Download - Larsen & toubro constructions

G +23 STOREY TOTAL PRECAST RESIDENTIAL

BUILDING

PRAGATI TOWERS

BY LARSEN & TOUBRO CONSTRUCTIONS

Structural elements are standardized and cast in

factory

Transported to site on trailers

Erected on site by Cranes

PRECAST TECHNOLOGY

DEFINITION: Precast Technology is Technological innovation suitable for manufacturing process

ELEMENTS ASSEMBLED TOGETHER WITH APPROPRIATE JOINTSSTANDARDIZATION OF ELEMENTS

PROJECT DESCRIPTION

G+23 Storey fully Precast Residential Building

Total BUA = 1.2 M. Sq.ft.

Divided in to 2 phases viz.,

Phase 1 – Tower A, B, C (Completed)

Phase 2 – Tower D, E, F (Ongoing)

Challenge of Building 24 storied residential towers using Precast in seismic zone 3 in Mumbai.

PROJECT BRIEF:

Total BUA 1.2 M Sq.ft.

Unit Configuration 14-16 Units/ Floor

Sub Structure Pile foundation

Ground & Terrace Floor Conventional Construction

1st to 23rd Floor Precast Large Wall Panel System

SITE LAYOUT

Phase - 1

Phase - 2

ELIGIBILITY FOR ENGINEERING EXCELLENCE – PRAGATI TOWERS

1. DESIGN

2. PRODUCTIVITY ENHANCEMENT

3. SPEED OF CONSTRUCTION

4. STANDARDIZATION

5. QUALITY CONTROL

6. SAFETY

7. SUSTAINABILITY

8. ENVIRONMENTAL BENEFITS

1. DESIGN

BEST DESIGN PRACTICES IN ASIA

BEST DESIGN PRACTICES IN EUROPE

DESIGN OF PRAGATI TOWERS

INDIAN CODAL PROVISIONS

DUCTILITY REQUIREMENTS IN

SEISMIC ZONE

IN C

ON

FORM

ANCE

W

ITH

PUT

TOG

ETH

ER T

O

COM

PLET

E


2. PRODUCTIVITY ENHANCEMENT

CONSTRUCTION INDUSTRY

FACING SHORTAGE OF SKILLED

MANPOWER

L&T ENVISAGED THE SOLUTION IS TO BE

MORE DEPENDENT ON MACHINES

ADOPTING MECHANIZATION

IN CONSTRUCTION

LEAD TO INCREASE IN PRODUCTIVITY IN

PRAGATI TOWERS

MANPOWER REQUIREMENT REDUCED

BY AROUND 30% AT PRAGATI TOWERS


3. SPEED OF CONSTRUCTION

Reduction in the number of activities & materials along with reliability on mechanized production lead to increase in speed of construction at Pragati Towers.

Formwork

• Stage 1

Reinforcement

• Stage 2

Concreting

• Stage 3

Blockwork

• Stage 4

Formwork

• Stage 1

Reinforcement

• Stage 2

Concreting

• Stage 3

Blockwork

• Stage 4

Plastering

• Stage 5

POP works

• Stage 6

Painting

• Stage 7

Activities – on site

Reduction in the number of activities

Reducing the dependency on labour.

Savings in Precious Project Time & thereby costs.


Conventional Construction

Precast Construction

PRAGATI TOWERS

WALL PANELS SLABS PODS BEAMS SPAND

RELCOLUM

NSSTAIRC

ASE

4. STANDARDIZATION

WALL PANELS

SOLID SLAB PANELS POD ELEMENTS

PARAPET BEAMS SPANDREL

COLUMNS STAIRCASE

ALL ELEMENTS WERE STANDARDIZED FOR ECONOMISING CONSTRUCTION AT PRAGATI TOWERS

ENTIRE TOWER WAS BROKEN UP INTO STANDARDIZED ELEMENTS TO GAIN MAXIMUM REPETITION OF MOULDS


5. QUALITY CONTROL Precast Elements of Pragati Towers were cast in strictly controlled factory conditions


Rigorous inspection at all stages ensures smooth and high quality finish.

ELIGIBILITY FOR ENGINEERING EXCELLENCEPRAGATI TOWERS – HIGH QUALITY INTERIORS

6. SAFETY All Casting activities of Pragati Towers were carried out at ground level


7. SUSTAINABILITY

Pragati Towers demonstrated ‘Elimination of activities like brickwork, block work, plastering’ etc at site.

Savings in Sand, labour, formwork material, scaffolding material such as wood,

timber, plywood etc.

Reduction in wastage of materials as casting processes are carried out in stringent

quality controlled factory environment.

Savings of construction material will not only result in savings of our construction

materials but also natural resources from which these materials are derived.


8. ENVIRONMENTAL BENEFITS

Frequent Transportation of construction materials in conventional construction creates congestion in the city and nuisance to the public.

ADVANTAGES: Transportation of all precast elements

at Pragati site was done during night / off peak hours.

Relief to public as traffic congestion was reduced in

jam-packed area of South Mumbai (Parel).

Reduction in nuisances to nearby population like

dust, noise, air pollution.

Relief to Motorist.


1. TECHNOLOGY

ELIGIBILITY FOR INNOVATIVENESS IN CONSTRUCTION – PRAGATI TOWERS

INFRASTRUCTURE PROJECTS

Pragati towers demonstrated technical feasibility of using ‘Precast

Technology’ for 24 storeyed towers & paved the way of using Precast

Technology in Indian Residential Building Construction.

Potential offered by precast technology was limited to infrastructure

projects such as airports, stadiums, bridges, dome roofs, metro projects etc.

First time in India, 24 storied residential building structures are constructed by using Precast Technology

KANTEERAVA STADIUM CHENNAI METRO RAIL PUTTAPARTHY

2. DESIGN


G+23 Storey ‘Total Precast System’ in Seismic Zone-3,

Mumbai.

Designed in conformance to all ‘I.S. codal requirements’.

Structural connections designed to comply with design codes.

Innovative combination of ‘Modular units’ and ‘Large Panel

system’ to suit the construction needs of the project.

Designed & Detailed in conformance to I.S. Codal

requirements to prevent progressive collapse in Precast system.

3. PRECAST PANEL FABRICATION – ‘INDIGENEOUSLY DEVELOPED MODULAR UNITS’


MOULD - MODULAR BLOCKS INTERIOR COREEXPLODED VIEW

MODULAR BLOCKS ( 3D POD) TRANSPORTATION REAR VIEW


3. PRECAST PANEL FABRICATION – ‘INDIGENEOUSLY BATTERY MOULDS’

MOULD – BATTERY MOULD TOP VIEW

• DESIGNED FOR CASTING WALL PANEL ELEMENTS.

Monolithic casting of WC & Bathrooms in

Pragati Towers ensures water tightness

Joint detail should ensure

water tightness

4. WATER PROOFING


5. SPEED & SAFETY


Reduction in number of construction activities & Labour requirement helped in achieving

higher speed of construction.

Precast Staircases and Slabs offered rapid installation and early safe access to subsequent

floors.

Zero accidents at Pragati Towers demonstrates the safety standards.

1. RECORD ERECTION TIME

ELIGIBILITY FOR OPERATIONAL EXCELLENCE OF PROJECT – PRAGATI TOWERS

Superstructure (1st Floor to 23rd Floor) of Tower A,B & C completed in a record time of 12 months.

Planned erection = 3 Dwelling Units/day

Peak erection achieved at Pragati Towers = 10 Dwelling Units/day

Precast Technology @ Pragati Towers has addressed the ‘DEMAND & SUPPLY’ issue faced by our construction

industry.

Speedy completion reduced time for construction and thereby reducing costs associated with the lifecycle of

the project. NOISE FREE ERECTION EVEN DURING NIGHTEXECUTION OF LOGISTIC PLANNING IN CONGESTED AREAS

2. REDUCTION IN NUMBER OF ACTIVITIES AT SITE


Elimination of activities like block work, plastering & brickwork reduced

the turn around time of the project.

3. LESS LABOUR INTENSIVE Labour requirement at Pragati site was found to be 30% lesser

when compared to a similar conventional construction project

(similar magnitude).

4. MOULDS

Battery Moulds – Specialized for high speed of

production of Precast Wall Panels without offsets

Flat Bed Moulds – Specialized moulds for Precast Wall

Panels with offsets.

Maximum Utilization of Moulds was planned for

achieving savings in cost of moulds.

INSIDE A BATTERY MOULD

FLAT BED MOULD

5. RELIEVING TRAFFIC CONGESTION


Reduction in number of repeated trips of materials ( debris, workers, equipment, materials)

during day time.

Finished product was transported to site during night/off-peak hours for erection.

Relief to Motorist and nearby population.

1. CONVICTION IN CONSTRUCTION TECHNOLOGY

ELIGIBILITY FOR ADDING SELF RELIANCE OF INDIA IN CONSTRUCTION SECTOR

– PRAGATI TOWERS

Proved that Precast Technology is feasible for Indian Residential Construction Industry.

2. SERVICEABILITY OF STRUCTURE

Longer Life Span of Structure free from plaster spalls & Wall Cracks

3. INHOUSE DEVELOPMENT FOR PRODUCTION YARD, MOULD FABRICATION

Methods of Mould Fabrication & Yard set up was suitably modified to cater to Indian Construction Industry.

These methods can be used in future to lend cost competitiveness to the future precast projects.

4. PROGRESSION IN DESIGN & JOINT DETAILING

ELIGIBILITY FOR ADDING SELF RELIANCE OF INDIA IN CONSTRUCTION SECTOR

– PRAGATI TOWERS

Entire ‘DESIGN & JOINT DETAILING’ in accordance to codal provision was developed.

5. WASTE REDUCTION & SUSTAINABLE DEVELOPMENT

Stringent controls in factory based production helped in reducing wastage of materials.

1. Proved ‘PRECAST TECHNOLOGY’ is feasible for high rise in seismic conditions.

ELIGIBILITY FOR KEY IMPACTS THIS PROJECT HAS MADE – PRAGATI TOWERS

2. Successfully Addressed ‘The DEMAND & SUPPLY’ gap faced by Construction Industry.

3. Immaculate finishes without compromising cost competitiveness of the Project.

5. Timely Project Completion

4. ‘AMAZEMENT OF PEOPLE’ to view massive structures erected with great ease.

1. ‘FEASIBILITY & ACCEPTABILITY’ of Technology.

ELIGIBILITY FOR FUTURE READINESS OF THE PROJECT – PRAGATI TOWERS

2. ‘BRISK PACE’ of Erection of 24 storey towers in a period of 12 months in congested area.

3. ‘ CUSTOMIZATION OF ARCHITECTURAL FINISHES’ as per the requirement of client.

5. ‘REDUCING THE DEPENDENCY OF LABOUR BY INVOLVING TECHNOLOGY OR MECHANIZED

CONSTRUCTION.’

4. ‘INDIGENEOUS DEVELOPMENT IN MOULD DESIGN’ to increase cost effectiveness.

6. MULTIFOLD INCREASE in ‘Quality, Durability, cost effectiveness, speed with high quality

end products.’

CURRENT STATUS- PRAGATI TOWERS

THANK YOU