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A Case-study on use of Precast Technology for Construction of High-Rise

Buildings

Conference Paper · November 2016

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A CASE STUDY ON USE OF PRECAST TECHNOLOGY FOR CONSTRUCTION OF HIGH-
RISE BUILDINGS

Mr. Ram Kumar Mr. Manoj Patterson Mr. Sandeep Jain

Project Director Assistant Vice President Assistant Manager
Amrapali Group, India Amrapali Precast Infrastructure Amrapali Precast Infrastructure
r.kumar@amrapali.in m.patterson@amrapali.in sandeep.jain@amrapaliprecast.com

1. ABSTRACT

Housing, the basic need of every human being. At the outset there was mud. Primitive houses were built simply
of mud & straw blocks heated in the sun. The Romans were the pioneers in construction technology to
experiment blending of lime and volcanic rock to create sublime and awe-inspiring structure like Pantheon in
Rome, still the largest unreinforced concrete dome on the planet. Use of precast in construction is not new.
Ancient Romans made the use of moulds to cast their mind-boggling system of tunnels & aqueducts. With ever
increasing demand for housing, a need to automate and modernize the construction industry was deemed. In
the present scenario, engineering and architectural innovation & improvisation has enabled the construction
world to explore the neo-arena of precast technology.
Innovation & development is not creating something new, but redefining the existing thing in a modern way. The
construction industry discarded the load bearing structure owing to its limitations and to match the demand of
housing. This favoured the adaptation of reinforced concrete framed structure to make construction more
reliable and faster. But, to fulfil the growing market aspirations, precast technology is the next possible solution.
Precast technology offers precedence over conventional framed construction with regards to speed, durability,
modularity, quality control, efficiency, automation, aesthetics, affordability, accuracy, optimisation, and low
maintenance.
Most of us have played with Lego toys as a child. We can envision the future of construction just the same. With
Precast, we can envisage a sustainable, speedy, sturdy, safe and stylish future for the construction industry.
Precast holds the key to success, in achievement of “Housing for all” by the year 2022.
This paper highlights the case study for adoption of Precast Technology to achieve fast-track, sustainable, and
cost-effective construction of high-rise buildings in Indian Scenario.

Keywords: Precast Technology, High-rise residential buildings, Cost-effective construction,

Manpower reduction, Speedy construction, controlled manufacturing conditions, Quality
improvement.
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2. INTRODUCTION

2.1 GENERAL

India is the world’s fastest developing country with an economic growth rate averaging 7.5% for last 5 years.
We are currently on the verge of large-scale urbanisation hence facing a huge demand for building houses. The
construction industry contributes to about 10% of Gross Domestic Production (GDP) of the nation, registering
an annual growth of about 9% (www.ecobrick.in, 2015). To cope up with this housing necessity, the country
needs to build 30 to 35 thousand units of houses per day at least for the next 8 years. Housing is the primary
need of every human being. With the rapidly growing population, and to fulfil the aforementioned housing
demand, a more reliable, faster, sustainable method of construction is deemed necessary by the construction
industry. The concept of “built it fast” in the most economical way has not changed since the beginning; however,
new technologies have been developed to suit the modern world construction. One such solution is precast
concrete construction technology. Precast technologies is not only helping contractors and builders get their
buildings faster and more economically but it also helps to reduce construction waste and produce high quality,
energy efficient buildings which results in long term benefits to projects.
Precast constructions has been a common construction method in United States of America and many
European countries. On the other hand Precast for residential construction has been used in India for only less
than a decade, but it has been growing very fast in the past 5 years. Recently, there have been any new
developers and contractors who have switched from traditional construction to precast to keep up with this new
trend in the Indian residential market.

2.2 BACKGROUND & PRESENT SCENARIO

Precast play an important role in the modern world construction of every building today, it refers to the making
of parts in an offsite workshop or factory prior to the installation at the site. “The primary purpose of precast
construction is to produce building components in an efficient work environment with accesses to specialized
skills and equipment in order to reduce cost and time expenditures on the site while enhancing quality and
consistency” [Anderson and Anderson 2007]. It is clear that most new construction will have to use more and
more precast. From primary structures to small architectural ornaments, precast has become a major part of
building construction. In the near future, precast is expected to play a vital role in Indian construction, especially,
in the residential building construction.
Over the past 15 years, India has experienced the huge increase in housing demand in a very short period of
time, requiring a massive production of residential buildings with the changing face of realty market. The large
projects comprising of townships, mass housing, commercial mall, IT parks, SEZ’s etc. are common now a days

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and will grow exponentially. Most of these projects are still being constructed using conventional technologies.
Due to this, the inherent benefit these projects offers in terms of repetition and huge volume turnover remains
unexploited and it also makes the project management complicated in terms of speed and quality of
construction. This fast growing economy forced builders to build faster and affordable with high quality. To meet
high demand, some builders tried to innovate and bring about transition from the conventional cast-in-situ (CIS)
construction and move to precast construction by making building components off-site, and then install them on
site. Precast technology, the so called unconventional method in Indian arena can facilitate both speed and
quality and exploit the advantages that projects offer in terms of repetitions and volume. Today, the world agrees
that precast/prefab construction makes significant impact on both time and budget as shown in [Jaillon and
Poon 2008].

3. TRANSITION TOWARDS PRECAST

Although, pre-stressed precast concrete buildings however utilized all through the world has not discovered its
legitimate spot in Indian construction scenario. Regardless of its incredible points of interests like speed, quality,
and economy in development it is yet to become regular with architects, builders, and Government
organisations. In spite of the fact that it has gotten to be standard item for metro, mono rails, bridges, and
infrastructure projects on account of its intrinsic advantages over traditional construction.
The current practice in India is the cast-in-situ (CIS) reinforced concrete structures. The other construction
methodology is using structural steel. In general, most residential and commercial projects are CIS in nature.
Steel structures are restricted to industrial projects. The ratio between CIS and steel structures is approximately
70:30. The third construction is using precast concrete. Most of us have played with Lego toys as a child. We
can envision the future of construction just the same. With the economic contribution of about 11% in the nations
GDP, construction industry seeks a rapid development in its technology, which is also required to keep up its
growth phase. In this line, Indian construction industry now marches towards high-rise construction in housing
& commercial buildings. Especially, for commercial and residential building construction, precast is increasingly
seen as an economic, and high quality option.
The present economic growth demands faster construction without losing quality aspects and without project
delay, project cost outfit in labour shortage or similar related construction uncertainties. One of the only real
disadvantages to CIS concrete is the high amount of labour it requires. Builders must first construct forms for
the structure they plan to cast and then install the forms and mix the concrete, pouring the concrete & waiting
time to remove the forms all takes time that extends the length of a construction job and results in more hourly
pay for work crews, dependency on workmanship, environment and other factors. Even advanced techniques
like aluminium forms takes 12-14 days slab cycle time. This further justifies the use of precast technology.

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The current structural system uses a rigid frame with infill masonry walls. This system is very inefficient to resist
lateral loadings like earthquakes etc. and it has lot of redundancy in structures [ Brietbach D. 2014].
In the recent past, apart from bridge decks, precast elements are widely used increasingly in non-structural
parts such as railway sleepers, road dividers, etc. But precast can also be successfully used in all structural
elements of building such as columns, beams and slabs. This is made possible with the help of modern
automatic/semi-automatic factory installed concrete handling and placing units. Precast is made feasible with
the advancement of production and equipment for transportation and erection.

4. BENEFITS OFFERED BY PRECAST

There are many benefits associated with the use of precast concrete components. Of course these require
proper design, use of the correct materials and manufacturing processes with skilled and knowledgeable
personnel. Properly designed and specified precast concrete go a long way toward reducing and eliminating
many common utility construction problems, while the economics of precast translate into faster, more cost-
effective projects. Benefits available include:

4.1 SPEED-TO-MARKET

Precast structural components are fabricated in a controlled plant environment and can be erected in weather
conditions that would delay the full erection of steel components or CIS concrete. In general, the advantage of
precast is that faster erection reduces the overall construction schedule and overhead costs. Compressed
schedules, fewer on-site trades, and eliminating weather delays add up to reduced project costs.

4.2 QUALITY & DURABILITY

Precast, prestressed products provide a long service life that far exceeds field-placed concrete partly because
members are manufactured in plants under strictly controlled conditions. The controlled plant environment has
offers easy verification of quality and a dedicated workforce. This means high-quality product can be
manufactured every day, regardless of weather. The low water-cement ratio used in precast concrete creates a
denser product that does not allow penetration of chlorides and other harmful elements as easily as field-placed
concrete.

4.3 INTEGRATED PROJECT DELIVERY

Structural precast components can be erected in a relatively short period of time because they interlock to
support one another. Simpler installation requires fewer crew members, which means which means fewer
personnel to manage, fewer trades to pay and fewer trade-related delays. Precast advantage is a cleaner and
safer job site with less risk and more assurance of a smooth and successful project flow. The combination of

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precast with steel or cast-in-place concrete in hybrid construction can have cost and program benefits. Precast
concrete brings accuracy, high-quality finishes and speed of erection to any hybrid concrete construction project.

4.4 ENHANCES SAFETY

Precast products eliminate many of the dangers associated with on-site construction by providing a controlled,
off-site fabrication environment. Precast reduces the amount of wet trade work on site, making them cleaner,
tidier and safer.

4.5 SUSTAINABILITY

Precast is perfect for today’s focus on preserving resources and protecting the environment though sustainable
building practices. It’s a perfect Green Building product. Precast reduces overall life cycle impact on environment
compared to other methods as it has lower wastage and high potential to recycle waste.

4.6 OPTIMIZATION & FLEXIBILITY

Advanced automation and technologies used in precast plants optimizes the resource utilization, and produces
an improved quality product with reduced tolerances, thinner sections, and engineered solutions. Also, it offers
flexibility of space planning by allowing for longer spans which create larger open floor plans and increased
flexibility in design. For architects, it can offer variety of different profiles. It is possible to cast the member of
very complex design and shapes.
Innumerable other advantages like high dimension accuracy, tight tolerances, minimal maintenance, acoustic
insulation, thermal inertia, various surface finishes, colours, etc. can also be availed as desired.

5. PRECAST COMPONENTS & CONNECTIONS

Structural precast elements can largely be classified into two categories based on their production methodology,
namely tilts and hollow core. For a typical residential unit construction the major elements are columns, beams,
canopy, wall panels, cladding, balcony, staircase, slabs etc. Out of these columns, beams, canopy, wall panels,
cladding and balcony, stair case, landings are tilts and slabs are hollow core of varying thickness. The common
area of a building has many other precast elements such as lift core, boundary walls, curb stones, etc. Figure
5.1 shows the typical precast elements and their assembly for a residential unit.

5.1 PRECAST COMPONENTS

5.1.1 PRECAST SLABS

Main types of slabs used in precast frames are: hollow core slab and solid slab. The details of hollow core slabs
are shown in the Figure 5.2.

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The hollow core slabs are prestressed, precast concrete slabs, with hollow portions in the zones of zero
stresses. They reduces the overall concrete dead load, concrete requirement and provides for better insulation.

Figure 5.1: Precast Concrete Structural Elements for a Typical Residential Unit

It is possible to achieve larger unsupported spans. Their general thickness used are 150, 200, and 265 mm.
These slabs are casted 140m long at a time, with a fixed width of 1.2m. After steam curing the slabs are cut into
smaller pieces as per site requirement. They are then delivered to site and installed in position using tower
cranes. After installation as per drawings, a thin reinforcement screeding of 50-75mm is laid on the top, to seal
the joints.

Figure 5.2: Precast (a) Hollow Core & (b) Solid Slab Details
Another common type of slab used are solid slab. These slabs are casted on a tilting bad with lateral and
longitudinal reinforcement. These slabs are generally used for long span in the common areas and toilets where
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it is required to facilitate for various MEP services. They are helpful to reduce weight thus easy for site crane
handling. It also eliminates the shuttering cost, and helps to attain a superior slab soffits.

5.1.2 PRECAST COLUMNS

Columns (Shear walls) in precast construction can either be done in CIS or precast. They are most suited in
commercial, industrial bay buildings where thicker sections are needed. Precast columns are provided with
corbel for simple beam column connections. Precast also allows for casting of triple height columns, thus faster
erection.

Figure 5.3: Typical Precast Column Details

5.1.3 PRECAST BEAMS

There are two main categories of beams used in a precast structure. Internal beams are used where floor
loading is approximately symmetrical, and external beams are used where floor loading is predominantly non-
symmetrical. The use of precast beams with proper designed connections ensure higher structural stability.

Figure 5.4: Precast Beam Details

5.1.4 PRECAST WALL PANELS

Precast wall panels and claddings are smart substitute for conventional infill blockwork or brick walls. These
walls offers superior finish surface, eliminates the plaster and touch ups, facilitate for desired & accurate
openings of doors, windows, ventilators etc. These wall panels also improves the overall lateral stability of the
structure.

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 Figure 5.4: Precast (a) Wall Panels & (b) Claddings
5.1.5 PRECAST STAIRCASE

Precast staircase eliminates the complicated on site shuttering & reinforcement, and provides high quality finish.
They can either be a single precast unit containing all flights and landings or separate precast flights & landings.

Figure 5.5: Precast Staircase Details

Some other elements are precast balconies, canopies etc. and in common areas boundary walls, kerb stones,
main gate, etc. are shown in.

Figure 5.6: Details of (a) Boundary wall, (b) Kerb Stone, & (c) Main Gate

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5.2 DESIGN & CONNECTION DETAILS

The design philosophy of precast concrete construction is based on the buildability, economy, and
standardization of precast elements. All loading & restraint conditions from casting to end use of structure are
considered in design of precast members & connections. Connections are needed not only to transfer load but
also to provide continuity and overall monolithic behaviour of the entire structure. A complete system of precast
elements is integrated to form a structure that behaves monolithically with sufficient strength, stiffness &
durability to resist seismic & other dynamic loadings. The connection can be classified into horizontal & vertical
joints. Some typical connections details are shown in.

Figure 5.7: Connection illustration for (a) Beam-Column and (b) Slab to Beam (Source: Paradigm)

Figure 5.8: Typical Connection Details between In-Situ Shear wall & Hollow Core Slabs

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 Figure 5.9: Typical Vertical Connection Details between Precast Wall Panel to Panel

6. A REAL-TIME CASE STUDY

After successful developing the foundation of precast construction technology in the aforementioned details of
the research paper, an effort is made hereafter to present a detailed case study with a focus to share the real
life experiences for use of precast concrete construction technology at Amrapali Dream Valley, mixed CIS-
Precast high-rise residential towers, designed by Architects Gian P Mathur (GPM, India), and E.Construct, U.A.E
are the structural designers. The project is vetted by IIT Delhi.

6.1 PROJECT DETAILS

Dream Valley project is located in Greater Noida (West), Delhi NCR, India. It’s a residential township with total
47 high-rise residential towers, 379 villas, commercial & institutional building, and other developments. The total
built-up area of project is more than 10 million Sqft. The high-rise residential towers are divided in to six series
from A to F with further classification as A1 to A7, B1 to B6, C1 to C12, D1 to D2, E1 to E8, and F1 to F12. After
a lot of brainstorming and feasibility study, Series A, D, E & F were planned to be constructed by using precast
construction technology. All towers of series A (2B+G+18 Floors), D, E1 & F (2B+G+24 Floors) rise about 60m
above ground with floor to floor height of 3.05m. A total of 3.7 million Sqft area was planned to be constructed
with precast.
To make the case easy to understand, this study will discuss the construction of series A having total seven
towers. As of today all the seven towers are nearing completion. There are 12 apartments per floor with carpet
area of about 430 Sqft. for 1BHK. All apartments at of series A are identical that made precast technology a
viable option.
Figure 6.1 shows the overall layout of group housing project with high-rise towers along with the tower
constructed with precast concrete constriction technology.
Table 6.1 shows the overall scope of precast construction for Dream Valley series A buildings with other project
details.

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A typical floor plan for a wing of tower A1 along with precast elements layout is shown in Figure 6.3.

Figure 6.1: Dream Valley: Overall Layout Plan Figure 6.2: Typical apartment floor plan

Table 6.1: Dream Valley-Precast Project Details

Dream Valley – Series A (Tower A1-A7), High Rise Residential Buildings

Overall built-up Area (Precast+CIS) 10 Million Sqft

Built-up area planned in Precast 3.79 million Sqft

Built-up area of A series (A1-A7) 8.82 lacs Sqft

Structural frames 2B+G+18 Floors

Total apartments 1500 apartments; 12 apartments per floor

Structural system (Sub-structure) Raft foundation (CIS)

Structural system (Super-structure) Hybrid Precast Construction (Shear walls & Core in CIS)

Basement, Ground & terrace work Cast In Situ

Precast beams, wall panels, balconies, claddings,

1st to 18th floor
staircase, & hollow core slabs

Total precast concrete volume (m3) ~16000

Total Nos. of Precast elements (Tilts + HCS) 25000

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 Figure 6.3: Typical Precast Elements layout for A1 Tower wing (4 flats)

6.2 DESIGN IMPLEMENTATION & CONNECTIONS

The foundation system of the project was designed & constructed as raft foundation. As per the project and
structural requirement, the project was constructed by using a hybrid design with Precast & CIS together. In this
hybrid construction foundation, substructure, terrace work & all the shear walls for all floors were completed
using conventional CIS method. Superstructure (i.e. 1st to 18th floor) consisted of precast construction of beams,
balcony, staircase, wall panels & hollow core slabs. The vertical members (shear walls) were constructed in CIS
considering the economy and design aspects along with erection plan of other members. This hybrid design
facilitated the overall faster erection and allowed for timely production & delivery of other precast members.
Also, from design point of view it’s preferred to have monolithic vertical members. Although, it was possible to
make precast vertical members, but that would have required to consider for special connections.
The current connection were simple and special dowel bars, corbels and provisions for connection were planned
in advance for the members as per the design. The joints were made monolithic by grouting them with non-
shrink grout. Onsite, wet grouted joints for horizontal connections between wall to wall, slabs to wall, termed as
stitched joints were selected. This precast design system ensured the structural performance equivalent to that
of a conventionally designed CIS, monolithic concrete structure. After placing the hollow core slabs as per the
layout, a structural topping of 50-75mm was poured to make the slabs behave like a diaphragm. Solid slabs
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were used in the toilet and common areas to allow for basic MEP services. M40 grade of concrete was used for
all the tilt elements and M60 was used for the production of hollow core slabs.

6.3 CHALLENGES EXPERIENCED

It was a mammoth task to construct a high-rise residential building using precast construction technology. It was
a roller-coaster ride for everyone involved which, towards the end became a steep learning curve. This learning
experience made it possible to develop a deeper understanding of the technology, global standard practices, &
apply these learnings to the other projects in a workable way with available resource constraints. Several design,
production & erection aspects of standard practices used abroad were modified to suit the Indian scenario.
Following are some of the key learning challenges which were encountered on the way.
 As the project was located in seismic zone IV, the suitable design was adopted.
 Lack of skilled manpower with the knowledge of precast industry, operation of various machineries &
erection, which was overcome by providing detailed training.
 It was difficult to counter the typical mind-set of people to adapt to change in construction technology,
patience & willingness to experiment with a new technology.
 Although, European and other standards were available for ready reference but unavailability of IS codes
was deemed important. The designers from India had only few Indian Standard to refer.
The knowledge and understanding acquired during this case was carried forward to the projects underway.
Many improvisations were based on the experiences of this projects.

6.4 RESULTS ACHIEVED

Some astonishing results along with learning experiences achieved through this landmark project are noted as
follows:
 7 buildings of 2B+G+18 floors were completed in 18 months of timeline was made possible through precast
technology.
 Achieved a slab cycle of 10-12 days for a slab area of 7000 Sqft.
 Superior quality & finish of construction.
 Cost & time optimisation with the use of hollow-core slabs.
 Reduction in concrete & steel factor per Sqft of built-up area.
 Elimination of brick work and plaster by the use of precast wall panels & cladding.
 Automation & mechanisation of construction project improved overall productivity.
 Improved site safety & considerable reduction in wastage, dust & noise on site, thus reduced ecological
footprint of project.

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7. CONCLUSIONS

The precast concrete technology has already arrived in India, due to large size projects, need for quality
construction with speed & reduced labour force. All these advantages can be exploited to the maximum by
careful planning & designing. This case study was aimed to share the hands-on-experience, and to aware the
people about the potential the precast offers. Following learnings could be the key takeaways though this case
study:
 From the above case study, it can be concluded that precast construction, if designed and executed with
thorough planning, has a great potential to respond to new market demands.
 Adopting mix of CIS & factory made precast units wherever required, instead of usually considered ‘all
precast or no precast’ approach offers more benefits in terms of time, cost, and quality.
 Repetition of precast components is essential in order to meet quantity for cost effectiveness.
 The adoption of precast compared with traditional constriction demonstrated significant advantages, such
as improved quality control, reduction of construction time, construction waste, dust & noise on site, and
labour requirement on site. In addition, it results in higher useful gross floor area which contributed to
significant cost benefits.
 A considerable reduction in steel factor can be achieved even for seismic zones IV & V.
 It becomes easy to perform non-destructive testing (NDT) if the need arises and becomes easy to mitigate.
 Precast has evolved towards the use of non-standard design approach with modular elements optimising
site opportunities & constraints.
 For commercial construction and other standard products like boundary wall etc. precast has unprecedented
benefits.
 Precast technology allowed for flexible design and longer clear spans in the non-tower areas like parking.
 Precast is smart way to achieve the sustainability objectives of Green Building.

8. REFERENCES & BIBLOGRAPHY

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