INTRODUCTION

The construction projects nowadays are becoming very complex, expensive and time
consuming. The increasing population has led to greater demand of residential, industrial and
commercial construction. Construction projects have been experiencing delays from long time
and timely delivery of projects has become a prime concern for developers. Especially after
Real Estate (Regulation and Development) Act (RERA) was passed in 2016, timely completion
of projects is very important. Therefore, the developers are forced to adopt modern
technologies and survive the already slow construction market.

Modi government has set an ambitious goal of ‘Housing for All’ in which nearly 2 million
houses are to be built by 2022. Building 2 million homes in such a small duration is a herculean
task and can only be achieved by adopting newer technologies, which will not only reduce
time but will also improve the quality and durability of construction.

The new technologies and materials that are available are self-climbing formwork, pre-cast
concrete technology, autoclaved aerated concrete blocks, durable concrete etc. These
technologies are not only advantageous in terms of cost but they also help in minimising time,
labour and maintenance, it also provides more durability and smoother finish. As per the
McKinsey & Company study engineering and construction industry is slowly moving towards
accepting new methods to design, plan and execute projects.

NATURE OF THE PROJECT

This project is a residential high rise development which comes under the smart city mission.
The project consists of 5 identical buildings with each building having 24 floors. Each building
houses 132 flats. The flats in the project range from 60-110 square metre thus making it
eligible for affordable housing scheme. Each building has provision for stilt parking. The
development also has recreational facilities such as playground, garden, club house and gym.

1
 NEW CONSTRUCTION MATERIAL, EQUIPMENT AND
TECHNOLOGY FOR THE PROJECT

1. Autoclaved aerated concrete (AAC) blocks

Bricks are one of the most traditional building material and it has been extensively used in
most of construction projects. The replacement for bricks are the AAC blocks. It is eco-friendly
and it is also certified as a green building material. AAC blocks are porous which makes them
lightweight, they are load bearing, they can be reused, recycled and also durable. These
blocks are produced in various sizes and strengths. These blocks are produced from mix of
quartz sand or fly ash, cement, lime, gypsum anhydrite, water and aluminium powder and is
hardened by steam curing in autoclaves.

The CO2 emissions from clay brick production is nearly 8-9 times to that of AAC block
production. The various sizes available of AAC blocks are 600x200x75,100,150,175,200,225
mm. The dry density of AAC blocks ranges from 551-600 kg/m3 whereas that of bricks is nearly
1900 kg/m3 thus making it lighter by a great extent. This will in turn reduce the dead weight of
the structure hence leading to great savings in steel and cement (Rathi & Khandve, 2015).
The blocks are used with thin mortar bed and can be coated with stucco or plastered.

2. Crushed Rock Sand

Sand is one of the most important material required for any construction site. The decrease in
availability of natural river sand due to ban on dredging has led to shortage of sand and hence
construction activities have come to standstill. Sand is one of the major constituent of Concrete
and accounts for nearly 35 % of its volume. With the increasing cost of natural sand, crushed
rock sand (CRS) came as an replacement. As per the study conducted by IIangovan (2000).
Sahu et al (2003) there was a steep decrease in cost of production of concrete by crushed
rock sand compared to natural sand without compromising on compression or tensile strength.

From the study done by (Mundra, et al., 2016) it was noted that if the CRS replacement is
greater than 50% there was reduction in compressive strength, it is desired to have washed
crushed rock sand with proper screening to get the desired strength. The use of CRS not only
reduces the cost but also helps in maintaining ecological balance.

2
 3. Exposed POLY-AS combined waterproofing system

It is a 3-ply exposed waterproofing system. The first layer being the turbo seal which forms a
gel that expands after it comes in contact with water. Second is the turbo sheet which consists
of styrene butadiene styrene (SBS) improved asphalt, polyethylene and polyester and the third
is the exposed sheet which has got similar components but it is also topped with coloured
sand which makes it 4mm thick unlike the turbo sheet which is 2mm. The materials are non-
degradable and the added advantage is self-sealing when it comes in contact with water.

Stepwise procedure for waterproofing: -

i. Surface preparation wherein projections greater than 2mm are to be levelled

ii. Using a trowel or a brush turbo seal has to be applied evenly with 2mm thickness. Corners,
concrete joints, pipes are to be reinforced with 25cm wide turbo sheet.

iii. The turbo sheet has to be applied on turbo seal with ambient temperature of minimum 5oC.

iv. The air trapped inside the sheet has to be removed.

v. Exposed sheet has to be attached on the turbo sheet such that the sheets do not overlap
with the connection part of the turbo sheets.

4. Precast Construction Technology

Precast construction is a technology in which the structural components of buildings are

manufactured in factory and then transported to site. This type of technology is normally
incorporated if there are many building to be constructed with similar structural dimensions.
The use of precast technology will lead to shorter delays in construction projects. With the
reduction in time it will indirectly result in reducing cost. It not only leads to lower cost it is also
quality assured as manufacturing is done in controlled environment. Various processes such
as shuttering, deshuttering and curing are also eliminated.

Checklist and preparatory works: -

i. The site should be accessible for delivery of precast components

ii. The crane should have adequate capacity for lifting the precast concrete
components

3
 iii. Some samples are to measured and inspected to check if the dimensions are
accurate.
iv. Unloading and storage area should be easily accessible.

Installation sequence: -

i. Setting out of reference line and offset line to find the exact position where the
precast element has to be installed.
ii. Providing and checking shim plate’s level and stability.
iii. For external walls/column fix the compressible backer rod on the outer perimeters
of the wall.
iv. The panel should be lifted and placed at designated location with use of wire ropes.
v. Panel should be placed in position and secured with diagonal props.
vi. Non-shrink mortar should be applied to seal gaps along inner bottom edge of the
panel.
vii. The installed panels should be kept undisturbed for at least 24 hours.
viii. Joint rebars are to be installed for panels with cast in-situ joints.
ix. Formwork should be properly set up for casting vertical joint followed by concrete
casting.
x. Formwork should be removed after sufficient strength is achieved.

5. Putzmeister 20Z-Meter Truck Mounted Concrete Boom Pump

Concrete boom pump are of two types stationery and truck mounted. The truck mounted ones
are normally used because of their ability to shift depending on the place of work. Boom pumps
are used in large construction projects as they are able to complete large concreting works in
short duration of time unlike the traditional way which consisted of joining numerous pipes
manually. There are various lengths of boom pumps available such as 20m, 32m, 36m, 38 m,
etc.

The pump is aided by Ergonic Pump Control System (EPS) which monitors the pumping
operation and makes sure that the pump is at its peak performance always. Ergonic Output
Control reduces fuel consumption and adjusts the engine speed according to the requirement
as set by the operator on the remote control. The four-section z fold design of the boom makes
it easier for placement in congested areas. This pump has a greater output due to efficient
use of all available energy.

4
 6. Sensitile Terrazzo
Sensitile terrazzo is fine concrete mix into which light conducting channel are inserted.
They are then formed into tiles or slabs. Whenever there is any light, shadow or
movement the tiles/slabs shine and twinkle. This material is very eye catching and
playful. These tiles/slabs can be used for flooring, feature walls, horizontal and vertical
surfacing. These tiles are available in polished, honed, sandblasted and factory finish.
Tiles are available in these standard sizes 6”x6”, 12”x12”,24”x24”, 12”x24” and slabs
are available up to 4’x8’. Sensitile terrazzo is a sustainable material which contains at
least 20% of post-consumer waste thus giving LEED credits.

7. Mini Road Roller Compactor

A mini roller can be used for compaction of asphalt, sand, soil, gravel and it can also be used
to flatten lawns or grasslands. It can be used in places where the normal road roller cannot be
used. In places, such as underground water tanks it is very difficult to lower the normal road
roller for compaction thus in such places mini roller can be used for preparation of ground. It
comes with electric starting option, height adjustment of handrail and a very powerful engine.
Its weight is nearly 530 kg and its dimensions are 1.8x1.2x1.1 m. Its size also allows it to be
easily transported to different places easily with the help of loader.

Figure1. mini roller

5
Formwork and Scaffolding

The formwork that will be most suitable for construction of this project is ‘Automatic climbing
formwork Xclimb 60’ by Doka. This formwork works on hydraulics but if sufficient craneage is
available then it can directly be raised by crane. There is a provision for attaching working
platform anywhere on the scaffolding.

Self-climbing of the scaffold with formwork is achieved by fixing the quick mount hydraulic
cylinders with the lifting mechanism. There is a firm link between system and the structure
which makes its climbing easier even in case there are strong winds. There are provisions for
ladder, stair tower and integrated platform which provides high safety. The workers feel safe
even at heights which speeds up the work.

It is cost efficient as when the platforms are raised along with that payloads can also be raised
which saves the craneage cost. The hydraulic systems are easy to operate thus there is hardly
any time loss on explaining the crew about the procedure. The hydraulic cylinders are
lightweight which makes it easy for the workers. Since the residential building is high rise
therefore this is most suitable and would also reduce time by a considerable extent.

Figure 2. Doka formwork and shuttering Figure 3. Ladder and stair tower

6
Conclusion

With the increase in incomes of people, the demand for homes has been increasing. The
existing technology that is available is not enough for the huge requirement. There are delays
in almost every project in India therefore there is a urgent need for using newer materials,
technologies and equipment’s to speed up the construction industry. The goal of the smart city
is also to provide housing opportunities for all at the same time promoting ecological balance.
Modern materials such as AAC blocks, Crushed sand help in reducing pollution by a great
extent at the same time reduces time as well as cost of construction. New technologies such
as poly-as waterproofing, precast improve the durability and speed, equipment’s also help in
reducing the time required for construction. From the above examples we can say that modern
construction trends will help us in achieving our goal of housing for all in Smart Cities.

7
References
Anon., n.d. Precast concrete elements. [Online]
Available at: https://www.bca.gov.sg/Professionals/IQUAS/others/precastinstallation.pdf
[Accessed 01 November 2017].

Automatic climbing formwork Xclimb 60, n.d. [Online]

Available at: https://www.doka.com/in/system-groups/doka-climbing-systems/automatic-climbing-
formwork/xclimb60/index#
[Accessed 02 November 2017].

Blanco, J. L., Mullin, A., Pandya, K. & Sridhar, M., 2017. McKinsey & Company. [Online]
Available at: https://www.mckinsey.com/industries/capital-projects-and-infrastructure/our-
insights/the-new-age-of-engineering-and-construction-technology
[Accessed 01 November 2017].

Ministry of Housing and Urban Affairs, Government of India, 2017. Smart City Mission. [Online]
Available at: http://smartcities.gov.in/content/innerpage/smart-city-features.php
[Accessed 01 November 2017].

Mundra, S. et al., 2016. Crushed rock sand – An economical and ecological alternative to natural
sand to optimize concrete mix. Elsevier, Volume 8, pp. 345-347.

online, F., 2017. New age technologies in construction industry key to achieve Housing for All by
2022: Colliers Research. Financial Express, 05 July.

Putzmeister America, 2013. Putzmeister. [Online]

Available at: http://www.putzmeisteramerica.com/data/products/documents/20Z_CB_4428_US.pdf
[Accessed 02 November 2017].

Rathi, S. O. & Khandve, P. V., 2015. AAC Block - A New Eco-Friendly Material For Construction.
International Journal of Advance Engineering and Research Development, 2(4), pp. 410-414.

Re-Systems Singapore Marketing, 2015. [Online]

Available at: http://www.re-systemsingapore.com/RSS_Brochure.pdf
[Accessed 01 November 2017].

Sensitile Systems, 2017. [Online]

Available at: https://www.sensitile.com/concrete-families/sensitile-terrazzo#documentation
[Accessed 02 November 2017].

Turai, V. & Waghmare, A., 2016. A study of cost comparison of pre-cast concrete vs cast in place
concrete. International Journal of Advanced Engineering Research and Applications, 2(2), pp. 112-
113.

Zhenghou Cosin Construction Machinery Co.,Ltd, 2015. [Online]

Available at: http://www.cosinmachine.com/sell-176243-cosin-cyl31-mini-road-roller-
compactor.html#.WfxwoLpuJEY
[Accessed 02 November 2017].