PRECAST DEVELOPMENT SO FAR IN INDIA

IMPLEMENTATION CHALLENGES
PLANNING FOR PRECAST
Awareness of precast
Future of precast
Development of Precast in India so far
• Number of precast manufacturing
units have been set up and are
being set up in India.
• The demand for precast systems is
rising day by day
• The developers and Govt.
Institutions have felt the necessity
of completion of projects faster and
thus pass on benefits to the
customers early as well as for
themselves
• Spirol from UK have set up a
facility in south India to supply the
steel plates required for beds duly
tying up with a local firm
• Bianchi from Italy have set up the
facility near to Mumbai and are
supplying the tilting moulds
required for making walls, as well
as for forms for columns, beams
and have already supplied to
number of precast manufacturers
in India.
S.N Client Equipment supplied from Unit
o

I Hyderabad
1 Janapriya Developers, Elematic, FINLAND Battery Mould
2 PRECA Prensoland, Spain
3 Skill promoter Nordimpianti, Italy
II COIMBATORE
TEEMAGE PRECAST ECHO, from 5 bed HCSplant
NETHERLANDS, & Battery Mould
WECKENMANN, Germany

III CALICUT Weckenmann, Germany Battery Mould

IV Chennai
VME PRECAST Elematic, Finland HCS & Tilting
Table wall unit
Precast construction is fast
catching up and is
establishing itself as the
construction technology for
the future
The different precast projects
so far came up in India and are
built by the different precast
companies are a testimony of
the same which are indicated
below:
Brigade Orchards
Brigade Orchards
Precast Multi-
Multi-Level Car Park, Terminal 1B, Domestic
Airport Mumbai
Multi-level Car Park (MLCP)
was a unique project that
has been successfully
completed by L&T despite
the challenges of being
situated at busy junction of
Domestic Airport and
Western Express highway
surrounded with many live
line underground services.
 Precast Multi-
Multi-Level Car Park, Terminal 1B,
Domestic Airport Mumbai
Built up area – 30,497sqm
8 Levels car parking
Comprising 2B + G+ 4
Bharat Forge Research and
Development Centre (BFRD)
Total Area: 1.1 lakh sq.ft
Total No. of Floors:
G+L1+L2+L3+Terrace
Delivered in 7.5 months
 Schmersal India
Built up area – 8880 sq m
 PRODUCTION FACILITY
FOR SCHMERSAL India Pvt. Ltd, PUNE
TRANSPORTATION OF COLUMNS
ERECTION OF COLUMNS
ERECTION OF COLUMNS
ERECTION OF COLUMNS
ERECTION OF COLUMNS
ERECTED COLUMN
ERECTION OF STAIRCASE
STAIR CASE
COLUMNS AND BEAMS
COLUMNS AND BEAMS
COLUMNS AND BEAMS
COLUMNS, BEAMS AND SLABS
DOUBLE T-SLAB
COLUMNS, BEAMS AND SLABS
ERECTION OF BOUNDARY WALL ELEMENTS
BOUNDARY WALLS
Infosys Multi Level
Car Parking

Total Area = 4.5 Lakh Sq.Ft

Total No of Floors
Basement+10 Floors
Infosys multi level car
park pune
FACADE

INFOSYS MLCP
INFOSYS MLCP
INFOSYS MLCP
INFOSYS MLCP
INFOSYS MLCP
INFOSYS MLCP
INFOSYS MLCP
INFOSYS MLCP
INFOSYS MLCP
INFOSYS MLCP
 WTC-
WTC-WORLD TRADE CENTRE, PUNE

Built up area :16.5 Lakh Sq.Ft

Total No of Floors:
Basement+Podium+10 Floor
BDA Project

Bangalore Development
Authority (BDA) B+S+18 floor
housing project
Doddabanahalli Bangalore
B+S+18 FLOOR HOUSING
PROJECT, DODDABANAHALLI,
BANGALORE
M/s. B.G.Shirke Construction
Technology Pvt Limited, Pune
built the structure using
Prefab technology
Office Building
in Hyderabad:
• Stilts- 2no’s + G +4 ; 1,65,000 sft
• Delivered in 4.5 months
 Hospital Building:
G+4 – 1,20,000 sft : Built in 4
months
Precast elements used are, viz.,
Precast Prestressed Hollow
core slabs,
Prestressed beams,
Precast Retaining walls, Precast
Stairs,
Precast Lift walls,
Precast Architectural elements,
Precast ducts
 Industrial Building in Hyderabad

• Cadbury’s project-
2,20,000 sft
• Composite
Construction:
Steel columns and
Beams + Precast
Hollow core slabs
• Delivered in 5
months
INTERNATIONAL SCHOOL BUILDING in Hyderabad
 IT SEZ Office Building in
Hyderabad
Stilt+ G+4 – 1,65,000 sft –
built in 4 months
Precast elements used are,
viz.,
Precast Prestressed Hollow
core slabs,
Prestressed beams,
Precast Retaining walls,
Precast Stairs,
Precast Lift walls
 Industrial
Buildings
Industrial Wagon
loading building in
Hyderabad
Delivered in 4 months
Few of the projects carried out by
VME Group, Chennai
D.R.D.O, CABS HANGER & OFFICES BUILDINGS,
BANGALORE.
NOVOTEL IBIS COMBO HOTEL, CHENNAI.
KHIVRAJ MOTORS – CAR SHOWROOM, CHENNAI
CHENNAI SILKS SHOWROOM, TIRUNELVELI
OFFICE BUILDING – GUINDY, CHENNAI
LAKESIDE, CHENNAI
Few of the projects carried out
by TEEMAGE, Coimbatore
 M s TSM Canteen Block
• Built-up Area : 13,500 Sq.Ft
• Scope : Beams, Columns,
Hollow core slabs, Wall
panels, Solid Slabs and
Staircase
• Time: 38 days
 M s. Rotary School,
School Tirupur, Tamilnadu
• Duration : 28 Days
• Built-up Area : 19,000 Sq.Ft
• Scope : Beams, Columns, Hollow
core slabs, Wall panels, Solid
Slabs and Staircase
 M s. SCM Silks (P) Ltd : Tirupur, Tamil Nadu
• Duration : 30 Days
• Built-up Area : 52,300 Sq.Ft
• Scope : Beams, columns, Hollow
core slabs, Wall panels and
staircase
 M s.Christian Medical
College
Vellore, Tamil Nadu
• Duration : 27 Days
• Built-up Area : 49,500 Sq.Ft
• Scope : Beams, Columns,
Hollow core slabs, Wall
panels and Staircase
• Supertech, from Noida,
Shobha Developers are
meeting their in House
requirements, while, KEF
Infra, and other companies
have also done different
structures across India.
 Planning for
Precast
• For any project, precast needs to be
planned right from the beginning of
involving all the consultants.
• Sound design and planning is a must
involving all the consultants, viz.,
Architects, Structural, and MEP.
• In precast, after the design is frozen,
elements will go for production.
Thereby, there is a distinct advantage
of design freezing point happens to
the builders and developers.
 Challenges in implementation
of Precast
The following are the challenges in
implementation of precast into
projects, viz.,
• Understanding of the Technology of
Precast
• Affordability of Precast
• Setting up cost of Precast units and
Payback period
• Viability of Precast Industry
• Entrepreneurs to set up
• Demand for Precast and Customers for
absorbing/using the Precast units
Challenges in implementation
of Precast
• Precast Awareness
amongst the builders and
Developers
• Resistance to change from
Conventional construction
• Taxes on precast elements
is also one of the main
retarding factors in precast
development, compared
with conventional
construction
 Challenges in implementation
of Precast
• By adopting for precast, Builders
and developers should consider
that the time for completion of
projects will be reduced by 40 to
50% .
• This will in turn reduce overheads
on men and machinery .
• The space could be leased out
early or occupied and revenue
accruals on early leasing will in fact
give lot of savings compared to
conventional construction
 PRECAST SET UP SCALE VS COST

Parameter Units Case-1 Case-2 Case-3

Scale Built up area required mn.sft 1 2 3
Precast plant Rs cr 13 17 22
Investment Additional site machinery Rs cr 3 4 4
Any other major capex required Rs cr 2 3 4
Total 18 24 30
Operating cost of plant Rs/sft
Material costs Rs/sft
Total cost of production Rs/sft
Operating costs in precast Transportation costs Rs/sft
Labour costs Rs/sft
Operating cost of onsite equipment Rs/sft
Total cost of construction Rs/sft 1000 950 900
Material costs Rs/sft
Operating machinery Rs/sft
Costs in conventional construction
Labour costs Rs/sft
Total cost of construction Rs/sft 1200 1200 1200
Skilled labour required no. 40 40 40
Labour
Unskilled labour required no. 20 20 20

Time of construction using precast days 12 to 15 months 15 to 18 months 20 to 24 months

Time
Time of construction using conventional days 36 months 48 months 60 months

Assumptions:
Unit size 500 sft
Design Simple
Configuration G+4

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 Awareness of Precast in
Design community in India
• There is a big need for making aware
of precast technology and its modular
construction to the people involved in
construction sector
• Architects and Structural Engineers in
India, also need to imbibe these
technology issues, and start
implementing them into their projects
and help the clients reap the benefits
of using them
 Awareness of Precast in
Design community in India

• This time, PEPSCON 2017 is being

held in New Delhi with the main
theme of Housing for all (HFA) by
2022, and precast requirement for
HFA, besides dealing about other
technologies suitable for
construction
• The details of projects constructed
so far using precast, composite
construction and other
technologies will be presented in
the conference duly giving
information related to Design
aspects, execution and costing, etc.,
• PSI (Pre Engineered structures society
of India, www.pessi.in) is making
efforts by conducting workshops in
the name of PEPSCON every year in
Hyderabad and other cities and
thereby creating awareness of precast
buildings and dissemination of
knowledge amongst Design
Engineers, Entrepreneurs and
Developers.
• Engineering associations like ACCE(I) ,
ICI, and other agencies at Mumbai
and Delhi are also conducting the
workshops on precast
 Future of Precast
• From the conventional
construction of framed structure
type, the Industry have moved
forward for monolithic
construction using Aluminum
formwork.
• Now, precast is fast catching up,
and more and more developers
are looking for precast as a way
forward, to construct the projects
faster and precast have
established itself as a strong
technology for quicker
deliverables along with high
quality and strength
 Future of precast
• DDA, Bangalore development
authority, Bhubaneshwar
Developemnt authority, Chattisgarh
state Govt., and various other state
govt organisations have been calling
the tenders for construction of houses
based on precast type of construction
to construct the projects faster.
• Brigade, Shobha and Supertech have
already constructed Multi story
residential towers in Bangalore and
Noida. Shapoorji Pollongy &
Contracting are building multi story
residential towers for Peenya project
to Tata housing which is totally precast
 Future of Precast
• Even the MES / Defence establishment
have opted for construction of precast
to realise Quality and faster
construction.
• VME have recently delivered a
structure for DRDO at Bangalore
covering an area of 1,20, 000 sft in a
very short time
• Developers in Mumbai are looking
forward for the precast companies to
come forward and construct buildings
for them, and there is a need for
number of precast companies to be set
up in Mumbai and Delhi to meet the
present demands, and in other cities to
meet the demand for construction
 Requirements
• Number of Entrepreneurs are also
required to set up the precast companies
across the country
• Banks will be required to lend the loans
required for setting up of the precast
industries
• Precast is the solution to meet the
demands of HFA mission too
• Government should promote the precast
industry in a big way to achieve the HFA
mission and remove the excise duty on
precast products for construction of
houses for ESW and LIG, such that the
cost of unit comes down and will be
affordable to the beneficiaries and the
mission of HFA will be achievable
 KETHANAKONDA

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