Precast Technology

Timeless Technology

Unlike the conventional construction process using wet building, BCC uses state-of-art German Precast Technology. This ensures that is built to last, literally a 100 years. This process uses huge high strength concrete moulds without any bricks. It helps protect against seepage which further protects the structure reinforces the wall and delivers unfailing durability.

Key Advantages of Precast

  • Production can continue in any weather condition.
  • Electricity conduits, pipes and boxes can be embedded in the precast panels.
  • Thin precast walls and façade panels increase the carpet area.
  • Precast concrete requires less maintenance and is highly durable.
  • Pre-caster can buy material for multiple projects thus discount can lower costs.

Precast construction is a process to build concrete structures using prefabricated components which are manufactured on/off-site and assembled into their final position at construction site, instead of the conventional method to form the structure using formworks and in situ placed wet concrete. This is a more mechanised construction method which is faster, neater and uses much less site labour. In particular this type of construction requires arestructuring of entire conventional construction process to enable interaction between design phase and production planning in order to improve and speed up construction

Precast construction delivers significant cost savings by reducing formwork by up to 70% and reliance on wet trades by up to 90%. The need for access scaffolding can be reduced by anything up to 90% and site supervision by the main contractor is also greatly reduced. Other advantages include reduced construction programmes, greater project control, greater accuracy and quality of finish and larger clear spans.

Advantages of Precast Concrete

  • Production in controlled environment results in high quality precast units.
  • Repetition of standard precast elements will lead to cost reduction.
  • Plastering on precast walls and floor slabs is not needed because of smooth finishing.
  • Production can continue in any weather condition.
  • Better health and safety standards compared to conventional construction methods.
  • Project can be better planned, managed and controlled. High speed can be achieved.
  • Fast construction, less manpower required on site, and no shuttering required on site.
  • Door and window frames can be installed in the wall panels before erection.
  • Electricity conduits, pipes and boxes can be embedded in the precast panels.
  • Large span floor system leads to more flexibility as internal columns are avoided.
  • Production in controlled environment results in high quality precast units.
  • Repetition of standard precast elements will lead to cost reduction.
  • Plastering on precast walls and floor slabs is not needed because of smooth finishing.
  • Production can continue in any weather condition.
  • Better health and safety standards compared to conventional construction methods.
  • Project can be better planned, managed and controlled. High speed can be achieved.
  • Fast construction, less manpower required on site, and no shuttering required on site.
  • Door and window frames can be installed in the wall panels before erection.
  • Electricity conduits, pipes and boxes can be embedded in the precast panels.
  • Large span floor system leads to more flexibility as internal columns are avoided.

WBK Engineering Services Pvt. Ltd. was given the task to carry out a structural feasibility study on the usage of precast concrete construction methods for the proposed residential buildings of Phase II at “Bharat City”, Ghaziabad. The main task of the study was to convert the existing building plans of one of the typical residential towers from conventional construction to precast construction. And after that the structure had to be further worked out in detail and structural analysis and design had to be carried out. The following steps were taken to analyze the structure of Wing B1, Phase 1, “Bharat City”:

  • Convert building plans from conventional to precast.
  • Comparison between different precast systems
  • Optimizing the proposed layout plans
  • Preparation of concept plans and details
  • Structural analysis of full residential tower
  • Design of typical precast elements
  • Design of typical connections
  • Preparation of typical precast element drawing
  • Preparation of BOQ and pricing
  • For the precast load bearing systems basically two options are possible:
  • Precast frame structure with columns and beams in combination with few shear walls.
  • Precast wall panel structure
  • Convert building plans from conventional to precast.
  • Comparison between different precast systems
  • Optimizing the proposed layout plans
  • Preparation of concept plans and details
  • Structural analysis of full residential tower
  • Design of typical precast elements
  • Design of typical connections
  • Preparation of typical precast element drawing
  • Preparation of BOQ and pricing
  • For the precast load bearing systems basically two options are possible:
  • Precast frame structure with columns and beams in combination with few shear walls.
  • Precast wall panel structure

After reviewing both the options the consultant has advised us to go for precast load bearing wall panels which have following advantages compared to frame structures.

Conclusion:

Precast concrete plants can produce precast components in short amount of time even before the site is ready. The components can be stored in a yard and later transported as per the construction sequence. The quality control department in precast plants can ensure that the concrete products will exhibit high standard of quality and uniformity. Precast concrete products are manufactured due to which project time is not lost waiting for ideal weather conditions. Precast plants can provide organised construction industry where engineers, technicians and labours can be stationed at one place and production can be delivered at large distances from the location of plant. To increase the infrastructure in a developing country like India in the next decade, there will be a requirement of 4-5 such plants in each state which can help build the required infrastructure. Erection crew needs to be aware of correct erection sequence; welding and bolting process to keep the structure stable when it is in erection phase.

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