Emerging Construction

Systems for Mass

Housing

by

Dr. Shailesh Kr. Agrawal

Executive Director

Building Materials & Technology Promotion Council

Ministry of Housing & Urban Affairs
Government of India
 Growing Opportunities with Rapid Urbanization
• With US $3.7 trillion GDP, India is one of the
largest (fifth) and fastest growing economies in
the world. It is witnessing massive public
investment, robust private consumption, and
structural reforms leading to rapid growth (>
7%).
• India is poised to become $7.3 trillion economy
by 2030 & aspiring to become a $30 trillion
economy by 2047.
• Construction in India is emerging as the third
largest sector globally; it may reach US $750
billion in value by 2022.
• Cities, which will contribute over 80% to GDP by
Source: UN report on World Urbanisation Prospects (2014 revision) 2050, need to be Receptive, Innovative and
Productive to foster sustainable growth and
To cater to this growing population, India has to ensure better quality of living.
build 600-800 million m2 urban space every year till
2030 i.e. a new Chicago every year. • Hence, a comprehensive strategy of 3-S
Mantra has been adopted: Skill, Scale and
Speed.
 Conventional Construction Systems
business as usual approach
The prevalent construction systems in India are:
Load bearing Structure
In this system, walls are constructed using
bricks/stone/block masonry and floor/roof slabs
are of RCC/stone/composite or truss. It is cast in-
situ system and called load bearing system as
load of structure is transferred to foundation and
then to ground through walls.
RCC Framed Structure
In this cast in-situ system, the skeleton of a
structure is of RCC column and beam with RCC
slab. The infill walls can be of bricks/blocks/stone
/panels. The load of the structure is transferred
through beam and column to the foundation.
Steel framed Structure
Here RCC beam and columns are replaced by
hot rolled steel sections.
CONVENTIONAL CONSTRCTION SYSTEMS
business as usual approach

• There is too much of dependency on cement,

aggregates and water in these traditional
constructions. In particular, the fine aggregate
(sand) and water to-day are quite scarce.
• It is also seen that, on account of shortage of skilled
labour, these constructions today, in general, are not
upto the mark in terms of quality.
• In addition, traditional construction cannot be green
buildings normally. But green buildings are the order
of the day, in view of energy scarcity and, fast
depletion of precious natural materials.
 Green Aspects Ignored?
• Resource
Efficiency
• Energy Efficiency

SOURCE : INTERNET

• Eco-friendliness
• Health
SOURCE : INTERNET
 business as usual approach

❖ Buildings consume
– 40% of energy
– 25% of water
– 40% of resource

❖ Buildings activities contribute

– 50% of air pollution
– 42% of GHG emission
– 50% of water pollution
– 48% of solid wastes
SOURCE : TERI-GRIHA
Why New Technologies for Mass Housing?

Sustainable Buildings
❖ 30%-50% reduction in energy use
❖ 40% reduction in water use
❖ 35% reduction in GHG emission
❖ 75% reduction in waste
Courtesy :
D f MA
Design for Manufacture & Assembly

Design for Manufacture

Design for Assembly

Manufacturing of Buildings

Prefabricated Prefinished Volumetric Construction

3D Printed
House at
Kanchipurum
by L & T
3D Printing
3D Printing - Chandigarh
CIDCO L&T Mission 96
DRDO - Flight Control System Complex in 45 days
Teemage - Largest Hospital Constructed by Precast Concrete Technology in 45 days
Emerging Trends in Housing construction
1. Engineered Formwork Systems

2. Stay-in-Place Formwork Systems

✓ Insulating Concrete Formwork Systems
✓ Structural stay-in-place Formwork Systems

3. Precast Sandwich Panel Systems

✓ EPS Panel Systems
✓ GFRG panel Systems, Cement Panel Systems

4. Light Gauge Steel Structural Systems

5. Steel Structural Systems

6. Precast Concrete Construction Systems

✓ 3D volumetric construction
✓ 2D large panel systems
✓ Beam, column, components based systems
Requirements for mass housing

•Quality of construction
(Safety, Performance, Durability)

•Time required for construction,

(Fast Track Construction)

•Cost of construction
(Economy of Scale)
Quality in any construction
•Safety of the structure
– against anticipated live loads.
– safety and stability with respect to the prevailing wind loads and with respect to the possible
earthquake loads and other loads such as snow, cyclone etc.

•Performance of the structure during its life span

– Thermal efficiency of the construction during summer and winter
– Acoustics efficiency, Damp proof-ness/water tightness of the construction during rains
– Efficiency of the joinery systems, Fire resistance characteristics of the structure

•Durability of the structure

– Deterioration of components with age
– Deterioration of components due to atmospheric pollutions
– Deterioration of foundation system due to polluted/chemically adverse soil media
– Life expectancy (Our normal housing constructions are designed for a life of 60 years and
above)
Speed of Construction

• In the present day context, it has become essential to go in

for faster constructions in order to meet the heavy demand
and in order to cut down wastage and overhead charges.

• The traditional constructions being adopted around us is

basically ‘slow track construction’ and not amenable for
mass housing projects.
• On account of the undue time taken, the overheads and
wastages are quite high leading to time & cost overruns.
Cost of Construction

Economies of scale also plays an important role while deciding the cost/m2
End User Benefits through Technology Intervention
• Safer and disaster resilient house

• Better quality of construction

• Low maintenance

• Speedy construction resulting in early occupancy

• Cost effective and environment friendly

• Better fire resistance & thermal efficiency

ENGINEERED FORMWORK
SYSTEM
 Formwork Systems
Formwork is temporary or permanent moulds into which concrete is poured.

✓ Traditional timber Formwork

✓ Steel Formwork
✓ Engineered formwork systems
✓ Insulated formwork systems
✓ Stay-in-place structural formwork systems
• Replacing cast-in-situ
Formwork with factory
made customized
formwork systems
• Formwork material is
Aluminium / composites
/ steel having 100 to 500
repetitions
• Assembly line
construction i.e. placing
the formwork, pouring
the concrete, moving
the formwork to upper
level
Monolithic Concrete Construction Technology

• The conventional mode of construction is

RCC framed structure with infill masonry
walls whereas in this system, all walls,
floors/slabs, stairs together with door &
window openings are cast in-situ
monolithically using specifically custom
designed modular formwork made up of
aluminium/plastics/steel/ composite.
• The appropriate grade of concrete and
reinforcement is used as per design and
the entire casting of a modular unit is
done in a single pour.
• Being modular predesigned formwork
system, it acts as a assembly line
production and enables rapid construction
of multiple/mass scale of units of
repetitive type.
Monolithic Concrete Construction
Modular Tunnel form
➢ Tunnel formwork is a mechanized
system for cellular structures. It is based
on two half shells which are placed
together to form a room or cell. Several
cells make an apartment. With tunnel
forms, walls and slab are cast in a
single day.
➢ The formwork is set up for the day’s
pour in the morning. The reinforcement
and services are positioned and
concrete is poured in the afternoon.
Once reinforcement is placed, concrete
for walls and Slabs shall be poured in
one single operation. The formwork is
stripped the early morning and
positioned for the subsequent phase.
➢ Here the walls and slabs are cast in a
form of a tunnel leaving two sides open
whereas in monolithic concrete
construction the entire room is cast in a
single pour..
 STAY-IN-PLACE
FORMWORK SYSTEM

Insulated Concrete Structural Stay-in-

Formwork System Place Formwork
System
• Replacing cast-in-
situ Formwork with
factory made
formwork systems
• It is sacrificial
formwork or lost
formwork means
formwork is left in
the structural system
to later act as
insulation layer
Insulating Concrete Forms (ICF)

➢ These are formwork systems

which are left in the structure
after concreting and act as
insulation.
➢ Insulating concrete Forms (ICF)
System is a patented system of
M/S Reliable Insupacks (P) Ltd
and comprises of a panel of two
walls of Expandable Polystyrene
(EPS) separated by a nominal
distance of 150mm by hard
plastic ties. These are assembled
on site to hold reinforced
concrete.
Monolithic Insulated Concrete System (MICS)
➢ Monolithic Insulated Concrete System
(MICS) is a patented system of M/s Maiwir
Ecotech Pvt. Ltd.. It is a formwork system
for reinforced concrete made with a rigid
thermal insulation that stays in place as a
permanent interior and exterior substrate
for walls, floors and roofs.

➢ This system consists of two layers of

modules i.e. Expandable Polystyrene
(EPS) separated by hard plastic ties. The
modules are interlocking modular units that
are dry stacked (without mortar) and filled
with cast-in-place concrete. The units lock
together and create a form for the
structural walls or floors of a building.
When cured, the wall supports the
structural loads from floors and roofs, and
the shuttering provides thermal insulation.
Reinforcing steel shall be as required from
design.
Structural Stay-in-Place
Formwork System (Coffor)

• Replacing cast-in-situ
Formwork with factory
made formwork systems
• It is sacrificial formwork or
lost formwork means
formwork is left in the
structural system to later
act as reinforcement
(shear/flexure)
Structural Stay-in-Place Formwork System (Coffor)
• It is a patented structural stay in place
formwork system to build load bearing
monolithic concrete wall structures based on
shear wall concept.
• The formwork is composed of two filtering grids
comprising of rib meshes which are made up
of galvanized plain steel (GP) sheets with a
herringbone mesh pattern (rib lath) reinforced
by C profile GP sheet vertical stiffeners. These
grids are further connected by articulated
horizontal MS rebar loops in one direction and
Cold Rolled Close Annealed (CRCA) plate/GP
horizontal connectors in other direction.
• After the erection of formwork panels in
alignment, corners, edges of door and window
frames are closed with rebar positioning &
concrete of required Grade is poured in the
panels. The concreting may be done with a
pump, bucket or with a shovel loader. The
inside and outside walls are finished with
cement plaster of suitable grade.
Stay-In-Place PVC Wall Forms
• This is a prefinished wall formwork from
M/s Novel Assembler Pvt. Ltd. comprising
of rigid Poly-Vinyl Chloride (PVC) based
polymer components that serve as a
permanent stay-in-place durable finished
form-work for concrete walls.
• The extruded components slide and
interlock together to create continuous
formwork with the two faces of the wall
connected together by continuous web
members forming hollow rectangular
components. The web members are
punched with oval-shaped cores to allow
easy flow of the poured concrete between
the components.
• The hollow Novel Wall components are
erected and filled with concrete, in situ, to
provide a monolithic concrete wall.
Permanent Wall Form (PVC)
• “Permanent Wall form” of M/s Kalzen
Realty Pvt. Ltd. is an innovative
permanent structural walling system
consisting of rigid Poly-Vinyl Chloride
(PVC) formwork that serve as a stay in
place finished form-work for concrete
walls.
• The extruded components slide and
interlock together to create continuous
formwork with the two faces of the wall
connected together by continuous web
members forming hollow rectangular
components. The web members are
punched with holes to allow easy flow of
the poured concrete between the
components.
• Wall components are erected and filled
with concrete, in situ, to provide a
monolithic concrete wall with enhanced
curing capacity due to water entrapment.
Glass Fibre Reinforced Gypsum (GFRG)/ Rapidwall
Building System Technology (evaluated through PACS)
➢ Glass Fibre Reinforced Gypsum
(GFRG)/ Rapidwall is a building panel
product, made essentially of gypsum
plaster, reinforced with glass fibres.
➢ Used since 1990 in Australia. Although
Australia
its main application is in the
construction of walls, it can also be
used in floor and roof slabs in
combination with reinforced concrete.
➢ The panels may be unfilled, partially
filled or fully filled with reinforced
concrete as per the structural
requirement.
Glass Fibre Reinforced Gypsum (GFRG)/ Rapidwall
Building System Technology (evaluated through PACS)..contd.
PREFABRICATED SANDWICH
PANEL SYSTEMS
• EPS Core Panel Systems

• Other Sandwich Panel Systems

– Fibre cement board
– MgO Board
– AAC panels
• Replacing brick
and mortar walls
with dry
customized walls
made in factory
Advanced Building System – Emmedue
• This system is based on factory made panels
consisting of self-extinguishing expanded
polystyrene core (generally corrugated)
sandwiched between two welded wire
fabric mesh made of high strength
galvanized wire. A galvanized steel truss wire
is pierced completely through the core at an
offset angle for superior strength and
welded to each of outer layer welded wire
fabric mesh.
• The panels are finished at site using
shotcrete of mix of cement and coarse
aggregate of required thickness on both
sides.
• The panels are used for load bearing walls
and floors and suitable upto 3 to 4 storey
buildings.
Rapid Panels

• Rapid Panel is Worldhaus Construction Pvt.

Ltd. patented EPS Core Panel System.
• It is a prefabricated assembly of high-Strength
steel wire forming a panel with core of
expanded polystyrene (EPS).
• The basic unit of the Rapid Panel is the zig-zag
truss. Steel wire is bent into a zigzag shape to
form a continuous chain of web members. This
bent wire is then welded to continuous chord
wires at every node to form the complete
truss.
• During construction, Rapid Panels are installed
as walls and/or slabs. Specified mixtures of
mortar or concrete are applied to the surfaces
of the panels to complete the structure.
Reinforced EPS Core Panel System
• Reinforced Expanded Polystyrene Core Panel
System is a factory produced sandwich panel
system for the construction of low rise
buildings up to G+3 and as filler walls in high
rise RCC and steel frame buildings. These
panels are being produced by Jindal Steel &
Power Ltd., India.
• A core of undulated polystyrene is covered
with interconnected zinc coated welded wire
mesh on both sided reinforcement and
shotcrete.
• The panels are finished on site by spraying
concrete to realise the different structural
elements i.e. Vertical Structural Walls,
Horizontal Structural elements (slabs, floors)
and non structural cladding elements.
QuickBuild 3D Panels

• QuikBuild panel system (Patented) of

Beardsell Ltd. consists of a welded wire
space frame integrated with expanded
polystyrene insulation core.
• The wall panel is placed in position and a
wythe of concrete of required thickness is
applied to both sides. The wall panel
receives its strength and rigidity from the
diagonal cross wires welded to the welded-
wire fabric on each side.
• The shell of the structure is built manually by
erecting the panels directly onto the slab
with protruding reinforcement rods and then
finished by plastering with cement using the
traditional method or by shotcreting to
create a monolithic structure.
Concrewall Panel System
• The Concrewall is patented system of Schnell
Wire System. It comprises of panels of
expanded polystyrene (EPS) insulation and
steel reinforcement which are applied with
concrete, onsite.
• The Concrewall panel comprises of a layer of
welded wire mesh on either side of EPS core
welded together by steel orthogonal trusses
which penetrates through EPS core. The panels
are joined together in a desired configuration
on site and sprayed on both sides with
shotcrete to form a sandwich type
construction.
• The exterior of the panels may be finished with
weather proof coating such as plaster while
interior surfaces (walls) and ceilings can either
be plastered or lined with conventional lining
material.
BauPanel System
• BauPanel System consists of panels of
expanded polystyrene (EPS) and steel wire
mesh which are applied with concrete at site.
The system comprises of a layer of steel
mesh on either side of EPS core welded
together by steel trusses (orthogonal) which
penetrate through EPS core.
• The panels are joined together in a
configuration on site and sprayed on both
sides with shotcrete to form a sandwich
panel type construction for walling/roofing.
• The exterior of the panels are finished with
weather proof coating or lined with
conventional lining material while interior
surfaces (walls) and ceilings shall be finished
with water/ solvent based coating or lined
with conventional lining material.
Sismo Building Technology
• Sismo (patented) Building Technology is
an insulating shuttering kit for whole
building unit based on a three-
dimensional lattice made of galvanized
steel wire and EPS panels. The lattice is
filled with materials of different nature to
serve as formwork.
• The basic structure of the Sismo building
module is steel wire lattice. At the exterior
sides of the lattice, infill panels (EPS) are
inserted, which transform the lattice into a
closed structure that can be filled with
concrete.
• The steel wire also acts as armature and
anchoring for the finished material and it
holds reinforcement bars in place during
concrete filling.
• The various components of the system
are 3D lattice, infill panels, structural filler
and finishing.
Prefabricated Fibre Reinforced Sandwich Panels
• The Prefabricated Fibre Reinforced
Sandwich Panels known as Aerocon
Panels are patented panels of M/s HIL
Ltd. These are sandwich panels, made of
two fibre reinforced cement facing
sheets, on either sides of a lightweight
concrete core.
• These panels have a unique tongue and
groove jointing system that facilitates
rapid construction and are fully cured at
the factory itself. These panels are
manufactured by using Flexo Board
(FOB)/ Fibre Cement Board (NT).
• These panels can be used for variety of
applications such as for partitions,
cladding, mezzanine floors, boundary
walls, etc.
Rising EPS (Beads) Cement Panels
• Rising EPS (Beads) Cement Panels are
patented panels from M/s Rising Japan
Infra Pvt. Ltd. These are lightweight
composite wall, floor and roof sandwich
panels made of thin fiber cement/calcium
silicate board as outer and inner faces with
a core of EPS granule balls, adhesive,
cement, sand, fly ash and other bonding
materials in mortar form.
• The core material in slurry state is pushed
under pressure into preset molds. Once
set, it shall be moved for curing and ready
for use with RCC or steel framed
structure.
• These panels are presently manufactured
by the firm in China and shortly a plant will
be installed in India.
Flyash EPS (Beads) Cement Sandwich Panels
• EPS Cement Sandwich Panels by M/s
Bhargav Infrastructure Pvt. Ltd. are
lightweight solid core sandwich panels
made of 5mm non-asbestos fiber cement
boards on both sides of panels as facing
sheet and the core material of expanded
polystyrene beads, admixture, cement,
sand, fly ash and other bonding materials
in mortar form.
• The core material in slurry state is pushed
under pressure into preset moulds. Once
set, it is moved for curing and ready for
use with RCC or steel framed structure.
These panels are installed without any
structural support up to 5m. The
prefinished panels do not require
plastering and water curing and are
joined with tongue & groove jointing
system.
V-Infill Wall (Light Weight EPS Wall)
• V-Infill Wall is factory made 8/10mm fibre
cement boards (V-board) on either side of GI
studs and erected to produce straight to finish
walls which are filled with light weight
concrete made of EPS, cement, sand and
additive.
• The system is integrated with conventional
column and beam for pre-engineered
buildings. The walls are used as partition walls
for external and internal applications.
• The GI studs are “C” cross-section with built
in notch, slots, service holes etc. fixed with
floor and ceiling channels using anchor
fasteners at spacing of 300mm c/c. Provisions
for doors, windows, ventilators and other
cutouts and electrical and plumbing
pipes/conduits are provided in the service
holes of studs before concreting is done.
PIR Dry Wall Pre-Fab Panel System
• PIR Dry Wall Pre-Fab Panel by M/s Covestro
(India) Pvt. Ltd is a walling system where
two fibre cement boards (FCB) of 10 mm
thickness are filled with insulation material
namely Poly Isocyanurate (PIR) and erected
to produce straight to finish walls.
• These non-load bearing walls are integrated
with conventional framed construction of
column and beams for pre-engineered
buildings.
• Insulation core provides effective insulation
and strong bonding for better structural
stability to facilitate higher loading and
wider spans.
Lost-in-Place Formwork System
– Plaswall Panel System
• Plaswall Panel System is a lost in place
formwork (patented system of M/s FTS
Buildtech Pvt. Ltd), where two fibre
cement boards (FCB) of 6mm
thickness each are bonded through
HIMI (High Impact Molded Inserts)
spacers.
• These panels are erected in situ to
produce straight-to-finish panels. A
monolithic structure is then created by
filling the entire structure with suitable
grade of concrete to produce panels for
structural applications.
• Reinforcing steel shall be as required
from design. Presently, the fibre
cement board (FCB) are imported from
Malaysia for use in the construction of
structures.
Lost-in-Place Formwork system
– Plasmolite Wall Panels
• Plasmolite Panels are lost in place
formwork system (patented system of M/s
FTS Buildtech Pvt. Ltd), where two fibre
cement boards (FCB) of 6 mm thickness
are bonded together through High Impact
Molded Inserts (HIMI) spacers. These
panels are erected in situ to produce
straight to finish panels which are filled
with light weight foam concrete.
• The thus finished walls may be used as
partition walls for external and internal
applications and can be integrated with
conventional RCC/Steel framed structure.
• Reinforcing steel shall be as required
from design. Presently, the fibre cement
board (FCB) are imported from Malaysia
for use in the construction of structures.
Nano Living System Technology
• Nano Living System Technology comprises of
an inner and outer skin of magnesium oxide
(MgO) board, with an injected core of closed
cell, polyurethane foam, free of
Chlorofluorocarbon (CFC) blowing agent. Cold
formed metal studs are incorporated within
the foam and between the magnesium oxide
board skins at nominal 600mm centres.
• The panels are manufactured in 150mm
thickness having 80 mm cold formed steel
studs, 10mm magnesium oxide board on each
side and 50mm thermal packer between the
internal stud and exterior magnesium oxide
board with core insulation of 130mm closed
cell and polyurethane foam.
• The Nano Living System Technology is suitable
for use as load bearing walls in residential
buildings up to G+3 storey.
 STEEL STRUCTURAL SYSTEMS

Light Gauge Steel Hot Rolled Steel

Structural Structural
Systems Systems
PREFABRICATED STEEL
STRUCTURAL SYSTEM
• Replacing cast
in situ RCC
structural
frame with
factory made
steel (hot
rolled)
structural
system
Concept
Factory Made Fast Track Building System
• Factory Made Fast Track Modular Building
construction system (Patented) is hot
rolled steel frame structure with different
walling components, manufactured and
fabricated in a controlled factory
environment.
• The steel-modules pre-fitted with flooring,
ceiling tiles, electrical and plumbing
fittings are transported to the site for
installation.
• Once all the components are assembled
and erected at site, shortcreting is done
on the factory made 3-D Expanded
Polystyrene (EPS) panel walls making it a
monolithic structure.
• The floor is composite steel floor deck
slab.
Continuous Sandwich (PUF) Panels
with Steel Structure
• Continuous sandwich panels are single piece,
prefabricated, modular, factory made units
which consist of an insulating layer of rigid
polyurethane foam between two layers of
metal sheets.
• The panels comprise of PUF bonded between
two sheets of Pre-coated GI sheets of 0.5 mm
thick to produce straight-to-finish panels.
Insulation core provides effective insulation
and strong bonding for better structural
stability to facilitate higher loading and wider
spans. These panels are available for both wall
and roof.
• The system can incorporate all types of
architectural features like coving, boxes,
cantilevers, projections, infill walls, mezzanine
floors etc. This system can also incorporate all
types of services viz. electrical, gas and
plumbing etc.
Factory Assembled Insulated Sandwich
Panels using Mineral Wool
• The panels are factory assembled
insulated sandwich panels consisting of
an insulating layer ‘sandwiched’ between
two layers of metal sheets.
• The panels are manufactured using
mineral wool bonded between pre-
coated steel sheets to produce profiled
finish panels.
• The steel sheets can either be PPGI or
PPGL, and, with a maximum thickness of
0.8 mm.
• An insulation core provides insulation and
sturdy bonding for better structural
stability and facilitates better load
bearing capacity and wider spans for
panels.
Factory Assembled Insulated Sandwich
Panels using PUF
• The panels are factory assembled
insulated sandwich panels consisting of
an insulating layer ‘sandwiched’ between
two layers of metal sheets.
• The panels are manufactured using rigid
Polyurethane Foam (PUF) bonded
between pre-coated steel sheets to
produce profiled finish panels.
• The steel sheets can either be PPGI or
PPGL, and, with a maximum thickness of
0.8 mm. An insulation core provides
insulation and sturdy bonding for better
structural stability and facilitates better
load bearing capacity and wider spans for
panels.
 LIGHT GAUGE STEEL
STRUCTURAL SYSTEMS
• Replacing cast
in situ RCC
structural frame
with factory
made light
gauge steel
(cold rolled)
structural
system
Light Gauge Structure System
➢ Frame is made of cold rolled high strength
steel sections and EPS panels for walling.
➢ Internal walls covered with gypsum and
cementitious board. Exterior wall Sprayed with India
cementitious material directly onto the studs.
➢ Faster construction by prefabricated panels.
All structural components are precisely pre-
manufactured and simply assembled on site.
➢ Enhanced Thermal & Acoustic insulation with
Boarding/Expanded Polystyrene (EPS)
/Rockwool/Vapour Barrier.
➢ Eco friendly structure. Superior and
sustainable performance. Minimum Impact on
natural resources.
 G+3 – Residential Building

Perspective View Framing View of the model

ERECTION –DIFFERENT STAGES
Light Gauge Steel Framed Structure with
Infill Concrete Panels (LGSFS-ICP)
• LGSFS-ICP Technology is a patented
technology using factory made Light
Gauge Steel Framed Structure (LGSFS).
The infill wall comprises of factory made
precast panels filled with light weight
concrete at site.
• The LGS frame is a “C” cross-section with
built in notch, dimpling, slots, service
holes etc. produced by computerized roll
forming machine.
• The frames are assembled using metal
screws at site to form wall on a prebuilt
concrete floor. The provisions for doors,
windows, ventilators and other cutouts as
required are incorporated in the frame.
The roof structure is conventional RCC
slab.
 PRECAST CONCRETE
CONSTRUCTION SYSTEMS

2D Precast 3D Precast
Concrete Volumetric
Construction Construction
 2D Precast Concrete Construction
• Replacing cast in situ
RCC structural frame with
factory made structural
components – 2D planar
elements
• Customized Factory made
beams, columns, wall
panels, slab/floors,
staircases etc.
Precast Large Concrete Panel System
• Precast Large Construction Panel (PLCP)
system is a structural system comprising of
various precast elements such as walls,
beams, slabs, columns, staircase, landing
and customized elements.
• There are two types of precast concrete
elements, namely precast reinforced
concrete elements and precast pre-
stressed concrete elements, prefabricated
in a precast yard or site.
• The precast elements are installed on site
and supported by temporary jacks. Shims
are used to carefully align the elements
and grouted after the final adjustments.
• A typical construction involves design,
strategic yard planning, lifting, handling,
transportation and assembly of precast
elements.
Concrete components prefabricated in precast yard or
site and installed in the building during construction

Wall Panels Parapet Beams Spandrel

Solid Slab Panels Staircase

Pod Elements
Industrialized 3-S system using RCC precast columns, beams &
slabs with/without precast RCC shear walls
• The industrialized total open prefab
construction technology is based on factory
mass manufactured structural prefab
components conforming to norms of IS
standards and BIS Certification mark.
• In this Patented system, precast dense
concrete hollow column shell of
appropriate size are used in combination
with precast dense concrete rectangular T
Shape/L shape beams and lightweight
reinforced autoclaved cellular concrete
slabs for floors and roofs. The hollow
columns are grouted with appropriate
grade of in–situ concrete.
• All the connections and jointing of various
structures are accomplished through in situ
concreting along with secured embedded
reinforcement of appropriate size, length
and configuration to ensure monolithic
continuous resilient ductile behavior.
Factory set-up at Delhi
Precast yard and factory
set-up at Delhi
Urbanaac Precast Construction Technology
• Precast construction Technology from M/s
Urbanaac Infrastructures Pvt. Ltd. is
essentially a offsite precast concrete
construction system under controlled
environment using a reusable mould or
“form”. The components produced are then
transported to the construction site and later
lifted & assembled to produce structure.
• Precast Construction Technology consists of
various precast elements such as walls,
beams, slabs, columns, staircase, landing and
some customized elements that are
standardized and designed for stability,
durability and structural integrity of the
building.
• This technology is suitable for construction of
high rise buildings resisting seismic and wind
induced lateral loads along with gravity loads.
The building framing is planned in such a way
that maximum number of repetitions of
moulds is obtained.
Pre-stressed Precast Prefab Technology Using Hollow
Core Slab, Beams, Columns, Solid Walls, Stairs, etc.
➢ Pre-stressed precast RCC technology using hollow
core slabs, beams, columns, solid walls, stairs etc.
are designed and manufactured in factory, shipped
and erected at site.
➢ Multi-storey precast concrete frames are
constructed with columns and beams of different
shapes and sizes, stair and elevator shafts and floor
Finland
slabs.
➢ The joints between the floors elements are executed
in such a way that concentrated loads are
distributed over the whole floor. This system is
widely used for multi storey buildings.
➢ The structural frame is commonly composed of
rectangular columns of one or more storeys height.
The beams are normally rectangular, L-shaped or
inverted T-beams. They are single span or cantilever
beams, simply supported and pin-connected to the
columns. Hollow core floor slabs are by far the most
common type of floor slabs in this type of structure.
Pre-stressed Precast Prefab Technology Using Hollow Core
Slab, Beams, Columns, Solid Walls, Stairs, etc…contd.
PMAY Project at Naya Raipur, Chhattisgarh
Technology: Hollow Core Slabs and Precast Large RCC Panels
Walltec Hollowcore Concrete Panel

• Walltec Hollowcore Concrete Wall Panels

of M/s B N Precast Pvt. Ltd. are extruded
non-load bearing concrete hollowcore
wall panels.
• These panels are factory produced using
light weight concrete made of river sand,
crushed stone aggregate, light weight
aggregate and Ordinary Portland cement.
• The concrete are extruded and cut while
still wet to the requisite length. Walls
have cylindrical hollow cores which helps
to reduce weight, facilitate mechanical,
electrical and plumbing services through
hollows and provide better sound and
thermal insulative properties.
• The sides of all panels are tongued and
grooved to facilitate jointing.
K-Wall Panels

• K-Wall panels of M/s Pioneer Precast

Solutions Pvt. Ltd. are factory produced
non-load bearing hollow core wall panels
using light weight concrete made of
ordinary Portland cement, fly ash, perlite,
foam, fevicol DDL, fiber-glass mesh, river
sand and water.
• Panels have cylindrical hollow cores with
7 no. of 60 mm dia voids in the 100mm
thickness, 8 no. of 50 mm dia. voids for
the 80 mm thickness and 9 no. of 39mm
dia voids for the 65mm thick panels.
• Hollow cores in K–wall panels help
reduce weight, facilitate mechanical,
electrical and plumbing services enhance
sound and thermal insulation properties.
The panels are joined using tongue and
groove system.
Robomatic Hollowcore Concrete Wall Panels
• Robomatic wall panels are extruded non-
load bearing concrete hollowcore wall
panels manufactured in fully automated
machines. These wall panels are factory
produced using light weight concrete made
of manufactured sand, crushed stone
aggregate and Ordinary Portland cement.
• Hollowcores are incorporated in the walls
to reduce dead weight, facilitate
mechanical, electrical and plumbing
services through hollows, increase sound
and thermal insulation properties. The sides
of all panels are tongued and grooved to
facilitate jointing.
• These wall panels can be used as non-load
bearing walls/partition walls and
compound/ boundary walls in residential/
commercial/ industrial/ institutional
buildings.
Kon_Crete Reinforced Autoclaved Aerated Concrete Panels

• KON_CRETE Reinforced AAC wall &

floor/roof panels are innovative
Autoclaved Aerated Concrete (AAC)
products, having properties such as
light weightness, high thermal
resistance, acoustics & energy
efficiency. It is a steam cured
cementitious material manufactured
from a mix of flyash, cement and
other additives giving the material a
unique cellular lightweight internal
structure.
• The panels can be used for external
& internal walls, floor & roof
applications in any type of buildings.
Integrated Hybrid Solution - One (IHS-One)
• IHS-ONE of M/s Aap Ka Awas LLP is an
Intermediate Building System (IBS) having
three main components namely,
interlocking walling system, precast floor &
roof system and ferrocement building
elements i.e. stairs, shelves, etc. All three
components are integrated to construct a
building and hence named as “Integrated
Hybrid Solution – ONE”.
• This system uses Hydraform prefabricated
mortarless interlocking blocks, precast RC
Planks & Joists system to build load bearing
G+3 structures.
• Both roof/floor and walling system can also
be bridged with RC framed structure as
well as steel structure in multistoried
structure providing a complete solution for
a building structure.
 3D Precast Volumetric Construction

• Replacing cast in situ

RCC structural frame with
factory made structural
components – 3D
• Customized factory made
volumetric construction
i.e. the entire module
(room)
Moducast® System
• The Moducast® System (Mooreliving India
Building Solutions LLP) combines a series
of modules to create the overall building,
this provides complete flexibility in the
layout.
• The structure is designed in splitable
transportable modules. These panels are
assembled on specially designed steel
beds and floor concrete is done linking the
panels to the floor reinforcement forming
a monolithic structure.
• This module is moved to various stages to
complete the secondary operations and
finishing works just like in a car assembly
line. Finished module is then transported
to site and erected together to form the
final structure. It is suited for low to
medium rise mass housing projects.
3D MONOLITHIC VOLUMETRIC Construction

Courtesy :
 Typical Offsite construction facility

Robotics & Automation for Prefabricating Precision Components for Buildings

Precast Hollow Core Slabs,

Prefabricated Marble and granite
Double Walls, Retaining Walls Sealant Injection for Aluminum
Bathrooms + Modular cutting and polishing
Lift Cores and Mesh Welding Glazing
MEP

In-house
Design &
Engineering
Team with
Integration and turnkey solution
Global including MEP and finishes
Spraying Machine for Wood
Expertise Products Manufacturing instead of
construction
Reduced labor on site
Complete coordination and
execution of full scope

Courtesy : KEF Infra

BMTPC under Performance Appraisal Certification Scheme (PACS) Identified, Evaluated,
Certified and Promoted New Emerging Technologies
(Gazette Notification No. I-16011/5/99 H-II in the Gazette of India No. 49 dated December 4, 1999)

PRECAST CONCRETE CONSTRUCTION SYSTEM – 3D PRECAST VOLUMETRIC 21 Prefabricated Fibre Reinforced Sandwich Panels 1030-S/2017

1 1059-S/2022 22 Concrewall Panel System 1031-S/2017

Volumetric (3D) Concrete Printing Technology (VCPT)
23 Rising EPS (Beads) Cement Panels 1032-S/2017
PRECAST CONCRETE CONSTRUCTION SYSTEM – PRECAST COMPONENTS ASSEMBLED AT SITE
24 PIR Dry Wall Pre-Fab Panel System 1039-S/2018
2 SRPL Building System (Waffle-Crete) 1021-S/2015
25 Baupanel system 1041-S/2018
3 Walltec Hollowcore Concrete Panel 1022-P/2015
4 Precast Large Concrete Panel System 1027-S/2016 26 Flyash EPS (Beads) Cement Sandwich Panels 1042-S/2018

Industrialized 3-S system using RCC precast with or without shear walls, columns, 27 V-Infill Wall (Light Weight EPS Wall) 1045-S/2019
5 -
beams, Cellular Light Weight Concrete Slabs/Semi-Precast Solid Slab 28 Nano Living System Technology 1047-S/2019
6 Robomatic Hollowcore Concrete Wall Panels 1040-S/ 2018 29 Factory Assembled Insulated Sandwich Panels using Mineral Wool 1057-P/2021
7 K-Wall Panels 1043-S/2019 30 Factory Assembled Insulated Sandwich Panels using PUF 1058-P/2021
8 Urbanaac Precast Construction Technology 1046-S/2019 31 Everest Rapicon Panel / Solid Wall Panel 1061-S/2022
9 Integrated Hybrid Solution - One 1048-S/2020 MONOLITHIC CONCRETE CONSTRUCTION
10 Kon_Crete Reinforced Autoclaved Aerated Concrete Panels 1056-P/2021
32 Monolithic Concrete Construction System 1006-A/2011
LIGHT GAUGE STEEL STRUCTURAL SYSTEM & PRE-ENGINEERED STEEL STRUCTURAL SYSTEM
33 Modular Tunnel Form 1018-S/2015
11 Factory Made Fast Track Modular Building System 1011-S/2013
STAY IN PLACE FORMWORK SYSTEM
12 Speed Floor System 1013-S/2014
34 Glass Fibre Reinforced Gypsum Panel System 1008-S/2011
13 Light Gauge Steel Framed Structure (LGSF) 1014-S/2014
35 Sismo Building Technology 1025-S/2016
14 Light Gauge Steel Framed Structure with Infill Concrete Panel Technology 1028-S/2016
36 Insulating Concrete Forms 1029-S/2017
15 Continuous Sandwich (PUF) Panels With Steel Structure 1038-S/2018
37 Lost-in-place formwork system- Plasmolite Wall Panels 1033-S/2018
16 PUF Sandwich Panel with Pre Engineered Building Structure 1060-S/2022
PREFABRICATED SANDWICH PANEL SYSTEM 38 Lost-in-place formwork system- Plaswall Panel system 1034-S/2018

17 Advanced Building System – Emmedue 1010-S/2014 39 Structural Stay-in-place formwork system 1035-S/2018

18 QuickBuild 3D Panels 1019-S/2015 40 Monolithic Insulated Concrete System 1036-S/2018

19 Reinforced EPS Core Panel System 1020-S/2015 41 Stay-In-Place PVC Wall Forms 1044-S/2019
20 Rapid Panels 1026-S/2016 42 Permanent Wall Form (PVC) 1050-S/2020
A Novel initiative to Transplant Best Global Technologies for
Indian Construction Sector

https://ghtc-india.gov.in/
 Global Housing Technology Challenge - India (GHTC-I)
Categories Technology Tech.
Providers
1 Precast Concrete Construction System - 3D 4
Precast volumetric
2 Precast Concrete Construction System – 8
Precast components assembled at site
3 Light Gauge Steel Structural System & Pre- 16
engineered Steel Structural System
4 Prefabricated Sandwich Panel System 9
5 Monolithic Concrete Construction 9
6 Stay In Place Formwork System 8

Total 54
 Light House Projects under GHTC-India

Location Technology Houses

Indore Prefabricated Sandwich Panel System 1,024

Rajkot
❑ GHTC-India was launched to identify
Monolithic Concrete Construction System 1,144 and mainstream innovative proven
construction technologies from across
the globe which are Cost-effective,
Chennai Climate & Disaster Resilient,
Precast Concrete Construction System-Precast Components
1,152 Sustainable and Green.
Assembled at Site
❑ Shortlisted Technologies will
Ranchi
showcase 6 Light House Projects
(LHPs) in 6 States through challenge
Precast Concrete Construction System-3D Pre-Cast Volumetric 1,008
process as Live Laboratories.
❑ 3S Mantra of Skill, Scale & Speed for
Agartala
Light Gauge Steel Structural System & Pre-Engineered Steel superior quality of construction
1,000
Structural System

Lucknow
Stay in-place Formwork System 1,040
 Global Housing Technology Challenge - India (GHTC-I)

1 Precast Concrete
Construction System –
3D Volumetric

114
 Global Housing Technology Challenge - India (GHTC-I)

2 Precast Concrete Construction

System – Precast components
assembled at site

1 Precast Large Concrete Panel (PLCP) System with structural Larsen & Toubro
members (wall, slab etc.) cast in a factory/ casting yard and
brought to the building site for erection & assembling

2 Pre-cast Concrete Structural system comprising of pre-cast B.G. Shirke

column, beam, precast concrete / light weight slab, AAC Construction
blocks/ infill concrete walls. Technology Pvt. Ltd
3 Optimal Pre-cast concrete System through structural Elematic India,
Analysis, design & equipment support
4 Precast concrete construction system using precast walls PG Setty
with precast plank floor Construction
Technology Pvt Ltd,
5 Precast components comprising of beams, coloumns, Teemage
staircase, slab, hollow core slab etc. manufactured in plant
& erected on site
6 Pre-cast sandwich panel system & Light weight Pre cast Nordicflex
Light Weight concrete slab
7 Prefabricated Interlocking Technology (without mortar) with Adalakha Associates
Roofing as Mechnized Precast R.C. Plank & Joist system Pvt. Ltd

8 Large Hollow wall prefab concrete Panel (lightweight, William Ling,

interlocking, concrete panel) using factory produced large 115
standard hollow interlocking concrete block
 Global Housing Technology Challenge - India (GHTC-I)

3 Light Gauge Steel

Structural System & Pre-
engineered Steel Structural
System
1 LGS Framing with various walling & roofing options Mitsumi Housing Pvt. Ltd,

2 LGS Framing with various walling & roofing options Everest Industries Ltd,
3 LGS Framing with various walling & roofing options JSW Steel Ltd.,
4 LGS Framing with various walling & roofing options Society for Development
of Composites
5 LGS Framing with various walling & roofing options Elemente Designer Homes
6 LGS Framing with various walling & roofing options MGI Infra Pvt. Ltd.,
7 LGS Framing with various walling & roofing options RCM Prefab Pvt. Ltd,
8 LGS Framing with various walling & roofing options Nipani Infra and
Industries Pvt. Ltd.,
9 LGS Framing with various walling & roofing options Strawcture Eco
10 LGS Framing with various walling & roofing actions Visakha Industries Ltd.
11 Prefabricated steel structural system with Dry wall RCC Infra Ventures Ltd.
system as AAC panels, PUF panels etc
12 Hot rolled steel frame with speed floor Jindal Steel & Power Ltd.
13 Hot rolled steel section with AAC Panels as floor & HIL Ltd.
slab
14 AAC wall and roof panel system to provide integrated Biltech Building Elements
solution. AAC products are reinforced and used in Ltd
both load and non-load bearing applications
15 AAC Panels are Wire mesh/ steel reinforced for use as SCG International India
wall & slab. Appears to be non load bearing panels to Pvt Ltd
be used with structural framing.
16 Precast Light Weight Hollow-core wall Panel is a non- Pioneer Precast Solutions
structural construction material with framed Private Limited 116
structures.
 Global Housing Technology Challenge - India (GHTC-I)

4 Prefabricated Sandwich Panel

System

1 Reinforced Expanded Polystyrene sheet core Worldhaus

Panel with sprayed concrete as wall & slab
2 EPS Cement sandwich Panel: wall & slab with EPS Bhargav
Cement sandwich Panel to be used with RCC or Infrastructure
Steel structural frame. Load bearing upto G+1 Pvt.Ltd
storey
3 EPS Cement sandwich Panel: wall & slab with EPS Rising Japan Infra
Cement sandwich Panel to be used with RCC or Private Limited
Steel structural frame. Load bearing upto G+1
storey
4 Reinforced Expanded Polystyrene sheet core Bau Panel Systems
Panel with sprayed concrete as wall & slab India Pvt Ltd,
5 Reinforced Expanded Polystyrene sheet core BK Chemtech
Panel with sprayed concrete as wall & slab Engineering
6 Reinforced Expanded Polystyrene sheet core MSN Construction
Panel with sprayed concrete as wall & slab
7 Reinforced Expanded Polystyrene sheet core Beardshell Ltd.
Panel with sprayed concrete as wall & slab
8 Pre-fab PIR (Poly-isocyanurate) based Dry Wall Covestro India Pvt.
Panel System" as non-load bearing wall Ltd., 117
9 Sandwich panels as wall & slab Project Etopia
Group
 Global Housing Technology Challenge - India (GHTC-I)

5 Monolithic Concrete
Construction

1 Aluminium formwork system for Monolithic Maini Scaffold Systems

Concrete construction
2 Aluminium formwork system for KumkangKind India
Monolithic Concrete construction Pvt. Ltd
3 Aluminium formwork system for S-form India Pvt. Ltd.,
Monolithic Concrete construction
4 Aluminium formwork system for Monolithic ATS Infrastructure Ltd.
Concrete construction
5 Aluminium formwork system for Monolithic Innovative housing &
Concrete construction Infrastructure Pvt. Ltd
6 Aluminium formwork system for Monolithic MFS formwork
Concrete construction Systems Pvt. Ltd.
7 Aluminium formwork system for Knest Manufacturers
Monolithic Concrete construction LLP
8 'Tunnel form' construction technology, an cast Outinord Formworks
in situ RCC system, based on the use of high- Pvt. Ltd.
precision, re- usable, room-sized, steel forms or
moulds for monolithic concrete construction
9 Aluminium formwork system for Monolithic Brilliant Etoile 118
Concrete construction
 Global Housing Technology Challenge - India (GHTC-I)

6 Stay In Place
Formwork System

1 Expanded-Steel Panel reinforced with all- galvanised Steel JK Structure

Wire-Struts serving both as the load- bearing steel structure
and as the stay-in-place steel formwork filled with EPS-
alleviated concrete
2 Factory made prefab Glass fibre reinforced Gypsum cage panels FACT-RCF Building
suitable for wall & slab with reinforcement & concrete as infill Products Limited
as per the requirement
3 Structural Stay In Place Galvanized Steel formwork system for Coffor Construction
walling with the same bottom single layer formwork for slabs/ Technology Pvt.Ltd
in-situ slab
4 Factory produced PVC Stay in place formwork with concrete & Joseph Jebastin (Novel
reinforcement in walling units with cast insitu RCC Slab Assembler)
5 Fully load bearing walls with 150 mm monolithic concrete core Reliable Insupack
sandwiched inside two layers of EPS as walling The forms are
open ended hollow polystyrene interlocking blocks which fits
together to form shuttering system
6 Ready to use Stay in place polymer formwork, light weight, Kalzen Realty Pvt. Ltd
with flooring slab (combination of ferro cement and natural
stone) placed on RCC precast joists)
7 Fast Bloc, Insulated Concrete Form (ICF), acts as formwork for Fastbloc Building
concrete and rebar, Co1oumn/post and beam construction, Systems
creating an strong skeleton in the walls.
8 Formwork system "Plaswall with Two fibre cement boardsFTS Buildtech
(FCB) & HIMI (High Impact Molded Inserts) bonded betweenPvt.Ltd 119
two sheets of FCB in situ and erected to produce a straight-to
finish wall with in-situ concrete
Light House Projects

Hon’ble Prime Minister laid the foundation stone of

six LHPs on 01.01.2021
 Light House Project (LHP) at Chennai, Tamil Nadu
(Technology: Precast Concrete Construction System-Precast Components)

No. of Dwelling Units : 1152 Nos. (G+5)

No. of Block / Tower : 12 Blocks
Units in each Block / Tower : 96 Nos.
 Light House Project: Chennai, Tamil Nadu
Construction Process
Manufacturing of Pre-cast
Construction M/s B.G. Shirke Constriction 1 building components (columns & 2 Transportation & Erection of
Private Ltd. beams, slabs, stairs etc.) in Pre- cast beams & columns at site
Agency
casting yard
Precast Concrete
Technology Construction System - Precast
Used Components Assembled
at Site

No. of Houses 1,152

No. of Towers 12 (G+5)
Technology • Individual precast building
Brief components (columns & Infill walls constructed using
beams, slabs, stairs etc.) are Placement of pre-cast slabs & Autoclaved Aerated Concrete (AAC)
3 Assembly through in-situ 4 Block masonry along with
manufactured in the casting concreting (wet jointing) with services (electricity, plumbing)
yard under controlled beam and columns followed by plastering
conditions.

• Finished components are

then transported to site,
erected & assembled through
in-situ concreting (wet
jointing).
 Light House Project (LHP) at Rajkot, Gujarat
(Technology: Monolithic Concrete Construction System)

No. of Dwelling Units : 1144 Nos. (S+13)

No. of Block / Tower : 11 Blocks
Units in each Block / Tower : 104 Nos.
 Light House Project: Rajkot, Gujarat
Construction Construction Process
M/s Malani Construction Co.
Agency Customised Tunnel Formwork Placement of Tunnel formwork
1 (mould) of steel manufactured in 2 in already erected reinforcement
Technology Monolithic Concrete Construction the factory cage for walls at site
Used using Tunnel Formwork

No. of Houses 1,144

No. of Towers 11 (S+13)

Technology • Reinforced Concrete

brief walls and slabs are cast
monolithically in single
pour (one go) using Placement of slab reinforcement Infill walls constructed using
3 & Concreting of walls & slabs 4 Autoclaved Aerated Concrete
Tunnel Form work. together in one go along with (AAC) Block followed by plastering
services (electricity, plumbing)
• It is a customized
engineered steel formwork
consisting of two half
shells which are placed
together and then
concreting is done to
form a room size module.
Several such modules
make a house.
 Light House Project (LHP) at Indore, M.P.
(Technology: Prefabricated Sandwich Panel System & Pre-Engineered Steel Structural System)

No. of Dwelling Units : 1024 Nos. (S+8)

No. of Block / Tower : 8 Blocks
Units in each Block / Tower : 128 Nos.
 Light House Project: Indore, Madhya Pradesh
Construction Process
Construction M/s KPR Construction Pvt. Ltd Customised steel columns & Deck slab installation in already
Agency 1 beams manufactured in the 2 erected steel structure
factory are erected at site
Technology Prefabricated Sandwich Panel
Used System with Pre-Engineered
Steel Structural System

No. of Houses 1,024

No of Towers 08 (S+8)
Technology brief • The factory-made
Prefabricated Sandwich
Panel System comprises
of core cement mortar with Concreting of deck slabs with Factory made Prefabricated
EPS granules balls 3 reinforcement along with services 4 sandwich panels are installed as
infilled walls along with services
sandwiched between
calcium silicate boards on
both sides.
• These panels are being
used in combination with
pre-engineered steel
structural system as a
dry wall construction in
this project.
 Light House Project (LHP) at Lucknow, U.P.
(Technology: Stay in-place Formwork System & Pre-Engineered Steel Structural System)

No. of Dwelling Units : 1040 Nos. (S+13)

No. of Block / Tower : 4 Blocks
Units in each Block / Tower : A(494), B(130), C(208) &
D(208)
 Light House Project: Lucknow, Uttar Pradesh
Construction Process
Customised steel columns & Deck slab installation in already
Construction M/s Jam Sustainable LLP 2
1 beams manufactured in the erected steel structure &
Agency factory are erected at site Concreting with services

Technology Stay in Place PVC Formwork

Used with Pre-Engineered Steel
Structural System

No. of Houses 1,040

No. of Towers 04 (S+13)

Technology • Poly-vinyl Chloride (PVC)

brief based permanent stay-in- Factory made prefinished PVC Filling of infill walls with
3 Wall forms are installed as infilled 4 concrete
place form work acting as walls along with services
pre finished walls filled with
concrete which requires no
plaster and paint
• These pre finished walls are
used in combination with
Pre-Engineered Steel
Structural System
 Light House Project (LHP) at Agartala, Tripura
(Technology: Light Gauge Steel Structural System & Pre-Engineered Steel Structural System)

No. of Dwelling Units : 1000 Nos. (G+6)

No. of Block / Tower : 7 Blocks
Units in each Block / Tower : A(112), B(154), C(118),
D(168), E(168), F(168) & G(112)
 Light House Project: Agartala, Tripura
Construction Process
Construction M/s Mitsumi Housing Pvt. Customised steel columns & Erection of factory made LGSF
Ltd 1 beams manufactured in the 2 panels and Fixing of Precast
Agency factory are erected at site concrete panels for walling
Technology Light Gauge Steel Framed
(LGSF) System with Pre-
Used
engineered Steel Structural
System
No. of Houses 1,000
No. of Towers 07 (G+6)
Technology • This system uses factory
made galvanized Light
brief
Gauge Steel wall
components in Filling of light weight concrete Deck slab installation in already
3 between the wall panels 4 erected steel structure &
combination with pre- Concreting with services
engineered steel
structural system for
structure
• The light gauge steel
wall sections are
assembled at site
which are then cladded
with concrete panels on
both sides and filled
with light weight
concrete.
 Light House Project (LHP) at Ranchi, Jharkhand
(Technology: Precast Concrete Construction – 3D Volumetric Construction)

No. of Dwelling Units : 1008 Nos. (G+8)

No. of Block / Tower : 7 Blocks
Units in each Block / Tower : 144 Nos.
 Light House Project: Ranchi, Jharkhand
Construction Process
M/s SGC Magicrete LLP Casting of structural modules & Placement of modules at site
Construction 2
Agency
1 slabs in the casting yard using cranes

Technology Precast Concrete Construction

Used System – 3D Volumetric
No. of Houses 1,008
No. of Towers 07 (G+8)
Technology • A latest technology where
brief precast concrete structural
modules like room, toilet,
kitchen, bathroom, stairs
etc. & any combination of
these are cast monolithically Placement of pre cast floors on Step 2 & 3 are repeated like
3 already erected structured 4 Lego Blocks to complete a
in casting yard under modules Tower
controlled condition.
• These Modules are
transported and installed
using cranes & push-pull
jacks and integrated together
at site to form a complete
building unit.
 https://ghtc-
india.gov.in/userhome/index
 Demonstration Housing Projects (DHPs)

Completed Ongoing

Bhubaneshwar, Odisha Panchkula, Haryana Guwahati, Assam

(PMAY(U) Beneficiaries) (Working women hostel) (Contractual Safai Karamcharis)

Agartala, Tripura Ayodhya, UP

Biharshariff, Bihar (Destitute Widow Ashram and
(Sports Hostel & other social welfare (Old Age Home)
Orphanage)
activities)
Hathijan, Ahmedabad,
Lucknow, UP Gujarat Dimapur, Nagaland
(Rental basis to Hospital patients & (PMAY (U) Beneficiaries) (Working Women Hostel)
their attendees)
Bhouri, Bhopal,
Madhya Pradesh Jammu, J&K
Nellore, Andhra Pradesh (Sports Hostel) (Sports Hostel)
(Social welfare activities)

Tiruppur, Tamil Nadu

Hyderabad, Telangana (Working Women’s Hostel
(Training Hostel) and Widow Home)
 Completed Demonstration Housing Projects (DHPs)

Model housing projects

containing up to 40 Houses
each with sustainable, cost
and time effective emerging
alternate housing construction
technologies suitable to the
geo-climatic and hazardous
conditions of the region. Nellore, Andhra Pradesh Hyderabad, Telangana Bihar Sharif, Bihar

Light Gauge Steel Frame System & Stay-in- Stay in Place - CR Steel Formwork System
Glass Fibre Reinforced Gypsum Panel System
place formwork - Coffor

Lucknow,Uttar
Lucknow, UttarPradesh
Pradesh Bhubaneswar,
Bhubaneswar, Odisha
Odisha Panchkula, Haryana Agartala, Tripura

Stay in Place - EPS Double Walled Panel EPS Core Panel Technology Light Gauge Steel Framed Structure with Stay-in-Place Formwork System- Coffor
System fibre cement board and infill of rockwool
Completed Demonstration Housing Projects (DHPs) during the Year

Bhopal- Sports Hostel Ahmedabad - PMAY (U) Beneficiaries

Insulated Concrete Forms (ICF) Integrated Hybrid Solution-ONE

 Ongoing Demonstration Housing Projects (DHPs)
Guwahati- Contractual Safai karamcharis Jammu- Sports Hostel Ayodhya - Destitute Widow Ashram & Orphanage

Light Gauge Steel Frame Structure with V-infill concrete wall EPS core panel using Quikbuild Panels Light Gauge Steel Frame structure with cement fiber board

Tiruppur - Working Women Hostel & Widow Home Dimapur - Working Women Hostel
Activities at DHP sites:

❑ Dissemination of innovative
technologies

❑ Periodic Training programs for

students/ Professional on use
of new technologies in DHPs

❑ Capacity building of local

Artisans

❑ Knowledge dissemination
through Webinars

Precast Concrete Construction System Flyash EPS Cement Sandwich Panels with steel structure
 Adoption of New Technologies by States

State Technology
54
Alternate
Andhra Pradesh EPS, Monolithic and Steel Technology
technologies
Identified
Chhattisgarh Monolithic and Precast Technology

54
Gujarat Monolithic, Precast (Waffle-crete)

Glass Fibre Reinforced Gypsum

Kerala
(GFRG)
technologies
Maharashtra Precast (3S) & Monolithic Technology approved by
CPWD
Odisha Precast concrete construction

AHP houses in Pune, Maharashtra using Precast Construction

Technology
Jharkhand Global Tender floated
34
SoRs issued
Tamil Nadu Precast Concrete Technology
for alternate
• More then 16 Lakh houses are being built using technologies
States like Assam, Karnataka, Madhya Pradesh, Telangana &
innovative technologies under PMAY(U) & other state Uttarakhand have also expressed interest in Technology by CPWD
schemes. neutral bidding process (27+7)
 DISTRIBUTION OF USE OF INNOVATIVE TECHNOLOGIES

BY NUMBER OF BY NUMBER OF
PROJECTS DWELLING UNITS
(Al Formwork Systems)
(47%)

(5%)

(2%)

Total Projects: 146 Total Units: 3,62,765

 नवरीत िः (NAVARITIH)
(New, Affordable, Validated, Research Innovation Technologies for Indian Housing)

Certificate Course on Innovative Construction Technologies

Target Group Objectives

➢Any person who has ➢ Familiarise the professionals with the latest materials
successfully completed and technologies being used worldwide for housing.
and in possession of a ➢ Provide an awareness of the state of art of materials
minimum qualification and technologies in terms of properties,
of B.E. / B.Tech (Civil) or specifications, performance, design and construction
B.Arch. (or equivalent) methodologies so that professionals can successfully
or Diploma in Civil with employ these in their day to day practice.
5 years’ experience. ➢ Provide exposure to executed projects where such
materials and technologies have been implemented.
 नवरीत िः (NAVARITIH)
(New, Affordable, Validated, Research Innovation Technologies for Indian Housing)

Certificate Course on Innovative Construction Technologies

Hon’ble Prime Minister of India launched NAVARITIH

during Foundation Stone Laying ceremony of six Light House Projects (LHPs) on 1.1.2021
 नवरीत िः (NAVARITIH)
(New, Affordable, Validated, Research Innovation Technologies for Indian Housing)

Certificate Course on Innovative Construction Technologies

1 Online Classes through video conferencing

2 Course Fee : Rs.2,500 per participant

Salient
Features 3 MCQ based Online Examination

4 Three Attempts Permissible in 45 days

5 Field visits for hands-on exposure

Impediments & Actions Required for using Emerging Construction Systems
Impediment Action
Misconceptions about new systems Develop a knowledge base on new technologies
Risk avoidance by policy makers and Technocrats Policy level interventions through a committee of experts
representing technical and financial departments.
Apathy at Implementation level Incentivize innovation in construction
User Acceptability Awareness creation and construction of some public
buildings to build confidence in public
Inadequate Capacities at Professional level Create a pool of specialists
Paucity of Contractors Build a platform for technology providers & contractors
High Initial cost & Economies of Scale Digress from initial cost to life-cycle cost
Do away with item rate business and adopt EPC Bring new Procurement Policy
contract system
Conventional pre-qualification criteria Modify and relax existing pre-qualification criteria in tender
documents.
Lack of modular/standardized planning & design Prepare modular plans & design for different geo-climatic
regions of India.
Absence of Demonstration at grass-root level Demonstration Construction with new technologies
Skill Development Capacity Building & Skill Development
 Let us be part of India’s growth story of

Reform, Perform & Transform

www.bmtpc.org

@bmtpcdelhi bmtpc.mhua www.bmtpc.org [email protected]

“Creating Enabling Environment for Affordable Housing for All”