The 3D Monolithic Volumetric Precast

EVOLUTION OF THE CONSTRUCTION INDUSTRY

S. J. Vijay, Chairman, Salmon Leap Associates India

Unlike other industries, the Construction Industry has been stagnant and slow to adopt new technologies and has never undergone a major transformation. As a result, productivity has stagnated over the years, or in some cases, even declined. The image below depicts the evolution of the Construction Industry


The construction industry is buoyed by predicted growth and expansion, however, it continues to underperform in four strategic areas: Productivity, Certainty in Delivery, Skills Shortage, and Data Transparency. Poor productivity and project uncertainty can be countered by introducing technology into construction. The right technology would ensure reduction in the project development cycle and reduction in labour.

Construction Industry Globally

Smaller but advanced countries like Singapore as well as larger but thinly populated continents like Australia have been developing and deploying construction technologies and methodologies for decades. These have been tried, tested and proven, and can be the solution to the challenges faced in housing for the billion+ Indians.

Construction of the built environment has continually been adopting “increasing levels of manufacturing” as the solution to address the challenges relating to:
  1. Speed of Construction
  2. Quality of Construction
  3. Reduction in Wastage
  4. Productivity in Construction
  5. Dwindling number of Construction Workers/ Labourers
  6. Health Safety and Environment Issues of Construction
  7. Efficiency of Resources in Construction
The chart below summarizes the decades long path from material-based construction to the current manufacturing of buildings as modules, assembling them into pre-finished transportable Volumetric Modules for installation as Built Environment.

3D Monolithic

Indian Construction Industry

The surging construction activity in Infrastructure and Buildings coupled with rapidly diminishing labour pool has already pushed the leading players to adopt mechanized and precast methods of construction, be it for bridges or flyovers or metros or even roads, canals, waterlines, airports, seaports et al.

Formwork-based cast-insitu construction while accelerating the speed of building has also increased demand of skilled labour, and safety issues of handling the formwork at increasing height by the multitude of workers.

In July 2017, the Prime Minister of India also directed the use of 3D Technology to speed up housing construction in India. India needs the highest number of houses of possibly at the lowest price point and also in the shortest timeframe.

India has increasingly been adopting different levels of machine-driven construction. The cast-insitu construction using conventional and newer formworks is being replaced by offsite manufacturing / precast of the elements of the built environment as 2D or planar elements. As shown in the diagram above, India by doing this would still be stuck in Stage 3 of the construction evolution.

Stage 3 of construction should be by manufacturing the houses not as components, not as just 2D elements but as modules that deliver a room or more from each precast as 3-Dimensional Monolithic Modular Volumetric Precast. Construction Methods Currently Prevalent in India

Indian construction activity has increasingly been moving away from conventional column, beam, slab-based construction to formwork-based cast insitu shear wall construction during the past decade. The newer types of skills required to efficiently execute the formwork-based construction be it with MIVAN or with ALUFORM or with JUMPFORM or with TUNNEL FORM have all been struggling to cope with the rapidly diminishing quantity of construction workers and more so by the miniscule of fitters and formwork handling workforce.

3D Monolithic

2D Precast

A spurt in Affordable and other Social Housing requirements have led to the developers establishing their own 2D Precast Panel Production facilities as captive plants in Delhi, NCR, Bangalore and a few other cities.

Third Party manufacturers of 2D Precast Panels in the offsite factories are transporting a multitude of panels to building sites and erecting them with equipment and a large number of installation crew in Bangalore, Hyderabad, Vizag, Gurgaon, Mumbai, Pune etc.

Most of these 2D plants are designed and configured to Precast Columns, Beams, Hollow Core or Solid Slabs and Wall Panels as disparate elements in the dimensions of Commercial, Retail and Institutional Buildings as well as Multi Level Car Parking facilities.

However, offsite production of 2D elements, their transportation to building sites, erecting them, aligning them for plum and level, jointing the multiple pieces to secure the targeted strength and shape, and sealing the numerous joints, etc, still pose significant and critical challenges when it comes to building apartments or individual houses. Because of the fragmented nature of manufacturing in the 2D Precast panels, the installation of services like plumbing, electrical wiring, air-conditioning etc. pose additional constraints and are not able to shrink the timelines of construction.

Grinding the misalignments between panels as well as treating the numerous joints between the columns, wall panels, slab panels and beams is also tedious and demands skilled workforce, expensive material like grouts and PU sealants, but still remain vulnerable to leakages and seepages since these are not made as monolithic.

3D Monolithic

3D Monolithic Modular Volumetric Precast

3D Modular Volumetric Precast (Onsite / Offsite) construction is an alternative to this current construction status-quo by promising transformative improvements in Time, Cost, Quality, Health and Safety. And most importantly, it offers predictability.

The 3D Monolithic Volumetric Precast eliminates the problems inherent in 2D Panel-based construction, and employs the least possible number of qualified engineers and trained technicians without leaving the construction to unskilled labour.

3D Monolithic Volumetric construction (also known as modular construction) involves production of three-dimensional modular units in controlled factory conditions prior to transportation to site. Modules can be brought to site either as a basic structure or with all internal and external finishes and services installed, and ready for assembly.

This unique method of construction offers the inherent benefits of concrete such as thermal mass, sound and fire resistance, as well as factory quality and accuracy, together with speed of erection on-site.

The 3D Volumetric Construction offers schedule benefits as most of the activities are undertaken away from the building site with minimal work at the building site. This enables taking some activities off the critical path and bringing certainty in the delivery of the project.

3DMVP Project

Key Advantages of Modular Construction
  • Achieves superior quality through factory-based quality control
  • Standardized design details for modular buildings simplify and reduce need for continued design inputs
  • Reduced site labour: erection and finishing teams that install and complete modular buildings involve less workers on site than conventional buildings or 2D Precast
  • Improved site productivity
  • Reduced wastage during manufacture and on-site installation
  • Greater reliability and quality as it is a monolithic structure with no, or minimal vertical joints
  • Greater certainty of completion on time and on budget
  • Modular construction sites have proved to be significantly safer than conventional construction methods.
3DMVP Process

3DMVP Project

This technology is unlike the conventional and 2D Precast methods and is cast complete with window and door frames, electrical and plumbing conduits already inlaid. A brief write-up of the process is illustrated below:
  • The modules casts five sides in a single pour, or a three- dimensional shape creating a pre-designed shaped room or multiple rooms.
  • The moulds are customizable during the modules’ design process. All openings - doors and windows, access points—piping and conduit and insulation are designed into the mould.
  • Building all the features into the mould’s design reduces project turnaround time and costs.
  • The openings for Windows, doors are so precise that they can be ordered straight from the drawings.
  • The first fix MEP is installed at the time of casting thus reducing the time and labour required for chasing the walls, fixing the conduits and plastering the walls.
  • This method is replicated and the modules are fitted together—side-by-side or atop of each other. This allows the roof of the first module to become the floor of the second module as they are vertically stacked, similar to Lego blocks or bricks. This ability to fit the modules together reduces construction time.
3DMVP Project

India’s first 3DMVP Project

The application of the 3DMVP technology was developed and optimized to meet the demands of Indian Market. In addition, recruitment and training of the Engineers in 3DMVP, its transportation and installation was undertaken. Armed with the above and with the personal presence and guidance of the technology owner from Australia, construction of a Pilot Building for Tata Housing was undertaken with 3DMVP.

A five-storey building with 20 apartments was manufactured and installed in 33 working days.

The images of the Casting, Transportation and Installation of the Tata’s Boisar Project is presented here:
NBM&CW November 2018
3DXB Group Sets Guinness World Record for Largest 3D-Printed Villa in Dubai

3DXB Group Sets Guinness World Record for Largest 3D-Printed Villa in Dubai

3DXB Group, a leading innovator in 3D printing solutions for the construction industry, unveiled its achievement in making the world’s largest 3D-printed villa in Dubai. This groundbreaking project signifies a pivotal moment in the UAE

Read more ...

Rapidcast Boundary Walls: Best Quality Concrete Precast Textured Walls

Rapidcast Boundary Walls: Best Quality Concrete Precast Textured Walls

Rapidcast LLP brings to you for the first time in India the best quality concrete precast elements such as RCC precast compound walls and RRC precast stormwater UDrains. The new generation Rapidcast boundary wall/fence is a high quality precast

Read more ...

Elematic's Large Precast Concrete Plant for My Home GRAVA Project

Elematic's Large Precast Concrete Plant for My Home GRAVA Project

Hyderabad is witnessing the construction of Asia's tallest towers with a planned built-up area totalling 3.7 million sqm. The two 180-meter towers, each comprising 43 storeys, will be accompanied by six more similar towers. With each tower

Read more ...

Benefits of Shear Keyed Surfaces in Precast Building

Benefits of Shear Keyed Surfaces in Precast Building

Depending on the finish of the concrete surface, different coefficients are assigned by international codes in the calculation of shear resistance. The American Concrete Institute Code ACI318, Nov.19, states the following: Chapter 16.2.1.1 – Transfer of forces by

Read more ...

Revolutionizing Precast Industry with Advanced Tracking of Precast Concrete Elements

Revolutionizing Precast Industry with Advanced Tracking of Precast Concrete Elements

The precast concrete industry is undergoing a transformative change with innovative software solutions that offer enhanced tracking of precast concrete elements. One of these pioneering software solutions is StruSoft’s Impact Precast, which aims

Read more ...

Emerging Trends & Growth of the Prefab Industry

Emerging Trends & Growth of the Prefab Industry

Prefabricated technologies are becoming increasingly popular in the construction industry, particularly for large-scale construction. As prefabricated structures continue to evolve and improve, they are being used to construct warehouses, factories

Read more ...

Precast RCC Structures versus Pre-Engineered Steel Structures

Precast RCC Structures versus Pre-Engineered Steel Structures

A comparative study on Industrial Building Adopting Structural Frames as Precast RCC and Structural Steel Frames with Prestressed Precast Hollow Core Slabs as Flooring Slabs, presented by C. A. Prasad, Director, METEY Engineering Consultancy, Hyderabad

Read more ...

My Home Mega Project Shows Potential of Precast Construction Technology in India

My Home Mega Project Shows Potential of Precast Construction Technology in India

Storey by storey, Asia’s tallest precast towers with a total planned built-up area of 3.7 million sqm are rising towards the sky in Hyderabad. These two 180-meter towers of 43-stories each will be followed by six more similar towers. With each tower

Read more ...

Mekuba: A Leader in Mould Releasing Agents for Concrete

Mekuba: A Leader in Mould Releasing Agents for Concrete

With over 47 years of experience in the petrochemicals industry, and an expert in the formulation and production of mould-releasing agents, Mekuba Petro Products is growing rapidly in the construction chemicals segment with a daily production

Read more ...

Dextra Groutec Coupler - A Unique Solution for Reliable Joints in Precast

Dextra Groutec Coupler - A Unique Solution for Reliable Joints in Precast

Dextra has added yet another customer-centric, innovative, and custom engineered product - the Groutec Coupler - an efficient product that has been qualified and tested successfully on several major infrastructure projects in the recent past. With the

Read more ...

India an Important Market for TOPWERK

India an Important Market for TOPWERK

Sachin Shetty, India Head – Operation & Sales, and Rajesh Jha, India Head - Sales & Market Development, TOPWERK INDIA, discuss the potential of precast concrete construction in India, localization of non-critical components to bring down cost, and the possibilities of digitalization

Read more ...

Vollert: Building A Stronger India with Precast

Vollert: Building A Stronger India with Precast

Vollert India has recently expanded its production capacity in Sikandrabad (UP) India. As a global leader in precast concrete components, systems, and machine solutions, Vollert’s investment in India indicates a growing interest among German companies

Read more ...

Precast India Connector - Helping Precasters Overcome Cost & Time Overruns

Precast India Connector - Helping Precasters Overcome Cost & Time Overruns

Precast India Connections, a new entity of Precast India Infrastructures, has innovated and patented a method of achieving a Dowel-Sleeve connection that functions even in the horizontal direction. Kapilesh Bhate, MD, Precast India Connections, shares

Read more ...

Prensoland Modern Precast Floors Appearance of the iHCS

Prensoland Modern Precast Floors Appearance of the iHCS

Pre-stressed concrete hollow core slabs used for building floors are unidirectional members; they are laid one next to the other until the complete carpet area is covered. In the presence of lateral loads like wind, or due to seismic episodes, they behave

Read more ...

Vollert India Expands Production Capacity

Vollert India Expands Production Capacity

The expansion of the Vollert plant in India marks an important milestone in the company’s commitment to provide high-quality products to customers. With the increased production capacity, the company aims to expand its market share and strengthen

Read more ...

Brimax AAC: An Indian Lighthouse Project from HESS AAC SYSTEMS, Netherlands

Brimax AAC: An Indian Lighthouse Project from HESS AAC SYSTEMS, Netherlands

Brimax AAC Products LLP contracted Hess AAC Systems to supply a new AAC plant in Vadodara, India, with a capacity of 680 cbm/day (expandable up to 900 cbm/day with reinforcement for panel production). This order strengthens Hess´ position as

Read more ...

Vollert India Expands Production Capacity to Cater to Infra Development Sector

Vollert India Expands Production Capacity to Cater to Infra Development Sector

Vollert India, based in Sikandrabad, near Greater Noida (UP) since 2017, is strengthening its commitment to India; it is now expanding its production capacity of precast machinery and components to meet the greater demand from India’s fast

Read more ...

Elematic Precast Technology Solutions for Building, Industrial and Infra segments

Elematic Precast Technology Solutions for Building, Industrial and Infra segments

Elematic offers a comprehensive range of precast technology solutions for the Building, Industrial and Infra segments. Elematic precast technology enables clients to automate the production of walls, slabs, columns, beams, and stairs, providing an efficient

Read more ...

Advanced Concrete Curing Systems from Kraft Curing

Advanced Concrete Curing Systems from Kraft Curing

Kraft Curing Systems GmbH is offering advanced concrete curing systems that optimize the hardening process of concrete. Kraft Curing’s Advanced Concrete Curing System provides numerous solutions, from vapor-based (steam) systems mainly for the precast

Read more ...

Why Automating Production is the Solution

Why Automating Production is the Solution

Automating the production processes will lead to reduced wastage, fewer errors, more precision, greater safety, and higher quality of the end-products, and in a shorter period of time. First, we need to understand where we stand today as regards industrialisation

Read more ...

To get latest updates on whatsapp, Save +91 93545 87773 and send us a 'Saved' message
Click Here to Subscribe to Our eNewsletter.