PowerPoint Presentation · Publication (1996) Economics of load bearing brick walls residential...

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PROMOD ADLAKHA

Managing Director

Adlakha Associates Pvt. Ltd.

(Architectural consultants)

F-70, Bhagat Singh Mkt, Near Gole Mkt,

Near Connaught Place, New Delhi – 110001

Ph: 011-23344471, 72; Mob: 09811118803

Email: [email protected]

Website: www.adlakhaassociates.com

GREEN BULDING CONGRESS 2014 CONFERENCE ON GREEN HOMES

6 Sep’14, Hyderabad

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EVERYONE TALKS ABOUT “GREEN” “AFFORDABLE” HOUSING

WE HAVE PROVED IT

TOGETHER WE CAN TRANSFORM THE LIVES OF MILLIONS

AND OUR URBAN LANDSCAPES

HOW?

COST SAVING OF 20% NOT AT THE COST OF QUALITY

BUT

THROUGH TECHNOLOGICAL INNOVATION

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ABOUT US

Our Landmarks in Affordable Housing

• 50,000 low cost affordable houses

• 25 Awards on Low Cost Housing

• “Rajiv Gandhi Housing Project” – won 8 Awards

• The largest single housing project under JNNURM (18,760 houses)

• 16 Million sqft area completed with alternative cost effective technologies

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Member Confederation of Construction Products & Services (CCPS) (National Advisory

Group on Door & Window & Glass)

Member Performance Appraisal Committee, Ministry of Housing & UPA, Govt. of India.

Member Governing Council, Indian Buildings Congress. (1997, 1998 & 1999)

Member Bureau of Indian Standards on various Technical Committees

Member National Building Code – 2005

Member Executive Committee, Delhi State Centre I.E.(I) 1986 – 2008

Member Editorial Board : Poly Engg. News, Forum News and ACETEMPERS (Formerly)

Member IBC Committee to evolve techniques & standards for low cost housing & fast

track construction

Member IBC Committee on Buildings specifications for Built Environment

Member Committee on sustainable Building Technologies for Engg & Arch. UG courses.

Hony. Advisor (former) National Capital Region Planning Board, for “Shelter & Housing” (1998 & 1999)

Guest Faculty Visiting Faculty to Engg. & Arch Institutions, Human Settlement Management

Institute (HUDCO), ALTTC (Ministry of Telecom) NIIF, I.M.A.

Area Representative International Forum of Interior Designers & Architects (IFIA) (Formerly)

Board Member Architectural Engineering Division of I.E. (1994-1995, 1995-96 & 2002-2003)

Panel Arbitrator Panel Arbitrator appointed by Indian Council of Arbitration.

Consultant BMTPC (Building Materials Technology Promotion Council) Ministry of

Housing & UPA for various studies

Examiner & Moderator Faculty of Technology, University of Delhi (Formerly)

Valuer Govt. Approved Valuer, Panel Valuer for LIC, PNB, SBI, UCO Bank, PFC and

various Banks, High Court of Delhi

Surveyor Regd. Surveyor & Loss Assessor under Insurance Act 1938 (1984 - 1994)

ABOUT US

PROFESSIONAL RECOGNITION

ABOUT US

HONOURS/AWARDS/RECOGNITION Year Conferred by (Name of Organisation) Award Conferred/Competition Won

1977 IAHS (International Association for Housing

Services) (USA)

Commendation Award

1977 Hungarian Institute for Building Science,

Budapest

Design included in World Survey of successful low cost

houses

1982 Lalit Kala Akademi, Delhi Completion of Regional Art Centre, Lucknow

1987 Gujarat Housing Board & IE (I), Ahmedabad First prize, low cost housing competition

1988 U.P. Housing & Development Board, Lucknow Commendation Award on low cost housing

1992 Interiors Today, Mumbai Award for Excellence in Design & Architecture

1995 All India Achievers conference, Delhi Hind Gaurav Award

1996 Riverside Sports & Recreation Club, Delhi Meritorious Award

1998 & 1999 NCR Planning Board Hony. Advisor for housing & shelter

2000 I.E. (I) Merit Certificate for “Cyclone resistant housing” – AR

Journal

2001 International Council of Consultant, (ICC) Accreditation

2001 HUDCO & Hari Om Ashram Trust Sir M. Viswesvaraya Award for “Disaster resistant

housing”

2001 National Design & Research Forum (NDRF),

Hyderabad

National Design Award

2001 Indian Buildings Congress, IBC, Delhi Award for Excellence in built Environment for

“Corporate office of Greater Noida Authority”

2005 ICS – UNIDO, Italy Member Expert Group, Appropriate Technology for

sustainable buildings in Developing Countries, Bangalore

2005 India Tech Foundation, Mumbai & Ministry of

Housing, Govt. of India

Constru India Excellence Award for

“Rajiv Gandhi Housing Project”

ABOUT US

HONOURS/AWARDS/RECOGNITION

Year Conferred by (Name of Organisation) Award Conferred/Competition Won

2006 Builders Information Bureau (BIB), Delhi Building Industry Leadership award for


2006 Ministry of Housing & Urban Poverty

Alleviation, Govt. of India

Awas Ratna Award for


2007 Real Estate Observer, Delhi Real Estate Observer Achievement Award for “Rajiv

Gandhi Housing Project”

2007 Indian Building Congress, (IBC), Delhi Award for Excellence in built Environment for “Rajiv

Gandhi Housing Project”

2008 Association of consulting Civil Engineers (ACCE) ACCE Gammon Award for


2009 World Council for Corporate Governance &

World Environment Foundation, UK

Eco – Innovation Golden Peacock Award for


2009 Indian Buildings Congress (IBC) Award for Excellence in built Environment for “Poetry

in Bricks”

2011 Construction Industry Development Council

(Planning Commission), Govt. of India

CIDC Vishwakarma Award for


2012 CBRI (CSIR – council of scientific & industrial

research)

Recognition for adoption of cost effective technologies

2013 Indian Building Congress, (IBC), Delhi

Award for excellence in built environment: Trophy-2011

for Community Centre at Naggal Khojkipur, Ambala

2014 Indian Building Congress, (IBC), Delhi "InnoGeocity, Oragadam, Chennai" for Award of Trophy.

2014 Indian Building Congress, (IBC), Delhi Housing for Urban Poor at Bawana-Narela-Bhorgarh" for

the IBC Award.

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RECOGNITION OF EXPERTISE in low cost housing

national & international forums

International Association for Housing Science, USA (IAHS)

Confederation of Indian Industries (CII)

The Associated Chambers of Commerce and Industry of India (ASSOCHAM)

Federation of Indian Chambers of Commerce and Industry (FICCI)

Housing & urban Development Corporation (HUDCO)

Human settlement & Management Institute (HSMI)

Indian Green Buildings Council (IGBC)

Indian Buildings Congress (IBC)

National Association of Real Estate Developers Council (NAREDCO)

Confederation of Real Estate Developers Association of India (CREDAI)

Association of Consulting Civil Engineers (ACCE)

Construction Industry Development Council (CIDC)

(Under Planning Commission, Govt. of India)

Building Materials Technology Promotion Council (BMTPC)

(Under Ministry of Housing, Govt. of India)

National Buildings organization (NBO)

Central Building Research Institute (CBRI)

Institution of Engineers (IE)

Good Governance India foundation (Municipalika)

Chotu Ram University of Science & Technology (CRUST)

Centre for Environment Planning Technology (CEPT)

(chaired sessions/ keynote speaker/ special presentations/ guest lectures, foundation day lectures)

RECOGNITION BY MINISTRY OF HOUSING, GOVT. OF INDIA

& GOVT. OF NCTD, DELHI CALENDER/NEWS PAPER/BOOK PROJECTS PUBLISHED

HUDCO (Ministry of Housing, Govt. of India) –

Calender - 2002

Corporate Office, Greater Noida Industrial

Development Authority

BMTPC (Ministry of Housing, Govt. of India) –

Calender - 2012

Low Cost Housing at Baprola, Delhi

Demonstration housing at Amethi

Community Centre at Ambala

Demonstration project at Pinjore

Ministry of Housing, Govt. of India :JNNURM

(Times of India, The Hindustan Times &

Others)

Housing at Bawana, under JNNURM

Indian International Trade Fair -2008 Delhi

Pavilion

Facade of Pavilion with Rajiv Gandhi, Housing

Project, Bawana.

HUDCO (Ministry of Housing Govt. of India)

Publication: Is it possible?

(Awarded project)

Corporate Office, Greater NOIDA Industrial

Development Authority

BMTPC : News letters Demonstration Housing at Amethi

Community Centre at Ambala

Demonstration Project at Punjab

RECOGNITION BY Ministry of Housing, Govt. of India

& Govt. of NCDT, Delhi

FAÇADE IN PRAGATI MAIDAN “DELHI

PAVILION” MADE TO REPRESENT “RAJIV

GANDHI HOUSING PROJECT”

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RECOGNITION BY Ministry of Housing, Govt. of India

& Govt. of NCDT, Delhi (recognition of low cost housing projects)

RECOGNITION BY National and International Dignitaries who visited

our housing sites at BAWANA, Delhi

Our Expertise in Earthquake Resistant Structures &

Green Building Concepts

Reflected in our Projects and Programmes

Member of Technical Committees of BIS (including that of EQ and cyclone resistant structures)

Member of National Building Code

Awarded Merit Certificate for Cyclone Resistant Housing

Awarded Sir M. Visveswarya Award for Disaster Resistant Housing.

Workshops Training Programmes on EQ resistant buildings organized and attended: School of Planning & Architecture,

Institution of Engineers, Indian Buildings Congress, Bureau of Indian Standards, BMTPC, IGBC, CII, National Disaster

Management Authority, Indian Society of Earthquake Technology, Disaster Risk Management Programme, GOI – UNDP,

Deptt. of EQ Engg, IIT (Roorkee).

Awarded Eco-Innovation Award by World Council for Corporate Governance.

Member IBC committee on Building & specifications for Built Environment.

Member, committee on sustainable Building Technologies for Engg & Arch, UG courses.

Publication (sponsored by BMTPC): Cyclone Resistant Housing

Publication (1996) Economics of load bearing brick walls residential buildings in Highly Seismic areas.

Publication (2000) Learning from failures of cyclone damaged structures for better construction practices.

Publication (2005) construction of EQ resistant houses using cost effective technologies.

Publication (2007) Materials & Technologies for sustainable Development.

Publication (2011) Affordable Green Homes

Publication (2011) Adoption of appropriate & green construction technologies – case studies.

Publication (2011) International Seminar on Cost effective, energy efficient & ecologically appropriate building materials &

technologies for housing: Real Estate housing project using alternate technologies at Chennai.

Publication (2011) Green Homes, Page 92-93, Architect & Interiors India, (Green Book)

Publication (2012) Municipalika 10th International Conference on Good Governance for safe, green & smart cities: Making

social housing affordable through innovative technologies.

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FOR ROOFING:

R.C. Ribbed Slab

Precast Channel Roofing

Precast RC Plank Roofing

Precast RC Ferrocement Panel Roofing

Precast RC Hollow Slab Roofing

Cast-in-Situ Hollow Slab Roofing

R.B. Filler Slab Roofing

R.B.C. Roofing

Precast R.B. Panel Roofing

Precast R.B. Arched Panel Roofing

CRF Sections and Ferrocement Panel Roofing

Precast Ferrocement Segmental Shells Roofing

Precast RC panel roofing

Funicular shell roofing

FOR WALLING:

Rowlock bond (Rat – trap bond),

Stretcher bond,

Hollow concrete blocks,

Interlocking mortar less block walking,

Perforated mechanized modular bricks,

FAL-G modular bricks,

Stone block masonry.

AAC blocks (in multistoried)

Cement Flyash mortar

INNOVATIVE TECHNOLOGIES USED FOR AFFORDABLE HOUSING

SHEAR WALL TECHNOLOGY

OTHER COMPONENTS:

Precast Ferrocement Cupboard &

Kitchen Shelves

Precast Ferrocement Sunshades

Precast R.C. Lintels

R.B.C. Lintels

Precast Ferrocement steps

Precast concrete door & window frames

Ferrocement water tanks

RCC monolithic technology

Precast elements such as

o Lintels,

o Sunshades,

o Kitchen slabs,

o Water tanks,

o Stair case steps,

o Drains and chambers,

Under reamed piles (for load bearing

walls)

Interlocking pavers

CRF beams

HOUSINGS

WITH COST EFFECTIVE

TECHNOLOGIES

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YEAR 1976 –DEMONSTRATION HOUSE, K.K. NAGAR, CHENNAI

TECHNOLOGIES

ROOFING

Precast hollow

roofing

WALLING

Precast RCC hollow

wall

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LOOK OF FINISHED

WALL

STOCKED STONE

BLOCKS AT

CASTING YARD

STONE BLOCKS BEING

CASTED

RCC HOLLOW

‘KULAR’ PANELS

BEING CASTED

RCC

HOLLOW

‘KULAR’

PANELS

BEING

CASTED

YEAR 1978 -BHOPAL DEVELOPMENT AUTHORITY HOUSING

TECHNOLOGIES

• Under Reamed Piles

• Stone Block Masonry

Walls

• Precast Cast-in-situ

Hollow ‘Kular’ RCC Slab

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YEAR 1982 - HOUSING FOR PUNJAB KHAND UDYOG LTD.

(PUNJAB GOVT. UNDER TAKING) AT GURDASPUR & ZIRA

TECHNOLOGIES

ROOFING

Precast RC Plank & Joists

WALLING

Stretcher bond

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STAFF HOUSING MODI FIBRE CO,

MODINAGAR STAFF HOUSING FOR MODI XEROX, RAMPUR

STAFF HOUSING FOR MODI CEMENT LTD,

RAMPUR

STAFF HOUSING FOR VAM ORGANIC

CHEMICALS LTD. AT GAJRAULA DISTT.

MORADABAD

YEAR 1982 – 1985

TECHNOLOGY

• Filler Slab

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YEAR 1992

STAFF HOUSING, DAURALA

ORGANICS LTD.

TECHNOLOGIES

•Filler slab

VAM ORGANIC CHEMICALS LTD.,

GAJRAULA

TECHNOLOGY

• Filler Slab Roofing

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YEAR 1992 - STAFF HOUSING FOR MAWANA SUGAR WORKS

TECHNOLOGIES

ROOFING:

Precast RB Panel

RC panel

RC Ribbed slab

WALLING:

Stretcher band

Rat trap bond

PRECAST BEAM BEING CASTED

PRECAST BEAM BEING

ERECTED

CEILING OF RC RIBBED SLAB 2” THICK RCC CAST IN SITU ROOFING WITH ONLY

6MM DIA BARS AND PRECAST RCC BEAMS

PARTIALLY PRECAST BEAMS

BEING FINISHED


PRECAST BEAM

BEING CASTED

(SEQUENCE 1)

PRECAST BEAM

BEING CASTED

(SEQUENCE 2)

PRECAST BEAM BEING

CASTED (SEQUENCE 3)

PRECAST BEAM BEING

CASTED (SEQUENCE 4)

PRECAST BEAM BEING

FINISHED (SEQUENCE 5)

PRECAST BEAM BEING AT CASTING

YARD (SEQUENCE 6)


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YEAR 1992 - STAFF HOUSING DAURALA SUGAR WORKS

TECHNOLOGIES

Precast panel roofing

Stretcher bond

Boundary Wall in Zig Zag 7 1/2 “ Brick Wall

Boundary wall in rat trap bond

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STAFF HOUSING FOR DCM TOYOTA LTD., SURAJ PUR

YEAR 1993 – DCM TOYOTA LTD, SURAJ PUR

TECHNOLOGIES

• Filler slab roofing

• Stretcher bond 190mm wall

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CUPBOARDS

CEILING VIEW

(PRECAST BEAMS

AND FERROCEMENT

RCC PANELS)

BOYS HOSTEL MODI NAGAR

YEAR 1993 – BOYS HOTEL, MODI NAGAR

TECHNOLOGIES

• Precast Ferrocement

panel

roofing

• Stretcher bond wall

BRICK PYRAMID ROOFING

YEAR 2000 - CORPORATE OFFICE, GREATER NOIDA INDUSTRIAL

DEVELOPMENT AUTHORITY

TECHNOLOGIES

• Rat trap bond wall

• Stretcher bond

• Flyash Brick

• Precast Ferrocement panel

roofing

• Precast R.B. Panel roofing

• Precast curved panel roofing

• Precast Ferrocement segmental

shell

• Precast double curved shell

• Vernacular architecture

• Prefab CRF beams

RAT TRAP BOND

WALLING BEING

DONE

RECEPTION ENTRANCE

(CORBELLED ARCH UNDER

CONSTRUCTION)

CORBELLED PYRAMID ROOFING

SEGMENTAL ARCH PROJECTIONS

CORNICE/BANDS AT ROOF LEVEL

ARCH OPENING OVER

WINDOWS USE OF FLYASH BRICKS USE OF FLYASH BRICKS



PANEL CASTING

PRECAST RC/FERROCEMENT PANELS LAID

(ROOFING OVER BLOCK A,B,C)



7 1/2” LOAD BEARING WALLS

IN CORRIDOR

COMMON TOILET BLOCK TOILET BLOCK FILLER SLAB

ROOFING

FLYASH BRICK PANELS

PROJECTIONS FOR AESTHETICS PREFAB CRF BEAMS FOR ROOFING



CASTING OF

BRICK PANELS

BRICK PANELS BEING ERECTED

& PLACED

BRICK PANEL ROOFING DONE BRICK PANELS BEING ERECTED & PLACED



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STOCKS OF BRICK PANELS CASTED AS

BATTERY BRICK PANEL CASTING

BRICK PANELS, PLASTERED

& CURING

BRICK PANELS CASTED IN

BATTERY SYSTEM

PRECAST CURVED BRICK PANELS

PLASTERED IN INVERTED POSITION AT

CURING YARD PRECAST BEAMS LAID



PANEL CASTING

PRECAST RC/FEROCEMENT PANELS LAID

(ROOFING OVER BLOCK A,B,C)



BRICK ARCH PANEL ROOFING

BRICK ARCH PANEL ROOFING BRICK ARCH

PANEL ROOF

PRECAST ARCH BRICK PANELS

BEING CASTED IN STACKS



CURVED BRICK PANEL ROOFING CRF BEAMS

AESTHETICALLY DESIGNED PIERS

CURVED BRICK PANEL ROOFING

SEGMENTAL SHELL ROOFING

FERROCEMENT

SEGMENTAL SHELLS

BEING CASTED



INSIDE VIEW

OF

CORBELLED

DOME

FILLER SLAB

HEXAGONAL

BRICK TILE

PYRAMID

ROOFING

HEXAGONAL BRICK TILE

PYRAMID ROOFING



FEROCEMENT SEGMENTAL SHELL

ROOFING OVER TOILET BLOCK

GREATER NOIDA

PRECAST DOUBLY CURVED

BRICK TILES SHELL ROOFING

SEGMENTAL ARCH OVER WINDOWS CORBELLED ARCH ROOFING OVER

RECEPTION ENTRANCE BRICK PYRAMID ROOFING



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YEAR 2009 - OUR FARMHOUSE

in VERNACULAR TECHNOLOGIES

YEAR 2009 - OUR FARMHOUSE

in VERNACULAR TECHNOLOGIES

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Year 2011 – COMMUNITY CENTRE AT AMBALA

Technologies for walls

Mechanized Fly-ash bricks 230/115 mm

Mechanized clay brick 230/115 mm

Mechanized modular Claybrick 200/100 mm

Conventional clay brick wall in Rat trap bond (Row

lock bond) 230mm

Perforated bricks

Wire cut bricks

Hydraform interlocking blocks

Stretcher bond 190 mm

Modular brick wall

Technologies for roofing

Precast RC plank & Joists

Precast RB panel

Precast RB curved panel

Precast Doubly Curved Shells

Filler Slabs

Micro Concrete roofing tiles

Hollow slabs with ‘kulars’

Other technologies:

Precast Ferro-cement

staircase

Flat Arch Lintels

Concrete door

window frames

Precast sunshades

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MATERIALS & TECHNOLOGIES

FOR

Green Affordable Mass Housing

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m Low Rise high Density Concept

Walkable Structure

CASE STUDY – HOUSING AT BAWANA, DELHI

(4348 HOUSES)

Cluster plan – courtyard concept


(4348 HOUSES)

Meeting places around tree


(4348 HOUSES)

Vehicle parking spaces near

and around each cluster


(4348 HOUSES)

Layout plan


(4348 HOUSES)

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Road section


(4348 HOUSES)

Soft paving pathways


(4348 HOUSES)

Perception of space

Building Blocks

The design of the building blocks cover following

parameters for efficient performance:

· Orientation aspect

· Space Efficiency

· Grouping

· Privacy – usual & acoustical

· Circulation

· Sanitation

· Economy

· Elegancy

Use of Cost Effective Innovative Technologies

· 200 mm thick load bearing wall in Super Structure

· Modular bricks with Cement + Flyash blended mortar

· Precast Reinforced Concrete planks and joist for

roofing and flooring

· Ferrocement staircase treader – riser units

· Precast ferrocement sunshades, kitchen platform

· Precast ferrocement water tanks


(4348 HOUSES)

Services networks


(4348 HOUSES)

Dwelling units

Shows the Dwelling Unit plan in G+2

31.73 Sqm – Type I


(4348 HOUSES)

Dwelling units


36.73 sq m - Type II


(4348 HOUSES)

Dwelling units


39.60 sq m - Type III

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TECHNOLOGY

• Row lock bond wall

MASS HOUSING WORKS - YEAR 2003

AFFORDABLE HOUSING GR. NOIDA (800 D.U.)

Client: Greater Noida Authority

Contractor:

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TECHNOLOGIES

• Modular perforated Brick Walls

• Precast RC Planks & Joists Slab

• Precast Ferrocement Elements


NARELA, DELHI 1892 HOUSES Client: DSIIDC

Contractor: ERA Infra Engg. Ltd.

TECHNOLOGIES





BHORGARH, DELHI 1272 HOUSES

Client: DSIIDC


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TECHNOLOGIES





NARELA (CETP), DELHI 1652 HOUSES Client: DSIIDC


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TECHNOLOGIES





BAPROLA, DELHI 5568 HOUSES

Client: DSIIDC

Contractor: IVRCL Ltd.

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TECHNOLOGIES





OMICRON, G. NOIDA, 1848 HOUSES

Client: Greater Noida Authority

Contractor: Sai Constructions

MASS HOUSING WORKS - ongoing

EWS Housing, Faridabad

TECHNOLOGIES

• Modular perforated

bricks

• Precast RC Planks &

Joists Roof

Client: ERA Landmarks Ltd.



POOTHKHURD, DELHI - 14200

TECHNOLOGIES

• RC Planks & Joists Roof

In framed structure

• Flyash brick walls

Client: DSIIDC

Contractor: Ramky Infrastructure Ltd. &

IVRCL Ltd.

Under construction pictures


POOTHKHURD, DELHI - 14200


TIKRI KALA, DELHI – 4560 + 6480

TECHNOLOGIES

• RC Planks & Joists Roof

In framed structure

• Flyash brick walls

&

• Shear wall monolithic

technology

Client: DSIIDC

Contractor: Supreme Infrastructure Ltd. &

Pande Construction Ltd.

Under

construction

pictures


TIKRI KALA, DELHI – 4560 + 6480

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TECHNOLOGIES

•Mechanized bricks

•Flyash bricks

• Precast RC Planks

& Joists Roof


EWS HOUSING, BAKARWALA, DELHI – 240

Client: NDMC

Contractor: Adharstamb

Construction Pvt. Ltd.

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COMPLETED PICTURES

TECHNOLOGY

Projects using Shear Wall

Technology


BAWANA, DELHI - 896

Client: DSIIDC

Contractor: Sintex Industries Ltd.

TECHNOLOGY


Technology


GHOGHA, DELHI - 3680

Client: DSIIDC

Contractor: Sintex Industries Ltd.


BAWANA, DELHI - 704

Under

construction

pictures

Client: DSIIDC

Contractor: Sintex Industries Ltd. MASS HOUSING WORKS

Monolithic technology


DELHI POLICE HOUSING, DHEERPUR, DELHI - 5202 Client: Delhi Police

Contractor: Punj Lloyd Ltd.

TECHNOLOGY


Technology

17-09-2014

13


DELHI POLICE HOUSING, DHEERPUR, DELHI - 5202


INNO GEOCITY, CHENNAI 500 HOUSES

TECHNOLOGIES

• Hydraform

interlocking block

walls

• Precast RC Planks

& Joists Roof

• Stone Block

masonry in

foundation

• Precast Boundary

wall

Client: Oragadam Developers Pvt. Ltd.

Contractor: Tempus Construction Pvt. Ltd.


ANJAR & VAPI, GUJRAT

Under construction pictures

TECHNOLOGIES

• Hydraform interlocking block walls

• Precast RC Planks & Joists Roof

• Precast sunshade, Ferrocement staircase

• Concrete Block masonry in foundation

• Precast Boundary wall

Client: Welspun Group

Contractor: Welspun Projects Ltd.

TECHNOLOGY EXPLAINED

IN BRIEF

For Affordable Housing

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R.C. PLANKS AND JOISTS SLAB

The plank and joist

technology consists of

60mm thick specifically

designed precast planks

supported over precast

joists.

Cast in situ concrete is

poured over the slab

forming a monolithic

structure.



17-09-2014

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PRECAST R.C.C LINTEL CUM SUNSHADES


FERROCEMENT STEPS & KITCHEN SHELVES

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IS : 13990 : 1994 Precast reinforced planks & joist & flooring

specifications.

IS : 13994 : 1994 Specifications

CBRI Building Research Note (4) 1982 &

1987 Precast RC planks flooring/Roofing scheme

IS : 4326 : 1993 Code of practice for EQ resistance design &

Construction of buildings improvised

NBC : 2005 (part 6) clause 6.3.1, 7.3.1.1 Part

6 section 7B Prefabrication system accepted standards

TECHNOLOGY VALIDATION

PRECAST RC PLANKS AND JOIST SYSTEM

APPROVED TECHNOLOGY BY CBRI

APPROVED TECHNOLOGY BY BIS (BUREAU OF INDIAN STANDARDS)

IS:13994

IS: 13990

APPROVED TECHNOLOGY BY IIT, DELHI

APPROVED TECHNOLOGY AS PER NBC- 2005

17-09-2014

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TECHNOLOGY VALIDATION

LOAD TEST


PERFORATED MODULAR & FAL-G BRICKS & HYDRAFORM BLOCKS

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Boundary wall in Interlocking Blockwork

With hydraform blocks


in Vapi & Anjar, Gujrat project (client: Welspun Group)

Steps in interlocking

block walling

Concrete Door frame

Vertical EQ

reinforcement

View of roof:

RC planks & joists in

Interlocking block walling

system with EQ bands.


in Vapi & Anjar, Gujrat project (client: Welspun Group)


in InnoGeocity, Chennai project

Casting of

blocks Interlocking blockwork

RC planks &

Joist roofing

17-09-2014

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Under Construction pictures


RC Planks & Joist in framed structure

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300mm x 300mm

Precast Framing Beams

300mm x 300mm

Precast Joists

150mm x 210mm

Precast Planks

60mm thick

FRAMED COMPOSITE PRECAST SYSTEM

FRAMING PLAN

AFFORDABILITY IN

TECHNOLOGY

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m Item Conventional Alternative

technology used Advantages Savings

In Cost

Foundations Isolated and step

footings Under-reamed piles

In load bearing

Structure

Economical as well as

speedy construction 10%

Walls 230 mm Brick wall in

English bond (using

conventional FPS,

Clay Bricks)

200 mm thick brick

wall in Flemish

bond (using

machine made

modular perforated

bricks)

Reduction in wall

thickness due to

high strength bricks

No plaster on

external faces

Heat & Sound

resistance

20%

Intermediate

floors & roof Cast-in-situ

RCC slab Precast RC Plank

system Saving in cement,

Steel & shuttering

Cost effective (no

Plaster required)

Controlled

conditions

Speedy

construction

Better finishes &

Aesthetics

21%

Stair case Cast-in-situ

RCC joist slab Precast ferrocement

steps 25 mm thick

(tread & riser unit)

30%

Sunshades

Cum Lintels Cast-in-situ

RCC slab Precast RC 25%

Kitchen

Platforms Cast-in-situ

RCC slab

Precast ferrocement

25 mm thick 30%

Water Tanks RCC, PVC Ferrocement 20%

AFFORDABILITY IN TECHNOLOGY

COMPARISON CHART – SAVINGS IN COST

17-09-2014

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Conventional

(230 mm wall)

Alternative

(200 modular perforated bricks)

Brick work 0.23 cum @ Rs 1545.15

= Rs 355.38

Brick work 0.20 cum 1851.15

= Rs 370.23 Internal Plaster (1.6) 15mm 1Sqm

@ Rs 51 = Rs 51.00

Extra for superstructure 0.20 Cum

@ Rs 262.45 = Rs 52.49 External grit plaster 1Sqm @ Rs 169.3

= Rs 169.3

Internal 12mm plastic 1Sqm @ Rs 44

= Rs 44.00

Groove 2m @ Rs 9.50 = Rs 19.00 External silicon treatment 1Sqm

@ Rs 23.10 = Rs 23.10

Total = Rs 594.63 Total = Rs 489.82

Savings = Rs 10.481 = 17.62%

for 1 Sqm

COST COMPARISON

CASE STUDY - WALLING

Case study done for Bawana, Delhi

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for 1 Sqm

Conventional

Cast-in-situ

Cost effective alternative

Precast RC Planks system

RCC (1:1.5:3) 0.10 cum

@ Rs 2324.20=232.42

RCC 1:1.5:3 in joints 0.0096 cum

@ 3208 = Rs 30.80

RCC 1:1.5:3 in planks 0.0602 cum

@ 4192.45 = Rs 252.39

Steel Reinforcement 9 Kg

@ Rs 21.85 = Rs 196.65

Steel reinforcement 6.265 Kg

@ Rs 21.85 = Rs 136.89

Centering & shuttering 1Sqm

@ Rs 111.20 = Rs 111.20

Ceiling plaster 1 Sqm@ Rs 40.00

= Rs 40.00

Total = Rs 580.27 Total = 420.08

Savings = 580.27-420.08= Rs 160.19

= 27.60%


COST COMPARISON

CASE STUDY - ROOFING

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For 1 flight of 10 steps

Conventional (Cost in Situ) Alternative (precast ferrocement)

R.C.C 1:1.5:3 = 0.346cm

@ Rs 2324.20 = Rs 804.17

Mortar 1:1.5 0.122 cum

@ 2701.60 = Rs 329.60

Centering and shuttering = 3.15 sqm

@ Rs 106.40 = Rs 335.16

Chicken Mesh 9.90 Sqm

@ 30 = Rs 297

Reinforcement 31.14 kg @ Rs 21.85

= Rs 680.41

Welded fabric 6.78kg

@ 34.70 = Rs 166.73

Brickwork in step 0.22 cm

@ Rs 1545.15 = Rs 339.93

Labour = Rs 148.74

Flooring 4.75 sqm @ Rs 86.05

= Rs 408.74

Reinforcement 4.2 kg @ Rs 21.85 =

Rs 91.77

Angle iron nosing 18 kg @ Rs 21.95 = Rs

395.10

Sundries 23.4 Units @ Rs 1.66 =

Rs 38.84

Water charges, 0.H., Contractor Profit

= Rs 90.30

Total = Rs 2568.41 Total = Rs 1558.08

Savings Rs. 1010.33 = 39.33% Case study done for Bawana, Delhi

COST COMPARISON

CASE STUDY - STAIRCASE

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Per sq m


Conventional (Cast-in-situ) Alternative (Precast Ferro-cement)

R.C.C 0.08 cum @22324.20 cm

= Rs 185.94

Mortar (1:1.5) 0.027 cum

@ Rs 2701.60 = Rs 72.94

Cutting & shuttering 0.84 sqm

@ Rs 111.20 = Rs 93.41

Chicken Mesh 2.20 Sqm @ Rs 30

= Rs 66

Finishing 0.94 Sqm@ Rs 13.30 = Rs 12.50 Welded fabric 1.50kg @ Rs 24.70

= Rs 37.05

Steel reinforcement 7.20 kg @ Rs 21.45

= Rs 154.44

Labour = Rs 10.80

Sundries 5.20 Units @ 1.66 = Rs 8.63

Water charges, 0.H., Contractor Profit =

Rs 17.58

Total = Rs 446.29 Total = Rs 213.00

Savings = Rs 233.29 = 52.27%

COST COMPARISON

CASE STUDY – SHELVES & SUNSHADES

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COMPARISON CHART – TIME SAVING

S. No Description Conventional Cost effective Proposal

1. Foundation 6 days 6 days

2. Superstructure: Casting of column,

beams, slabs including shuttering, placing

reinforcement, casting and removal of

form work (each Floor)

16 days 6 days

(precast slab)

3. Raising Brick wall (each floor) 3 days 3 days

4. Internal plastering (each floor) 2 days 1 day (no ceiling plaster)

5. External plastering (each floor) 3 days No Ext. plaster

6. Flooring (each floor) 1 day 1 day

7. Plumbing & Elec.(each Floor) 4 days 4 days

One Block 122 days 71 days

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m Consumption of reinforcement steel

Cost effective housing: less than 1.0 kg per sq ft.

Conventional housing: 3 to 4 kg per sq ft.

Consumption of cement

Cost effective housing: 0.25 BAGS per sq ft.

Conventional housing: 0.45 BAGS per sq ft.

Case examples were taken of each housing block from 4 of our projects (ie. Bawana, Baprola, Bhorgarh and Narela) and estimates were prepared using one example of a conventional technology and one using precast systems. The comparison charts prepared by us are as follows:

SAVINGS IN STEEL AND CEMENT

Thus, savings in

Resource Material

Embodied energy

CO2

STEEL

Less than 1.0 kg per sq ft

CEMENT

Less than 0.25 bags per sq ft

17-09-2014

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• RC planks Casting machines 7 Nos @ 85000 = 5.60 lacs

• Twin moulds 14 Nos @ 20000 = 2.80 lacs

• Pellets 700 Nos @ 1000 = 8.00 lacs

• MS Channels for Joists 70 Nos. @ 2500 = 1.75 lacs

• MS Angles for Steps, Sunshades, Shelves = 0.50 lacs

Cost per Sft = Rs. 0.93 say Rs. 1.0 per Sft 18.65 lacs

• Open platform (20000 sft) & Temporary

shed (10000 sft) = 10.00 lacs

Total = 28.65 lacs

Total cost per Sft = Rs. 1.43 per Sft (say Rs. 1.50 per Sft)

(For 20 lacs Sq ft built-up area for roofing) (Time period: 27 months)


CAPITAL INVESTMENT of mechanization

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With Conventional Specification Amount

With Cost Effective Technologies Amount

Civil Work 2485384.00 Civil Work 1929027.00 Internal Services Internal Services • Sanitary Water Supply

(Dual Stack System)

171425.00

• Sanitary Water Supply

(Single Stack System)

132468.00 • Internal Electrical 224116.00 • Internal Electrical 224116.00

2880925.00

2285611.00 Add 34.34 % Cost Index on Civil & Sanitary items

on Rs 2656809.00 912348.00

Add 34.34 % Cost Index on Civil &

Sanitary items on Rs 2061495.00 707917.00

3793273.00

2993528.00

Cost per dwelling unit 237079 Cost per dwelling unit 187096.00

Savings Achieved = 799745.00

21.08%

Construction of Type - III 1184 Units Houses with Conventional Specifications

Vs Cost Effective Technologies at BAWANA

CASE STUDY 1

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With Conventional Specification Amount With Cost Effective Technologies Amount Civil Work 2380810.00 Civil Work 1788415.00 Internal Services Internal Services • Sanitary Water Supply

(Dual Stack System) 171425.00


(Single Stack System) 132468.00 • Internal Electrical 224116.00 • Internal Electrical 224116.00 2776351.00 2144999.00 Add 34.34 % Cost Index on Civil &

Sanitary items on Rs 2656809.00 1076277.00

Add 34.34 % Cost Index on Civil & Sanitary

items on Rs 2061495.00 810036.00

3852628.00 2955035.00 Cost per dwelling unit 240789.00 184690.00


23.30%

Cost Comparison Conventional Construction Vs Cost Effective Technologies

at NARELA (Plinth area of dwelling units 39.74 sqm) Comparative cost of one

block of 16 dwelling units (G+3)

CASE STUDY 2

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Vs Cost Effective Technologies at BHORGARH Cost for 1 Block Area for one flat 39.74 sqm

With Conventional Specification Amount With Cost Effective Technologies Amount RCC Framed Structure

Civil Work 2485384.00 Civil Work 1879066.00

Internal Services Internal Services


(Dual Stack System) 171425.00


(Single Stack System) 146401.00

• Internal Electrical 224116.00 • Internal Electrical 224116.00

2880925.00 2249583.00

Add 42.17% Cost Index on Civil &

Sanitary items on Rs 2656809.00 1214886.00 Add 42.17 % Cost Index 948649.00

4095811.00 3198232.00


Cost per Dwelling Unit 255988 199890

Savings = 21.91%

CASE STUDY 3

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S.No Description Conventional

construction

Load bearing using

Cost Effective

Technologies

Saving Percent-

age

1 Civil Work 4240365.00 3305145.00 935220.00 22.05

2 Internal Sanitary and

Plumbing

434384.00 300675.00 133709.00 30.78

3 Internal Electrical Works 375858.29 375858.00 0.00

TOTAL 5050607.29 3981678.00 1068929.00 21.61

Cost per Dwelling Unit 315663 248855

Saving – 21.16%

EWS Housing at BAPROLA (Plinth area: 33.60 Sft.)

Cost of 1 Block (16 D.U) (G+3)

Cost Comparison Between Conventional Specifications & Cost Effective

Technologies

CASE STUDY 4

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Economics per sft of Built up area

Total Built up Area = 1655670 sft

Total no. of precast elements = 456278

Wall length per sq feet = 0.87 R.ft

Material consumption per sft built up area

Bricks (Conventional, Fly ash, Modular) = 24 Bricks

Cement = 0.275 bags

Reinforcement steel = 0.97 Kg

Coarse Sand = 0.52 cft

Fair Sand = 0.86 cft

Conduits = 0.46 ft

Wires & Cables = 1.95 ft

Main Water Line = 0.01 ft

Main Sewer Line = 0.0086 ft

Main Drains = 0.018 ft


(4348 HOUSES)

17-09-2014

19

Year Project No. of houses Plinth Area of one

house (sqft)

Virtual Completed Cost i/c

Bldg. & Services (lacs)

Cost per sqft

(excluding dev.)

1 2 3 4 5 6

2003-2006 Bawana, Delhi 3164 406

340

1.42

1.21

350

360

2007-2008 Bawana, Delhi 1184 425 2.95 695

2007-2009 Narela-I, Delhi 1892 425

345

2.45

2.03

575

590

2008-2011 Narela-II, Delhi 1652 425

345

2.85

2.35

670

680

2008-2011 Bhorgarh, Delhi 1272 425

345

2.75

2.25

650

650

2008-2011 Bawana, Delhi 896 290 2.00 690

2009-2012 Bawana, Delhi 704 345 2.30 670

2008-2012 Baprola, Delhi 5568 360 2.45 680

2008-2011 Ghoga, Delhi 3680 300 2.20 730

2012 Poothkhurd (I & III), Delhi 14200 360 3.30 910

2012 Tikri Kalan, Delhi 4560 360 3.30 910

2001-2004 Sector Pi,

Greater Noida 800 400 1.40 350

2008-2011 Omicron,

Greater Noida 1848 350 1.95 560

2014 Bakarwala, Delhi 240 360 3.20 890

• Average Density : 325 DU/Hactare

• Average capital savings achieved : 18% to 20%

• Long term sustainability with no extra cost.

ACTUAL COST OF AFFORDABLE HOUSING PROJECTS

COMPLETED/ONGOING (IN NCR)

Two room housing (Cost of

construction Rs. 2.00 to Rs. 3.50 lacs)


Interlocking blocks and RC planks system – Case study

Housing at Anjar for WELSPUN

G+2 (EQ Zone – V)

Housing VAPI for WELSPUN

G+3 (EQ Zone – III)

Workers Housing

WIL

Cost/Sqft. Rs

Bachelor

Accommodation

WIL

Cost/Sqft.

Family

Accommodation

WIL

Cost/Sqft.

Workers Housing

Cost/Sqft.

Civil Works

Sanitation

Work

Electrical

Work

492

22

61

513

29

59

555

72

73

553

67

71

Total

Cost/Sqft.

Rs. 575 / sft. Rs. 601 / sft. Rs. 700 / sft. Rs. 691 / sft.

Case study for Welspun Group projects.

I RE-BAR WORK Factor per sq ft Unit

• Foundation 0.1477 Kg/sq ft

• Col 0.9677 Kg/sq ft

• Beam 1.247 Kg/sq ft

• Stairs & R C Planks 0.84 Kg/sq ft

Total 3.20 Kg/sq ft

II R.C.C.

• Foundation 0.00465 Cum/sqft

• Col 0.0046 Cum/sqft

• Beam 0.0056 Cum/sqft

• Stairs & R C Planks 0.006 Cum/sqft

Total 0.02085 Cum/sqft

III SHUTTERING

• Beams 5039 Sqm

• Col 3820 Sqm

• Stairs & R C Planks 267 Sqm

• Foundation 312 Sqm

Total 9438 (0.1021) Sqm (sq m/sqft)

FACTOR FOR COSTING (13 STORIED) 1 block - 92,433 sft.

Description Factor per Sq ft

of built-up area

Unit

IV BRICK WORK/ BLOCK WORK:

•

Brick work in

foundation 0.0005 Cum/sq ft

•

Brick work Stair Steps

Only. 0.0004 Cum/sq ft

• 200 mm thk.

Interlocking Hydra-

form Block in Super

Structure.

0.0276 Cum/sq ft

• Half brick masonry 0.0368 Sqm/sq ft

V PLASTER & EXT. PAINT

•

Cement Plaster

Internal walls 0.2251 Sqm/sq ft

•

Silicon external

walls Exposed 0.1264 Sqm/sq ft 111

BUSINESS MODEL for RAJASTHAN

G+3 housing with cost effective technologies

For EWS

(Area of 1 DU – 358 sqft)

For LIG

(Area of 1 DU – 509 sq ft)

S.no. Description/

subhead

Amount in

Rs/DU

Rate per sq ft

(Area of DU)

Amount in

Rs/DU

Rate per sq ft

(Area of DU)

1 Civil cost 2,07,713 579 2,68,644 528

2 Internal Sanitary 15,059 42 15,059 30

3 Internal Electrical 18,733 52 25,380 50

Total for building 2,41,505 673 3,09,083 608

4 Infrastructure cost 20,406 57 20,406 57

Total for building &

infrastructure

2,61,911 730 3,29,489 665

.

Note: Items excluded are Transformers and

cables, ESS, DG sets, STP, WTP 1. Foundations and Plinth – Load bearing structure

2. Super structure

• Interlocking blocks technology with EQ resistance

3. Slab – Precast R.C. Planks & Joists system

4. Staircase - Precast, Ferro-cement

5. Flooring - Vitrified Tiles flooring

6. Wall finishes (Internal) – Cement based putty

7. Wall finishes (External) - Exposed with

silicon coating

8. Joinery work - RCC frame, Flush doors

9. Plumbing & Electrical

BUSINESS MODEL for AFFORDABLE HOUSING PROJECT

At Neemrana, Rajasthan

Type Category Area Building Cost Infra Cost

@ 275/-

(Rs. in

lacs)

Land Cost

@ 175/-

(Rs. in

lacs)

Total

Cost

(Rs. in

lacs)

Sale

Price

(Rs. in

lacs)

Rate Cost

(Rs. in

lacs)

Type I EWS 360 sqft 750 2.70 1.00 0.63 4.33 5.90

Type II LIG 550 sqft 705 4.00 1.51 0.96 6.47 9.90

Type III MIG A 750 sqft 700 5.25 2.05 1.31 8.61 13.50

Total Cost of Dwelling Units :

A. Sustainable affordable housing project

The aim for sustainability lies in adopting materials & technologies that reduce the cost of time frame

construction, and that cover environmental protection and energy conservation.

No heavy equipment or sophisticated T&P required = Saves energy & fuel

Less consumption of cement, Steel & aggregate = Saves energy

No shuttering = Saves forest

Flyash mixed in C.M = Saves cement & energy

Perforated bricks = Better insulation

Ceiling & walls, white finish = Improve day light

No external paint or plaster = Less maintenance

Controlled quality concrete (due to pre-casting) = Less maintenance

Precast Ferrocement elements = Less maintenance

Less weight of structure = Safer in EQ

All pre-casting at site = Saves transportation and fuel

B. Savings in Embodied Energy

No shuttering used - Saves wood & steel

30 % reduction in consumption of cement – Saves embodied energy

60 % reduction in steel reinforcement (less than 1 kg/ sft. in comparison to 3.5 kg/sft)

in conventional construction - Saves embodied energy

Perforated hollow Bricks - Saves fuel & enhanced Insulation

GREEN BUILDING FEATURES AT NO EXTRA COST

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20

C. Seismic Resistance

The houses have been designed as per IS : 4326

with

Load bearing walls concept with box behavior

which has lateral stiffness much higher than

framed structure

Vertical reinforcement at T & L junctions

Vertical reinforcement around openings

Plinth band, lintel band & roof band

Building Form - Rectangular, therefore more

stable

Building configuration is symmetrical w.r.t mass

and rigidity

Structure is light due to 15 % less thickness of

walls, 30 % reduction in concrete slab and use of

ferrocement thin elements.

D. Saving in Water Consumption (Water Conservation)

Less water consumption during construction:- due to

lesser volume of masonry, less volume of concrete, due

to no ceiling plaster, due to no external plaster.

The precast slab panels, stairs, sunshades, shelves etc.

cured with spray of water. There is no free flow of

water, thus conservation of water during construction

The precast elements covered with thick cloth / gunny

bags and then water sprayed on them. This avoids water

rebound and ensures sustained and complete curing;

conserving water.

Water ponding done in sunken portion of WC/ Bath

and then ponding used for curing. This conserved water

and avoids water flowing away.

The mechanized bricks have high compressive strength

and low water absorption –thus saves water.

Ferrocement elements also being thin elements –

consume less water.

Hardy plants species used in Horticulture which require

less water.

Soft permeable pathways to reduce run off rain water

Ground water recharging through Rain Water Harvesting

wells.

GREEN BUILDING FEATURES AT NO EXTRA COST

THANK YOU!

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