KNR Constructions: Optimizing Project Delivery with Advanced Equipment

Mechanization is helping projects become more financially viable. At KNR, we have become self-reliant by deploying our own equipment and new construction methodologies, which is also helping us optimize cost and time during execution.

K. Jalandhar Reddy - Executive Director, KNR Constructions

How is KNR enhancing productivity in its projects?

Innovative use of materials, technologies, methodologies, etc., is a general practice in all our projects for optimizing time, cost and spatial management, and for overcoming site constraints during job execution at project sites. For instance, in our Kerala 6-lane Highway Projects, we encountered hard laterite soils all along the alignment. Extensive excavation was required due to multiple Vehicle Overpasses (VOPs). We found it difficult to excavate the hard laterite soils even with heavy-duty excavators such as our 35-T class machines. Output for the excavators was abnormally low. After all attempts, we started using Single Tooth Rippers attached to the heavy-duty excavators for loosening the laterite for easy excavation. We could manage time efficiently due to this innovative idea of using Single Tooth Rippers. After observing the performance, we were happy to see many contractors doing the same.


We used a Spider Boom attachment on our Stationery Concrete Pump for pouring concrete in inaccessible parts of massive structures in our Pump House Project in Telangana for effective concreting. We used PERI SCS Climbing System forms for concreting of Delivery Cistern in one of Irrigation Projects in Telangana.

Another advanced type of lightweight forms by PASHAL are being used for effectively reducing skilled manpower and time required for fixing and removing the forms. Vibro Hammers are being used to drive pile casing for deeper depths to save time in pile foundations.

Another recent addition is the Pile Driver for driving the Poles of Metal Beam Crash Barriers mechanically for fixing the crash barriers. We have been using this equipment in our Chittor-Tatchur and Kerala Projects.

We are using Ground Granulated Blast Furnace Slag (GGBS) in Pavement Quality Concrete (PQC) for optimizing cement quantity in the mix design, and are using materials such as micro silica in structural concrete.

We are currently using an integrated pile cap with diaphragm walls for cost effectiveness, reduction in size and (hence) weight of the element, and are optimizing the vertical profile for better stability in one of our Flyover Projects.

How is KNR addressing cost and schedule overruns in its projects?

Construction companies need to use their resources optimally in the ever-growing competitiveness. The most successful model which we have been following is that of self-reliance in all aspects apart from the so-called Project Management Tools for procurement and execution such as SAP, Microsoft Project, Primavera, etc.

We leave no stone unturned in the procurement of state-of-the-art machinery like crushers, tippers, hot mix plants, concrete batching plants, concrete carriers, pavers, graders, dozers, specialized equipment such as launchers, piling rigs, gantry cranes, heavy-duty cranes, etc., required for the execution of projects awarded to us.


We prefer to have our own equipment rather than depend on hired equipment to avoid uncertainties in terms of time and cost, which lead to overruns in cost and schedules. Even if we mobilize a little more equipment than required, it is not a wasteful expenditure as the equipment can be utilized elsewhere when required. We also ensure that the life of the plants and performance of plants are adequate for the type of work to be executed and timelines for completion of projects. This way we have control on expenditure on the R&M of our plants and equipment.

Focusing on captive mining and crushers has helped us avoid cost and schedule overruns since we do not have to depend on external sources for aggregates, which are abnormally expensive. We utilize our manpower optimally and do not indulge in unnecessary recruiting multi-level officers/managers. Rather, we encourage our managers to acquire multi-tasking skills so that they can be effectively transferred between departments.

What challenges are being faced in implementing innovative methods in KNR’s projects with respect to investment, availability of skilled workers, etc?

No doubt, the initial investment is a concern sometimes. Plus, the conservative talent pool that we have has to be adequately trained for using the innovative methods and materials. We had to convince our workers to use the advanced formwork in structural elements. They gradually got used to it and understood the ease of handling them. Hence, resistance for innovation has to be tactfully tackled by making stakeholders aware of the advantages that innovative systems bring to construction.

In many cases, there is resistance from the employer or the authority when alternatives are proposed by the contractors; this is against the spirit of the MoRTH guidelines. There is no openness and transparency in the minds of the authorities. They are reluctant to approve the alternatives for replacing the traditional methods and materials as they only look at the project completion schedules and cost savings, which can be enhanced, and in spite of the fact that we have to bear the risk of innovation.

In one of our projects, we were unable to get consent for using alternate pavement type in place of what was given in the schedule, despite the fact that the former enabled more effective time management.

Mechanical paving, digital operation of plants and equipment, etc,. are reducing waste in construction. Bar bending machines with PLCs are being deployed for minimizing waste in steel. We are looking for software companies for intelligent handling of bar bending schedules of reinforcement in structures.


But there is no appreciation at all and unless there is a sea change in the attitude of the employer/authority on the use of innovative methods and materials, it will always be a challenge for contractors who are keen to implement them. Alternate materials and methods can have a considerable impact on project quality, cost and time, but the resistance from the employer/authority has to be addressed by the stakeholders, and the media too should create awareness on the benefits of alternate materials and methods.

Despite all the advancements in the construction industry, why do we still experience unfortunate incidents of structures collapsing?

Please give your insights and possible solutions.

This is a valid question as we have been seeing structures collapsing either during their construction or before they are put to use. Most of the failures are due to human errors and poor implementation of safety measures during construction. Impractical construction schedules are also one of the reasons as the contractors are forced to expedite execution, ignoring safety measures. Inadequacy of trained manpower is also a big reason. Design inadequacies are also responsible to some extent. Assessment and understanding of design should be taken up at least at 3 levels.

Training of skilled and unskilled manpower, engineers, etc., should be made mandatory and there should be periodic assessment of manpower and certifications for ascertaining the quality of manpower at project sites, at all times. Contractors should factor in these expenses in their quotes so that the safety and training requirements can be implemented religiously. Quality supervision is also lacking as there is cut-throat competition in this area; this is leading to deployment of agencies without quality staff for supervision.

The contractor company should have a QA & QC division for ensuring checks at different levels before taking up execution of any job. There should be continuous supervision during execution with the appropriate level of engineers as per the complexity of the execution.

There should be thorough review of the upcoming projects and the manpower needed for their execution. The timing and phasing of future projects should be done such that the manpower would be available when needed.