WELCOME

PRESENTATION
ON
CONSTRUCTION TECHNOLOGIES
(Pre-Fab Technologies)
1

PREFACE

Govt., of A.P. invited EOI from the reputed, experienced,

technically
and
financially
sound
companies/
firms/
Contractors/ Institutions / Individuals/ Developers for
Construction of Houses / Structures on Design and Built Basis
using Alternate Technologies preferably Pre-cast concrete/
Pre-Fabricated (fully/ Partially) etc., other than conventional.

18 no. of bids were received in response to the EOI .

Technical Committee meeting held on 10-3-15 and 11-3-15

under the Chairmanship of the ED, BMTPC for evaluation of
Technologies.

Of the (9) alternative technologies presented by the Agencies

(7) Technologies were accepted by the Technical Committee.

Technology/Agencies participated

1.
2.
3.

1.
2.
3.

Glass Fibre Reinforced Gypsum Panels for Walls &

Roof slabs.
M/s. Nanobright Solar Technologies Pvt., Ltd., Hyderabad
M/s Belasia Engineers & Developers (P) Ltd, Kochi.
M/s. R.P.P.Infra Projects Ltd., Erode

Expandable Polystyrene Panels for Walling and

Roofing
M/s DSP Infra Pvt. Ltd CTSPL - (JV), Hyderabad
M/s. RMN-BKCHEM-PREVISE HOMES (JV), Hyderabad
M/s Beardcell Ltd., Visakhapatnam

1.

Light gauge Steel structures

1.

M/s.B.G.SHIRKE Construction Technology Pvt Ltd., Pune

M/s Everest Industries Ltd., New Delhi

Pre-cast Concrete System (3-S Pre-Fab Technology)

Technology/Agencies participated

Steel frame with Aerocon Panels/PUF panels

1.
2.
3.

M/s. PANDHE INFRACONS PVT.LTD.,Solapur ( with aerocon panels)

M/s. Jindal Mectec Pvt., Ltd.,Gurgaon ( with PUF panels)
M/s. ENERTECH ENGINEERING PVT.LTD.,Hyderabad (with PUF
panels)
M/s. Satec Envir Engineering (I) Pvt., Ltd., Mumbai

4.

1.
2.
3.

1.

Monolithic Concrete Walls (Shear Wall Technology)

with Plastic/Aluminium frame work
M/s Sintex Infra Projects Ltd., Kalol (Plastic frame work)
M/s M.V.Omni Projects (INDIA) Limited. Ahamadabad (with
Aluminum frame work)
M/s NCC LIMITED, Hyderabad ( with Aluminum frame work)

Waffle Crete Pre-cast Concrete Panels

M/s KCL-SRL Houses, Ahmedabad (Load bearing wall - Waffle
Crete concrete panels for walls and slabs with vertical and
horizontal ribs)

Glass Fibre Reinforced Gypsum PANELS

FOR WALLS AND ROOF SLABS

Glass Fiber Reinforced Gypsum (GFRG) Panel, called

RAPIDWALL . is an alternative building material to
replace bricks / concrete blocks which will also save
river sand, water etc and protect the environment
GFRG wall panels are 124 mm thick which are factory
molded from fiber glass reinforced gypsum creating
two 15+/-3 mm thick sheets spaced apart by web
members at 250 mm centre
Cavities may be filled with concrete for multistoried
buildings
The cavities can be used to accommodate building
services such as plumbing, electrical conduits and
insulation
GFRG Wall panels can be used for hybrid construction

Advantages of GFRG Panel

system

Light weight and accurate

Load bearing
Flexible in all aspects of home plan designs
Reduces construction time and space saving
High quality finish
Good sound attenuation
Earth quake resistant, Termite resistant, Fire
Resistant & Water resistant
Environment friendly and Recyclable
Substantial reduction in the structural weight of the
building
Escalation of project time schedule can be avoided
Validation of Technology:
Validated by SERC Chennai, IIT Madras duly
conducting various Tests.

Hybrid Building in which RCC columns & beams are

framed & walls & floor slab is with Rapidwall

APPLICATIONS OF GFRG
PANELS

Load Bearing walling and

Partition infill walls.

Compound Wall and fencing

Mass housing

Horizantal roof slabs and

multi storied buildings

Costing of the Dwelling Unit on Sq. ft. Plinth area Basis

Name of
Agency

Technology Proposed
Foundati
ons

Walling

Roofing

No of
Houses
Propos
ed

Cost
Per
Sft in
Rs.

M/S Nanobright Conventi GFRG Panels

Solar
onal
technologies
Ltd., Hyderabad

GFRG Panel
with Screed
slab with Micro
T-Beams

500

1738/to
1994/-

Belasia
Engineers &
Developers
Ltd., Kochie

Conventi GFRG Panel

onal
with M20
Concrete as
infilling

GFRG Panel
with Screed
slab with Micro
T-Beams

Not
particip
ated
ion
bids

RPP Infra
Projects Ltd.,
Erode

Conventi GFRG Panels

onal

GFRG Panel
with Screed
slab with Micro
T-Beams

Not
particip
ated
ion
bids

Panel being placed / seated on RCC plinth beam over a

10
thin layer of cement mortar slurry.

2 panels erected as
corner walls. Angles
are provided from two
sides using nuts&
bolts. After setting of
concrete in-filled,
these angles are
removed.
For supporting panel
in position, adjustable
slanting prop is
provided.
11

First pouring of concrete into wall corner joint.

12

All the walls of ground floor are erected in two days.

13

For roof/floor, panel to be lifted horizontally / flat as

seen in picture.

14

RW roof panel placed on walls.

15

100 mm x 100 mm, 10 gauge weld mesh provided for 50

mm thick RCC screed. Embedded RCC micro-beams16

Simultaneous concreting of RCC horizontal tie beams,

micro-beams and screed concrete
17

Wall panel with

window and
ventilator
opening is being
placed in first
floor

18

EPS PANELS

for walling and Roofing

Concept:

Expanded Polystrene Panel Systems

EPS Panel comprises of a layer of mesh on
either side of EPS core welded together by
steel octogonal (trusses) which penetrates
through EPS core.
The panels are joined together on site and
sprayed on both sides with shotcrete to form
a sandwich type construction.
The exterior of the panels finished with
weather proof coating such as plaster
Interior surfaces (walls) and ceilings can
either be plastered.

Time required for completion

6 months for 500 units

EPS PANELS

for walling and Roofing

The EPPS construction system is

based on a series of polystyrene
panels and galvanized steel wire
meshes.
The EPPS fulfils the required
structural and load-bearing
functions.
Offering high thermal and sound
resistance.
After the panel assembly,
structural plaster should be
sprayed and/or poured on the
panel, depending on panel type.

EPS Panels
ADVANTAGES OVER CONVENTIONAL BUILDING
Description

Conventional

EPPS Panels

Floor Area

612

670

Insulation

POOR

EXCELLENT.

Average of 5 times more R value is

obtained.

EXCELLENT

With stood more than 7.6 ric scale in

testing also meets Govt. of India's
Earth quake disaster management
recommendation.

Seismic Resistance

Dead Weight

Life Of The Building

POOR

Remarks
58 Sq.Mtr of more usable area is
obtained

Less dead weight requires less

High ( more Low ( less than
foundation and is more stable and
than 2000 tons)
700 tons)
has better life.

Good

Panels are made with G.I wire which

Give better life
is rust resistance and EPS is non
by 1.5 times
Degradable material.

Costing of the Dwelling Unit on Sq. ft. Plinth area Basis

Name of
Agency

Technology Proposed
Foundation
s

Walling

Roofing

No of
Hous
es
Propo
sed

Cost
Per
Sft in
Rs.

M/S DSP
Infra-CTSPL
(JV),
Hyderabad

Convention EPS
al RCC
Panels
insulated
with
concrete

EPS Panels
covered
with RCC

2000

1296/to
1496/-

RMNBKCHEMPrevise
Homes (JV),
Hyderabad

Micro
foundation
s with
Piling or
Convention
al RCC

EMMEDU
Es EPS
panels
insulated
with
concrete

EMMEDUEs
EPS panels
Strengthen
edwith
concrete

Not
partici
pated
in bids

Beardsell
Ltd.,

Not
Specified

Quick
build EPS

Quick build
EPS Panels

Not
partici

FIXING OF DIFFERENT FIXTURES ON

QUIKBUILD WALLS SHOWING THE
STRENGTH OF THE WALLS

Different Models of G+1 AND G+2 Construction.

Pre-Engineered Structures with Light Gauge Steel Frame

Agency Presented: M/S Everest Industries Ltd.,

SECTION DETAILS OF LIGHT GAUGE STEEL FRAME

Light
Gauge
Steel
Frame is lipped C
steel sections. The
sections are with Zinc
coating of 275GSM
and
steel
yield
strength of 550 MPa
custom designed and
fabricated in factory
through
fully
automated
CNC
controlled machines.
The section sizes will
be in required length
as
per
structural
design.
LIP
= 11mm

WEB =
89mm

FLANGE
= 41mm

SECTION PROFILE

SWAGE

A section that fits

into another is
swaged. This gives a
leveled outer
surface.

NOTCH

A section through
which another
section passes is
notched (web is
knocked-out) in that
portion.

PUNCH& DIMPLE
Wherever a screw
comes, the section is
punched and dimpled.
This helps in easy
screwing and getting
leveled surface after
screwing.

Advantages of Building with Steel

A Durable and safe material

Consistent material quality
Superior seismic and wind performance
Non-combustible material
Dimensionally Stable
100% recyclable
Insect and rodent resistant and does not root

High Strength to weight ratio

Ease of handling, transportation
and installation
Complete design flexibility

Costing of the Dwelling Unit on Sq. ft. Plinth area Basis

Name of
Agency

M/S Everest
Industries Ltd.,
New Delhi

Technology Proposed
Foundati
ons

Walling

Conventi Light Gauge

onal
steel frame
with
Rockwool
walling

Roofing

Deck sheet of
concreting

No of
Houses
Propos
ed

Cost
Per
Sft in
Rs.
2250/to
2750/-

Pre-cast Concrete System- 3 S Prefab Technology

3-S
3-S is the brand name of Prefab
Building Construction System
fully developed and perfected by
SHIRKE after years of strenuous
R & D supplemented by
extensive field trials.
Structural
components
like
Slabs,
Walls,
Columns
and
Beams are precast in casting
yard
having
factory
like
condition.
Manufactured
precast
components are erected, aligned
and
connected
using
SelfCompacting
Concrete
of
appropriate grade along with
embedded reinforcement.
38

Pre-cast Concrete System- 3 S Prefab Technology

Sustainable green Technology due
to
-Judicious use of construction
materials
-Reduction
in
wastage
of
materials
-Using more durable materials
-Use of energy efficient building
materials
-Use of products that contribute
to
a
safe,
healthy
built
environment
-Use
of
construction
system
minimizing air, water and noise
pollution during construction
Tested and Evaluated by
-IIT, Mumbai
-CBRI, Roorkey
-Stanford University
-Civil AID Technoclinic, Bangalore

39

Costing of the Dwelling Unit on Sq. ft. Plinth area Basis

Name of
Agency

M/S BG Shirke
construction
technology Pvt.
Ltd., Pune

Technology Proposed
Foundati
ons

Walling

Roofing

Conventi Precast Plinth Roof Panels

onal
Beams,
Lattice girder
Columns and slabs
Shear wall for
exterior

No of
Houses
Propos
ed

Cost
Per
Sft in
Rs.
Approx
2000/-

Projects Executed
HOUSING PROJECT FOR MHADA,
MAZGAON, MUMBAI- EWSProject

HOUSING PROJECT FOR MHADA, GHATKOPAR,

MUMBAI (G+7 EWS/LIG)

41

A VIEW OF PRECAST CONSTRUCTION

SITE

SHEAR WALL TECHNOLOGY

Concept
In-situ RCC walls and Roof with modular
Shuttering made up of Aluminium / Fibre
shuttering.
Monolithic Construction.
Experience in Actual Use
- Delhi Ind. Infra Board- construction of 6740
units.
- Delhi slum Development Board- construction
of 7260 units.
- Tumkur KSEB construction of 1200 units.
- Boiser, Mumbai TATA- construction of 1200
units.
- 990 houses in Ahmadabad.
Cost of construction:
- Approximately from Rs. 1530 to Rs. 2800/per Sq.Ft.
43

SHEAR WALL TECHNOLOGY

Adopted in private projects and JnNURM projects at Delhi and

44
Bangalore

MONOLITHIC CONCRETE WALLS (SHEAR WALL

TECHNOLOGY)
Monolithic Concrete
Construction System using
Aluminum Formwork
Eliminates Traditional
Column & Beam
Construction.
Walls and Slabs are cast in
one operation at site.
Specially Designed, Light
Weight Pre-Engineered
Aluminum formwork used.
Entire operation essentially
comprises fitting and
erecting of Formwork.
Then carrying out
concreting of the walls and
slabs

ADVANTAGES OF SHEARWALL
TECHNOLOGY
Labour Requirements Minimal.
No Requirement of Any Specialized Equipment's.
Dimensional accuracy of the formwork is of high order, hence
errors are minimal.
Rapid Construction of Repetitive Type Dwelling Units.
Earthquake Resistant Box Type Structure.
Very High Life 50 Yrs Plus.
Structurally Superior as Very Few Construction Joints.
Four day Casting Cycle Compared to 14-20 Days conventional
Cycle.
Completed RCC structure is available for subsequent finish
trades much faster.
Limitations:

Prior and proper planning is in all aspects including

services at the Zero date of the project is very very
essential.
Large volume of work is necessary to be cost effective
i.e. at least 200 repetitions of the forms should be
possible at work.

COMPARISON BETWEEN
CONVENTIONAL AND SHEARWALL
TECHNOLOGY

S. No

FACTOR

CONVENTIONAL

IN SITU ALUMINIUM SYSTEM

In Situ casting of
whole structure and
transverse walls done in
a continuous operation

Quality

Speed of
construction

The pace of
construction is slow
due to step by
step completion
of different stages

In this system, the walls

and floors are cast together
in one continuous operation
in matter of few hours.

Aesthetics

In the case of RCC

structural framework,
the columns and
beams show unsightly
projections in room
interiors.

The Room Sized wall panels

and the ceiling elements cast
against steel plates have
smooth finishing and the
interiors have neat and clean
lines without unsightly
projections in various corners.

External
finishes

Finishing needs
painting every in
three years.

This will need no frequent

repainting.

REMARKS

Superior quality in
System housing

System construction
is
much faster.

Permanent facia
finishes feasible with
minor extra initial
cost.

COMPARISON BETWEEN CONVENTIONAL

AND SHEARWALL TECHNOLOGY
S. No

FACTOR
Useful carpet
area as % of
plinth area.

CONVENTIONAL

Efficiency around 83.5%

IN SITU ALUMINIUM
SYSTEM

REMARKS

More efficient utilization

Efficiency around 87.5% of land for useful living
space.

Consumption of
basic raw
materials
Consumption somewhat strength and durability
more
is also more

Cement.
6

Reinforcing steel required

Reinforcing Steel is less as compared to the It may, however will be
in situ construction as RCC slightly more than
framework uses brick wall corresponding load
as alternative
bearing brick wall.

Maintenance

Steel requirement is
more, as it is required
for the shear wall
construction. But shear
wall construction
increases safety against
earthquake.

In maintenance cost, the

major expenditure is
involved due to

The walls and ceiling

being smooth and high
Repairs and maintenance quality concrete repairs
of plaster of walls/ ceiling for plastering and
etc.
leakages are not at all
Painting of outer and
required frequently.
inner walls.
Leakages due to plumbing
and sanitation installation.

It can be concluded that

maintenance cost is
negligible.

Shear Wall Technology

Shear Wall Technology Construction in progress

JnNURM, EWS Projects,

Vadodara(2928 DUs)

JnNURM, EWS Projects,

Ahmedabad.(5952DUs)

PANDHE INFRACONS PVT. LTD., Solapur

Prefabricated steel building with aerocon panel partition
walls
Framing System:- Entire building frame will be of Prefabricated
steel building of I, C and angle sections
Partition Walls:- All the Partition walls will be of Aerocon Blocks
and panels of having Male and Female connection system
supplied by well known suppliers HIL
Flooring :- All the Flooring system will be of Deck slab (sheet
profiled) of min. thickness 125mm.
Top Slab :- Galvalume Sheet with false ceiling
Doors and Windows, Finishing, Sanitary and internal
Electrification:- As per specification

Steel Frame with Aerocon/PUF Panels

Concept
Building construction designed based on Steel structure
with different walling components.
Fabricated in a controlled factory environment and erected
at building site.
Once all the components are assembled and erected at site,
Walling is made with the factory made Aerocon
Blocks/Panels or Poly Urethane Foam (PUF) Panel walls
making it a monolithic structure.
Experience in actual use
Mass housing Projects in Solapur (10000 units),Andaman
Project (5000), RGK-APHB at Suraram (4324) & VAMBAY
Yojana (Apna Ghar)
Time required for Completion
6 Months period.

ABOUT AEROCON PANELS

A sandwich panel of two fiberreinforced

cement
sheets
enclosing
a
light
weight
concrete core composed of
Portland cement and Fly-ash
Fully cured at factory, they are
ready for installation right away
Unique Tongue and Groove
jointing system facilitates rapid
construction
with
minimum
effort

Applications AEROCON PANELS

Residential Qtrs

Commercial Building - Hyderabad

Jindhal Project Accommodation unit

PUF INSULATED SANDWICH

PANEL

COMPARISON B/w INSULATED PEB & RCC BUILDING

MULTISTOREY STEEL BUILDING

MULTISTOREY RCC BUILDING

Self Weight of the overall structure is

less than RCC building.

Self Weight of the overall structure is

Higher than steel building.

Base shear in steel building is lesser

than RCC building.

Base shear in RCC building is higher

than steel building

Time taken in the construction is less

Time taken in the construction is more

Alteration and Strengthening of floor

are relatively easy as compare to RCC

Alteration and strengthening is complex

Costing of the Dwelling Unit on Sq. ft. Plinth area Basis

Name of Agency

Technology Proposed
Foundatio
ns

Walling

Roofing

No of
Houses
Propos
ed

Cost Per
Sft in
Rs.

1500

1310/to
1870/-

M/S Pandhe
Infracons Pvt.Ltd.,
Solapur

Conventio
nal RCC

Aerocon Panels
External 75mm
Internal 50 mm
thick

Galvonised
sheet with
Zipsum false
ceiling

M/S Jindal Mectec

Pvt Ltd., Gurgaon

Conventio
nal

Insulated PUF
Panels 50 mm
thick

Deck sheet
roofing

1826/to
2066/-

M/S Enertec
Engineering
Pvt.Ltd.,
Hyderabad

Conventio
nal

CLC Blocks for

External walls
and Insulated
PUF sandwitch
Panels

Steel Deck
sheet with
concrete for
Roof slab

1957/to
1990/-

M/S Satec Envir

Engineering Pvt.
Ltd., Mumbai

Not
furnished

Not
participa
ted in
the bids

LOW COST
ACCOMODATIONS

MULTI-STORIED BUILDING,
GUJRAT

ADVANTAGES & HIGHLIGHTS

WAFFLE CRETE PRE-CAST CONCRETE

PANELS

Also named as SRPL Technology suitable for low

rise building construction.

Wall and Slabs will be M30 grade concrete. Vertical

ribs of Walls will act as columns and horizontal ribs
of walls acts as beams.
Architectural Design Consideration of the
proposed technology
a Aesthetic Consideration- Excellent
b Min/Max Size As per requirement
c Finishes DetailsNo plaster is required
only paints
as per requirement

WAFFLE CRETE PRE-CAST CONCRETE

PANELS
Advantages
Reduce construction time
Reduction in the need for skilled labor
Low maintenance cost
30-35% lighter compared to brick walls in weight
Options available with insulation system
Curing time is reduced by trapping the moisture generated from the
concrete.
Costing of the Dwelling Unit on Sq. ft. Plinth area Basis

Name of Agency

M/S KCL-SRL
Houses,
Ahmadabad

Technology Proposed
Foundations

Walling

Roofing

Convention
al

Precast concrete
Panels for
walling

Precast
concrete Panels
for walling

No of
Houses
Proposed

Cost Per
Sft in Rs.

Approx.
1200/-

MERITS AND DEMERITS

Sl.
No.

Prefab
Technology

Merits

Demerits

EPPS panels
(with or
without RCC
frame)

Fast to construct .
Thermal comfort - Good
Structurally sound.
Low maintenance.

Higher cost
No scope for alterations
Validation required.

GFRG Panels
(with or
without RCC
frame)

Fast to construct .
Thermal comfort - Good
Structurally sound.
Low maintenance.

Higher Cost
No scope for alterations
Validation required.
Prone for cracks during transport
Joint handling
Peeling / fading due to rain/ sun
Beneficiary acceptance issues.

Steel Frame
with
Aerocon/PUF/E
PS wall Panels

Fast to construct .
Thermal comfort - Good
Structurally sound.
Low maintenance.

Moderate cost
No scope for alterations
Validation required.
Beneficiary acceptance issues.

Light Gauge
Steel Frame
with Rock wool
wall Panels

Fast to construct .
Thermal comfort - Good
Structurally sound.
Low maintenance.

Moderate cost
No scope for alterations
Validation required.
Beneficiary acceptance issues.
72

MERITS AND DEMERITS

Sl.
No

Prefab
Technology

Merits

Demerits

Precast
Concrete
Systems
(3-S prefab
technology)

Fast to construct .
Thermal comfort Not
Good.
Structurally sound.
Low maintenance.

No scope for alterations

Difficulty in ensuring quality of joints
Scope for cracks/ breakages during

Shear Wall
Technology

Superstructure and Roof

can be completed in
7 -12 days.
Structurally strong.
Cost of repairs &
maintenance is minimal.

No scope for alterations.

Aluminum/ Plywood / Heavy Plastic s
used in Form work.
Limited Agencies having required
shuttering material.
Designs are to be wetted.
Higher cost

Waffle Crete
Pre-cast
Concrete
Panels

Fast to construct
Thermal comfort Good if
insulation is provided.

Maintenance required.
Validation required.
Windows sizes restricted.
No scope for alterations.
Moderate Cost

transport & handling.

Designs are to be wetted.
Higher cost

73

THANK YOU

74