larsen & toubro constructions
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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
ELIGIBILITY FOR ENGINEERING EXCELLENCE – PRAGATI TOWERS
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
ELIGIBILITY FOR ENGINEERING EXCELLENCE – 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.
ELIGIBILITY FOR ENGINEERING EXCELLENCE – PRAGATI TOWERS
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
ELIGIBILITY FOR ENGINEERING EXCELLENCE – PRAGATI TOWERS
5. QUALITY CONTROL Precast Elements of Pragati Towers were cast in strictly controlled factory conditions
ELIGIBILITY FOR ENGINEERING EXCELLENCE – PRAGATI TOWERS
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
ELIGIBILITY FOR ENGINEERING EXCELLENCE – PRAGATI TOWERS
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.
ELIGIBILITY FOR ENGINEERING EXCELLENCE – PRAGATI TOWERS
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.
ELIGIBILITY FOR ENGINEERING EXCELLENCE – PRAGATI TOWERS
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
ELIGIBILITY FOR INNOVATIVENESS IN CONSTRUCTION – PRAGATI TOWERS
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’
ELIGIBILITY FOR INNOVATIVENESS IN CONSTRUCTION – PRAGATI TOWERS
MOULD - MODULAR BLOCKS INTERIOR COREEXPLODED VIEW
MODULAR BLOCKS ( 3D POD) TRANSPORTATION REAR VIEW
ELIGIBILITY FOR INNOVATIVENESS IN CONSTRUCTION – PRAGATI TOWERS
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
ELIGIBILITY FOR INNOVATIVENESS IN CONSTRUCTION – PRAGATI TOWERS
5. SPEED & SAFETY
ELIGIBILITY FOR INNOVATIVENESS IN CONSTRUCTION – PRAGATI TOWERS
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
ELIGIBILITY FOR OPERATIONAL EXCELLENCE OF PROJECT – PRAGATI TOWERS
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
ELIGIBILITY FOR OPERATIONAL EXCELLENCE OF PROJECT – PRAGATI TOWERS
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
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