GROUP ASSIGNMENT

ACM C C09- PRECAST, PREFABRICATED AND PRE-ENGINEERED STRUCTURES

NOVEMBER 21, 2022

SUBMITTED BY
GROUP A1[ AH21001-AH21010]
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Q.1.Discuss the technology of structurally insulated panel commonly known as sandwich panel.
Elaborate its applications in the form of one case study from construction industry.

SIP is a sandwich-structured composite material used in building that consists of two layers of structural
board and a hard-core insulating layer. The core could be built of sheet metal, plywood, cement,
magnesium oxide board (MgO), extruded polystyrene foam (EPS), polyisocyanurate foam (PIF),
polyurethane foam, composite honeycomb, or oriented strand board (OSB) (HSC). SIPs also share the
structural features of an I-beam or I-column. The hard insulating core of the SIP acts as the web, while
the sheathing acts as the flanges. SIPs incorporate a number of elements of traditional construction,
including.
METHOD OF MANUFACTURING
The majority of SIPs are produced in conventional plants. Pressure and heat are uniformly and regularly
regulated using processing equipment. For materials used in SIP cores, there are primarily two processing
techniques. Pressure and heat are both necessary for the glue to fully penetrate and cure when creating a
panel with a Styrofoam core. There are some variances, but in general, the skins are bonded after the
foam core has been coated with glue.
1. The three pieces of the huge jig should be heated and under pressure. Until the glue has dried,
the three pieces should be retained in the jig.
2. Owing to the foam's expansion during the foaming process, pressure and heat are produced when
polyurethane core panels are manufactured. Fill a sizable jig that will act as a mould with leather.
3. In order for the liquid polyurethane material to enter the device, the skins must be kept apart.
Bubbles will start to rise once they are inside the gadget. Molds and presses are typically made
to withstand the pressure and heat that chemical foaming produces.
4. The SIP is withdrawn from the mould or press after it has somewhat solidified there for a few
days. Both approaches previously needed a factory reset.
However, recent developments have made it possible to manufacture SIP on-site utilizing SIP processing
machinery as an alternative. This is good news for home builders in underdeveloped nations where the
technology may be most useful for lowering greenhouse gas emissions and enhancing sustainability.

CASE STUDY ON APPLICATION OF SANDWICH PANELS IN DESIGN AND BUILDING OF

DREDGING SHIPS
INTRODUCTION
The application of sandwich panels in the ship structure of dredging ships and in detail for a full, sandwich
superstructure has both undergone thorough feasibility studies at IHC. Additionally, IHC collaborated on
national and international projects with other shipyards, ship owners, sandwich suppliers, research
institutions, and universities. Research has been conducted closely in conjunction with classification
societies. Internal research that included actual application tests in the yard fabrication facilities led to a
better knowledge of avoiding the challenges that come with implementing novel ideas in an established
production environment. With the outstanding technological benefits and significant cost and fabrication
time savings, IHC decided to start employing steel sandwiches on a modest scale with the hope that the
applications would grow significantly.

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APPLICATIONS
FIRST SANDWICH APPLICATION
1. At the moment of writing this paper IHC Holland Dredgers B.V. has built its first sandwich
application.
2. I-core sandwich panels have been applied for the structure of a Switch Board Room (SBR) in
the engine room of a 6000 m3 TSHD
3. IHC decided to actual design and build the all sandwich SBR, based on an estimation of the risk
being smaller than the cost benefit

Fig.1.Structural design of sandwich switch board room

DESIGN
1. Design of the SBR was done in close cooperation with the Meyerwerft, as a supplier of I-core®
sandwich panels.
2. Static and dynamic calculations have been performed at IHC Dredgers, Meyerwerft has supplied
results of a finite element analysis of the bottom panel of the SBR. Standard I-core panels have
been applied with a shell and core thickness of respective 2.5 and 4.0 mm and a distance between
shell and core plates of respective 40 and 120 mm.
3. The sandwich panel geometry has been compared with a conventional panel structure with 6 mm
shell plate and HP120x7 bulb profiles at a distance of 614 mm, being the minimum scantling
design for this particular application.
PRODUCTION
1. The fatigue strength of specific details of the sandwich structure is determined by the detailed
geometrical and weld design, the stiffness and strength of both structural designs (sandwich and
conventional).
2. Fatigue calculations haven’t been made for the structure of the SBR. However the fatigue life of
the sandwich structure has been improved compared to the conventional design based on the
number of (fatigue sensitive) parts like cutouts and brackets (roughly 50% parts reduction).
3. All openings and holes were investigated during the detailed design of the SBR, indicated in the
section drawing and sent to the Meyerwerft. Large opening for doors were strengthened with
square tubes and holes for the penetration of electrical cables were strengthened with curved flat
profiles both during production already of the sandwich panels. This was done because of the

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 wide experience at the Meyerwerft with making and strengthening of cut-outs in steel sandwich
panels.
4. The sandwich panels were transported by lorry to IHC Dredgers and hoisted from the trailer
making use of vacuum clamps. First impression was the flat panel area compared to conventional
welded steel structures. The box structure of the SBR was build up quite fast, in a couple of days,
one of the short sides of the SBR was left open to install switch board and several other equipment
including foundations, piping and electrical cabling before closing and final welding of the SBR
structure.
“Why not use sandwich panels for our accommodation and engine room superstructures?”
The hour report showed slightly more hours to place and weld the panels (15% more) compared to the
preliminary cost calculations, but hours to produce the conventional structure were estimated to be far
more compared to the preliminary estimations (50%) resulting in a total cost reduction by applying
sandwich panels equal to 34% (equal to estimated value) and a reduction in throughput time of 71%.
FUTURE APPLICATIONS
1. The results of research at IHC Dredgers and the actual design and production of the sandwich
switch board room has shown, that the application of steel sandwich panels in the ship structure
of dredging ships can lead to significant overall cost reductions, weight reductions and a large
reduction of the throughput time.
2. IHC is ready for the production of a larger sandwich application, which would probably be a
deckhouse or funnel structure.
3. A sandwich deckhouse has already been engineered and a sandwich funnel structure has been
produced at the Flensburger Schiffbau Gesellschaft with SPS sandwich panels as well as I-core®
panels.
4. The production of such sandwich applications could lead to a larger extent in application of
sandwich panels in ship structures, because experience and confidence are build up.
ADVANTAGES OF THE APPLICATION OF SANDWICH PANELS
1. Sandwich panels are made up of a relatively light-weight core made of the same material or
plastic and two steel or aluminum skins that are separated from one another.
2. Due to the gap between the skins, sandwich panels have a greater sectional area to sectional
modulus ratio than plates alone.
3. In dredging ships, local bending moments brought on by loads or water pressures are crucial in
establishing the strength of the ship's structure.
4. According to the case study, the use of sandwich panels may often
5. Lower the structure weight of a particular component ship by 39%.
DISADVANTAGE OF THE APPLICATION OF SANDWICH PANELS
1. The disadvantages of using sandwich panels over conventionally stiffened panels include the low
resistance of the shell plates to impact loads and local (point) loads, the low shear strength of the
metal or polymer sandwich panel's core, the panel joints, as well as the limited design options.
2. When recommending steel-cored sandwich panels to shipyards or ship owners, one of the main
criticisms is the possibility of lessening impact resistance. When utilized for sandwich panels
with a thickness of 2.5 mm or less, the local impact strength of the shell plates for metal core
panels will naturally be reduced.
3. If the cores are made of polymer, the local impact strength will be significantly higher.

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 4. A regular I-core panel behaved far better than a conventional panel with comparable strength
attributes, according to the investigation's findings; once damaged, it could bear more in-plane
stresses before collapsing.
5. Sandwich panels outperformed conventional panels when hit by small, sharp pebbles (as
determined by a 120-mm indenter), but they fell short when hit by larger stones (as measured by
a 600-mm indenter).

Q.2. Draw and explain different types of connections between beam and column in pre cast
construction

COLUMN TO FOUNDATION

1. IN SITU SOCKET FOUNDATION

The connection between column and foundation in this type of connection is where part of the
precast column is assembled into the foundation block by an external socket base with smooth
internal walls. Usually, the socket base is precast and then it is connected into the foundation
block. Also, the socket base may be cast in a monolithic way with the whole foundation or even
the whole foundation may be one precast piece. The last one is more used when small pads are
necessary. The construction of a connection between column and foundation block begins with
the fitting of the column into the socket, using a centralization device located in the inside
bottom of the socket base. In this process, wooden wedges are placed to facilitate the provisional
fixation and also to correct the deviations that may occur. The space that lies between the socket
and the column is then filled with grout or concrete.

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2. MECHANICAL SPLICE

Mechanical splices are used to establish a mechanical connection between two pieces of
reinforcing steel in concrete construction for joining reinforcing bars. This system aligns and
secures the joined rebar ends in an in-line connection suitable to meet appropriate splice
requirements. These are being adopted in project sites due to their flexibility of use in congested
reinforcement places at construction joints. These connections are also more reliable than the lap
systems because they do not depend on the concrete for load transfer and also allow structural
designs to achieve an ideal balance of steel and concrete by eliminating the additional rebar lap
zone by meeting building code requirements in many areas. In seismic prone zones, these splices
provide structural engineers the ability to design and build concrete structures that meet or exceed
today’s stringent construction codes and federal regulations regarding seismic frame construction.

3. BASE PLATE

In base plate connection the bolted connection between a column and a footing is designed to
resist tension, compression, and shear. It will be best to use a template for setting anchor bolts
and for punching holes in the base plate to ensure proper fit in the field and it is a good practice

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to set the base plate overall dimensions slightly less then column dimensions to ensure proper
placement.

4. WELDED REINFORCEMENT

In this connection, the longitudinal reinforcements of the pre cast members were extended out
and made into a U-type reinforcement ferrule (URF). The vertical pre cast components, the U-
type ferrule of the upper and bottom pre cast members overlapped with each other and distributed
reinforcements were inserted through the corners of the U-shaped rings, formingthe clamping
mechanism between the reinforcements of the connected parts. This overlapping region was then
filled with concrete on the construction site. Therefore, there is only a small amount of concrete
grouting work at the connecting region, and the overall connection has a good fault-tolerance
ability and a low cost of construction as well as a simple operational process. However, since the
longitudinal reinforcements only overlapped with each other and the internal forces were simply
transferred through the mechanical clamping effect of distributed steel bars so the spliced part
would quickly lose the bonding mechanism once the post pouring concrete got crushed. Then,
this connection presented weaker energy dissipation ability than traditional CIP shear walls.

However, this URF connection presented a simple connecting idea for pre cast structures, and the
main deficiency comes from the weak connection between the spliced U-type ferrules. Therefore,
a modified connection detail was proposed to improve the internal force transmission and
integration of the URF connection. The construction of the modified URF connection is given in
figure as the exposed U-type longitudinal reinforcement ferrules were welded together after being
overlapped with each other, and the distributed steel bars were also supplemented in the U-shape
ring. In this way, the longitudinal reinforcements were bonded together to strengthen the internal
force transmission, increasing the connection integrity. The modified URF connection still
possesses a simple connecting and construction process as shown in fig. In the construction site,
the pre cast columns can be lifted above the desired location and be positioned to overlap the U-
ferrules conveniently and after that the distributed steel bars are installed at the corner positions.
The spliced U-ferrules are welded together beforethe concrete is cast at the splicing region. The
pre cast column can be self-supported through the welded U-ferrules. Then, the need for lifting
or supporting work is limited, and the compactness of the spliced region is easily ensured.

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WALL PANEL TO FOUNDATION

1. WALL PANEL TO CAST IN SITU FOUNDATION USING ANCHORS

These types of connections are used to tie the load-bearing walls to the foundation. Any
connection joining a wall panel to a foundation wall or a continuous footing should provide a
means of levelling and aligning the panel. The attachment method also should be capable of
accepting the base shear in any direction. The capacities of these connections are the embed edge
distances and other design assumptions that should satisfy production and design standards. The
connection is not tolerance sensitive. The embed plate and recessed pocket plate need to be
properly sized to accommodate the loose angle and the associated welds. Perimeter bars exist as
confinement in the precast concrete final. Connections centerline is a minimum of

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60 mm from the edge of the precast concrete panel and the edge of the foundation. Shims, dry
packs are used in fixing column in foundation using screwed anchors.

Mainly used for connecting precast column and foundation, precast shoe can also be used to
connect precast wall panel to foundation. They are especially suitable for anchoring in flat
structures such as the foundations or walls that have sufficiently large edge distance. The
advantage of this precast system with screw connection is the quick assembly. The connection
is easy to adjust with a healthy tolerance and immediately loadable so that bracing is not required
which results in less labour at site. However, they are not specifically designed for walls and
therefore have a limitation on the wall thickness and thin walls cannot be connected using this
type of product. The system comprises of the precast shoe (cast into the precast wall) and the
suitable anchor bolts (cast into the foundation) for the foundation base. Both elements are joined
by load bearing nuts during assembly on site.

Casting Duct into the precast element is the traditional method to connect precast walls to
foundation. Duct is used as a hole former for a variety of precast and cast-in-situ concrete works.
The hot dipped galvanized metal duct is strong and durable for casting into precast wallsand then
to relate to rebars from the foundation. Although duct has been a commonly used method for
precast connections, one of the major disadvantages of duct application is the huge amount of
grout needed to fill up the duct in order to secure the connection between the precast wall and
foundation. Eventually, this traditional method will increase the cost and time of the overall
construction. The rebars protruding from the foundation are simply inserted into the grout
coupler, which has been casted in the precast wall. When pumped with 100MPa grout, the grout
coupler system is a bar break technology and is capable of carrying very high barloads
regardless of the rib profile on the reinforcing bar. Although this is not the most popular
application of grout coupler but the application of grout coupler for precast wall to foundation
is still widely accepted in the market.

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BEAM TO COLUMN CONNECTION

1. BILLET BEAM COLUMN

The billet connector is based on the conventional steel haunch but without reinforcing bars welded
to the sides of the box section. Billet as beam-column connector the beam and column members
under dynamic loading. Previous research has proved the assimilation of fibre reinforced concrete
in the CIP connectors had produced more ductile, increased energy absorption, reduced and better
shears resistance connections during earthquake movements, besides reducing the complexity of
joint reinforcement in the conventional design. The CIP High Performance Fiber Reinforcement
Cement Composite (HPFRC) connection successfully acts as a plastic hinge by spreading
yielding from the center of the connection to the interfaces. This nature of the joint had increased
the strength and stiffness of the column by relocating the beam plastic hinge zone away from the
column interface. The utilization of steel fiber reinforced concrete in the connections has led to
increased energy dissipation capability of upto 350% over previous normal reinforced concrete
connections. At the same time, the increment of strength was reported up to 30%, displacement
and rotation resistance up to 65 and 85% respectively while shear deformation was decreased up
to 30%.

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CORBEL

A corbel is a short cantilever projection from the face of column which supports a load bearing
component. Normally in construction corbel is a pinned connection which is it can transmit shear
and axial loads. However, this type of connection can be a ductile connection with some
modification such as makes it a hybrid connection or combine with the wet joint. Usually, the
beam is a single vertical dowel which is either a waiting bar cast into the corbel or site fixed into
a hole. The diameter of the dowel is between 16 and 25mm typically, with the dowel holeis 35
to 50mm. Then the hole will be filled with non-shrink grout from the top. Figure shows beam
supported on corbel.

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12
Beam to Slab Connection

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Q.3. Draw and explain the components of any typical Pre-Engineered structure.
Pre-Engineered buildings or PEBs structures are made up of various components that give them their unique
properties and make them sturdy and durable. Pre-Engineered Buildings are known for their flexible design,
high structural strength, and ease of construction. But all this is made possible due to the various components
that go into building a PEB. Just like any assembled structure, a PEB consists of components that can be
categorized into 3 main types and a few accessories.

A PEBs Structure (Pre-Engineered building) is made of:

• Primary Components
• Secondary Components
• Roofing or Cladding
• Other Accessories

Primary Components:

• Primary members are the main load-carrying and support members of a pre-engineered building.
• The main frame members include columns, rafters, and other supporting members.
• The shape and size of these members vary based on the application and requirements.
• The frame is erected by bolting the end plates of connecting sections together.
• All the steel sections and welded plate members are designed in accordance with the applicable
sections as per the latest international codes and standards such as AISC, AISI, MBMA and IS to meet
all the customer specifications.

The Primary components include 3 main parts: Main Frame, Columns, and Rafters.

Main Frame:

The main frame is the building’s basic structure, which is made of rigid steel. It is built using tapered columns
and rafters, sometimes also referred to as built-up members. There are spliced plates welded to the end of these
tapered sections. The splice plates of connecting sections are bolted and the frame is erected.

Columns:

Columns are used to transfer the vertical load to the foundations. These are generally made up of I sections
which give benefits in terms of strength while being economical to produce.

Rafters:

Rafters are sloped structural members or beams that extend from the ridge or up-to-the wall-plate. They are
designed to support the roof deck and other loads associated with it.

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Secondary Components:

Purlins, Bracings, Tie rods, Angle bracings, High Tensile Bolts, and washers are classified as secondary
components used in a PEB. These parts are used to support walls and roof panels. In addition to that,
the secondary members also help the building withstand the longitudinal loads that the building may
see during earthquakes and heavy winds. Purlins are mostly unique cold roll-formed sections used to
fix roof and side claddings. They are available in variations such as Z, C, and Sigma purlins denoted by
their cross-section.

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Roofing/Cladding
Tin shades & Curtain Wall made of Glass & Roll-formed steel sheets usually come in this category.
Roofing sheets, as their name suggests, provide protection to the building interior from the environment.
They can be designed to either block sunlight or allow partial sunlight to illuminate the interiors,
depending on the requirement. A Standard supply of material for Roof Sheets is 0.47 mm Bare
Galvalume and for wall Claddings it is 0.50mm Colour coated Galvalume.

Sandwich Panel
Sandwich Panel is made of three layers, in which a non-Aluminium Core is inserted b/w two aluminium
sheet.

Other Accessories
Sliding Door & Canopy

Canopies are narrow roof systems that provide various functions such as a shade to block direct
sunlight on the building walls; an extended cover to protect the buildings against the rain; and a cover
at entrances of the buildings or adjacent to the walls for car parking.
Louver

Louvers are used in buildings wherever there is a need for creating resistance to rainwater, excessive
noise, hurricane-type winds, or a combination of these problems – while also ensuring proper airflow.
Louvers can be utilized in a range of performance types, including drainable, non-drainable, wind-
driven rain resistant, combination, thin-line, acoustically rated, adjustable, and even extreme-weather
resistant.

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 Louvers in PEB
Ridge Ventilator

Building experts to come up with the most effective ridge ventilators (RV) for our pre-
engineered buildings. It requires an excellent design of the whole building to ensure the
ventilation on the roof and wall is perfect. Standards ridge ventilators for pre-engineered
buildings are RV 3.0, 5.0, 6.0, and 7.0.

Ridge Ventilators in PEB

Flashing and Trims

Each trim or flashing accessory is factory-formed in the specific shape and accurate size. Precisely-
matched color and high quality are assured, which allows designers and users to dramatically
improve the aesthetics of the building as well as creating modern architectural lines

Gutter and Downspout

A gutter is a cold-formed “channel-shaped” member designed to carry water from the roof of the
building to the downspouts. There are two types of gutters: eave gutters and valley gutters. Valley

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gutters are normally located between two adjacent buildings or gables, having equal or unequal
eave heights.

Skylight

These are roof opening covered with translucent or transparent glass or plastic designed to admit
daylight.

Fascia

The parapet fascias are extensions of the building walls in such a way as to conceal the
building peak and are intended primarily to project a solid flat roof appearance. Adding a
fascia to the roof increases its value and enhances its aesthetic appearance and beauty.
Although the standard projection of this fascia is 600mm, wider projections up to 1,500mm
are common. The height of this type of fascia is variable and is determined mainly by the
roof slope of the building.

The roof gutters are located in such a way as to prevent water from seeping through the
fascia projection thus providing protection from the rain and shade from the sun.
Turbo Ventilator

Turbo ventilator (Eco Ventilator) which is a self-driven equipment installed on industrial roofs to
extract inside air. Turbo ventilators are driven by wind, hence no electricity or any other power
source is required.

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 Turbo Ventilators over the roof

As the Eco ventilator is rotated by wind, the stale inside air is exhausted through it and natural inward
flow of fresh air is boosted. The turbo ventilator operates by utilizing the velocity of the wind to induce
air flow by centrifugal action. The centrifugal force caused by the spinning vanes creates a region of
low-pressure area which draws air out through the vanes. Air drawn out by the vanes is continuously
replaced by fresh air from the outside. The slightest breeze will cause the turbine to spin and even after
the breeze has stopped, the flywheel effect of the rotor cage will use its stored energy to continuously
remove air giving rise to ventilation. Suction is maintained even at low wind velocities

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Q.4. Discuss in detail the light house project at Agartala. Discuss the need and advantages of
adopted technology in this project.

Light house project is being built at Akhura Road, Agartala, Tripura with total built up area of 45,273
sq.mt. including social infrastructure. light house Agartala using RCC pile foundation with Pre-
engineered steel structural frame. Walling have been decided to be Light gauge steel structural system
with cement concrete panels and light weight concrete as infill and High tensile galvanized deck sheet
with required reinforcement and 50 mm Concrete for roofing.

To be in detail, Agartala has chosen to be using following materials for an exclusive finish:

Door Frame/Shutters:

• Pressed steel door frame with flush shutters

• PVC door frame with PVC Shutters in toilets.

Window Frame/ Shutter:

• uPVC frame with glazed panel and wire mesh shutters.

Flooring:

• Vitrified tile flooring in Rooms & Kitchen

• Anti-skid ceramic tiles in bath & WC

• Kota stone Flooring in Common area.

• Kota stone on Staircase steps.

Wall Finishes:

• Weather Proof Acrylic Emulsion paint on external walls

• Oil Bound distemper over POP on internal walls

Infrastructure: Internal Water Supply, Laying of Sewerage Pipe Line, RCC storm water drain,
Provisions for Fire Fighting, Internal Electrification, Internal Road & Pathway (CC Road and
Bituminous Road), Providing Lifts in building blocks, Landscaping of site, Street light with LED
lights, Solar Street Light System, Sewerage Treatment Plant, External Electrification, Water Supply
System including underground water reservoir, Compound wall with Boundary Gates, Horticulture
facilities, Rain Water Harvesting, Solid Waste Management.

Technology: Light house of Agartala is remarkable for its Light Gauge Steel Framed Structure with
Infill Concrete Panels (LGSFS-ICP) technology adopted from Global housing technology challenge-
India.

Details:

Light Gauge Steel Framed Structure with Infill Concrete Panels (LGSFS-ICP) Technology is an
innovative emerging building and construction technology using factory made Light Gauge Steel
Framed Structure (LGSFS), light weight concrete and precast panels. The LGS frame is a “C” cross-
section with built in notch, dimpling, slots, service holes etc. produced by computerized roll forming
machine. These frames are assembled using metal screws to form into LGSF wall and roof structures
of a building. Provisions for doors, windows, ventilators and other cutouts as required are

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incorporated in the LGSFS. The technology is used for construction of Low rise residential buildings
up to G+3 storey , Schools, Health centers, Community centers, independent houses and rehabilitation
buildings.

Manufacturing/Making procedure of LGSFS-ICP Technology:

1. The LGS frames are manufactured in a factory and assembled in to LGSF wall structures and
then transported to the construction site and erected wall by wall on a pre-built concrete floor
as per the floor plan of the building.
2. Steel reinforced concrete panels of size 800mm X300mm X20mm thick are manufactured at
factory and transported to site.
3. These panels are fixed on either side of the LGSFS wall using self-drilling/tapping screws to
act as outer and inner faces of the wall leaving a gap between them. This gap is then filled
with light weight concrete using a special mixing and pumping machine.
4. Electrical and plumbing pipes/conduits are provided in the service holes of the LGSFS before
concreting is done. Self-compacting concrete is mixed and pumped into the gaps between two
panels.
5. The concrete flows and fills the gap and provides adequate cover to the LGS frames and
joints. The concrete shall also adhere to the concrete panels.
6. After curing, LGSFS with in-fill concrete and panels (LGSFS-ICP) forms a monolithic
sandwich composite wall structure with thermal and sound insulation properties.
7. The roof structure of LGSFS-ICP building is constructed using metal/plastic formwork
system with steel reinforced concrete as per structural design.
8. Standard procedures are employed to concrete the roof slab. After curing for 96 h, the
formwork is de-moulded and the wall and roof are putty finished.
9. Door and window frames are fixed to the LGS frames and shutters fixed with necessary
accessories. Finishing work such as laying floor tiles, fixing electrical and sanitary fixtures
and painting is carried out using standard conventional methods.
10. After completion of ground floor, first, second and third floors of the building is constructed
using the same procedure that of the ground floor. The staircase, chajja and parapet walls of
the building are also constructed using LGSFS-ICP Technology.

Construction/Installation of

1. Construction of Foundation and Plinth: The foundation and plinth is constructed confirming
the floor plan of the building. The foundation depth, width, steel reinforcement, grade of
concrete etc. is determined by structural analysis report prepared on the basis of soil
condition, height of building, number of storeys, special live load requirement, if any.
2. Assembly of LGS Frames and Construction of Wall: The LSG frames manufactured using
numerically controlled roll forming machine using CAD design shall be transported to the
construction site. The frames shall be assembled into wall structure. All the wall structures
shall be connected together one by one as per the building plan by connecting screws. The
wall position shall be marked on the floor and the wall structure placed on the marking. After
completing the same, straightness, square and the levels shall be checked by magnetic spirit
level. The bottom track shall then be connected with the floor using anchor bolts at every 600
mm bolts.
3. Fixing of Pre-cast Panels: The precast concrete panels shall be fixed on the LGSF wall
structure on studs and tracks by using metal screws. The panels shall be fixed first on the
outer side of the LGSFS wall. Electrical/plumbing pipes/conduits shall be fixed as per the

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 electrical and plumbing layout. After completion, the panels shall be fixed inside the LGSFS
walls and allocations for electrical and plumbing cutouts shall be marked on the panel.
4. Concrete Mixing and Pumping: Self-compacting concrete of required grade/light weight
concrete shall be mixed using concrete mixing machine and then pumped into the gap
between two panels using a special pumping unit. Care shall be taken to pump the concrete
gradually and uniformly on all the walls. Concreting shall be done till the gap is completely
filled up to the top of the LGSFS wall.
5. Construction of Roof Slab : The roof slab of the building shall be constructed by using
metal/plastic shuttering and conventional concreting. Necessary steel reinforcement as per
design shall be provided over the formwork and concreting shall be done to required
thickness. Balcony and chhajja etc., wherever required shall also be constructed using
formwork. After curing the slab, shuttering shall be removed and bottom of the roof slab putty
finished.
6. Reinforcement, Staircase and Railing, Fixing Electrical and Plumbing Fixtures, . Fixing of
Doors, Windows & Ventilator Frames and Shutters ,Fixing Floor Tiles , Surface Finishing
and Painting.

Advantage and need of Light Gauge Steel Framed Structure with Infill Concrete Panels (LGSFS-ICP)
technology in Agartala light house project:

1. Weight of the LGSFS-ICP building is about 20-30% lighter when compared to conventional
building thereby resulting in material and energy savings
2. During the ponding on roof slab for 24 hours, no dripping or leakage of water through roof
slab or drop patches were observed on underside of the roof slab.
3. Due to low weight, significant reduction in design earthquake forces. Chance of progressive
collapse are marginal due to highly ductile and load carrying nature of closely spaced
studs/joists.
4. Reduction in temperature up to 4ºC inside the unit indicating that it has got a good thermal
comfort.
5. The structural details were designed to meet the durability and safety requirements of
applicable loads including earthquakes, cyclone, and flood as applicable in accordance with
the applicable Indian/International standards.
6. Cluster design include innovative system of water supply, drainage and rainwater harvesting,
renewable energy sources with special focus on solar energy
7. The period of construction will be maximum 12 months.

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Q.5 Identify and discuss any one case study related to precast technology either Bridge,
Marine or Metro construction (choose any one).

Metro Bridge
Among the many prestressed concrete bridges, the most commonly used bridge type is the one using
precast beams. This particular bridge has several precast PSC beams supporting the upper slab so that
vehicles and pedestrians can pass over it. The bridge can be composed of 1 span or multi span with
20~40m per span. Depending on the shape and construction method of the beam, the length of one span
can be as long as 50m.
A. COMPOSITE BEHAVIOR AND COMPOSITE GIRDER
A member made out of more than one material is called a composite member. In bridges, girders and
the slabs are combined and used as superstructures. These are called Composite Girders. The basis of
Composite members is to assume full convergence.

There are various composite girders according to the shape of the girder. Concrete materials are used
for Slabs while both steel and concrete materials are used for Girders.

Fig.5.1. Composite Steel Girder I

B. DECK SLAB

There are three main types of concrete decks used in the presetressed concrete bridges: In Situ concrete
deck, Full depth Precast deck, and Partial depth precast deck.
The In situ concrete deck is a universal type of concrete deck that has been widely used since ancient
times. Compared to other types of decks, construction is flexible for cross-sectional shape and bridge
geometrical shape. In addition, if the construction management is carried out smoothly, sufficient

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strength can be obtained, and there are certain advantages of combining the girder supports with the
concrete deck. However, since the installation of the formwork is essential and the concrete curing
period is required, there are certain disadvantages, including longer construction periods and labor-
intensive work.

Fig. 5.3 Deck Slab

5.1. CASE STUDY ON KOCHI METRO

The public company Kochi Metro Rail Limited (KMRL) was created in 2012, as a joint venture of the
Government of India and Government of Kerala, to build and operate a 25-km long elevated metro
system in Kochi, with 22 stations.
Length of line: 25.612kms fully elevated generally carried on pillars located on the median of the road.
Gauge: Standard gauge
Track: Heavy duty ballast- less track with a maximum speed potential of 90kms per hour and maximum
operational speed of 85kms per hour-average commercial speed is 33kms per hour including station
stops.

5.1.1. CONSTRUCTION METHODOLOGY

a) Substructure
The size of pier for the Kochi metro is limited to 1.2m circular for most of its height so that it occupies
the minimum space at ground level where the alignment often follows the central verge of existing
roads. Piers having circular or rectangular cross sections are being constructed. The station beams are
rectangular and also piers of extended pier cap and other special superstructures are also provided with
rectangular. To prevent the direct collision of vehicle to pier, a Jersey Shaped crash barrier of 1.0m
height above existing road level has been provided all around the pier. A gap of 25mm has been also
provided in between the crash barrier and outer face of pier. The shape of upper part of pier has been
so dimensioned that a required clearance of 5.5m is always available on road side beyond vertical plane
drawn on outer face of crash barrier. In such a situation, the minimum height of rail above the existing
road is 8.5m. Cantilever or portal piers would be provided in case of curved paths.
The various components of substructure are:

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o Pile /Open foundation
o Pile cap
o Pier- Normal, Portal, Cantilever and Extended type
o Pier cap
Piling was done by cast in situ-bored piles with the help of hydraulic drilling rigs sing partial depth
casing with Polymer and oscillator arrangement. Concreting was done by Tremie pipe method. As most
of the construction is to be carried out on the middle of the road, central two lanes including median
would be required for construction activities. During piling and open foundation work, a width of 8m
was found to be required for construction and the same was barricaded. Barricades will be removed
once the work on the piers and pier caps is completed for a stretch of about 200 meters, and shifted to
another stretch, which will restoring the complete width of way for traffic.

Fig. 5.4. Typical Section of Viaduct

5.1.2. Construction of Pier

In Kochi metro, the pile is cast in-situ using the DMC method (Direct Mud Circulation Method).

Each pile pit is drilled to sufficient depth so that hard stratum is found to transfer the loads acting on
the structure. The piles constructed in Kaloor were up to a depth of 50 m deep. First of all, using the
auger the top hard stratum is drilled to certain depth after which a liner plate made of steel is driven into
the burrowed pit. This casing will avoid the collapse of the top most loose soil layers into the pit. After
that, the depth is increased using the auger (in case of hard soil profile) and bucket with sharp protruding
blades or vanes (in case of relatively softer soil profile). As soon as the bucket is filled, the bucket is
pulled out to the surface, the bottom door of the bucket is pulled away and the collected soil is dumped
out. In certain cases, agitation should be given to the bucket in order to evacuate it fully. Meanwhile a
mixture of bentonite polymer in water is pumped into the pit in order to avoid the collapse of the pit
due to the impact and vibration caused due to the subsequent drilling. The polymer is a high slippery
liquid with low viscosity that can hold the soil together from collapsing. Adequate care should be taken
to avoid any leakage of the polymer mix into the road as that can cause slip to the vehicles plying on
the road and can cause accidents. For this, they are usually stored in storage tanks and are supplied into
the pit whenever required. After sufficient depth has reached, the reinforcement of the pile which was
already tied at the surface with sufficient steel and cover blocks are inserted into the pit. The
reinforcement can have either circular or elliptical transverse reinforcement. Cover block ensures that
the reinforcement does not get into contact with the soil so as to prevent its corrosion. Cover blocks are
mostly made of concrete. Tremie pipes are inserted into the pits filled with polymer -water mix.

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From the top, ready mixed concretes of sufficient workability (Slump of 120mm) is poured into the pit
through the tremie pipes. The concrete is mixed in the right proportion in the batching plants located
somewhere near to the location of work in casting yards. From the casting yards, RMC trucks carry the
concrete to the site of usage within the stipulated time so that the concrete does not lose much of its
workability. If any mix gets delayed to reach the site, then that concrete will not be used in concreting
for that affects the performance of the flow of concrete. Each batch of concrete from the RMC truck is
checked for slump and cube tests. Also, each truck carrying concrete also carries with it a note which
gives information on the time of mixing. Using this, we can determine whether the mix is good for
usage or not at the time of delivery. The tremie is always immersed in the concrete. But when concrete
is poured into the pit, the tremie pipe is withdrawn slowly. When sufficient depth is filled with concrete,
each segment of the pipe is removed from the top but always leaving the other end of the pipe within
the concrete. Compaction of concrete is done by agitating the tremie pipe up and down vigorously.
Whenever the concrete is poured into the pit, it displaces an equivalent volume of polymer water mix
which is collected into a tank.

CONSTRUCTION OF PIER CAP

The following are the activities involved in the construction of a pier.

- Leveling the formwork free/fixed end and support for bearing outstand.

- Closing the external formwork of pier cap.

- Application of shuttering oil or formwork releasing agent.

- Lifting and placing of reinforcement cage.

- Fix the anchor cones and check for their trueness.

- Placing of HDPE sheathing in the reinforcement as per profile.

- Placing and fixing the forms and completing of the formwork.

- Checking the dimensions and verticality of slides

- Checking the boom placer and its working condition and make ready for placing concrete with such
as priming, etc.

- Checking the vibrator for compacting concrete is working condition.

- Checking the quality control personnel available at site along with thermometer, slump cone and
required number of cubes.

- Receiving concrete and check for its workability by slump cone and temperature.

- Due to congestion in the reinforcement/ sheathing/ void former/ anchorages, pour and compact
concrete from the top and ensure there is no segregation.

- Stripping the side formwork.

- Wrapping hessian cloth and keep it moist always.

- Pier cap to storage/ stack yard and start curing by water sprinkling.

- The pre-stressing of strands would be done at the connection of pier and pier cap after the erection
of pier cap

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CONSTRUCTION OF PEDESTALS AND INSTALLATION OF BEARING

The following are the activities involved:

- Surface preparation

- Shuttering works

- Casting of pedestal

- Removal of formwork and curing

- Installation of elastomeric bearing and steel plate.

PRE-STRESSING OF U – GIRDER

The pre-stressing of U girder was observed at the casting yard. It consists of following stages:

Profiling

a) The strands are to be placed in to the rebar cage in the casting bed, to required spacing and
dimensions.

b) The ends of strands are pulled through the anchor wall at either ends.

c) For de-bonding lengths as specified in the working drawing. HDPE pipes are inserted at either ends
of the girder

Stressing

a) Strands at either ends of the anchor walls are fixed to the loading frames with barrels and wedges.

b) At one of the anchor walls the strands are stressed (initial tension) using a mono pulling jack, which
is to be placed between anchor frame and reaction frame. Maximum ram is kept to do de-stressing
operation with the same jacks .The initial slackness in the jack is removed by using multi jack.

c) Profiling is checked for correctness, if necessary, error found is corrected.

d) 2X600 T jacks at one end of the frames are operated with a common pump. The stressing is carried
out to the required force in increments as sequence given by the designer and the elongations are
recorded in format. The tendons are locked at this force.

e) Clearance is given by engineer for main contractor to carry out the concreting of girder.

f) Utmost safety precautions are taken before, during or after stressing to prevent accidents.

g) Only trained persons are allowed to conduct the stressing operations. And were observed to wear
safety equipments to protect them by wearing helmets and any other safety devices.

h) Full and accurate records of all operations connected with the pre-stressing are maintained. These
records shall include the jack pressure and extension and slip, if any of each pre-stressing tendon.

i) NO de-tensioning of steel shall takes place until the concrete has attained specific strength as
ascertained from the test on cubes cured and hardened under the same condition as concrete of the
member.

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De-tensioning of strands

a) Before de-tensioning the strands, ends of the strands are marked with marker, to measure the slip of
the strands. This is observed during the de-tensioning process and measurements are recorded.

b) Release the pre-stressing force in the cables through multi jacks gradually.

c) The recorded measurements are checked with the engineer for his approval, this value is also checked
with the respect to the values given in the drawings

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Q.6. Write a detailed note of production, handling and erection of precast products.
Production set up and planning:

• Components are made at factory or at site.

• Requirement – business model, market analysis, infrastructure requirement, plant capacity,
marketing strategy, sales targets and turnover, types of products and its range.
• Preferred at outside city – cheap land cost, ease availability of raw material, ease in traffic.
• Production set up – single or multiple bays of production yard, storage yard, curing yard,
mould fabrication yard, concrete batching yard, storage for raw materials, QC lab, stores,
offices, suitable cranes for lifting and handling the products.
• Effective planning – requirement of steel moulds, types of element and quantity, types of
inserts or cast in items, plan to reserve the plant for a particular project requirement, use of
software to align each element from production to erection and billing.

Types of Precast Concrete Products:

1. Foundations
• Isolated footing
• Pocket footing
• Precast piles
2. Beams
• RCC Beam •
• Pre-stressed beams
• Thin/Shell beam
3. Columns
• Continuous
• Non- Continuous
4. Slabs
• RCC Slabs
• Pre-stressed slabs (hollow/solid)
• Fiber reinforced slab (hollow/solid)
• Single / double Tee slab
• Waffle slab
5. Walls
• Load bearing
• Non- Load bearing
6. Staircase
7. Box culverts, storm water drains, UG sump, septic tanks, toilet blocks.

➢ Moulds requirement for Precast Concrete Products:

• Number of repetitions – above 200 – steel moulds, below 200 – plywood moulds.
Economy view
• Any shape and size is possible
• Steel Plates of 4mm to 30mm, C channels (50 to 200mm), angles (50 to 150mm). Depend
on span and dead load of element and span of mould.
• Hydraulic jacks of 2 – 50 ton capacity for prestressing or tilting the table mould
• Preferred weight for moulds must be less than 5 ton such as to handle with ease.

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 • Column Mould :
▪ Generally casted horizontally, rarely done in vertical (in case of round column).
▪ Mould consist of bottom and side plates, with end plates, top surface is trowel
finished. External Vibrator used.
▪ Holes or sleeve for overlapping bars or dowel bars to be provided.
▪ Rubber packing or lining may be used to avoid any leak in grout/concrete.
▪ Tolerance in all measurement is +2mm to - 3mm
• Beam Mould :
▪ Casted horizontally, as system moulds (Adjustable height and width)
• Battery Mould:
▪ Used for wall or slab elements
▪ Smooth surface on both sides
▪ Multiple elements can be casted at once
▪ Space requirement is very minimum
• Vertical wall Mould:
▪ Apart from general purpose uses, it is used for wall elements with non rectangular
shape. Such as Tee shape, wall with sunshade etc.
• Tilting Mould:
▪ Casted horizontally, than tilted vertically using hydraulic jacks.
▪ Convenient for providing window and door openings.
▪ Used in layered walls such as sandwich panels.
▪ Vertical position of mould saves the space in yard.
• Flat Mould:
▪ Casted horizontally. Used for wall panels and slab panels
• Hollow core mould:
▪ Casted horizontally. Used for wall panels and slab panels with hollow cores.
▪ Pipes are used to create cores.
• Pre-stressed beam mould:
▪ Arrangement is required to pre stress the tendons
• Bridge Elements
• Box Culverts

➢ Production Sequence:
1. Shop Drawing – consist of plan view, side view, cross sections of element, mould and
reinforcement. Details of inserts, cast in items location, bar bending schedule
2. Mould Fabrication – shall be prepared as per shop drawing requirement, accurate
measurement, mould releasing agent, external vibrator, crane suitable location
3. Reinforcement – as per BBS and shop drawing, cages of reinforcement are lifted and
placed with cover blocks.
4. Cast in items – lifting hooks, inserts, conduits shall be placed after reinforcement is
complete. All gaps, holes must be packed to avoid leakage.
5. Concreting – after completion of preparation, QC in-charge must verify, concreting with
approved grade and procedure, surface finish as rough, smooth.
6. Demoulding – elements to be demoulded after concrete attains required strength. Sides –
10 Mpa for RCC, 25 mpa Pre-stressed. For handling of element – 20 mpa for RCC, 30
Mpa for pre-stress. Any repair required like filling of minor honeycomb, grout leak

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 7. Curing and storage – Stored in yard until dispatch, the strength requirement is met before
dispatch, curing until strength achieved. Steam curing preferred (12 hr)
8. Delivery and installation

➢ Storage and transportation:

• Storage:
▪ All precast element should be stored job wise, product wise, type wise and
delivery schedule wise.
▪ Hollow core slabs, RC slabs/ Prestressed slabs - stacked one over the other, max
upto 2.5 m height. Wooden support between panels.
▪ Beams, columns, staircase, tee wall - stacked one over the other, max upto 2.5 m
height.
▪ Walls – any wall must be stored in vertical position. Wall rack usage is preferred.
Use of A Frame while storage and transportation.
• Transportation:
▪ Although a purpose-built trailer (specialised trailers) should be the first choice for
transport of precast concrete elements, but are not always transported on.
▪ Flat panels such as flooring, and stairs, are usually transported on a standard flat-
deck vehicle.
▪ Purpose-built trailers have a significantly lower centre of gravity as the precast
concrete panels sit in the centre of the trailer or on an outrigger on the side of the
trailer.
▪ This lowers the centre of gravity of the vehicle and the load. A lower overall
centre of gravity results in a more stable vehicle.
▪ Purpose-built trailers have a significantly lower centre of gravity as the precast
concrete panels sit in the centre of the trailer or on an outrigger on the side of the
trailer.
▪ This lowers the centre of gravity of the vehicle and the load. A lower overall
centre of gravity results in a more stable vehicle
▪ Purpose-built trailers have a significantly lower centre of gravity as the precast
concrete panels sit in the centre of the trailer or on an outrigger on the side of the
trailer.
▪ This lowers the centre of gravity of the vehicle and the load. A lower overall
centre of gravity results in a more stable vehicle.
▪ Loads must be well-restrained (chains, webbing straps) to prevent movement

➢ Handling and Erection –

Use of Cranes in Precast Industry

• Gantry Cranes- Capacity 5 – 500 T

• Gantry Cranes with cantilever- Capacity 3 – 20 T
• Gantry Cranes – Single Girder Overhead- Capacity 1 – 25 T
• Gantry Cranes – Double Girder Overhead- Capacity 5 – 450 T
• Gantry Cranes – Rubber Tyre Mounted- Capacity 5 – 450 T
• Tower Crane – Grounded
• Tower Crane – Mobile
• Hydraulic Mobile Crane – Pick and Carry

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