Apco Infratech: Construction with Advanced Equipment & Recycled Materials

Apco Infratech is at the forefront of sustainable road construction in India, leveraging advanced equipment and a commitment to using recycled materials for eco-friendly and efficient projects.
D Dilly Babu - Vice President (Business Development & Tendering), Apco Infratech

How do you perceive the current smart and sustainable road construction practices in the Indian industry?

The Indian Road construction industry is already sustainable due to the significant volume of roads being constructed and the increasing number of contractors entering the market daily. The infrastructure development market is further sustained by the well-established National Highways Authority of India (NHAI) and the meticulous procedures adopted by NHAI, the Ministry, and other state government organizations, which are closely regulated by the Planning Commission's documentation process. Banking norms supporting infrastructure projects are currently well controlled.

The road industry is therefore poised for long-term sustainability, with India outpacing other countries in road development. The organizations responsible for road development employ customized systems ensuring quality and adherence to various regulations.

Furthermore, new technologies are being continually introduced into the Indian market. Indian testing agencies like CRRI and SRS monitor these technologies, leading to modifications in IRC codes to incorporate advancements. Consequently, these modifications are seamlessly integrated into road construction practices, aligning with global standards.

How committed is Apco Infratech in using byproducts like waste plastic, fly ash, and recycled aggregates etc in road projects and what are the challenges?

Recycling materials have been integral to construction practices in India for a considerable time due to their environmental benefits. Apco has been particularly proactive in utilizing fly ash wherever feasible, ensuring both availability and commercial viability. While recycled aggregates are extensively used, plastic usage is currently limited to CRMB material, sourced from Indian oil industries, and incorporated into bituminous products.

Despite the benefits, challenges persist, primarily concerning commercial viability. Transportation costs and logistical challenges can hinder the practicality of using eco-friendly materials. However, when commercially viable, contractors readily opt for these materials, driven by substantial cost savings. For instance, utilizing recycled aggregates reduces costs significantly, especially in regions like Uttar Pradesh that lack mining areas, and therefore necessitating material importation from neighboring states.

How do you view mechanization in construction and the benefits of using high-tech equipment despite the burden of higher initial costs? How proactively are the equipment manufacturers helping you in completing projects on time, economically, and with quality?

Mechanization in construction is vital, particularly considering the minimal availability of manpower. When undertaking road construction, it's imperative to opt for well-established equipment to minimize the need for manpower.

Nowadays, all equipment is sourced from various countries, including Germany, with service centers established in India for convenient maintenance. Previously, labour costs constituted around 30% of project expenses; now, leveraging advanced equipment has slashed it to approximately 10%. These durable machines serve for extended periods, spanning 10-15 years across multiple projects, ensuring cost efficiency, and a gradual reduction in labor requirements with each project.

Consequently, the higher initial cost is not a problem at all, as most systems offer installment-based payment options, and the commercially viable appreciation of holding such equipment is evident due to the abundance of projects in India. Machines remain active, transitioning seamlessly from one project to another, ensuring continued cost efficiency.

Utilizing high-tech equipment reduces labor requirements significantly. Though initial costs may be higher, the long-term benefits, including reduced labor costs and enhanced project efficiency, outweigh these concerns. Equipment manufacturers, with service centers in India, actively support project completion by providing reliable machinery and maintenance services. The reduced dependency on labour has led to substantial cost savings and improved project timelines.

Equipment manufacturers, recognizing the demand from companies like APCO, offer competitive pricing, acknowledging the correlation between increased order books and equipment requirements. This symbiotic relationship between contractors and manufacturers fosters a proactive approach to project completion, aligning with APCO's commitment to quality and efficiency.

What is the way forward for making construction more sustainable? What are Apco’s future plans in this direction?

Apco's commitment to sustainability extends across various construction sectors, including roads, bridges, and tunnels. Recently, we have expanded into maritime infrastructure with projects in Mumbai, including the Versova Bandra Sea Link Project, coastal road project, water tunnel project, and others. Presently, APCO boasts a robust order book of approximately INR 25000 crore for the next four years, emphasizing our commitment to securing new projects and executing existing ones promptly.

We firmly believe that the key to sustainability lies in timely project completion. This entails leveraging advanced machinery, employing well-trained personnel, implementing efficient procurement practices, and utilizing local resources. By embracing these strategies, we aim to promote sustainable construction practices and deliver enduring benefits to communities and the environment.

Nowadays, smart technologies like LiDAR, Drones, and GPS are enhancing project planning, execution, and monitoring processes. Drone surveys and GPS systems have been prevalent in the Indian market for some time now. They are routinely used in project surveys and post-construction quality monitoring. NHAI mandates their use, ensuring widespread adoption across projects. The integration of such technologies offers numerous benefits, enhancing project efficiency and quality.