Rapid construction techniques

RAPID CONSTRUCTION
TECHNIQUES
Adoption of new technology
For construction practice
BUILDING ENGINEERING AND MANAGEMENT
Construction Management Tool and Technique [MBEM -112]
Deepak Pradhan
1210900048

IN GENERAL OUR CONSTRUCTION INDUSTRY DON’T
INCORPORATE NEW TECHNOLOGY THAT QUICK.
But,
Prefabrication is already becoming more common.
• "The benefits are quick to see and identify, Climate control, Safety,
Available equipment.
• It helps the contractor to control the schedule a little bit better and
the quality as well."
INTRODUCTION
WHY WE NEED RAPID CONSTRUCTION TECHNIQUES?
Construction industries faces lots of ongoing challenges of
maintaining, rehabilitating, expenditures and many more. All these
things are directly connected to the time, as the time increases it may
lead to increase in challenges or problems which will lead us to
Rework and as we all have budget constraints that’s why the main
target is to MINIMIZE THE CONSTRUCTION TIME.
To complete the work without compromising the quality and in a time
frame with minimal impact on public. Also there are many advances
of using rapid constructions. reduce congestion associated in the
construction flow.
Construction practice
Challenges / problems
Re work
Increase in time frame
Increase in budget
Compromise with Quality
Client un-satisfaction
Introducing new
Technology
-with unskilled labor

MAJOR TYPES OF RAPID CONSTRUCTION PRACTICE :
1. Pre-fabricated sandwich panel system
2. Monolithic Concrete Construction ( mivan shuttering )
3. Precast Concrete Construction System – Precast Components Assembled at Site
4. Precast Concrete Construction System – 3D Volumetric
5. Light Gauge Steel Structural System & Pre-engineered Steel Structural System (LGSF)
6. PVC Stay In Place Formwork System
Construction practice New technology with
skilled labor and machine
New technology which
doesn't require skilled
labor or minimize the size
of labor
Increase in one time cost
Completion in time Client satisfaction
The main aim is to place a greater emphasis on achieving a better construction technology
which meets the needs of the end user at the earliest possible.

1. Pre-fabricated sandwich panel system
PHYSICAL PROPERTIES
• length (2 to 18 m)
• thickness (40 to 230 mm)
• core type (EPS, Rock wool , polyurethane)
• profile (smooth, micro-profile, clear-line, grooved etc.)
• protective coatings (polyester SP
, SP polyester Mat Pearl, Cesar
PUR 55, Aluzinc), with panels also used with stainless steel
cladding
• cladding colours (both external and internal)
• PUF Sandwich Panels is a composite structures which are commonly used in the
construction industry for providing excellent thermal & acoustic insulation properties.
• PUF insulated sandwich panels consisting of an insulating layer of rigid core sandwiched
between two layers of structural board, used as a building material. The board can be pre-
coated GI sheet (PPGI), stainless steel (SS), Cement fiber board, ACP and the insulation
core will either be Polyurethane foam (PUF), Rock wool or EPS
ADDITIONAL FEATURES OF
PUF SANDWICH PANELS
• Adequate Insulation
• Customizable
• Light weight
• Zero Maintenance
• Energy savings
• Cladding options
• Best alternative
• Resistance
• Environmental friendly
Ppgi / ss / cement fiber /
acp board
polyurethane / rock wool / eps
Wall panels

These replace conventional brick & mortar walling construction practices and can be used as load-bearing and non-load
bearing walling for residential and commercial buildings. For buildings higher than single storey, the system can be used
either with RCC or steel framed structure.
In this system the EPS Cement Panels are manufactured at the factory in controlled condition, which are then dispatched to the
site. The panels having tongue and groove are joint together for construction of the building.
SPECIAL FEATURES:
• Being dry walling system, brings speed in construction, water conservation
(no use of water for curing of walling components at site).
• The sandwich panels have light weight material as core material, which brings
resource efficiency, better thermal insulation, acoustics & energy efficiency.
• Being light in weight results in lower dead load of building, decrease in
foundation size and steal count
• Save between 2% of floor space and 40%-50% heat and cooling cost .
Tongue and
groove are joint
Corner joint
Roof panel joinery detail

Cement board puff-
panel flooring
Ppgi sheet puff- panel roof
Acp sheet puff- wall panel
Steel skeleton structure ready for
the installation of wall panels

2. Monolithic Concrete Construction (MIVAN formwork system)
• This innovative form of work is actually suitable for
constructing houses in large quantities at a faster speed.
The speed of construction needs to be given greater
importance, especially for large housing projects or
township project.
• To minimize the unusual challenges in terms of time, cost
and quality, the real estate industry has come up with a
smart method of construction known as the “MIVAN
formwork system”.
• There are a number of buildings in India (Mumbai,
Bangalore, etc.) that are being constructed with the help of
the Mivan technology, which has been declared
economical as well as satisfying for the overall Indian real
estate market.
• concrete walls and slabs are cast in one go at site giving monolithic structure using high-precision, re-usable, room-sized,
Steel forms or moulds .
• this system intends to replace the conventional RCC Beam-Column structure which uses steel/plywood shuttering.
‘MIVAN formwork’ system uses customised engineered steel/aluminium formwork consisting of two half shells which are
placed together and then concreting is done to form a room size module. Several such modules make an apartment.

Major Components of Mivan Formwork
1. For Wall Components
• Wall Panel, d) Rocker, c) Kickers, and d) Stub Pin
2. Beam Components
• Beam Side Panel, b) Prop Head and panel for Soffit Beam
3. Deck Components
• Deck Panels, b) Deck Prop and Prop Length, c) Soffit Length
4. Other Components
• The other elements used to exclude the wall, beam, and
parts are internal and external soffit corners, exterior and
interior edges for wall panels
Beam shutters Wall shutters
Advantages:
•Mivan Formwork requires
relatively less labour
•Faster completion of floors
•Lesser number of joints and
reduced leakages
•Smooth finishing of wall
and slab
•Low maintenance
•More seismic resistance
•Huge carpet area
•Good quality construction
work
•Faster completion
•No need for plastering
Disadvantages:
•Alignment maintenance
needs skilled labourers.
•Initial setup takes time.
•It is expensive and used for
typical floors only.
•Construction joints should
be set properly.
•Leakage issue like seepage,
leakages during monsoon.

Sno. Parameter Mivan system Regular formwork
1 Speed of development 7 days/floor Minimum 21 days/floor
2 Quality of surface finish Excellent Putting is required
3
Pre-planning of formwork
system
Required Not required
4
Type of construction
Cast-in-situ cellular
construction
Simple RCC
5 Wastage Very little Comparatively higher
6
Accuracy in construction Accurate
Accuracy lesser than
modern systems
7
Coordination between
offices
Essential Not required
8 Seismic resistance Good resistance Comparatively lesser
9
Dismantling floor piece
frames without forcing
props
Possible Impossible
Mivan Construction V/S Conventional Formwork
Project for comparison
No of floors- 10
Floor to floor height- 3.0 m
It cost 25,00,000 more for sub structure and
300,00,000 more for superstructure
Items of Work
Mivan
Technology
Conventional
Method
Amount (In Rs) Amount (in Rs)
Substructure
RCC work 32,00,000 25,00,000
Shuttering 15,00,000 10,00,000
Steel 45,00,000 34,00,000
Block Work 3,60,000 2,50,000
Fly Ash NA NA
Plastering 3,00,000 2,50,000
Painting 1,40,000 1,00,000
Total 1,00,00,000 75,00,000
Superstructure
RCC work 3,30,00,000 2,00,00,000
Shuttering 3,00,00,000 1,50,00,000
Steel 2,70,00,000 1,00,00,000
Block Work NA 13,50,000
Fly Ash NA 1,50,000
Plastering 5,50,00,000 1,85,00,000
Painting 4,50,00,000 50,00,000
Total 10,00,00,000 7,00,00,000

3. Precast Concrete Construction System ( 2D Precast )
• Precast construction Technology is a system of casting concrete in a reusable moulds or
“form” which is then treated in a controlled environment, conveyed to the construction
site and lifted to the place.
• Precast Construction Technology consists of various precast elements such as walls,
beams, slabs, columns, staircase, landing and some customized elements that are
standardized and designed for stability, durability and structural integrity of the building.
• This technology is suitable for construction of high rise buildings resisting seismic and
wind induced lateral loads along with gravity loads. The building framing is planned in
such a way that maximum number of repetitions of moulds is obtained.
wall panels
Plinth beam
Staircase
Floor slab
Pod element

Construction Process
• The construction process comprises of manufacturing of precast
concrete Columns, Beams and Slabs in steel moulds. The
reinforcement cages are placed at the required position in the
moulds. Concrete is poured and compaction of concrete is done
shutter/ needle vibrator. Casted components are then moved to
stacking yard where curing is done for requited time and then
components are ready for transportation and erection at site.
• These precast components are installed at site by crane and
assembled together through in-situ jointing and/or grouting etc.
Special Features:
• Nearly all components of building work are manufactured in plant/casting yard & the
jointing of components is done In-situ leading to reduction in construction time.
• The controlled factory environment brings resource optimization, improved quality,
precision & finish.
• The concrete can be designed industrial by-products such as Fly Ash, Ground granulated
blast furnace slag (GGBFS), Micro silica etc. resulting in improved workability & durability,
while also conserving natural resources.
• Eliminates use of plaster.
• Helps in keeping neat & clean construction site and dust free environment.
• Optimum use of water through recycling.
• Use of shuttering & scaffolding materials is minimal.
• All weather construction & better site organization.

the price of prefabricated construction project is 324.78
yuan/m2, which are 21% higher than that of traditional
construction project. The cost difference between
refabricated construction and traditional construction
mainly comes from precast concrete components.
But,
Compared with traditional buildings, prefabricated
buildings have the advantages of convenient
construction, high construction efficiency, high quality
of prefabricated components, high safety, as
well as saving labor and construction costs.
Precast Concrete Construction V/S
Conventional Formwork

Pre-stretched hollow slab
Pre-stretched Beam
Tilting table for wall panels

4. Precast Concrete Construction System - 3D Volumetric
• This 3D Volumetric concrete construction is the modern method of building by which solid precast concrete structural modules
like room, toilet, kitchen, bathroom, stairs etc. & any combination of these are cast monolithically in Plant or Casting yard in a
controlled condition. These Modules are transported, erected & installed using cranes and push-pull jacks and are integrated
together in the form of complete building unit. Subject to the hoisting capacity, building of any height can be constructed
using the technology.
• This is cast complete with window and door frames, electrical and plumbing conduits already
inlaid. and are designed into the moulds.
• The modules casts five sides in a single pour.
• Building all the features into the moulds design reduces project turnaround time and costs.
• The openings for Windows, doors are so precise that they can be ordered straight from the
drawings.
• This method is replicated and the modules are fitted together—side-by-side or at top 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.
Design
Eng,
Permit and
approvals
Site development
& foundations
Install and site
restoration
Building
constructions
Time saving
Design
Eng,
Permit and
approvals
Site development
& foundations
Building constructions Site restoration
Modular construction schedule
Conventional construction schedule

Special Features:
• About 90% of the building work including finishing is complete
in plant/casting yard leading to significant reduction in
construction & occupancy time.
• The controlled factory environment brings resource
optimization, improved quality, precision & finish.
• With smooth surface it eliminates use of plaster.
• The monolithic casting of walls & floor of a building module
reduces the chances of leakage.
• The system has minimal material wastage (saving in material
cost), helps in keeping neat & clean construction site and dust
free environment.
• Use of shuttering & scaffolding materials is minimal.
• All weather construction & better site organization
Construction Process:
• Sequential construction in the project here begins with keeping the designed foundation of the building ready, while
manufacturing of precast concrete structural modules are taking place at the factory. Factory finished building units/modules
are then installed at the site with the help of tower cranes. Gable end walls are positioned to terminate the sides of building.
Pre stressed slabs are then installed as flooring elements. Rebar mesh is finally placed for structural screed thereby
connecting all the elements together. Consecutive floors are built in similar manner to complete the structure

5. Light Gauge Steel Structural System & Pre-engineered Steel Structural System (LGSF)
• Light Gauge Steel Frame (LGSF) System uses factory made galvanized light gauge steel components. The
components/sections are produced by cold forming method and assembled as panels at site forming structural steel
framework upto G+3 building. LGSF is used in combination with pre-engineered steel structural system for buildings above
G+3 for longevity, speedier construction, strength and resource efficiency.
• The sequence of construction comprises of foundation laying, fixing of
Pre-Engineered Steel Structural System, fixing of tracks, fixing of wall
panels with bracings as required, fixing of floor panels, decking sheet,
fixing of electrical & plumbing services and finally fixing of concrete
walling panels with light weight concrete as infill.
• The other options of dry walling components such as sandwich panels
with insulation material in between can also be used. Similarly, the
floors can either by composite slab/deck slabs/precast hollow core
slabs as per the need & requirements.

Special Features
• High strength to weight ratio. Due to light weight, significant reduction in design
earthquake forces is achieved. Making it safer compared to other structures.
• Fully integrated computerized system with Centrally Numerical Control (CNC)
machine primarily employed for manufacturing of LGSF sections provide very high
Precision & accuracy.
• Construction being very fast, a typical four storeyed building can be constructed
within one month.
• Structure being light, does not require heavy foundation
• Structural element can be transported to any place including hilly areas to remote
places easily making it suitable for far flung regions including difficult terrains.
• Structure can be shifted from one location to other without wastage of materials.
• Steel used can be recycled multiple times
• The system is very useful for post disaster rehabilitation work

Advantages
High Precision :Fully integrated computerised system with CNC machine provides very
high accuracy upto 1 mm.
Structural: High strength to weight ratio. Earthquake force generation is less due to light
weight. Chance of progressive collapse are marginal due to highly ductile and load
nature of closely spaced studs/joists.
Speed in Construction: Construction speed is very high. A typical four storeyed building
can be constructed within one month.
Saving in foundation: Structure being light, does not require heavy foundation.
Mobility: Structural element can be transported any place including hilly places to remote
places easily and structure can be erected fast. Structure can be shifted from one location
other without wastage of materials.
Environment friendly: Steel used can be recycled when required.
• LGSF is 20%-40% quicker build time compared
to traditional building methods.
• Considerable reduction in production of onsite
waste material, and up to 20% reduction in
embodied carbon in building fabric.
• Due to offsite nature, LGSF is less dependent on
'wet-trade' labour resource.

6. PVC Stay In Place Formwork System
• The plant manufactured rigid poly-vinyl chloride (PVC) based polymer components serve as a permanent stay-in-place
finished form-work for concrete walls. The formwork System being used acts as pre-finished walls requiring no plaster and
can be constructed instantly.
• This System is suitable for residential and commercial buildings of any height from low rise to high rise. In order to achieve
speedier construction, strength and resource efficiency, the composite structure with Pre-Engineered Steel Structural System
as structural members is being used in the present project.
• At first, the Prefabricated PVC Wall panels and Pre-Engineered Steel Structural Sections as per
the design are transported to the Site.
• Then, these Sections are erected on the prepared foundation using cranes and required
connections.
• Floor is installed using decking sheet. Once the structural frame and floor is installed and
aligned.
• wall panels are fixed on decking floor. The pre-fabricated walling panels having provisions of
holes for services conduits, are fixed along with the reinforcement & cavities inside the wall
panels are filled with concrete. Upon installment of wall panels, flooring and ceiling, the
finishing work is executed.

https://bmtpc.org/DataFiles/CMS/file/PDF_Files/59_PAC_Novel_PVC_Form.pdf

Government initiatives
https://ghtc-india.gov.in/Content/LHP.html

Bibliography
i. Pre-fabricated sandwich panel system
i. https://ghtc-india.gov.in/Content/LHP-Indore.html
ii. https://www.epack.in/puf-panels
iii. https://balex.eu/en/knowledge-base/news/6-reasons-to-choose-sandwich-panels
iv. https://multidecor.in/why-puf-panels-are-the-preferred-choice-for-modular-buildings
ii. Monolithic Concrete Construction ( mivan shuttering )
i. https://www.99acres.com/articles/construction-technology-mivan-shuttering-vs-conventional-formwork.html
ii. https://www.nobroker.in/blog/mivan-construction-technology-explained/
iii. https://theconstructor.org/building/mivan-formwork-components-procedure-comparision/37256/
iv. https://www.squareyards.com/blog/mivan-technology
v. https://ghtc-india.gov.in/Content/LHP-Chennai.html
iii. Precast Concrete Construction System – Precast Components Assembled at Site
i. https://theconstructor.org/building/methods-precast-concrete-constructions/26523/
ii. https://bmtpc.org/DataFiles/CMS/file/PDF_Files/61_PAC_Urbaanic_Final.pdf
iii. https://ghtc-india.gov.in/Content/LHP-Chennai.html
iv. Precast Concrete Construction System – 3D Volumetric
i. https://ghtc-india.gov.in/Content/LHP-Ranchi.html
ii. https://www.nbmcw.com/product-technology/precast/the-3d-monolithic-volumetric-precast.html
v. Light Gauge Steel Structural System & Pre-engineered Steel Structural System (LGSF)
i. https://bmtpc.org/DataFiles/CMS/file/PDF_Files/TP_08_LGSS_small.pdf
ii. https://ghtc-india.gov.in/Content/LHP-Agartala.html
iii. https://mgiinfra.com/lgsf.html
vi. PVC Stay In Place Formwork System
i. https://bmtpc.org/DataFiles/CMS/file/PDF_Files/59_PAC_Novel_PVC_Form.pdf
ii. https://ghtc-india.gov.in/Content/LHP-Lucknow.html

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