Why Precast Concrete Building’s construction is not popular ?

Can we construct 1,000 Villas in 18 months !!

This BLOG is written to share my personnel experience on Precast Housing projects.

Men have lived in caves and mud houses for many early centauries. Till 1900 the Building construction works were done at site which is still in practice in most of the projects. In 1905 a British Engineer, John Alexander Brodie invented construction using precast Concrete components.  This technology has become popular throughout the world as using this system helps  fast construction and saving of time . in 1954 Precast Institute was formed . China , USA , Germany , Iraq & UAE are among the major user of using Precast Concrete Building technology .

G+12 precast buidlings towers are common

In the early years only Single storey Precast concrete Buildings were constructed but later on G+2 floor were constructed . With the innovation and invention in the field of Precast construction , now a days G+10 to G+16 storeys building are being constructed in many cities as housing complexes. With precast technology improving day by day ,  in Rotterdam ( Netherland) Zalmhaven tower is being constructed with height of 215 mtr having 58 floors.

Precast construction gives best in Quality

Precast concrete buildings have several advantages over traditional cast-in-place construction. Here are some reasons why precast concrete buildings are considered better:

1. Quality control: Precast concrete is manufactured in a controlled environment, ensuring consistent quality. This reduces the risk of defects and meets the required strength.

2. Speed of construction: Precast concrete components can be manufactured off-site while site preparation and foundation work are carried out simultaneously. Once on site, they can be assembled quickly and efficiently, reducing construction time.

3.Durability: Precast concrete is highly resistant to weathering, corrosion, and fire. It can withstand harsh weather conditions and is less susceptible to damage from environmental factors such as moisture, temperature changes and snow etc.

4.Cost-effective: Although precast concrete construction requires higher initial investment, the overall project cost can be lower due to the reduced construction time, lower maintenance costs, and better durability.

5.Work continuity : Overall, precast concrete buildings offer several advantages over traditional cast-in-place construction including continue working during extreme weather like snow.

25% of time can be saved by precast construction

Precast construction is $16.0 Billion industry and growing by 2-4% every year.  The country where the weather is very extreme ( too hot or too much snow ) Precast building system suit the most because the production of precast components are done in a warehouse type shed in a controlled atmoshphere. Constructing precast Concrete building is 10 to 15 % expensive than the conventional one .  If the building project is completed in conventional construction method in 24 months , it can easily be completed in 18 month by Precast building method thus saving of 25% of Project time. Saving on time in construction is equal to money.

Precast Panels are reaching site are best in Quality

Concrete walls , Insulated walls , hollow core slabs , stairs , parapets , columns and beams are casted in the mould in PCC factory under full quality control for every stage of Panel’s making including curing which is prime important . Horizontal pallets, tilting pallets & vertical batteries are use to make precast panels. In cold country steam curing is done to obtain the right strength of the concrete in the mould. Steel mesh is used as reinforcement to all type of panels. After panels are made in the factory it is taken to stacking yard for curing and further transportation to site for erection. There is no match in quality of PCC panels and at site construction.

Imagine a builder want to construct 200 identical Villas . Every Villa have  50 precast panels to complete the villa. Every panels are given a unique number while casting which is designed to fit horizontally and vertically to adjoining panels and slab to millimeter perfection at site .  Builder will be producing 10,000 Precast panels in his precast factory with a production schedule which fit to project’s construction program . Work will commence at site with 2 to 8 Villas and completed rest  one after another in construction sequence .   Once a Precast panels are fabricated in PC factory well organised, the structure of the Villa at site can be complete in 7-10 days .  Then fit-out and finishes works commence in such Villas . The construction is so quick that in the matter of few months the structures of all the villas are visible and finishing works are going on , giving relief to buyer and investors.

Constructing 1,000 Villas in 18 month – only Precast panels can do it

One Chinese company constructed 1,000 Villa is 18 month in Iraq . Off course they have Precast factory setup done prior to start of actual construction at site . In conventional construction 1 Villa will take 2 years. I have privilege to works in one town ship project in Ramadi- Iraq using Precast technology. One Villa was being erected in one week time at that time. I also worked for G+12 housing tower project in Dubai using 100% precast wall , slabs and other panels. Not a single columns was constructed both cast in situ and precast. Precast Walls at Ground floor rest over ground beam , First floor walls rest on Ground floor wall on each floor and so on multistorey residential building is constructed.

Initial Heavy investment required for Precast Projects

Precast Building construction is still not that much popular . Builders still using conventional construction methods . Using Precast Building system is only viable for huge projects as it requires heavy set up for the Precast panel construction factory. To big openings in to walls also is a negative point to use precast panels ( it cracked while handling ) . It also require additional efforts for precast Panels transportation from factory to construction site and additional lifting cranes.  To tackle residential building’s shortage by any govt , Precast Building construction is the best option available as it is faster and reliable. Precast construction is picking up in India in recent years.