DNB Associates

Plot.No- GA 118, Niladrivihar

Chandrasekharpur, BBSR-21
 PROJECT INTRODUCTION
Assuming Residential Project of 1.0 Million Sqft BUA.
 TECHNLOGY
Use of Precast Technology for a Residential Project of 1.0
Million Sqft BUA consisting of Solid Walls & Floor Slabs
(Filigree/Prestressed Filigree Slab/Solid Slab)
 MANUFACTURING PROCESS
Use of Stationary System:
a) Tilting Tables for Load Bearing Walls
b) Flat Tables for Slabs
 EQUIPMENT DESCRIPTION
 Tilting Tables:
This is a flat table of size of 12 x 4M. The Tilting Tables is equipped with
Hydraulic Cylinders, Power Packs, Vibrators, Frequency Convertor, Distribution
Box, Shuttering System, etc.
The Tilting Tables can be raised to a angle of 88 deg. with the help of Hydraulic
Cylinders & Power Packs when the Walls have to be de-moulded from the
Tilting tables.
The Electric Vibrators provided at the bottom of the Tilting Tables is mainly for
compaction of concrete. The frequency of the Electric Vibrators can be varied
with the help of Frequency Invertor from 1 – 200 Hz.
 Flat Tables:

The Flat tables are for producing of Solid Slabs on the Tables which is the same
construction of Tilting Tables except that Hydraulic Cylinders & Power Packs not
required. The Floor Slabs are de-moulded horizontally since Slabs have to be
stacked in the Storage yard horizontally
 LIST OF END PRODUCTS
 Walls: (A) Solid Walls (B) Sandwich Walls
You can produce External Walls of any size since the Table size is of 12 x 4M. Normally the clear
floor height is between 3.0 to 3.2m and the length of the external walls with windows, doors &
inserts cannot be more than 6m.
So the Table is selected in such a way that in one Tilting Table you can produce 3 nos. of precast
elements (exterior walls, interior walls, partition walls) to get the maximum output. The
element size is basically planned and the detailing & designing of the elements is done by
structural consultants depending upon various factors.
Sandwich walls are walls with insulation sandwiched between 2 layers of concrete. An
Overturning Station is required to cast them.
The maximum size of the wall element you can produce is 11.5m x 3.5m in one Tilting Table.
 Slabs: (A) Solid Slabs (B) Filigree Slabs [C] Prestressed Slabs
For the floor slabs you can produce size of 6m x 6m or even more depending upon the room
size.
Although, it is then the work of the structural consultant to decide the slab dimensions which is
considered on various factors including the Tower Crane capacity.
In Flat Tables you can produce prestressed Solid Slab/Filigree (Half) Slabs with large spans. You
can produce pre-stressed Filigree Slabs upto 14m span.
 RAW MATERIALS
The raw materials required is the same what you are using for the conventional process for
making RCC structure. The basic raw materials required is
A) Cement
B) Sand
C) Aggregates
D) Water
E) Other Additives
Normally in precast technology the grade of cement used in M30 and above with slump ratio
depending of the recipe of the concrete mix and how fast you would like to de-mould the
elements after a fixed time of curing.
The above raw materials are required if you are putting your own Batching Plant. In case you
would not like to put up a Batching Plant then you can get the grade of concrete supplied from
the manufacturer who can supply in Transit Mixer.
 NUMBER OF TABLES REQUIRED:
Assuming 1Million sqft. BUA produced per year i.e, 300 working days.
1 Million sqft = 92903.04 sqm BUA
FLAT TABLES
Each Flat Table, taking 70% occupancy factor can cast 12*4*07 = 33.6sqm concrete slabs. Cycle
duration from start to stripping is 1 day, so we can cast 33.6 sqm per table per day.
Therefore, number of Flat Tables : 92903.04/(300*33.6) = 9 Flat Tables.
TILTING TABLES
We assume that quantity of Walls = 2.5 times quantity of slabs (including exterior and interior
walls).
Therefore, quantity of walls : 2.5*92903.04 = 232257.6 sqm.
Using the same calculations as before, number of Tilting Tables = 232257.6/(300*33.6) = 23
Tilting Tables.

The unique part about casting tables is that you do not have to purchase all of it at once. You
can start with as little as 4 Tables and grow organically, depending on your requirement and
expertise.
 OTHER EQUIPMENT
List of deliverables including Auxiliary equipment required apart from the Precast Equipment
are as given below:
a) EOT cranes 10T (Double Girder) – 1 No.
b) Concrete Spreader – 1 No.
c) Concrete Batching Plant OR Transit Mixer -- 1 No.
d) Tower Crane (Tip capacity – 9 Tonnes) -- 1 No.
e) Shuttle Car/ A- Frame for transportation of Precast elements to the storage yard – 2 Nos.

 The bay dimensions should be 160m x 24m to accommodate the 23 Tilting tables + 9 Flat
tables. The space for the reinforcement section needs to be discussed.
 The storage area of the precast elements can be of the same size as mentioned above. The
Batching Plant can be put outside the shed. This again depends on various factors which
needs to be discussed further.

 There are also other moulds like staircase moulds, beam-column moulds and other moulds
for special structural items. These moulds and the space required for them in the shed need
to be discussed further, depending on requirements.
 MANPOWER
Considering 1 Million sqft per year the production capacity is as follows:
 Wall elements per day : 774 sqm

 Slab elements per day : 310 sqm

 The manpower required:

 Equipment Manpower required

 1) Tilting Tables (23 Nos.) 46 Nos.
 2) Flat Tables (9 Nos) 18 Nos.
 3) EOT operator 2 Nos.
 4) Reinforcement 15 Nos.
 4) Supervisor 3 Nos.
 With Tilting Tables / Flat tables since curing is 14-16 hours so you can use one shift per day.
If the efficiency of the workers is at a point where they complete the whole process till
concreting in 2 hours then you can use the Tables (Tilting/Flat) 1 ½ times per day, which
reduces our requirements to 16 Tilting Tables and 6 Flat Tables.
 FINANCIALS
 The average cost of precast concrete, including manufacturing, transportation, and erection
costs about Rs. 14,000 per sqm.
 Vendors in the market typically sell it around Rs. 18,000 per sqm.
 This varies project to project, depending on size of project and the structural system used.
Loadbearing Structural Systems (load bearing walls and slabs) typically cost less that Frame
Structural Systems (beam-column system).
 The figures quotes above are an approximation, as costs also depend on materials,
equipment, labour, overheads, and the profit margin you wish to achieve.
 Typical equipment amortization occurs after 5 years, or 10lakh (1Million) sft of concrete
production.

 CONCLUSION
 We at Vollert hope you have had an informative read. Please do not hesitate to contact us
with any further questions.