C. A. Prasad, Director, Metey Engineering & Consultancy and President
C. A. Prasad, Director, Metey Engineering & Consultancy and President, PSI, Hyderabad, guides entrepreneurs on the various aspects of Precast and PEB construction business.

Quality assurance and timely construction using Precast and PEB produced elements are the reasons behind their increasing demand. These elements are cast by the industry at a centralised location where all facilities for production, testing, and curing are available. Elements produced in precast are:
 
  • Precast prestressed Hollow core slabs
  • Precast solid elements like slabs, columns, walls, beams, stairs, and (occasionally) precast footings.
Similarly, in the PEB industry, elements produced include:

  • Structural steel columns
  • Structural steel rafters, portal frames, trusses, and beams
  • Purlins, roofing sheets
All these are prefabricated as per the required size.

C. A. Prasad, Director, Metey Engineering & Consultancy and President

How to meet increasing demand for Precast & PEB structures
Demand for Precast and PEB structures is coming from the far interior regions, including tribal areas, so much so that the Indian Government is planning construction of high-quality, sustainable buildings for tribal people in the interiors and at sectors located far away from the cities.

However, precast industries are located near cities and towns, so how will the industry provide the prefabricated structures to the interior areas and to faraway places?

Option1: Produce the precast elements in the industry located in the city and transport them to the faraway areas.

Option 2: Set up a temporary precast facility in a nearby, centrally located area to reduce cost of transportation of the elements. There should be a sufficient number of precast productions for the temporary set up to make the project cost-effective.

In both the options, the precast production of elements should be done by a company experience in this field of work as it will have all the facilities for production, QA&QC assurance, testing, and automated curing system to make the elements produced robust and durable.

Challenges & Opportunities in Transportation and Erection
One of the challenges experienced by the Precast/ PEB industry is the transportation and erection of the precast elements. Many precast producing companies are looking for external agencies to offload this work.

If transportation of the elements is taken up by an entrepreneur, it will reduce the burden on the Precast/PEB industry, which is looking forward for entrepreneurs to come forward to undertake this activity.

However, entrepreneurs need to be trained on the Transportation and Erection systems such that they will get employment or business opportunities from the precast companies.

Certified Course for budding entrepreneurs
PSI (Pre-Engineered Structures Society of India www.pessi.in) is looking forward to running a certified course in Transportation and Erection of Precast and PEB elements with the help of the Precast Industry. Its aim is to impart knowledge to qualified engineers on how to transport and erect the elements safely at sites. (Details on the certified course will be announced shortly through this magazine).

C. A. Prasad, Director, Metey Engineering & Consultancy and President

Cost economics of transportation of elements
Precast elements are heavier while PEB elements are lighter. Usually, a distance of 60 to 80 km is considered as cost effective and is very competitive compared to conventional construction.

However, the Precast Industry is also transferring elements to faraway places of 300 to 400 km distances as per the demand of clients and project sites. Transporting long distances and setting up a facility to cater to faraway places poses the following challenges:
  • Non availability of labour in a remote place.
  • Providing labour accommodation is uneconomical and not viable.
  • Non availability of materials in the vicinity.
  • Time required to complete the structure is less.
Considering the above constraints, companies like Precast India Infrastructure in Pune and Inventaa Industries in Vijayawada are catering to clients requesting the precast industry to deliver the precast structures to faraway/remote places. The two companies have successfully delivered precast elements to far off distances of 250 to 300 kms and thereby set a trend for constructing precast structures in any part of the country.

Cost of Transportation & Erection
The prevailing market rates for transportation and erection rates are as follows:

Up to 25km: ₹500/ton
Up to 60km: ₹750/ton
Up to 80 km: ₹900/ton
Installation/Erection rate: ₹1500/ton

CPWD SSR (DSR/DAR) gives the desired information on costing of precast elements, transportation, erection, grouting, stressing strands, sims, etc.

Acknowledgement: The author expresses his gratitude to Inventaa Industry and to Kirby for providing the required information.
Mekuba Petro Products - Catering to Mega Precast Concrete Projects
Mekuba Petro Products has a strong presence in the petrochemicals industry since 47 years and has been growing rapidly in the construction chemicals segment over the past decade. An expert in the formulation and production of mould-releasing agents, its

Read more ...

Autoclaved Aerated Concrete Blocks
A sunrise segment in India’s building materials industry, the AAC block is finding preference over the red brick and emerging as the future of building construction. Mohit Saboo, Director & CFO BigBloc Construction

Read more ...

A Stellar Modernization of Construction With Precast in NCR, India
What influenced the Stellar Group’s decision to build with precast and invest in a precast plant. The well-known Indian ‘Stellar Group’, which has been successfully working in the construction business for over 25 years, is convinced that precast is the future

Read more ...

Sardinian industry leader invests in automated mould from Progress Group to advance production
Recently, a highly automated mould for the production of pillars from Tecnocom, a company of the Progress Group, has been installed to help industry leader Consultecna stay ahead. Francesco Pireddu explains the decision made in favour of automation although

Read more ...

AHCT’s Smart Solutions for Smart Contractors
Technology companies have developed hardware and software solutions to help manage every aspect of a construction project, no matter how complex or massive the project may be. Harsh Pareek, Regional Sales Director, India and SAARC, Trimble Solutions

Read more ...

Echo Precast Engineering Helps Modernize Pruksa’s Precast Plants
Thailand’s real estate developer Pruksa, a leader in the building sector, modernizes its building solutions with automated hollow core production plant equipped with machinery from Echo Precast Engineering, a company of the PROGRESS GROUP. Real estate developer Pruksa

Read more ...

Dongyue Machinery Group gearing up to meet rising demand for AAC Bricks in India
Dongyue Machinery Group is offering Autoclaves Aerated Concrete (AAC) blocks, brick blocks, hollow blocks, curb stones, color blocks etc. AAC Blocks, which are lightweight concrete blocks, use less cement compared to traditional cement bricks, and are therefore eco-friendly

Read more ...

B.E. Billimoria Changing the Face of India
BE Billimoria & Company is one of India’s leading firms of civil engineering construction contractors. Ranging from commercial, residential spaces to some of the most iconic buildings in the country, like the 316-meter Namaste Tower, are among their project list

Read more ...

Advanced Concrete Curing Systems from Kraft Curing Systems GmbH
Kraft Curing Systems GmbH is offering advanced concrete curing systems that optimize the hardening process of concrete. Kraft provide numerous solutions, from vapor-based (steam) systems mainly for the precast industry, to heating/air circulation systems

Read more ...

LARCO partners with ECHO Precast to set up production site for prefab elements
The production site of LARCO PREFAB S.A. in Welkenraedt, Belgium opened in 2018 and has grown consistently over the years. LARCO produces a range of prefabricated concrete elements such as hollow core slabs, columns, wall panels, soccles

Read more ...

Special prefabricated elements specialist Klaus relies on fully individualised automation solutions
Klaus Hoch- und Tiefbau GmbH is upgrading its machines in the precast concrete plant with several automated systems from progress Maschinen & Automation and Tecnocom - companies of the Progress Group. With the individualised reinforcement machines

Read more ...

Prefab Housing
Civil Construction in India has not been as much industrialized as it has been in the West. Presently, it shares barely 1-2% of the real estate market, though as per a recent study, it is expected to grow @8.5% in the decade of 2016-2026

Read more ...

Light House Projects by Skeleton
The increasing demand for residential units in the country with speedier construction, has encouraged use of innovative technologies that are being practiced the world over. Structural steel with its in-built attributes when integrated

Read more ...

Solutions from Mapei for Precast Concrete
Precast concrete is produced by casting concrete in a re-useable mould or form, which is then cured in a controlled environment. To ensure durability, high strength, low water cement ratio, and improved rheology, use of concrete admixtures is compulsory

Read more ...

Aurobindo Realty Teams up with Precast Expert Elematic to Create History
Aurobindo Realty & Infrastructure, one of the frontrunners in the realty sector in South India, is confident that the southern region will see numerous construction projects being launched during the next 10 years and even beyond

Read more ...

Construction Technologies for Speedy Delivery of Projects
C. A. Prasad, President PSI & Director, Metey Engineering & Consultancy, Hyderabad, discusses the various new construction technologies being adopted by developers and builders in India, and their merits and demerits

Read more ...

Prefabricated Volumetric Modular Construction Prospects & Challenges
Ajay Chourasia, Sr. Principal Scientist, CSIR-Central Building Research Institute (CBRI), Roorkee, reviews the general concepts, PVMC connections, and recommendations for technological interventions and alternate connection systems

Read more ...

Joints in Precast Construction
C. B. Kameswara Rao, Professor, National Institute of Technology, Warangal, gives a presentation of different types of joints in precast construction and of the research done at NITW. Connections and joints are responsible for stability as well as strength

Read more ...

Offsite Construction
Srinidhi Anantharaman explores offsite building construction in a holistic manner and provides an overview of the entire design and construction lifecycle of such buildings, along with the compulsions of architectural, structural and services, design decisions

Read more ...