Precast buildings in India

by Sthaladipti Saha Chief Engineering Manager Larsen & Toubro

Larsen & Toubro Limited, ECC Division, Chennai, India

Introduction

Precast concrete construction in India

With the advent of precast concrete construction in India post independence, L&T has used this method of construction to gain a stronghold in the construction sector. The methodology followed was the setting up of a site prefabrication yard close to the project site for ease of transportation and use.

Gantry

Casting yard

Introduction

L&Ts foray into precast construction . . .

Roof elements Folded plate Truss Shell Silo Waffle slab Pipe rack Special structures Wall panels

Miscellaneous

Folded plate

Roof elements

Mould

Tilting mould

Structural steel arrangement

Curing

Side shutter reinforcement

Roof elements

Folded plate

Demoulding

Temporary ties

Folded plates stacked in yard

Loaded on trailer

Roof elements

Folded plate
Techno-economic indices Erected using cranes Sl.N o 1 2 3 Description Concrete M40 Unit Cum Qty 6.20 130 1300 Qty / Sq.m # 0.103 2.17 21.7

Mould assembly Sq.m & demould Reinforcement Kg

# Quantity per Sqm of Roof (plan) area

Roof elements . . .

Folded plate
Used as large span roofing elements Efficient from viewpoint of material consumption

24m span precast concrete folded plate at Pearl distilleries, Ongole

24m span precast concrete folded plate with north light glazing on one side for MICO , Bengaluru

V shaped folded plate - 36m long, 6.5m wide & 2.35m height at Ocean Engineering Centre IIT Chennai

Roof elements . . .

Folded plate

Gabriel India Limited at Pune

Perfect Circle Victor at Pune

Roof elements . . .

Truss

40m span precast concrete A-frame supporting trussed purlins Silo for SPIC at Tuticorin 38m span precast trough slab Aframe silo State fertiliser manufacturing Corporation, Colombo

Truss

Roof elements . . .

30m span precast concrete roof truss in single piece as roof element for Food grain godown at Madras port trust 20m span precast concrete arch shaped truss and slabs as roofing system for Tamilnadu minerals at Chennai

Truss

Roof elements . . .

48m span precast concrete truss L&T cements, Awarpur

Truss

Roof elements . . .

27.7m precast concrete roof truss Foundry for Grindwell Norton at Renigunta

Roof elements . . .

Truss

18m span diamond shaped precast concrete truss with rafters and purlins as north light roof system at EWL, Chennai 16m span precast concrete truss supporting 13m span precast prestressed concrete slabs as roofing systems for indoor switchyard at Tuticorin

Roof elements . . .

Truss

13.5m span north light precast concrete portal during erection L&T McNeil at Chennai 22m precast concrete portals with 8m span precast purlin Heavy Engineering Workshop at L&T Hazira

Shell

Roof elements . . .

Erection of HP shell Finishing shop at L&T Bengaluru works

HP shell roof L&T Bengaluru works

Roof elements . . .

Silo

43.5m precast prestressed concrete truss (in 3 pieces) and slabs as roof for silo at Kakinada

Roof elements . . .

Silo

55m span urea silo at IGFL Jagdishpur

Waffle slab
Cyber park, Hyderabad

Roof elements . . .

Convention center, ECC HQ campus

Columns & Beams. . .

ITC Badrachalam 15m precast columns Weight of column 25MT Precast beams at gable end

Pipe rack. . .

Erection sequence

Pipe rack. . .

Erection sequence

Pipe rack. . .

Erection sequence

Pipe rack. . .

Erection sequence

Pipe rack. . .

Pipe rack. . .

Casting

Curing

Pipe rack. . .

Erection

Pipe rack. . .

Precast concrete trestles used for pipe rack structure at Kothari caustic soda project at Manali

Panipat Naphtha cracker project

Special structures . . .

Bengaluru International Airport Size 24 x 6 x 3m 160mm to 250mm c/s Weight 120MT No. of elements - 234

Wall panels. . .

Bengaluru International Airport

Wall panels. . .

Mumbai International Airport

Wall panels. . .

Cognizant at MEPZ, Chennai

Wall panels. . .

Beer bottle finish on the outside surface of precast wall panel at L&T Bengaluru works

14m high 2.5m wide precast concrete grooved wall panel with precast concrete gutter for the assembly shop of L&T Poclain Bengaluru

School rooms at Gujarat

6000 school rooms Each of 54 sq.m. BUA

Wall panels. . .

In stacking yard

Curing tank

In transit

Assembled school room

Compound wall. . .

Bengaluru International Airport

Delhi International Airport

Miscellaneous. . .

Precast concrete water tower with beer bottle finish on the outside surface at L&T Bengaluru works

15m span conveyor galleries in precast concrete at Awarpur cement works

TISCO housing, Jamshedpur

South city, Bengaluru

Stadiums

Miscellaneous. . .
Elliptical roof made of 120 V-type folded plates of 40m span Kanteerava indoor stadium in Bengaluru

Precast roof element and gallery units in Jawaharlal Nehru Stadium at Chennai built in 260 days

Precast bleachers and raker beams in Qatar football stadiums

Miscellaneous. . .

Precast L shaped duct units in staking yard

EDRC building, ECC HQ campus

Miscellaneous. . .

Box culvert under pavements

Delhi International Airport Precast element size 2.0m X 1.5m No of Pieces 1200 Pieces of 1.2m length 2.4 Kms completed in 4 months

Delhi International Airport Precast pipes

Miscellaneous. . .

Delhi International Airport Precast drains

Miscellaneous. . .

Delhi International Airport Precast baggage handling tunnel Precast Tunnel Element size 4.43m X 2.8m of 1.2m length Precast tunnel length 700m

Conclusion

Precast concrete construction in India the future . . .

Increase in urbanization and consequent shortage of skilled labor and better infrastructure will require construction to focus more on industrialized methods of construction like prefabrication. Move from site Prefabrication to Plant prefabrication . This will lead to speed, economy and reduce the need for skilled manpower. L&T is setting up a Hollow core factory inline with the changing scenario.

Thank you