Precast technology was used to construct a 24-story residential building in Mumbai's seismic zone 3 in record time. Standardized precast concrete elements like walls, slabs, and stairs were cast in a factory and assembled on site with joints. The use of precast construction led to increased productivity, speed of construction, quality control, worker safety, and reduced environmental impact compared to traditional construction. This project demonstrated the technical and economic feasibility of using precast technology for high-rise construction in India.

2. PRECAST TECHNOLOGY
DEFINITION: Precast Technology is Technological innovation suitable for manufacturing process
Structural elements
are standardized and
cast in factory
STANDARDIZATION OF ELEMENTS
Transported to site on
trailers
Erected on site by
Cranes
ELEMENTS ASSEMBLED TOGETHER WITH APPROPRIATE JOINTS

3. 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

4. SITE LAYOUT
Phase - 1
Phase - 2

5. 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

6. ELIGIBILITY FOR ENGINEERING EXCELLENCE
– PRAGATI TOWERS
BEST DESIGN PRACTICES
IN ASIA
BEST DESIGN PRACTICES
IN EUROPE
DUCTILITY
REQUIREMENTS IN
SEISMIC ZONE
INDIAN CODAL
PROVISIONS
DESIGN OF PRAGATI TOWERS
IN CONFORMANCE
WITH
DESIGN
PUT TOGETHER TO
COMPLETE
1.

7. ELIGIBILITY FOR ENGINEERING EXCELLENCE
– PRAGATI TOWERS
2.
PRODUCTIVITY ENHANCEMENT
CONSTRUCTION
INDUSTRY
FACING SHORTAGE
OF SKILLED
MANPOWER
ADOPTING
MECHANIZATION IN
CONSTRUCTION
L&T ENVISAGED THE
SOLUTION IS TO BE
MORE DEPENDENT
ON MACHINES
LEAD TO INCREASE
IN PRODUCTIVITY IN
PRAGATI TOWERS
MANPOWER
REQUIREMENT REDUCED
BY AROUND 30% AT
PRAGATI TOWERS

8. ELIGIBILITY FOR ENGINEERING EXCELLENCE
– PRAGATI TOWERS
3.
Formwork
•Stage 1
SPEED OF CONSTRUCTION
Reinforcement
•Stage 2
Concreting
•Stage 3
Blockwork
•Stage 4
Plastering
•Stage 5
POP works
•Stage 6
Painting
•Stage 7
Conventional Construction
Activities – on site
Reduction in the number of
activities
Precast Construction
Casting at yard
•Stage 1
Transportation
•Stage 2
Erection
•Stage 3
Jointing
•Stage 4
Painting
•Stage 5
Reduction in the number of activities & materials along
with reliability on mechanized production lead to
increase in speed of construction at Pragati Towers.
Reducing the dependency
on labour.
Savings in Precious Project
Time & thereby costs.

9. ELIGIBILITY FOR ENGINEERING EXCELLENCE
– PRAGATI TOWERS
4.
STANDARDIZATION
WALL
PANELS
SLABS
PRAGATI
TOWERS
PODS
WALL PANELS
SOLID SLAB PANELS
POD ELEMENTS
BEAMS
ENTIRE TOWER WAS BROKEN UP INTO
STANDARDIZED ELEMENTS TO GAIN
MAXIMUM REPETITION OF MOULDS
SPANDREL
PARAPET BEAMS
COLUMNS
COLUMNS
STAIRCASE
SPANDREL
STAIRCASE
ALL ELEMENTS WERE STANDARDIZED FOR ECONOMISING CONSTRUCTION AT PRAGATI TOWERS

10. ELIGIBILITY FOR ENGINEERING EXCELLENCE
– PRAGATI TOWERS
5. QUALITY CONTROL
 Precast Elements of Pragati Towers were cast in strictly controlled factory conditions
 Rigorous inspection at all stages ensures smooth and high quality finish.

11. ELIGIBILITY FOR ENGINEERING EXCELLENCE
PRAGATI TOWERS – HIGH QUALITY INTERIORS

12. ELIGIBILITY FOR ENGINEERING EXCELLENCE
– PRAGATI TOWERS
6. SAFETY
 All Casting activities of Pragati Towers were carried out at ground level

13. 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.

14. 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.

15. ELIGIBILITY FOR INNOVATIVENESS IN CONSTRUCTION
– PRAGATI TOWERS
1.
TECHNOLOGY
 Potential offered by precast technology was limited to infrastructure
projects such as airports, stadiums, bridges, dome roofs, metro projects etc.
 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.
First time in India, 24 storied residential building structures are
constructed by using Precast Technology
KANTEERAVA STADIUM
CHENNAI METRO RAIL
INFRASTRUCTURE PROJECTS
PUTTAPARTHY

16. ELIGIBILITY FOR INNOVATIVENESS IN CONSTRUCTION
– PRAGATI TOWERS
2.
DESIGN
 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.

17. ELIGIBILITY FOR INNOVATIVENESS IN CONSTRUCTION
– PRAGATI TOWERS
3.
PRECAST PANEL FABRICATION – ‘INDIGENEOUSLY DEVELOPED MODULAR UNITS’
MOULD - MODULAR BLOCKS
MODULAR BLOCKS ( 3D POD)
EXPLODED VIEW
REAR VIEW
INTERIOR CORE
TRANSPORTATION

18. 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.

19. ELIGIBILITY FOR INNOVATIVENESS IN CONSTRUCTION
– PRAGATI TOWERS
4.
WATER PROOFING
Joint detail
should ensure
water
tightness
Monolithic casting of
WC & Bathrooms in
Pragati Towers ensures
water tightness

20. ELIGIBILITY FOR INNOVATIVENESS IN CONSTRUCTION
– PRAGATI TOWERS
5.
SPEED & SAFETY
 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.

21. ELIGIBILITY FOR OPERATIONAL EXCELLENCE OF PROJECT
– PRAGATI TOWERS
1.
RECORD ERECTION TIME
 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.
EXECUTION OF LOGISTIC PLANNING IN CONGESTED AREAS
NOISE FREE ERECTION EVEN DURING NIGHT

22. ELIGIBILITY FOR OPERATIONAL EXCELLENCE OF PROJECT
– PRAGATI TOWERS
2.
REDUCTION IN NUMBER OF ACTIVITIES AT SITE
 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

23. ELIGIBILITY FOR OPERATIONAL EXCELLENCE OF PROJECT
– PRAGATI TOWERS
5.
RELIEVING TRAFFIC CONGESTION
 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.

24. ELIGIBILITY FOR ADDING SELF RELIANCE OF INDIA IN
CONSTRUCTION SECTOR
– PRAGATI TOWERS
1.
CONVICTION IN CONSTRUCTION TECHNOLOGY
 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.

25. ELIGIBILITY FOR ADDING SELF RELIANCE OF INDIA IN
CONSTRUCTION SECTOR
– PRAGATI TOWERS
4.
PROGRESSION IN DESIGN & JOINT DETAILING
 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.

26. ELIGIBILITY FOR KEY IMPACTS THIS PROJECT HAS MADE
– PRAGATI TOWERS
1.
Proved ‘PRECAST TECHNOLOGY’ is feasible for high rise in seismic conditions.
2.
Successfully Addressed ‘The DEMAND & SUPPLY’ gap faced by Construction Industry.
3.
Immaculate finishes without compromising cost competitiveness of the Project.
4.
‘AMAZEMENT OF PEOPLE’ to view massive structures erected with great ease.
5.
Timely Project Completion

27. ELIGIBILITY FOR FUTURE READINESS OF THE PROJECT
– PRAGATI TOWERS
1.
‘FEASIBILITY & ACCEPTABILITY’ of Technology.
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.
4.
‘INDIGENEOUS DEVELOPMENT IN MOULD DESIGN’ to increase cost effectiveness.
5.
‘REDUCING THE DEPENDENCY OF LABOUR BY INVOLVING TECHNOLOGY OR MECHANIZED
CONSTRUCTION.’
6.
MULTIFOLD INCREASE in ‘Quality, Durability, cost effectiveness, speed with high quality
end products.’

28. CURRENT STATUS
- PRAGATI TOWERS

29. THANK YOU