Precast Concrete Technology For Industrial Structures

Er Kapilesh Bhate, Precast India Infrastructures PL

 

Precast concrete is an age-old and age-tested methodology of construction all over the world. After a quiet start few decades ago, slowly, people are again exploring this option.

 

The prime reason for the client’s higher management to consider precast technology being, earlier ROI for fast track projects and high volume projects, where labour manpower requirement would have been otherwise high.

 

Usually, there are three models of development – leasing, selling or owning model. So, by using precast technology, if a developer is getting his leaseble/saleable product in 75% of the time (compared to conventional CIS/ PEB), his inbound cashflow can start that much earlier (once, and provided, the finishing and MEP works are done with equal pace, coordination and intensity). In case, if the production facilities are owned by the end user, he shall always be in urgent need to start production and supply (sale) as early as possible, which is also helped by using precast technology.

 

The amount of early cashflow may come back in tunes of crores, depending on the lease/sale rate/sales booking, which have other interest-saving effects on the overall project finances in totality.

 

The following advantages can be leveraged by making using of precast elements in industrial structures/multi-storey warehouses/production facilities:

  • Long Spans
  • Heavy Loading
  • Multi-Storey Usage for Industrial (v/s shed option)
  • Fire Protection (v/s structural steel)
  • Severe Saline Atmospheric Conditions (v/s structural steel)
  • Maintenance Free Structure
  • Aesthetically More Pleasing
  • Green Building Advantage
  • Lesser no. of Shop Drawings/Detailing (v/s structural steel)
  • Less no. of Components and Faster Installation

 

Another reason, needless to mention, is quality control, which is possible in a manufacturing environment as opposed to site concreting.

 

Although precast technology is extremely technically challenging, and it requires lot of pre-engineering and fast decision making from all professionals involved, like client, architect, service consultants and of course structural design teams, if it is handled by a professional and technically sound precaster, it is a phase which will not take more than 2-3 months. The client, thus, having completed all his major decisions regarding building systems, can be sure of the project budget right in the 3rd or 4th month, which is a luxury for any top management, as opposed to approving and recapping limits throughout the project’s timeline.

 

A fast track project with just enough time to pre-engineer the coordination requires a high quality standard spells precast all the way.

 

Project Details

Precast India Production Facility

Location: Wagholi, Pune

Duration: 12 months

Year of Completion: 2010

Area: 1,50,000 sq. ft

 

Special Features:

  • Fully Precast
  • Column Heights: 15 m
  • Rafter Spans: 25 m
  • Depth of Rafter: 1.2 m
  • of Production Halls: 4
  • Length of Production Halls: 150 m
  • Total Width of Production Halls: 100 m

 

 

Schmersal India Production Facility

Location: Ranjangaon, Pune

Duration: 10 months

Year of Completion: 2013

Area: 70,000 sq. ft

 

Special Features:

  • Column Height: 25 m
  • Rafter Spans: 15 m
  • Loading of 2 MT/sq. m
  • Depth of Rafter: 1.2 m
  • of Production Halls: 2
  • Length of Production Halls: 50 m
  • Width of Production Halls: 42 m

 

 

Cummins Technical Center India

Location: Kothrud, Pune

Duration: 24 months

Year of Completion: 2015

Area: 10,10,000 sq. ft

 

Special Features:

  • 10 m span
  • Columns of 3 floors are casted in one piece (10 m)
  • Extreme Site conditions due to lack of space
  • Special moment resisting connection at continuous junction
  • Segmental casting and post tensioning of 21 m beams

 

 

Schott Kaisha Production Facility

Location: Daman, Gujarat

Duration: 12 months

Year of Completion: 2019

Area: 1,00,000 sq. ft

 

Special Features:

  • Fully Precast
  • Column Height: 11 m
  • Beam Spans: 11 m
  • Precast Façade of 10 m length x 2.4 m width
  • Depth of Rafter: 900 mm
  • of Production Halls: 2
  • Length of Production Halls: 100 m
  • Total Width of Production Halls: 100 m
  • Load on First Slab: 1 MT

 

 

Kirloskar Oil Engines Ltd Warehouse

Location: Kagal, Kolhapur

Duration: 12 months

Year of Completion: 2018

Area: 2,00,000 sq. ft

 

Special Features:

  • Fully Precast
  • Column Height: 10 m
  • Rafter Spans: 10 m
  • Retaining Wall: 10 m
  • Depth of Rafter: 800 mm
  • of Warehouse Halls: 2
  • Load on First Slab: 1 MT
  • Length of Production Halls: 50 m
  • Total Width of Production Halls: 100 m

 

 

Infosys Water Tank 2 crore Litre

Location: Hinjewadi, Pune

Duration: 5 months

Year of Completion: 2019

Area: 40,000 sq. ft

 

Special Features:

  • Fully Precast
  • Column Height: 10 m
  • Beam Spans: 9 m
  • Depth of Beam: 1 m
  • of Water Tanks: 7
  • Length of Production Halls: 150 m
  • Total Width of Production Halls: 100 m
  • Load on Top Slab: 1 MT

 

 

A Raymonds Production Facility

Location: Chakan, Pune

Duration: 6 months

Year of Completion: 2013

Area: 8,600 sq. m

 

Special Features:

  • Column Height: 18 m
  • Rafter Spans: 22 m
  • Depth of Rafter: 1 m
  • of Production Halls: 2
  • Length of Production Halls: 80 m
  • Total width of Production Halls: 60 m

 

 

Seco Industries

Location: Wagholi, Pune

Duration: 0.5 months

Year of Completion: 2015

Area: 1,500 sq. m

Project Value: 1 crore

 

Special Features:

  • 3 MT Loading on DT
  • Beam Span 12 m and DTs of 6 m
  • Erection in existing production facility
  • Erection at night
  • Zero safety incidents

 

 

IKEA Store

Location: Navi Mumbai

Duration: 2 months

Year of Completion: 2019

Area: 10,000 sq. m

 

Special Features:

  • 16 m span hollow core slabs
  • PEB structure with hollow-core slabs
  • Transport of 16 m span slabs

 

 

Bharat Forge R&D Centre

Location: Keshavnagar

Duration: 6 months

Year of Completion: 2019

Area: 10,000 sq. m

 

Special Features:

  • Use of new Seismic Moment Resisting Connection Technology
  • In-house precast design with full input-output from 3D BIM software
  • 21 m V Beam - Arc Slab system for shell roof
  • 21 m long single T’s transported from plant to site by 70’ trailers
  • 11 m high single piece precast shear walls

 

 

 

  • Majority precast structure (only screed, OHWT and combined footings of shear walls were CIS, in a conscious effort)
  • Integration of BIM software with precast ERP planning and tracking software
  • To optimise consumption of available FSI, we used the area above the R&D shed, which is traditionally not usable, in case of truss structure to convert to G + 2
  • Stringent fire safety norms for R&D Centre – expensive in PEB
  • Longer slab span of 21 m was possible in precast in much leaner design as compared to CIS flat slab design, thus reducing the dead weight of the structure

 

 

  • 3 bays were more than traditional Triple Height (10 m height), which would have been difficult to cast in situ, with triple height staging, etc.
  • Shell roof aesthetics and elevation is unique which was only possible in precast
  • Scaffolding, labour and form work required is less considering site space
  • Green Building Advantage due to less transport trips to site, less wastage, less embodied energy, registered for LEED platinum rating
  • Durability and life is much more efficient for a robust RCC structure
  • Maintenance of RCC building was much lower than a steel Structure, considering emissions, vibrations, etc.
  • Client wanted something new, different, technologically advanced
  • Complex design due to irregular distribution of mass of structure
  • Precast arch at roof level installed with provision of natural roof light
  • Precast folded staircase
  • Transportation of 21 m long single T and V beam
  • Each element had a unique ID and stuck with QR code sticker, scanned by our own Android App and Cloud Computing Technology for tracking
  • Erection in night shift with zero unsafe incident reporting
  • All MEP, HVAC, Fire, Façade sleeves coordination done in
    pre-engineering stage itself
  • Method statements prepared in advance and submitted to client, including lifting plans of elements