.C.

buildings by AIJA

(Architectural Institute of Japan)

Mexico Mexico City Building Code

India IS 15916: Building Design and Erection using

Prefabricated Concrete –Code of Practice


White Space Mapping

2255

294 294

110 70 68 410

500

1000

1500

2000

2500

No

. o

f s

cie

nti

fic

pu

blic

ati

on

s

World USA China Germany Italy Canada India


Technologies

Prefabricated Technologies

Formwork

system

Precast

sandwich

panel

system

Light

gauge

steel

structural

system

Steel

structural

systems

Precast

concrete

construc

tion

system


Formwork system

Monolithic

Concrete

Construction

System --

Plastic

aluminium

formwork

Concrete

Construction

System-

aluminium

formwork

Modular

Tunnel

form

Kayson's

Formwork

System

Sismo

Building

Technology


Precast sandwich panel system

Advanced Building System

EMMEDUE (Expanded

polystyrene core panel)

Rapid

Panels

Glass Fibre Reinforced

Gypsum (GFRG)

Panel System

Concrete

wall Panel

System

QuickBuild

3D Panels

Reinforced

EPS Core

Panel

System


Light gauge steel structural system

• Light Gauge Steel Framed Structure1.LGSFS

• Light Gauge Steel Framed Structure with Infill Concrete Panels

2.LGSFS-ICP


Steel Structural Systems

1• Factory Made Fast Track

Building System

2• Speed Floor System

3• Composite Engineered Steel

Building Solution System


Precast Concrete Construction Systems

Industrialized 3-S system

Waffle crete slab

Precast Large Concrete Panel System

3D Monolithic Volumetric Construction

System

Types


Prefabrication: A Sustainable Approach

Sustainability: Meets the needs of the present without

compromising the ability of future generations.

Prerequisites :

Judicial use of construction materials there by

conservation of natural resources.

Use of products that avoid toxic or other emissions.

Reduction in waste materials during construction &

utilizing C & D wastes in construction.

Reducing emissions during the production of

construction materials.


Prefabrication: A Sustainable Approach

Using more durable materials in buildings thereby

requiring lesser maintenance cost.

Use of energy efficient building materials and

products that save energy or water .

Use of products that contribute to a safe, healthy

built environment.

Use of materials which can be recycled.

Use of construction system minimizing air, water

and noise pollution during construction.


Advantages

Faster construction and low labour costs.

Prefabrication allows for year-round construction.

Mechanization in prefabricated construction

ensures precise conformity to building code

standards and greater quality assurance;

Less on-site waste ,reduced by about 40%(Vivian et

al. 2006).

Less theft of material/equipment.

less property damage due to vandalism.


Worker safety higher.

Computerization in production process.

Quality control and factory sealing.

More comfortable work environment.

Improvement in efficiency and productivity of work

force.

Prefab companies are more likely to have quality-

control programs implemented into their

manufacturing process (Phil Mitchell 2009).

Advantages


Disadvantages

1.Transportation

issues

2.Shipping

limitations

Permit cost

Trailers

requirements Transport

distance

Load

constraintsDimensional

constraints


Summary

Pradhan Mantri Awas Yojna (PMAY)- Driving force

Technology not widespread in India –

- lack of proper guidelines

- awareness and

- skilled labours

Identifying new emerging construction systems

Prefabricated affordable housing for rural and urban

poor

low cost and quality conforming

Improve in the standardisation


Emerging Trends in Housing construction


Precast construction

Tunnel form construction

Large area formwork construction

Lightweight concrete construction

Cold-Formed Steel (CFS) housing system

GFRG building system

EPS Panel system

Monolithic Concrete Construction Technology


Assembly of Precast Concrete Elements


Industrialised 3-S Technology


Prefab Steel Construction


Light Gauge Steel Structural System


Composite construction with expanded polystyrene panels


GFRG Panel based Technology


Wafflecrete System


Pre-stressed Precast Prefab Technology Using Hollow Core

Slab, Beams, Columns, Solid Walls, Stairs


Precast Concrete Panel System


Technology Using Expanded Steel Mesh Panels,

Polystyrene Beads & Alleviated Concrete


Prefabricated construction systems in India- Precast Status and needed Impetus

Engineering

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