PRECAST

PROCESSES ASSEMBLY INNOVATIONS

CONSTRACTION TECHNOLOGY ASSIGNMENT-02

Introduction

Definition Why Precast

A construction method where structural This type of construction brings in advantages
components are manufactured in a controlled such as improved quality control, faster
environment, away from the construction site, construction and reduced waste
and then transported for assembly

Elements Usages
Precast elements include concrete panels for Precast construction is widely used in
walls, beams, columns, slabs for floors and residential buildings, commercial structures,
roofs, and even staircases and infrastructure projects like bridges and
tunnels
 PRECAST CONSTRUCTION TECHNOLOGY

MANUFACTURING
Design and Planning

Architectural and Structural Design:

Precast elements are planned during the initial design

phase itself, incorporating their sizes, shapes, load
capacities, and installation methods into the overall
structural design.

Shop Drawings:

Detailed shop drawings and Bar Bending Schedules (BBS)

are created for each component.

Connection Design:

Design of joints, reinforcements, and embedded items

(inserts, ducts, anchor plates) is finalized for on-site
assembly.

Pre-production Scheduling:

Planning for batching, casting, curing, and transportation

based on site readiness and erection schedule.

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 PRECAST CONSTRUCTION TECHNOLOGY

MANUFACTURING
Precast elements can be broadly classified into structural, non-structural, and architectural components
Mould Fabrication:
Reusable moulds are made of steel, wood, rubber, or plastic
depending on the complexity and scale of production.
Cleaning and Surface Treatment:
Moulds are cleaned and treated with chemical release agents to
prevent sticking and ensure smooth surface finishes.
Setting of Cast-in Components:
Items like lifters, sockets, electrical conduits, and pipe sleeves are
placed precisely within the moulds.

Formwork and Mould Technology

• Steel Moulds: Durable and reusable moulds, ideal for high-volume

production and precise finishes.
• Adjustable/Form-Flex Moulds: Flexible moulds that can be adjusted
for different dimensions.
• Rubber/Polyurethane Moulds: Used for custom shapes and detailed
architectural finishing

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 PRECAST CONSTRUCTION TECHNOLOGY

MANUFACTURING
Placement of Reinforcement
• Fabrication and Fixing: Concrete Mixing and Casting
Reinforcement bars are cut, bent, and tied or spot-welded as • Concrete Batching:
per the structural design. High-performance concrete is mixed using controlled water-
• Positioning: cement ratios, admixtures, and quality aggregates.
Spacers and chairs are used to maintain clear cover and precise • Transportation and Placement:
alignment of the reinforcement inside the mould. Concrete is poured into the moulds using buckets or
• Prestressing (if applicable): conveyors.
In prestressed precast elements, steel tendons or cables are • Compaction:
tensioned prior to casting the concrete. Vibrators or vacuum technology is used to eliminate air
pockets and ensure proper bonding with reinforcement.
• Surface Finishing:
Screeding and troweling tools are used for a smooth finish, or
textures may be applied if required.

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 PRECAST CONSTRUCTION TECHNOLOGY

MANUFACTURING
Curing
• Initial Curing:
Begins immediately after finishing to prevent moisture loss
(may include fogging, covering with sheets).
• Steam Curing (Common in factories):
Controlled temperature and humidity help accelerate the
strength gain and reduce curing time.
• Curing Duration:
Typically ranges from 12 to 24 hours, depending on
temperature and design strength

Demoulding
After sufficient strength gain (often 24 hours or less), components
are removed from the moulds.
Surface finishing may be done if required (polishing, painting, etc.).

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 PRECAST CONSTRUCTION TECHNOLOGY

PRECAST COMPONENTS
Precast elements can be broadly classified into structural, non-structural, and architectural components
Precast Beams

Function: Horizontal load-carrying members used in supporting floors,

roofs, and bridge decks.
Types:
Rectangular Beams – simple shapes for short spans.
T-Beams / L-Beams – provide wider flange for floor support.
Inverted T-Beams – used where slab rests on the beam.
Spandrel Beams – used in precast frames for supporting cladding.

Precast Columns

Function: Vertical load-carrying components transferring loads to

foundations.

Features: Often cast with corbels or inserts to support beams and slabs;
reinforcement is extended for on-site connections.
 PRECAST CONSTRUCTION TECHNOLOGY

PRECAST COMPONENTS

Precast Slabs / Floor Panels

Function: Horizontal elements forming floor and roof systems.

Types:
Hollow Core Slabs – reduced self-weight with internal voids.
Solid Slabs – full depth concrete, used where sound insulation is crucial.
Double Tee Slabs – long-span systems ideal for parking structures.

Staircases and Landings

Precast stair flights and landings are commonly used in multistory

buildings for speed and uniformity.

Precast Foundation Elements

Includes precast footings, pile caps, and base slabs.

Useful in repetitive foundations like industrial sheds.

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 PRECAST CONSTRUCTION TECHNOLOGY

PRECAST COMPONENTS
Precast elements can be broadly classified into structural, non-structural, and architectural components
Precast Walls

Function: Load-bearing or partitioning elements in buildings.

Types:
Solid Panels – used in load-bearing walls.
Sandwich Panels – layers of concrete with thermal insulation in between.
Cladding Panels – non-load-bearing exterior façade panels.

Utility Components

Precast manholes, culverts, water tanks, septic tanks, trench ducts, and cable
covers are factory-made for infrastructure needs.

Architectural Components

Precast facades, screens, fins, jalis, cornices, and decorative moldings.

High finish quality and variety of surface textures are achievable.

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 Plant to Yard
The concrete is stored in a site place where it
will stay until it is required on the project site.
The precast is inspected during this time to
detect flaws or cracks

Yard to Truck
The precast is checked one last time to ensure it
is ready for construction. The concrete is then
loaded onto the flatbed trailers to minimize

Transportation of
breakage and tied to ensure it is fitted well

Truck to Site
Precast The driver must be extremely precautious when
driving to the site. Once the concrete has arrived
to the site, care must be taken regarding
handling the precast and prepare for installation
 Quality Check
On approach to the site the precast must be
inspected for any damage. Any damage could
affect the structural integrity of the entire
building.

Site Preparation
The site must be prepared and ready for the
installation of precast. If the site is not ready for
the precast then time will be lost and needs to
be compensated

Protection

Installation of Protecting workers is the most crucial part of

the construction. Workers must ensure that
they have protective gear

Precast Machinery
Using appropriate machinery to ensure that the
precast is handled properly and avoid causing
damage of any sort in terms of workers,
equipment or the precast
Methods of Precast Construction System
Large Panel System
Multi-storey structures composed
of large wall and floor concrete
panels connected in vertical and
horizontal directions

These panels form a box like

structure walls are usually one
storey tall and slabs are either one
way or two way slab

The unity of wall panels is achieved

by means of splice bars welded to
the transverse reinforcement of
adjacent panel in the vertical joints
Methods of Precast Construction System
Frame System
Precast frames use linear elements
or beam-column subassemblages,
with the latter allowing
connections away from critical
frame regions.

Linear elements are preferred due

to challenges in forming, handling,
and erecting spatial elements.

Linear elements connect at beam-

column junctions, with beams
seated on corbels for easier
construction and effective shear
transfer.
Methods of Precast Construction System
Slab Column System with Shear Walls

All precast structural elements are

assembled by means of special
joints

Precast concrete floor slabs are

lifted from the ground up to the
final height by lifting cranes.

Temporary supports are used to

keep the slabs in the position until
the connection with the columns
has been achieved.
Advantages of Precast Construction
Faster High Quality Cost Efficiency Durability
Construction and Precision and Strength

Precast elements are Factory-controlled Reduced labor costs due Precast elements are
manufactured off-site environment ensures to less on-site work. highly durable and have
while site work is consistent quality and Faster project completion excellent load-bearing
ongoing, reducing total finish. leads to lower indirect capacity.
project duration. Minimizes human error costs (e.g., site Resistance to harsh
Quicker installation on- and environmental effects supervision, equipment weather conditions,
site due to prefabricated (e.g., weather) during rental). chemicals, and corrosion
components. casting. (especially with proper mix
design).
Advantages of Precast Construction
Improved Safety Environmental Better Aesthetics Less Site Disruption
Benefits and Flexibility

Less on-site work means Minimal on-site waste and Precise molds allow for Quiet and cleaner
fewer accidents and noise pollution. intricate architectural construction sites,
better control over Efficient use of materials finishes and textures. especially beneficial in
working conditions. and potential for recycling. Various surface treatments urban or sensitive areas.
Reduces hazards related and colors can be applied Less traffic and congestion
to formwork, scaffolding, during manufacturing. around the site due to
and wet concrete reduced material
handling. deliveries.
Limitations and Challenges of Precast Construction
Needs trained
Requires
professionals for
significant capital
design,
for factory setup,
Skilled Workforce production, and
molds, and
Requirement installation.
equipment.

High Initial 6 Jointing &

Investment
1 5 Connections
Complex detailing
is needed to
Large and heavy
ensure structural
elements can be
difficult to Transportation & 2 4 Design integrity at joints
and connections.
transport and Handling Issues Restrictions
require careful
planning.
3
Cranes and lifting Site Access Limited flexibility
equipment may for last-minute
Constraints
not be feasible in changes or highly
congested or customized
remote sites. designs.
Technological Innovations
Precast concrete is transforming the construction
industry by offering faster building times, superior
quality control, and significant waste reduction. This
innovative approach is not only reshaping how
structures are built but also contributing to more
sustainable construction practices.

BIM Integration: Precision and Collaboration

Precast concrete is transforming the construction

industry by offering faster building times, superior
quality control, and significant waste reduction. This
innovative approach is not only reshaping how
structures are built but also contributing to more
sustainable construction practices.
Revit Used For Fabrication Details and
Enhanced Accuracy level of development
Building Information Modeling (BIM) offers precision in
precast design and manufacturing. The 3D modeling It ensures that all precast components
ensures accurate dimensions and fit, leading to fewer integrate smoothly, contributing to a more
errors during on-site assembly. The cost savings can be efficient and cost-effective construction
up to 20% through optimized design. process.
Technological Innovations
Automation in Manufacturing: Efficiency and Accuracy
Automation is revolutionizing precast manufacturing
by enhancing efficiency and precision. Robotic arms
precisely place reinforcements and pour concrete.
Automated quality control systems utilize laser
scanning. Production speed increases by 30%
compared to manual methods, reducing labor costs by
up to 50%.

Automation In Manufacturing

Detailed Steps in Robotic Precast Concrete:

1. Shuttering and Mold Placement
Workflow Of Automated Precast Construction
2. Concrete Casting and Consolidation
The Data Is Given To The Computer In Form Of Cad,The 3. Deshuttering and Cleaning
Computer Then Connects to the Integrated Smart End 4. Surface Finishing
5. Assembly and Installation
for The computerised Fabrication In The Factory
6. Smart Concrete Integration
Environment.
Technological Innovations
Self-Compacting Concrete(SCC):Enhanced Performance

SCC enhances precast concrete performance. Better

flowability allows for complex shapes and intricate
designs. It minimizes imperfections, ensuring a
consistent and high-quality final product.
Technological Innovations
 Conclusion
PRECAST CONCRETE
STANDS OUT AS A
SUSTAINABLE CONSTRUCTION
CONSTRUCTION MATERIAL. TIMELINES CAN BE
ITS MANUFACTURING DRAMATICALLY
PROCESS REDUCES WASTE, SHORTENED WITH
AND PRECAST ELEMENTS PRECAST CONCRETE.
CAN INCORPORATE PRECAST PROJECTS
RECYCLABLE MATERIALS, ARE TYPICALLY 20-50%
LESSENING ENVIRONMENTAL FASTER THAN CAST-IN-
IMPACT. ALTERNATIVES LIKE PLACE
STEEL OFTEN HAVE A CONSTRUCTION,
HIGHER CARBON WHICH DEMANDS ON-
FOOTPRINT, WHILE TIMBER SITE FORMWORK AND
CAN CONTRIBUTE TO CURING TIME.
DEFORESTATION.

PRECAST CONSTRUCTION HAS REVOLUTIONIZED THE CONSTRUCTION INDUSTRY BY OFFERING EFFICIENCY, DURABILITY, AND
VERSATILITY. BY UNDERSTANDING ITS COMPONENTS, MANUFACTURING PROCESS, AND INSTALLATION METHODS, WE CAN HARNESS ITS
FULL POTENTIAL TO BUILD BETTER, FASTER, AND SMARTER.
WHILE PRECAST CONSTRUCTION BOASTS NUMEROUS ADVANTAGES, INCLUDING COST-EFFECTIVENESS AND ENVIRONMENTAL
BENEFITS, IT ALSO PRESENTS CHALLENGES SUCH AS TRANSPORTATION LOGISTICS AND DESIGN LIMITATIONS. HOWEVER, WITH
EMERGING TECHNOLOGICAL INNOVATIONS, THESE HURDLES ARE CONTINUOUSLY BEING ADDRESSED, PAVING THE WAY FOR MORE
SUSTAINABLE AND ADVANCED CONSTRUCTION PRACTICES.
ULTIMATELY, PRECAST CONSTRUCTION HOLDS THE KEY TO SHAPING A FUTURE OF STREAMLINED AND INNOVATIVE
BUILDING SOLUTIONS.
Case study 1:
Precast Concrete Construction System - 3S System
1. Introduction
Location: Nukkampal Road, near Perumbakkam road, Chennai,
Tamil Nadu. (near Sholinganallur)
Construction Agency: M/s B. G. Shirke Construction Technology

Rajiv Gandhi Salai

Pvt. Ltd.
Technique: Precast Concrete Construction System - 3S System
Number of houses: 1,152 (Ground +5)
Timeline: 1st January 2021 - 26th March 2022
cost: ₹116.27 Cr

GHTC-India is an initiative by the Government of India to modernize

housing construction and tackle urban housing shortages.
54 innovative construction technologies were globally shortlisted.
Six of these technologies were implemented in Light House Projects
(LHPs) across six states, including Tamil Nadu.
LHP-Chennai is the first completed project among the six LHPs.
The project's foundation was laid on 1st January 2021 by the Hon'ble
Prime Minister.
It was inaugurated on 26th May 2022, setting a benchmark for rapid
and sustainable urban housing.
2. PLANS

FLOOR PLAN

SITE PLAN UNIT PLAN VIEW

3. PRECAST COMPONENTS USED
Foundation: The foundation consists of RCC (Reinforced
Cement Concrete) isolated footings, which provide a
strong base to support the load of the precast structure.
These footings are designed to distribute the weight Excavation work for
Casting of footings
effectively across the soil. foundation

Structural Frame: The structural framework is

constructed using RCC precast beams and columns,
ensuring quick assembly on-site while maintaining
durability and precision.

Floor Slabs and Roofing: RCC precast slabs are utilized

for floor slabs and roofing. These precast slabs are cast Erection of precast stem Placement of precast slab
off-site and assembled on-site, enabling rapid columns from footings
construction without compromising on quality.

Walls: AAC (Autoclaved Aerated Concrete) blocks are

used for wall construction. These blocks are lightweight,
thermally efficient, and eco-friendly, reducing the
overall weight of the structure and enhancing energy
efficiency.
External plastering and
AAC block masonry work
painting
4. CONSTRUCTION PROCESS : MANUFACTURING

4. CONSTRUCTION PROCESS: TRANSPORTATION

Lifting and Loading: Precast pieces are lifted at designated points according to factory plans to avoid stress cracks.
Trailer Prep: They are carefully loaded onto trailers with spacers to prevent stains and secured with straps and supports to
prevent damage during transport.
Organized Stacking: Pieces are stacked on trailers based on size and shape, with separation and support to prevent damage.
Delivery Check: Upon arrival, the site crew inspects each piece for shipping damage and verifies it matches the delivery list.
Defect Handling: Damaged pieces are flagged for a quality check on-site to decide if they can be used or need to be returned to
the factory.
Safe Unloading: Straps and securements are carefully removed to avoid harming remaining pieces.
Trailer Departure: Once unloaded, straps are stored properly, and the empty trailer is sent back.
Delayed Unloading: If unloading isn't possible, the trailer is parked securely and disconnected from the truck until unloading is
clear.
4. CONSTRUCTION PROCESS: CONSTRUCTION ACTIVITIES

Precast plinth beam Placement of beams on columns External plastering

ADVANTAGES
1. SPEED OF CONSTRUCTION
Time taken completed within 12 months, 1,152 units across 12 blocks (G+5)
Precast technology significantly accelerates the building process. By manufacturing components simultaneously with site
preparation, the overall construction timeline is shortened.

2. EASE OF ASSEMBLY & ON-SITE EXECUTION:

Precast components are designed for straightforward on-site assembly. The use of cranes facilitates the erection process, and
in-situ jointing or grouting ensures structural integrity. This approach minimizes the need for extensive shuttering and
scaffolding, streamlining on-site operations.
This system allows for fast, “plug‑and‑play” assembly with minimal skilled labor required on site.

3. REDUCED LABOR DEPENDENCY

Precast construction reduces on-site labor dependency by shifting much of the work to a controlled factory setting. This not
only lowers labor costs but also addresses skilled labor shortages.

CONCLUSION
The system is ideal for mass housing due to its modularity and speed.
While initial setup costs are higher, long-term savings and durability
offset this. It also supports sustainable practices through efficient
resource use. Overall, precast technology is a practical and scalable
solution for affordable urban housing.
Case study 2:
THE LIVING BUILDING , CHANGSHA , CHINA
Location: Changsha, Hunan Province, China
1. Introduction Construction Agency: Broad Group (Broad Sustainable Building)
Construction Technique: Factory-produced modular steel structure system
No. of Houses/Units: 10-story residential/commercial mixed-use building
Timeline:
Pre-fabrication: ~60–90 days (off-site)
On-site Assembly: 28 hours total construction time
Cost: Approx. $1,300–$1,500 per square meter
(Economical due to reuse of factory components and minimized on-site labor)

This 10-story Living Building is a next-generation modular building,

representing the Broad Group’s vision for zero-emission, carbon-neutral,
fast-assembly buildings. It was built using the company’s "Living Building"
system, aimed at creating sustainable, high-performance structures that
can be assembled in a day or two.
Key Features:
Reusable steel modules
Fully factory-finished interiors
Energy-saving envelope
Earthquake- and fire-resistant
COVID-era hygiene features (e.g., air purification)
2. PLANS
2. PLANS
3. PRECAST COMPONENTS USED
a. Structural Steel Modules
Fully load-bearing steel frame units
Bolted together on-site
Compatible for reuse and disassembly
b. Precast Floor Panels Structural Steel Modules
Precast Floor Panels
Steel-concrete composite
Integrated plumbing, electrical conduits, and ducting
c. Wall Panels
6-layer composite insulation walls
Steel plate
Rock wool insulation
Waterproof barrier
Air-tight inner panels
Prebuilt Bathroom &
Installed with finished surfaces and embedded wiring PRECAST Wall Panels
Kitchen Pods
d. Prebuilt Bathroom & Kitchen Pods
Delivered fully fitted with fixtures, piping, and tile work
e. Facade Units
Glass curtain walls and aluminum cladding
Triple-glazed window modules pre-installed in panels
f. HVAC and MEP Modules
Ducts, pipes, air purifiers, and electrical systems all
integrated at factory level Facade Units
HVAC and MEP Modules
4. CONSTRUCTION PROCESS:
A. Off-Site (Factory Phase) — ~2 to 3 Months

Modules, panels, and interior pods produced

All mechanical, electrical, and plumbing (MEP)
integrated
Quality control and packing for transport

B.FOUNDATION - 10 DAYS
ADVATAGES

A.ULTRA-FAST ASSEMBLY
10-STORY BUILDING ERECTED IN 28 HOURS
REDUCES CONSTRUCTION-RELATED DELAYS AND DISRUPTION
B.LOW WASTE & ENVIRONMENTAL IMPACT
LESS THAN 1% CONSTRUCTION WASTE
NEAR-ZERO DUST, NOISE, OR DEBRIS ON-SITE
C.REUSABILITY
STRUCTURE CAN BE DISASSEMBLED AND REUSED IN ANOTHER LOCATION
D.ENERGY EFFICIENCY
20X CLEANER INDOOR AIR QUALITY THAN STANDARD
UP TO 80% REDUCTION IN ENERGY USAGE
EQUIPPED WITH AIR PURIFICATION AND THERMAL INSULATION
E. EARTHQUAKE AND FIRE RESISTANT
DESIGNED TO WITHSTAND MAGNITUDE 9 EARTHQUAKES
FIRE-RESISTANT STEEL AND WALL COMPONENTS
F. COST-EFFECTIVE
LOWER LABOR COSTS AND SHORTER CONSTRUCTION TIME LEAD TO
REDUCED TOTAL PROJECT COST
CONCLUSION

The 10-story Living Building in Changsha is a pioneering

example of next-gen modular architecture.
With record-breaking construction speed, factory-level
quality, and high sustainability, it showcases what’s
possible in modern construction.
This building isn’t just about speed—it represents a shift
toward circular construction, carbon neutrality, and
resilient urban design.
As the world faces rising urbanization and climate
challenges, buildings like this offer a promising solution.
 CASE STUDY 3 :
The Grand Mosque of Algiers (Djamaa el Djazair), Algeria
1. Introduction
PROJECT NAME: DJAMAA EL DJAZAIR (THE GRAND MOSQUE OF ALGIERS)
LOCATION: ALGIERS, ALGERIA
TYPE OF BUILDING: RELIGIOUS, CULTURAL, AND MONUMENTAL
ARCHITECT: KSP JÜRGEN ENGEL ARCHITEKTEN (GERMANY)
ENGINEERS: INGEROP, BUREAU VERITAS
CLIENT: ALGERIAN MINISTRY OF HOUSING AND URBAN PLANNING
TIMELINE:
DESIGN START: 2011
CONSTRUCTION: 2012–2019
INAUGURATION: OCTOBER 2019

2 . KEY FEATURES
The Grand Mosque of Algiers (Djamaa el Djazair) stands as a monumental example of
modern Islamic architecture, integrating traditional aesthetics with advanced construction
techniques. Key features include its capacity to hold over 120,000 worshippers and the
world’s tallest minaret at 265 meters. The project extensively utilized precast concrete
elements such as columns, beams, domes, cladding panels, and decorative screens,
allowing for faster construction, high precision, and detailed Islamic ornamentation using
GFRC (Glass Fiber Reinforced Concrete). Designed on a modular structural grid, the
mosque combines in-situ concrete cores with factory-made components, ensuring
durability, sustainability, and reduced on-site waste. This hybrid system allowed a seamless
blend of heritage and innovation, making it a benchmark in large-scale precast religious
architecture.
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DESIGN ASPECTS
Total Site Area: 400,000 m²

Key Facilities:
Prayer hall (holds 120,000 people)
World's tallest minaret (265 m)
Library, museum, conference center

Floor Plans & Sections:

Main prayer hall: Large open space with column-free
roof spans
Structural grid: Modular bay system to allow repetition of
precast elements
Minaret: Contains elevators and structural cores with
precast segments

Aesthetic Features:
Islamic geometric patterns
Domes, arches, mashrabiya-style screens, calligraphic
panels

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 3. PRECAST COMPONENTS USED
Columns & Beams – Precast Reinforced ConcreteThese
elements formed the main structural framework,
enabling fast and repetitive construction across the
mosque’s modular grid.Being precast allowed for high
strength, quality control, and quick on-site erection, COLUMNS AND BEAMS
reducing construction time and labor requirements.

Facade Cladding Panels – Precast Concrete with

Ornamental FinishUsed for the external envelope, these
panels carried intricate Islamic patterns and
calligraphic designs cast using custom molds.Provided
excellent weather resistance, durability, and visual
richness, while being easier to maintain compared to FACADE CLADDING
stone or plaster.

Mashrabiya Screens – GRC (Glass-Fiber Reinforced

Concrete)These lightweight, precast decorative screens
replicated traditional Islamic latticework while allowing
ventilation and filtered light.GRC made the elements
lighter, flexible for design detailing, and suitable for
large façade sections without structural load.
GRC SHEETS
 3. PRECAST COMPONENTS USED
Domes and Arches –Precast Hollow Segments Large
domes and arches were constructed using modular
hollow segments, reducing dead load on the structure.
Precasting allowed for precision alignment and easy
transportation and lifting of curved, geometrically DOMES AND ARCHES
complex forms.

Floor Slabs & Stairs – Large Precast Concrete Panels

Horizontal floor systems and staircases were installed
using factory-cast panels, ensuring fast and uniform
execution These panels were designed for load-bearing
and allowed for faster assembly compared to
conventional casting on-site. FLOOR SLABS

Minaret Core Walls – Precast Concrete Shaft Units The

265-meter-tall minaret used precast vertical segments
for the internal shaft, elevator cores, and stair
enclosures. This ensured geometric accuracy, reduced
formwork time, and enabled safe construction of high-
rise components with cranes.

MINARET CORE WALLS

 SECTION PLAN

VIEW

ISO SECTION NEXT SLIDE

Construction Techniques – Grand Mosque of Algiers
1. Manufacturing
Precast components were fabricated in off-site casting yards with high-quality
formwork and curing systems.
Custom molds were used to replicate Islamic ornamentation with precision —
including calligraphy, geometric patterns, and mashrabiya.
Special materials like GRC (Glass-Fiber Reinforced Concrete) were used for
lightweight decorative panels.

2. Transportation
Precast units were transported from the casting yard to the site using flatbed
trucks and trailers, with proper support to avoid damage.
Lightweight elements (like mashrabiya panels) required minimal support,
while larger items (like domes and columns) needed reinforced logistics
planning.

3. Erection Sequence
Construction began with in-situ foundations and core walls, followed by the
assembly of precast columns and beams.
Precast slabs, domes, and cladding panels were lifted into place using tower
cranes, following a modular grid for smooth alignment.
Decorative panels and GRC screens were fixed toward the later stages, after
the structural framework was complete.

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4. Equipment Used
Tower cranes, mobile cranes, and lifting beams were used to handle heavy
and large precast units like domes and minaret segments.
Advanced formwork systems, vibrating tables, and curing chambers were
used at the manufacturing plant for high finish quality.

5. Manpower
Required a skilled combination of site engineers, precast specialists, mold
designers, and crane operators.
Labor was divided between off-site production teams and on-site erection
teams, ensuring workflow efficiency and quality

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THANK YOU.
Done By:
Abdur Rasheed Imami | Dhruv Todi | Mehnaz Shaik | Naman Jalan
Pooja Mathi | Syed Yasir Ahmed | Vijayalakshmi