when restr|ctedtoas|ng|emater|a| and|s oten constra|nedby convent|ona| des|gn th|nk|ng. ln th|s context, Pre-cast con- crete systems are stead||y rep|ac|ng trad|t|ona| methods as lnd|a treads towards adopt|ng qua||ty assur|ng, qu|ck andeco-r|end|yconstruct|onpract|ces. These bu||d|ngs de||ver sure|t bene- |ts over trad|t|ona|, |n-s|tu bu||d|ng construct|on and are produced by cast|ng |nd|v|dua| concrete e|e- ments ||ke so||d wa||s, so||d |oors, ho||ow core s|abs, pre- stressed and precast ver bu||t a mode| skyscraper or your dream bunga|ow us|ng the ELEGO toy b|ocks, as a k|d? l yes, you w||| be ab|e to connect seam- |ess|yw|thth|samaz|ngtechno|ogy, wh|ch |n the past ew decades, has g|ven r|se toana|together new|ndustry |nlnd|a The Precast Concrete Bu||d|ng lndustry! W|th the onset o 12th FYP, con- struct|on act|v|ty |s peak|ng up across the nat|on as mu|t|-b||||on do||ar pro- |ects are current|y be|ng bu||t |n the orm o |arge sca|e commerc|a|, |ndustr|a| and res|dent|a| deve|opments and|nra- structure pro|ects. These pro|ects are tr|gger|ng extens|ve demand or many rawmater|a|s, ama|or shareho|der be|ng cement concrete, wh|ch |s at the heart o every bu||d|ng pro|ect and |s used |n many app||cat|ons, rom decorat|ve to unct|ona|. 120 The Masterbu||der - ApriI 2013 www.masterbu||der.co.|n beams and raters, sta|rcases, com- pound wa||s, roo t||es, paver b|ocks, etc. |n a contro||ed env|ronment, to be then transported to the construct|on s|te, ||tedand|xed|nto p|ace. AnaIysis Cmo|lomyo o, Ooyo| Cosl|mg o Comc|ele |ulu|e |mo|om -|e-cosl Comc|ele 0u||o|mg |mousl|y Pre-cast Concrete Buildings: Steadily materializingdemand Pea| estate |ndustry has been one o the astest grow|ng sectors |n the country over the |ast ewdecades. W|th demands or hous|ng and commerc|a| property |ncreas|ng |n the same pro- port|onas the rap|d popu|at|onand eco- nom|c growth, the sector |s under h|gh pressure to cater to th|s demand at aordab|e rates and |ower turnaround t|me. The demand or urban and rura| hous|ng has a|so been r|s|ng cons|s- tent|y ow|ng to the abnorma||y h|ghres|- dent|a| pr|ces wh|ch are aordab|e or r|ch |nvestors but not the needy lnd|an m|dd|e c|ass, wh|ch compr|ses ma|or- |ty o the popu|at|on. The lnd|an urban popu|at|on |s expected to reach 576 m||||on |n 2030 (current|y, |t |s around 350 m||||on). lnd|a |s thus ac|ng a short- ageo near|y25m||||onaordab|ehouses or wh|ch the lnd|an Govt. |s read||y pro- v|d|ng var|ous subs|d|es to bu||ders and customers. Another ma|or prob|em |s the unp|anned urban deve|opment wh|ch the c|ty mun|c|pa||t|es have enterta|ned over the decades, wh|ch has |ed to |nadequate and |nappropr|ate urban |nrastructure, s|umestab||shments, etc. o||ow|ng wh|ch the governments have |aunched s|um rehab|||tat|on schemes, wh|chaddtotheovera|| hous|ngdemand. ln th|s scenar|o precast construc- t|on techno|ogy |s g|v|ng encourag|ng resu|ts ||ke a|ready w|tnessed|n Amer|ca, Europe and M|dd|e East. So ar th|s techno|ogy has been used |n con- struct|ng |arge pro|ects ||ke br|dges, |yovers, tunne|s and metro ra||s |n lnd|a, but |t can now be |ncreas|ng|y w|tnessed |n construct|on o hote|s, hosp|ta|s, res|dent|a| bu||d|ngs, show- rooms, schoo|s, etc. Market Overview: Arisingindustry Though precast bu||d|ng construc- t|on |ndustry |s st||| at |ts nascent stage |n lnd|a, |ts rap|d|y com|ng to the ore- ront o theconstruct|on|ndustrybecause |ong term market prospects, |n th|s |ndustry, appear h|gh|y encourag|ng. 121 www.masterbu||der.co.|n The Masterbu||der - ApriI 2013 AnaIysis structura| products or res|dent|a|, com- merc|a| and |ndustr|a| bu||d|ngs. Prod- ucts that w||| are part|cu|ar|y we|| |n th|s market |nc|ude oundat|ons, wa||s and |oors. Growth w||| a|so be spurred by the r|s|ng use o arch|tectura| products ||ke decorat|ve aades, door and w|ndow surrounds, and s|d|ng. Poo|ng t||es w||| a|so support demand and w||| bene|t rom the|r popu|ar|ty |nthe rap|d|y grow- |ng res|dent|a| markets. lnd|an construct|on |ndustrys dr|ve towards susta|nab|e deve|opment shou|da|sobene|t th|ssector, duetothe h|gh |eve|s o recyc|ed mater|a|s used, lts est|mated that the |ndustry w||| grow 10 t|mes |n next 5 years rom the current |eve| o around 2500 crore. The key sectors wh|ch are ||ke|y to exper|ence |nrastructura| growth |n com|ng t|mes are o|ces, |ndustr|a| and reta||, educat|on, res|dent|a| and med|- ca| - though these growth sectors are dependent on und|ng streams rom Government and PFl sources be|ng ma|nta|ned. Some spec||c products w|th|n the broad categor|es o precast concrete product|on |nc|ude dense, ||ghtwe|ght and aerated concrete b|ocks, precast concrete t||es, precast c|add|ng and PCC hoste| bu||d|ng construct|on at SPM un|vers|ty, Chenna| Th|s sunr|se |ndustry may be the answer to lnd|as aordab|e hous|ng needs 122 The Masterbu||der - www.masterbu||der.co.|n ApriI 2013 and precast concretes h|gh therma| and acoust|c |nsu|at|onpropert|es. Substituting 'n-Situ': Advantages are many The growth |n demand o PCC bu||d|ngs |s not surpr|s|ng as precast concrete components prov|de a num- ber o bene|ts as ||sted be|ow: Architectural flexibility: The sp|en- dor o var|ety |n precast so|ut|ons g|ves space to breathe, to be creat|ve and |mag|nat|ve. These bu||d|ngs oer amaz|ng versat|||ty and ab|||ty to better w|thstand the extreme temperatures |n a reg|on. Time and Life cycle cost: E|ement bu||d|ng method creates a great|y acce|erated construct|on t|metab|e, wh|ch |owers the cost, because cap|ta| |snt t|ed up or years |n bu||d|ngs that are not yet ready. Th|s techno|ogy a|so |mproves construct|on qua||ty and extends the ||e cyc|e o bu||d|ngs, mean|ng any repa|rs needed |ater |n the bu||d|ngs ||e w||| be stra|ghtorward and muchmore cost eect|ve. Green and sustainable: These structuresareway moreecor|end|y and susta|nab|e, be|ng u||y recyc|ab|e and contr|but|ng to |ower ||ght|ng costs due to |ts re|ectance qua||t|es. PCCe|ements arecreatedromh|gh-strengthre|norced concrete, wh|ch requ|res |ess concrete. There |s |ess construct|on waste, w|th urther reduces the env|ronmenta| |mpact. Another th|ng |s that these e|e- ments canbeerectedw|thout thewooden shutter|ng used or on-s|te cast|ng. Structural Safety: Mass o struc- ture |s cr|t|ca| |n context o se|sm|c|ty |n lnd|a. The mass o structure contr|b- utes to the |atera| orces and adds upto the stresses, |ead|ng to uneconom|ca| des|gns. W|th |mp|ementat|on o pre- stressed precast components and s|en- der members ||ke ho||ow core s|ab, the mass o structure |s contro||ed and over- a|| econom|c des|gn and mater|a| sav- |ngs |s ach|eved. Structura| con|gura- t|on or stab|||ty and |ntegr|ty o PCC structures |n se|sm|c reg|ons has been tested met|cu|ous|y and |t |s be|ng used |n h|gh se|sm|c zones across the g|obe ||ke West SA, Ta|wan, New Zea|and, Korea etc. Easier to execute: lnd|an Monsoon |asts or near|y 3-4 months, creat|ng add|t|ona| cha||enges or the bu||d|ng pro|ect management. Precast e|ements can be manuactured |n surround|ngs where the eects o ra|n and other weather cond|t|ons canbe e||m|nated. Th|stechno|ogyhasa|sobeenproven to be a good so|ut|on or work saety. L|ke many other countr|es, lnd|a |s a|so ac|ng a shortage o sk|||ed |abor |n the bu||d|ng |ndustry. Precast |s |ess |abor- |ntens|ve. An add|t|ona| advantage o precast |s that dur|ng manuactur|ng and |nsta||at|on s|m||ar work-rout|nes arerepeated. Th|she|psworkersto|earn and become more e|c|ent, pro|ect ater pro|ect. Experts have been qu|ck to recog- n|ze a|| these bene|ts and are thus work|ng towards gett|ng th|s techno|- ogy - |ts r|ghtu| market share |n emerg- |ng lnd|a. Key Players: VolumebasedBusiness sage o tota| precast |n bu||d|ngs |s new to lnd|a and there |s a huge opportun|ty because o the |ack o sk|||ed manpower, cons|der|ngthe h|ghvo|ume |ndemand. P|ant eng|neer|ng spec|a||sts, E|emat|c, Beton| Mestar|t o F|n|and and Precast techno|ogy oers a var|ety o arch|tectura| products: lnosys Bu||d|ng, Chenna| Precast structures can save a tota| o 64% man hours needed to construct a Cast |n s|tu bu||d|ng AnaIysis RBBR Infrastructure Pvt.Ltd 124 The Masterbu||der - ApriI 2013 www.masterbu||der.co.|n vo||ert An|agenbau o Germany, etc. are some |nternat|ona| ma|ors p|ay|ng |mportant ro|e |n assoc|at|ng w|th and supp|y|ng lnd|an entrepreneurs and compan|es w|th PCC product|on tech- no|ogy through state o art mach|nes and systems enab||ng them to set up the|r actor|es. Lead|ng compan|es |n th|s sector |nc|udeH|ndustanPreab, Precast lnd|a, S|mp|ex Preab lnra, Precast Bu||dcon, KK lnd|a, vME Precast, Janapr|ya, Amarapa||, Supertech, Sa| Preeth| pre- cast, etc. A|| these compan|es own s|n- g|e or mu|t|p|e product|on ac|||t|es w|th 2 a capac|ty o 200,000 600,000 m per year. Estab||shed p|ayers |n th|s sector are now |ook|ng to |ncrease the|r capac|ty at the|r ex|st|ng set-ups and then move to estab||sh other p|ants. Some op|ne that there |s no po|nt |n br|ng|ng th|s bus|ness to lnd|a un|ess one |s prepared or s|gn||cant sca|e- up. Th|s may be done by add|ng more cast|ng beds and more tab|e mou|ds to theex|st|ngactoryor bu||d|nganewone. Services offered: What toexpect? Most o the estab||shed p|ayers |n the |ndustry oer turnkey so|ut|ons |nc|ud|ng des|gn, manuacture and erect|on o PCC modu|ar bu||d|ngs through co||aborat|ons w|th the|r part- ners. A customer and |nvestor can choose the best des|gn so|ut|on or h|s spec||c pro|ect ut|||z|ng a wea|th o pre- cast concrete opt|ons ava||ab|e. Estab||shed and reputed compa- n|es guarantee pro|t, saety and qua|- |ty, based on the|r extens|ve exper|ence |n econom|ca| des|gn, |atest manuac- tur|ng processes and the use o com- pos|te stee| and concrete mater|a|s most appropr|ate to the pro|ect. Technology: Deeper nsight Broad|y, precast concrete con|gu- rat|on or bu||d|ngs are categor|zed |n two ways, co|umn-beam rame struc- ture or wa||-rame structure w|th pre- stressed precast s|abs. For commer- c|a| and |ndustr|a| structures, requ|r|ng wa|| ree |arge spaces, co|umn-beam rame structure |s common|y |mp|e- mented. Wh||e or res|dent|a| bu||d|ngs, aesthet|c po|nt o v|ewand make use o ava||ab|e essent|a| wa||s, wa||-rame structure |s common|y dep|oyed. For bu||d|ngs, ma|n structura| com- ponents are precast co|umn, pre- stressed precast beams, pre-stressed precast s|abs (e|ther ho||owcore or so||d s|abs), and re|norced concrete pre- cast structura| wa||s and non-|oad bear- |ng part|t|on wa||s. O these, ho||ow core s|ab |s one o the most |mpress|ve |nno- vat|ons wh|ch orm a part o th|s tech- no|ogy. lt |s apre-stressedconcretes|ab w|thcont|nuous vo|ds prov|dedtoreduce we|ght and cost and |s pr|mar||y used as a |oor or roo deck system. These s|abs are ormed through a dry cast, extrus|on process where zero s|ump concrete |s orced through the mach|ne. The cores are ormed w|th augersandtubesw|ththeconcretebe|ng compactedaroundthe cores us|ngh|gh requency v|brators. As ar as the|o|nts requ|redto|t these structura| e|ements together are con- cerned, cr|ter|a can vary cons|derab|y depend|ng on the product type, s|ze and bu||d|ng movements. Typ|ca||y, |o|nts |n structura| products are 1" and arch|- tectura| products are". However, there are a number o cons|derat|ons ||ke From Let: F|tt|ng the re|norcement manua||y, Concrete spreader w|th mob||e operat|ng p|atorm Ho||ow Core S|abs stacked at s|te AnaIysis Preca Solutions India Pvt. Ltd precast sect|ons and hand||ng at s|te has been pos|nga prob|emunt|| recent|y. But, now that there |s cons|derab|e |mprovement |nthe qua||ty o roads (r|d- |ng surace) and a|so ava||ab|||ty o h|gh capac|ty hand||ng equ|pment |n most metros, th|s |ndustry |s expected to |our|shrap|d|y. A|so, rea| estate deve|opers, due to p|||ng up o extens|ve|y h|gh pr|ced, unso|d|nventory |n metros ||ke De|h| and Mumba|, are |ook|ng or aordab|e hous|ng opt|ons to augment the|r bus|- ness|nhardt|mes. Not surpr|s|ng|y, Home, Sweet Home r|ngs true a|so |n th|s part o the wor|d, and many lnd|ans |ook or- ward to home ownersh|p as very h|gh soc|a| and cu|tura| va|ue |s attached to property ownersh|p. The examp|es o precast concrete rom other countr|es show that there |s market potent|a| or the product |nhous- |ng prov|ded manuacturers promote sens|b|e opt|ons to a we||-|normed mar- ket. There are thus many |essons to be |earned romcountr|es that use a h|gher proport|ono |ndustr|a||zedhous|ngthan lnd|a. lndeed, take-up o precast may u|t|- mate|y depend on the ba|ance o con- struct|on costs and added va|ue. Th|s d||cu|t equat|onmayneedtobereso|ved on an |nd|v|dua| pro|ect bas|s, thereby oer|ng every house bu||d|ng c||ent a ta||ored package. For precast concrete to make |nroads |n the hous|ng and commerc|a| market, contractors and c||ents need to be made aware o the speedandqua||ty bene|ts |t oers, wh||e owners and occup|ers need to be made aware o the perormance bene|ts over t|me such as |re res|stance, se|sm|c re- s|st|v|ty,acoust|candtherma||nsu|at|on, etc. The soc|o-econom|c changes |n lnd|a have paved the way or precast techno|ogy to |our|sh and |arge-sca|e bu||d|ngpro|ects havemade|t evenmore |ucrat|ve as the h|gh |n|t|a| |nvestment costs can be covered |n a reasonab|e per|od o t|me. ln the upcom|ng decade, |t wou|dnt be surpr|s|ng | we w|tness a|most every lnd|an construct|on com- panyspresence|nth|sboom|ng|ndustry. 126 The Masterbu||der - ApriI 2013 www.masterbu||der.co.|n Extract|ng casted wa|| pane| rom t||ted tab|e Transportat|on o Large Precast e|ements has been a cha||enge bu||d|ng expans|on |o|nts, bu||d|ng |so- |at|on |o|nts etc. that w||| d|ctate the |o|nt s|zes. Growing popularity: ncreasing appli- cationinreal estate The need to |ncrease the pace o construct|on has become a d|re neces- s|ty. W|th shortage |n houses ga||op|ng by the day and the act that end users expect to get possess|on qu|ck|y, th|s techno|ogy has prompted some ma|or names |n the rea| estate |ndustry to embrace |t, a|m|ng to |ncrease the pace o de||very. lnter|or Crat, A|stone, Orr|s lnra- structure, Amrapa||, Supertech, Omkar bu||ders, L&T, Sweta Estates, Godre| Propert|es, Tata hous|ng, Panchshee| Pea|ty, Marve| Pea|tors, etc. haveadopted th|s new bu||d|ng system|n some o the|r pro|ects wh|ch he|ps |n sav|ng up to 64%o thetota| manhours needed us|ng convent|ona| methods. The use o PCS a|so br|ngs down the construct|on cost by 10-15% | |ts a mass hous|ng deve|- opment. Future: All set for aconcretechange The ma|n concern or PCC |ndustry |s transportat|on |n a country as b|g and var|ed as lnd|a. Transportat|on o |arge AnaIysis
Handbook on Construction Techniques: A Practical Field Review of Environmental Impacts in Power Transmission/Distribution, Run-of-River Hydropower and Solar Photovoltaic Power Generation Projects