Aurobindo Realty, when faced with the dilemma of creating modern sleek buildings with minimum time and manpower, and a safer environment for construction workers, began to look for alternate construction methods. “With conventional systems, we would have faced the challenge of getting skilled manpower, besides having to deal with high attrition, site logistics and safety issues,” said Ravindra Kumar VJ, Chief Executive of Aurobindo Realty.
“In fact, most construction companies in India are faced with similar problems,” he noted. “These challenges, coupled with project requirements are leading to cost and time overruns in projects along with huge costs in rectifying any defects.”
The company executives began to study other options for construction over the traditional methods and soon discovered the advantages of precast construction, which enables faster project execution at twice the speed of traditional construction and over 50 percent reduction in labour requirements. “We soon realized that using precast enables high quality and uniform products produced in a controlled environment. The other main gain is in construction time due to advantages of speed and consistency,” said Kumar.
Adopting precast technology for Aurobindo meant reduction in manpower, timely project completion and less wastage of materials - all of which gave the company a competitive edge. The company chose Elematic precast technology from Finland, which offered state of the art plants, proven technology and machineries that are being used across the globe, and complete end-to-end services.
Aurobindo soon finalized a 21-acre land in Sanga Reddy district of Hyderabad for setting up the precast plant. But the work was far from over. “We are providing a full gamut of services from setting up the plant, training the company’s team for efficient operations, as well as having an annual maintenance contract to ensure full production,” said Chander Dutta, Managing Director of Elematic India.
The Aurobindo Precast factory has a covered area of 180m x100m and has the following equipment:Aurobindo is now well on its way to reach its goal of completing its first project called Galaxy - a 24-story commercial tower located at the busy industrial hub of HITEC city. The company is also launching two more projects which will also use precast construction - Orbit, a 24-story tower at HITEC city and Lulu Mall - an Emirates-based mall operator. Aurobindo’s precast plant is already on an expansion mode. It has installed a third beam line to augment its production capacity and to meet the increased demand from their sites.
- Prestressed precast hollow core slab production capacity of 3 million sq.ft per year
- Prestressed precast beam production where using 2 beam lines, 36,000 linear meters of beam are produced
- Precast column production using one column line, 18000 linear meters of column are produced
- 30 Table circulation system with a production capacity of 3 million sq.ft per year
- Two precast staircase moulds that can produce 1200 staircases per year
- Complete automated concrete transportation and distribution system for all the halls
- Automated stockyard with 30 days storage capacity
Adopting precast method of construction bodes well not just for Aurobindo but for the Indian construction industry as a whole. With successful examples such as Aurobindo, the construction sector is set to see accelerated usage of precast technology and better quality of buildings in the years to come.