For a better India KEF Infra One Park starts production

KEF Infra One Park
In the KEF Infra One Park near Bangalore, most of the products required for the construction of residential and commercial buildings are being produced.

Faizal E. Kottikollon and his wife, Shabana Faizal
Faizal E. Kottikollon, Founder and President of KEF Holdings and his wife, Shabana Faizal
KEF Holdings is pursuing a vision as ambitious as it is unique: state-of-the-art production methods are to lay the foundations for a better and more equitable India. High-tech in the terms of "Industry 4.0" is to be used for massive expansion of education, health, residential and commercial sectors. The company believes that this expansion can be possible only if the major part of the materials and installations are prefabricated centrally in specialised industrial parks. Such a park - the first-of-its-kind was formally opened in 2016 under the name of "KEF Infra One Park". It has five key manufacturing areas with one area dedicated to the precast concrete plant.

"When giving back is at the centre of your actions, the possibilities for growth and improvement are endless." This statement sums up the basic principle of the founder of KEF Holdings, Faizal E. Kottikollon's commitment to India. With the company and the associated foundation, Kottikollon and his wife Shabana Faizal are pursuing an ambitious goal to use only the most modern, efficient, sustainable technologies to expand the Indian infrastructure substantially and thus improve the quality of life for the people. Their emphasis is particularly on education, health and accommodation.

A success story: taking the vision back to India from the Emirates

KEF Infra One Park
KEF Infra manufactures various wall elements using the highly-automated carrousel system.
Kottikollon's success story began in the mid-1990's. He had immigrated to the UAE, where, in 1997, he founded Emirates Techno Casting (ETC), a foundry for the manufacture of valves for the oil and gas industry. Thanks to an innovative production concept, the company flourished, and as the years went by, became one of the top 3 foundries in the world. In 2012, ETC was sold to Tyco International. There upon, Kottikollon and Shabana Faizal took the decision to invest the capital in Faizal & Shabana Foundation and in the setting up of a company in India. Since then the principle of giving back has been at the heart of all their activities.

KEF Holdings was registered in Singapore in 2012 and today is active in infrastructure, health, agriculture, education, metal and investments. The company formed its own foundation in 2007. It is involved in numerous initiatives and programmes for the expansion, conversion or building of new schools and hospitals and in fund-raising campaigns for the under-privileged and victims of natural disasters. One of its aims is to create affordable, high-quality accommodation and to construct commercial parks.

KEF industrial park; a unique concept

KEF Infra One Park
For the first time, double and sandwich walls are being produced in India. In double wall production, the turning equipment is used to place fully cured elements onto the freshly concreted second skin.
The basic idea of making India a better country was the mainspring for the construction of KEF Infra One Park in Krishnagiri, not far from Bangalore. In this industrial park, everything required for the construction of dwellings, commercial buildings, hospitals and schools could be manufactured. The aim was to not only to reduce construction time itself, but also to reduce the time for fitting out buildings with bathrooms, kitchens and furnishings.

KEF Infra One Park was officially opened on December 2016. There are 5 different production areas, where precast concrete elements, prefabricated bathrooms and modular building products are manufactured, plus furniture, aluminium fittings and windows. More than 1,000 people work in the 60,000 m2 site.

Precast concrete elements

Production of precast concrete elements is key to KEF Holding's construction plans. "Construction in precast concrete is highly attractive, since very complex structures can be built in half the time," states Kottikollon. Furthermore, according to him, production under controlled conditions maintains quality at a consistently high level, and the ROI is also higher than the traditional construction methods. However, the decisive factor for KEF Infra is time. "We are able to complete projects quickly and on schedule; this is a very important point especially for property developers," he says.

Development of the concept together with Progress Group

KEF Infra One Park
The three systems installed for the manufacture of reinforcement (the picture shows the mesh welding plant) contribute to optimum production continuity.
In 2014, KEF Infra began to hold discussions with a variety of suppliers of carrousel systems. The choice finally fell on the Progress Group, whose subsidiary companies, EBAWE Anlagentechnik, Progress Maschinen & Automation and Tecnocom were commissioned to devise the technical solutions. "The production plant is the result of close, successful collaboration," is the satisfied comment from Kottikollon. "We have succeeded in developing a plant concept tailored to the changing market needs." Since mid-2015, massive, double and sandwich walls, as well as structural precast concrete elements have been produced.

New to India: double and sandwich walls, shuttering robots

The highly automated carrousel system is a new phenomenon for India in two respects: not only are double and sandwich walls produced for the first time, but a fully automatic shuttering and deshuttering robot is also in use for the first time. "We have deliberately invested in high-tech and software solutions, because we are convinced that the construction industry needs new approaches and new pathways in the spirit of Industry 4.0," explains Kottikollon. "In this process, technology is the catalyst for the changes required."

Fully automated shuttering and deshuttering

KEF Infra One Park
Automated shuttering and deshuttering not only improves the quality of the end products and the rate of production, but it also increases safety at work.
Consequently, KEF Infra decided to completely automate individual operations, which are normally performed manually in India. For instance, the shuttering and deshuttering process has now been taken over by the Form Master shuttering and deshuttering robot. The process starts with a storage robot, which removes the shutter from storage and passes it to the shuttering robot. Guided by CAD specifications, this positions the shutter on the pallet and activates the magnets. At the end of the production process, the pallet is scanned, the shutter released, removed and delivered to the cleaning system. When the shutter has been returned to the store by the storage robot, the cycle is complete.

In Kottikollon's opinion, the use of this automated solution has brought KEF Infra many advantages. "Thanks to the Form Master, we can not only produce faster, but also spare our employees from almost all physical stress." He also believes that right at the start of the production process, the shuttering robot lays the corner stone for high-quality precast concrete elements.

Highly efficient integral manu-facture of made-to-measure mesh

KEF Infra One Park
An automatic concrete spreader places the fresh concrete precisely and at a steady rate on the pallet.
The manufacture of all the made-to-measure mesh also contributes to excellent production continuity. Developed by Progress Maschinen & Automation, three different plants are used for the production of bespoke mesh, lattice girders, and stirrups.

The M-System BlueMesh welding plant produces mesh from the coil and in accordance with individual specifications. Its outstanding features are its particularly high degree of efficiency and its low requirement in space and energy - features which integrate well into the corporate philosophy with its emphasis on sustainability. The lattice girders required for the production of double walls are produced by Type VGA lattice girder welding machine. For the manufacture of stirrups from the coil, together with the EBA S automatic stirrup bender, KEF Infra uses a compact, high-performance system, which cuts and bends the wire with high precision.

Automated concrete spreader conserves resources and improves quality

KEF Infra One Park
The Meitra Hospital is the first health facility in India to have been completely constructed by the prefabricated construction method. The 205-bed project in Kozhikode (Kerala) was completed within 21 months.
The use of an automatic concrete spreader, which distributes the concrete over the pallet with precision, further conserves resources. This avoids uneven spreading and also prevents too much concrete from being discharged. In KEF Infra's pallet circuit the concrete spreader has also been fitted with a second bucket for a second type of concrete or a second colour of concrete.

Special formwork for structural precast concrete elements

Additional special formwork has been installed by Tecnocom, another subsidiary company in the Progress Group. The 5m to 120m long system is capable of producing staircases, columns and pre-stressed girders.

Software solutions facilitate "Industry 4.0"

The erpbos® ERP system, developed by the Progress Group is used for controlling systems, and for monitoring and optimising all the business and production processes. This makes a substantial contribution to the optimum coordination of all processes, starting from sales, calculation, project management and installation planning right up to logistics, materials management, controlling and human resources. The system enables KEF Infra to implement the Industry 4.0 concept, the core elements of which are intelligent production, networking and transparency.

The production processes are also controlled by the ebos® MES system. The software continuously accompanies all the phases in the production process, and by means of numerous tools facilitates the planning, controlling and monitoring of production. In addition, process sequences can be retrospectively played back in detail and investigated. In this way potential bottlenecks are detected and productivity increased.

Direct BIM integration

Since KEF Infra is the first company in India to use BIM level 6, the software has another advantage. BIM (Building Information Modelling) systems are directly integrated. This means that any production or supply deadlines, or project and material, costs can be directly linked with the building model. This is indispensable for a transparent overview. "All this allows us to plan, design, build and maintain the most diverse buildings extremely efficiently," says Faizal E. Kottikollon.

First major project completed

KEF Infra One Park
In 2016, KEF Infra completed its first commercial construction - completely constructed in precast concrete. The first two floors of the 10-storey office building were completed in only two months.
The first of several major projects for the construction of a hospital in Kozhikode in Kerala has been finalised. This is the first hospital in India to have been built entirely by prefabricated construction methods. The installation, known as Meitra, was constructed within 21 months. In terms of the average, the construction period was more than halved. The pilot project, which currently provides more than 205 beds, will be expanded to around 500 beds in the second phase of construction.

A milestone was also achieved last year in Bangalore when KEF Infra completed a 10-storey office building. This project also used only precast concrete elements from their in-house production. Once again, the short construction period was impressive: the first two floors with a total area of almost 20,000 sq. m. were completed within two months only.

According to KEF Holdings, this is just the beginning; they have plans for the construction of more industry parks. Top Indian politicians have also noticed the company's commitment. Prime Minister, Narendra Modi has expressed that KEF has the potential to assist the Indian government in completing the pending projects in the residential and infrastructure sectors. By 2022, as part of the Housing for All programme, construction of 20 million dwellings at affordable prices is envisaged.

NBM&CW June 2017

Click Here
To Know More / Contact The Manufacturer
Please provide your details we will contact you as soon as possible
Please let us know your name.
Invalid Input
Please let us know your Designation.
Invalid Input
Please let us know your City.
Please let us know your State.
Please let us know your Country.
Please let us know your Contact Number.
Please let us know your email address.
Please brief your query.

Mesh Welding System from progress Maschinen & Automation leads to major savings; Sansiri invests in further automation of precast concrete carousel plant

Sansiri Public Co., Ltd, Thailand, has made a step into further automation of their carousel plant by complementing it with a BlueMesh M-System welding machine from progress Maschinen & Automation AG, one of the seven companies Read More ...

Laxmi En-Fab showcases tech-rich AAC block plant

Having geared up fast to meet the burgeoning infrastructure development requirements in the country, Laxmi En-Fab, manufacturer of plants and machinery, displayed its tech-rich equipment Read More ...

Vortex Hydra tile-making machine for roof, floor & wall tiles

Vortex Hydra S.r.l., the Italian world leader in designing, building and installing manufacturing plants to produce concrete roof tiles is celebrating its 50th year in business this year. During the last Read More ...

Tecnocom delivers moulds to produce V girder for Qatar’s extensive road construction project

Tecnocom Moulds V Girder
Tecnocom chosen to deliver V girder moulds for a major road construction project in Qatar. A major project should relieve the traffic problem in the region around Doha, the capital of Qatar. By the end Read More ...

Reva Engineering’s interlock block making machine

Reva Automatic Brick Block Making Plant
Reva Engineering Enterprises launched its new interlocking block making machine. Reva Engineering Enterprises manufacturer, exporter and supplier of Brick Making Machines, Fly Ash Brick Machines, Read More ...

Sommer Precast Construction Technology for Indian market

Sommer Anlagentechnik GmbH showcased its production engineering and automation systems for precast concrete element industry under its Sommer Precast Technology division. The company, a leading supplier of production technology to the precast concrete industry, has been supporting and helping in advancing the precast Read More ...

Vollert to set up factory and sales offices in India

Vollert Precast Concrete
Vollert presents its circulation and stationary systems for precast concrete production. As a global player with associated companies in Asia, South America and Russia, Vollert has projects in all continent Read More ...

Dongyue’s turnkey solutions for block making machines

Dongyue Block Making Machine
Dongyue highlights its range of turnkey solutions for block making machines for regular building blocks across the value chainat bauma Conexpo India 2016. Sharing details of the solutions Read More ...

Complete Range of Concrete Products from Columbia

Columbia Concrete Products
Columbia Machine with over 20 years of presence in India, offers a complete range of concrete products to suit the requirement of the market. From importing the machine from Read More ...

Precast technology for high-rise housing complex

Precast Technology for Highrise
The precasting work for the New Haven Complex was started in early 2014. The project, planned by an American architect, will provide a total of 35 residential towers with 1,892 units spread over Read More ...

Tecnocom’s precast mould successfully producing V girders...

Tecnocom Precast Mould
In many countries around the world, overloaded and outdated highways and roads are holding back economic development. This is the reason why massive investments are being made within the State Read More ...

Quality Construction with Speed- The first Acotec Pro Plant in India

Elematic Acotec Pro Plant
Construction with light, non-load bearing partition walls can be up to six times faster than traditional brick-work and twice as fast as blockwork. “The walls enable extremely fast installation of up to Read More ...

Pruksa opens new high-performance plant

Pruksa High Performance Plant
Pruksa Real Estate Public Co. Ltd., a leading company for residential construction using precast concrete elements in Thailand has commissioned its second precast plant together with the Progress Group, a full-range supplier Read More ...

Revomac’s Fly Ash Brick Making Machine

Revomac FlyAsh Brick Making Machine
Revomac launches sustainable Fly Ash Brick Making Machine. "The implementation of Hydraulic and Vibration technologies in our machines ensures the highest level of uniformity and quality. From putting in the raw Read More ...

Revomac Industries Strives to Achieve Excellence

Ahmedabad-based Revomac industries specialized in manufacturing and developing machineries, focuses on waste management and utilization. "Our company's first and foremost Read More ...

Hem Care Corporation: The Green Building Solutions Provider

Hem Care CLC Plant
CLC is called as Cellular Light Weight Concrete and it is also called as Foam Concrete. It is produced by initially making slurry of Cement, Sand (optional), Fly-Ash & Water, which is further mixed with the addition of Read More ...
NBM&CW

New Building Material & Construction World

New Building Material & Construction World
MGS Architecture

Modern Green Structures & Architecture

Modern Green Structures & Architecture
L&ST

Lifting & Specialized Transport

Lifting & Specialized Transport
II&TW

Indian Infrastructure & Tenders Week

Indian Infrastructure & Tenders Week