TOPWERK INDIA

We are meeting our Indian customers’ demand for cost-effective products and services by collaborating with local vendors for several non-critical components to bring down the manufacturing cost and avoid imports and transportation costs, and we have also established a local sales and service center in India.
Sachin Shetty, CEO and Rajesh Jha, Head of India, Sales & Market Development, TOPWERK INDIA

How is TOPWERK meeting the growing demand for industrial precast concrete products?

As a global leader in supplying machinery and plants for industrial precast concrete products, we offer a broad range of products and solutions that enables us to meet the growing demand for industrial precast concrete products, not only in India, but also in many parts of the world.

We have a diverse range of machines to produce Concrete Blocks, Pavers, Kerbstones, Slabs, Surface Finishes, Pipes, Box-Culverts, U-drains, Manholes, Lightweight AAC Blocks and Panels, Railway Sleepers, and other precast elements. These are available under our various brands, namely, HESS GROUP, SR SCHINDLER, PRINZING PFEIFFER, HESS AAC SYSTEMS, and TOPWERK LANGFANG.

How is digitalization in production units and machineries helping TOPWERK in improving efficiency and productivity?

We have digitalized all our production units and machineries, which is helping us further in controlling costs, while improving the efficiency, productivity, and safety of our products. We keep exploring new possibilities of digitization to bring more efficiency and more production output for the benefit of our customers. Our aim is to use digitization in a sustainable and value-adding way, for more efficiency, more production output, and an increase in the quality of work for our customers. Some of our digital solutions include the following:

Smart Vision digital solution from HESS GROUP: Using this, one can carry out an efficient and precise analysis in cooperation with a helpdesk employee by means of image transmission through digital glasses. With the Add-on Maintenance, your maintenance instructions can be displayed directly on your glasses by scanning a QR code, so that you can fully concentrate on the maintenance work.

Web-based visualization of PRINZING PFEIFFER: With web based visualization of the production statistics for pipe and manhole machines, all relevant data can be called up via a web browser and displayed on smartphones, tablets, and PCs, sorted by location, linked systems, and individual machines. This helps you to log into important parameters such as machine performance, availability, downtimes, and waiting times.

HESS AAC SYSTEM: This is a system extension that displays real-time operating information of your machines. With this function, you can quickly get an overview of the status of your machinery which will help you to optimize processes such as maintenance, machine performance, and availability.

We are constantly developing and integrating “preventive and predictive maintenance methods” in our digital systems such that they can provide forward-looking and preventive tools designed for maintenance and care of the systems. Our endeavor is to minimize machine downtime and reduce overall cost.

How has the mindset of the Indian construction industry changed towards precast technology and what growth prospects do you foresee?

In India, where precast technology is relatively new, this construction method has been under discussion for reasons such as labour availability, construction quality, cost, productivity, volume of work, etc.

Precast technology uses modern tools and technology that can improve the quality and speed of construction while using minimum resources like manpower, materials, budget, etc. Today, there is an increasing use of precast concrete products not only in residential and commercial projects but also in infra-development projects like tunnels, bridges, overbridges, flyovers, underpasses/overpasses, etc. Many RCC structures are being made in precast, including segmental box girders or u-girders, piers, pier caps, etc.

In India, there is a dire need to fulfil a huge demand for housing, commercial buildings, and infrastructure. To achieve this, the Indian construction industry needs a method of rapid construction technology like precast concrete. Currently, the application of precast technology is only 2% (approx) of the total Indian construction industry, and is limited to the construction of infrastructure projects like metro and monorails, bridges, etc. So, the potential growth of precast technology is immense.

What are the challenges in using precast technology in India?

It is mainly the smaller developers and builders who are resisting this technology. It could be because of lack of awareness of its application and benefits or the initial higher cost of construction. Another concern is the standardization of the various components of precast concrete and its joinery details, which need to be established through IS codes. The cost of transporting the components from the manufacturing unit to the project site entails transportation costs, which is another deterrent for the adoption of precast technology.

Though the initial investment for establishing a precast yard is very high, developers and builders need to look at the speedy construction precast construction enables, which mitigates delays in large-scale construction projects, allowing them to start earning revenue sooner.

How is the company bringing down the cost of its products to cater to the price-conscious Indian customers?

We strive to maintain a fine balance between the quality and pricing of our products. Our local vendors provide cost-effective products, which undergo quality checks based on professional QA inspection. By localizing the production of several non-critical components, we bring down the manufacturing cost and avoid imports and transportation costs.

Thus, localization is helping us in bringing cost-effectiveness to our products, without compromising on their durability and reliability. We have also established a local sales and service center in India for engaging more closely with our customers.

What are the practices/technologies being developed in your plant to reduce wastage and to preserve or recycle usable materials and reduce/eliminate carbon emissions?

TOPWERK GROUP has adopted the following strategies for adaptability, disassembly, and reuse:

• Developing an adaptation or disassembly plan with key information (e.g., as-built drawings, materials, key components, structural properties, and repair access and contact information).
• Using simple open-span structural systems and standard size modular building components and assemblies.
• Using durable materials that are worth recovering for reuse and/or recycling.
• Minimizing the use of different types of materials and making connections visible and accessible.
• Using mechanical fasteners such as bolts, screws, and nails instead of sealants and adhesives.
• Planning for the movement and safety of workers to allow for safe building adaptation, repair, and disassembly.

What is your outlook for the precast concrete market globally?

Rapid urbanization and infrastructural growth are leading to urban construction projects which are driving the industry’s growth. The global precast concrete market is anticipated to grow at over 5.6% CAGR from 2021 to 2027. The market revenue is forecasted to exhibit a revenue growth of USD 234 billion by 2033.