B.E. Billimoria Changing the Face of IndiaThe buildings feature a load bearing wall frame as their structural system

Moving to Precast Concrete Technology in Partnership with Elematic
BE Billimoria & Company is one of India’s leading firms of civil engineering construction contractors. Ranging from commercial, residential spaces to some of the most iconic buildings in the country, like the 316-meter Namaste Tower, are among their project list. In addition, Billimoria has a precast project in Pune - a mass affordable housing for the Maharashtra police.

Jeet Kapadia, the Executive Director of Billimoria
The company was established by Beji E Billimoria and Laxmidas K Kapadia in 1958. Jeet Kapadia, the Executive Director of Billimoria and the third generation of its founder, is continuing the family’s legacy in the construction business. “We cater to all sectors, and work with some of the biggest real estate developers, government organizations, and corporates. Our goal is to give the right quality, because today in India, quality is the most important aspect of any project,” says Jeet Kapadia.

While many factors have contributed to Billimoria’s success since its foundation, the company has always been the innovator and a pioneer in the construction industry of India - from deployment of sophisticated building systems to the adoption of new construction technology, including precast.

Growing demand for high-quality affordable housing
With the rapid economic growth and unprecedented pace of urbanization, there is a staggering demand for affordable housing in India. The government has already set an ambitious project to build 20 million affordable houses and 98 smart cities by 2022. Precast concrete building technology will be the key enabler for that mission, as it can not only ensure faster completion of a project but also bring down its overall cost.

The traditional construction methods used in India require a high amount of labor for extended periods of time. This results in high costs, long duration of construction, and quality variance due to human factors.

Precast concrete as a building method allows for more control over an entire building project. “As we increase the size of the projects and go to mega projects, the amount of labor required is a big variable. We wanted to avoid that variable, and bring everything into a factory so that we can have quality control, cost control, and timeline control. The only way was to precast,” says Jeet.

The best way to move forward
Even though there are some obstacles hindering the growth of precast concrete building technology in India, in Laxmidas Kapadia’s opinion, precast is one of the best ways to move ahead. “Quality is the best benefit, because your slabs, beams, columns and walls are produced in a controlled environment. As a result, you are sure of the quality which you are getting. Speed is another big factor, because in the end, your financials depend on how soon you can complete your project,” he explains.

Confidence rooted in a world-class partner
When evaluating suitable long-term partners among the many precast machinery companies, Elematic caught Billimoria’s attention. “We went through a lot of companies that are doing precast construction and finally decided that Elematic would be able to support us the best in terms of after-sales service and designing. We also felt that the machinery which we got from Elematic would last for a longer period of time, and not give us much trouble,” says Jeet Kapadia.

Billimoria’s precast factory is located within a 116-acre site in Pune. The 2-acre factory includes production and storage yard. It produces slabs, walls and staircases. The capacity is approximately 1.5 million square feet of construction area in a year. “We have three slab beds which are 120 meters long; for the walls, which are mainly load bearing walls, we have battery molds and mechanical tilting tables; and molds for staircase walls,” informs Jeet.

“I think the whole set up works well. The shuttle basically supplies the concrete bed, but the same shuttle can also go to the battery molds. The logistics has been worked out well by Elematic as well as our engineers. Also, the way the cranes were set up with the help of Elematic, in order to ensure the finished product was taken from the factory to the storage yard, the gantry cranes, the wagons, all of that has been excellent, and we are very happy with the result,” he adds.

With the service agreement, Elematic’s team has been on site to provide support for any quality or machine issues. For example, when the thickness of the wall elements needed to change from 170 mm to 160 mm, a swift solution was needed. Elematic’s experts helped to refabricate, ensuring the production continued with 160mm without much of a lag.

“I think the slab quality, which we are getting right now is beautiful and definitely helps us gain more confidence in precast,” affirms Jeet. “No doubt, there were a few hiccups, but I think, overall, Elematic and Billimoria did a great job coming together, getting the products on site and delivering on time.”

B.E. Billimoria Changing the Face of IndiaBillimoria factory in Pune, next to the Maharashtra Police housing project

No quality compromised in the Maharashtra Police project
The Maharashtra Police housing project is aimed to build affordable houses for the retired police personnel. The total land is 180 acres, of which Billimoria has started to develop approximately 40 acres for 5200 apartments, all of which must be completed within four years.

“All of the buildings are ground + 14 stories. And our aim is to ensure that after the ground floor, all the other floors are done with precast. The building design is pretty simple; there are only a few differences depending on the flat contributions,” informs Jeet. “We are very proud of the whole project, because we are doing it for the Maharashtra police. We aim to give them affordable prices and with the good quality that they deserve after serving the state.”

B.E. Billimoria Changing the Face of India

Direct savings from speedy construction
Onsite precast plant minimizes crane requirement. The Maharashtra police housing project uses 4 tower cranes, each of them handling three buildings at a time.

“The ingenious part is that we are using one tower crane on three different buildings, which are at different points in the lifecycle: if we are installing walls in one building, the other building is at the stage for steels, the second needs services for the structural topping, and on the third building, we are in the process of laying the screed,” says Sandeep Bedi.

The optimized way of working has enabled Sandeep Bedi and his team to get a floor cycle of 12 floors in 12 buildings in 12 days, basically, a floor a day. Speed of construction is the key because it also ends up saving costs. “The interest rates for real estate projects in many developing countries are very high. In India’s real estate, the interest rate is between 18-20% annually. So, If we can reduce the construction cycle by six months, it is a direct saving of almost 10%,” he states.

Not just an equipment vendor
“The journey thus far has been extremely interesting, and with a huge amount of learning. Elematic brings in a wealth of experience, which is global, but they also have pretty much the maximum amount of information on the Indian precast industry,” says Bedi.

“Elematic has held our hands to beat every challenge. So, we feel that Elematic is not a vendor from whom we’ve bought an equipment, but a partner through every challenge that we are facing, be it in production, any installation, and even in manpower training.”

“Due to the partnership that we have created with Elematic, with our team members, our clients, and the eventual end-users, we’ve created a very high-quality product, which will offer a lasting home cherished by families,” says Bedi.
The Potential of Precast in India
Technavio, a global technology research and advisory firm, has released a report claiming that the global prefabricated construction market is expected to grow at a CAGR of 6-7% until 2020. However, in India, the uptake of modular technologies continues to remain slow and, so far, prefabricated buildings comprise only 1% of India’s $100 Billion Real Estate Market.

“I think that with demand increasing every year, a lot more people are willing to take a chance on precast. As more and more people get educated, the field will gain traction. So, the outlook is positive, especially with the government now trying to get a lot of projects offering precast solutions,” reckons Jeet Kapadia.

B.E. Billimoria Changing the Face of IndiaWith precast, 90% of the building can be made in a controlled factory environment, free of weather unreliability and reduced labor dependency.

Fact File
Project: Maharashtra Police Mega City, Pune
Contractor: BE Billimoria & Company
Precast Contractor: Ingenious Quality Buildings
Project details:
  • 4.5 M sq.ft.
  • G+14 buildings, 60 towers
  • 1RK, 1BHK, 2BHK, 3BHK, 3.5/4.5 BHK Apartments
  • Structural system:
    • Load bearing wall frame for gravity and lateral load resistance for wind and earthquake forces. System includes load bearing walls and prestressed solid slabs. Structural walls at the perimeter act also as facade for the buildings. Facades will be painted for finishing.
    • Slab span around 6 meters designed for superimposed dead load for floor finish and internal partition walls, amounting to uniform loading of 3 kN/m2, and live load of 2 kN/m2
    • Prestressed solid slab is used for providing flexibility in the architectural layout, speed of construction, and reduction of steel consumption.
  • Following precast elements are used in the project:
    • Load bearing walls
    • Solid prestressed slab
    • Staircase
Buildings are designed for 50 years as per design requirement for RCC structure in IS codes. Precast products life can easily be assumed to be more than 50 years as the production is done in a controlled environment, resulting in good quality.

Check out the project via this link: http://mpmcpune.com/index.html

Elematic deliveries
  • Equipment:
    • Mechanical tilting tables
    • Three 120-meter slab beds with a slipformer
    • Battery molds (original and cold shutter)
  • Services:
    • Complete project design and engineering
    • Plant installation
    • Production and installation supervision
    • Annual maintenance agreement
About Elematic Oyj
Elematic is a world-leading manufacturer of precast concrete plants, production lines, and related machinery. During the 60 years of operation, the company has supplied precast concrete production technology to over 100 countries and to every continent. Its turnover is approximately 65 million euros, of which exports generate 95%. The company employs roughly 300 people and it has subsidiaries and sales offices in the USA, Germany, China, Russia, India, Hong Kong, and the United Arab Emirates, and agents in over 20 countries. The company headquarters is located in Akaa, Finland, with production units in Finland and India.
Click Here
To Know More or to Contact the Manufacturer
Please let us know your name.
Invalid Input
Please let us know your Designation.
Please let us know your Contact Number.
Please let us know your email address.
Please brief your query.
Our other Value-Added Services:

To receive updates through e-mail on Products, New Technologies & Equipment, please select the Product Category(s) you are interested in and click 'Submit'. This will help you save time plus you will get the best price quotations from many manufacturers, which you can then evaluate and negotiate.

Invalid Input
Invalid Input
Invalid Input
Recently, a highly automated mould for the production of pillars from Tecnocom, a company of the Progress Group, has been installed to help industry leader Consultecna stay ahead. Francesco Pireddu explains the decision made in favour of automation although

Read more ...

Technology companies have developed hardware and software solutions to help manage every aspect of a construction project, no matter how complex or massive the project may be. Harsh Pareek, Regional Sales Director, India and SAARC, Trimble Solutions

Read more ...

Thailand’s real estate developer Pruksa, a leader in the building sector, modernizes its building solutions with automated hollow core production plant equipped with machinery from Echo Precast Engineering, a company of the PROGRESS GROUP. Real estate developer Pruksa

Read more ...

Dongyue Machinery Group is offering Autoclaves Aerated Concrete (AAC) blocks, brick blocks, hollow blocks, curb stones, color blocks etc. AAC Blocks, which are lightweight concrete blocks, use less cement compared to traditional cement bricks, and are therefore eco-friendly

Read more ...

Kraft Curing Systems GmbH is offering advanced concrete curing systems that optimize the hardening process of concrete. Kraft provide numerous solutions, from vapor-based (steam) systems mainly for the precast industry, to heating/air circulation systems

Read more ...

The production site of LARCO PREFAB S.A. in Welkenraedt, Belgium opened in 2018 and has grown consistently over the years. LARCO produces a range of prefabricated concrete elements such as hollow core slabs, columns, wall panels, soccles

Read more ...

Klaus Hoch- und Tiefbau GmbH is upgrading its machines in the precast concrete plant with several automated systems from progress Maschinen & Automation and Tecnocom - companies of the Progress Group. With the individualised reinforcement machines

Read more ...

Civil Construction in India has not been as much industrialized as it has been in the West. Presently, it shares barely 1-2% of the real estate market, though as per a recent study, it is expected to grow @8.5% in the decade of 2016-2026

Read more ...

The increasing demand for residential units in the country with speedier construction, has encouraged use of innovative technologies that are being practiced the world over. Structural steel with its in-built attributes when integrated

Read more ...

Precast concrete is produced by casting concrete in a re-useable mould or form, which is then cured in a controlled environment. To ensure durability, high strength, low water cement ratio, and improved rheology, use of concrete admixtures is compulsory

Read more ...

Aurobindo Realty & Infrastructure, one of the frontrunners in the realty sector in South India, is confident that the southern region will see numerous construction projects being launched during the next 10 years and even beyond

Read more ...

C. A. Prasad, President PSI & Director, Metey Engineering & Consultancy, Hyderabad, discusses the various new construction technologies being adopted by developers and builders in India, and their merits and demerits

Read more ...

Ajay Chourasia, Sr. Principal Scientist, CSIR-Central Building Research Institute (CBRI), Roorkee, reviews the general concepts, PVMC connections, and recommendations for technological interventions and alternate connection systems

Read more ...

C. B. Kameswara Rao, Professor, National Institute of Technology, Warangal, gives a presentation of different types of joints in precast construction and of the research done at NITW. Connections and joints are responsible for stability as well as strength

Read more ...

Srinidhi Anantharaman explores offsite building construction in a holistic manner and provides an overview of the entire design and construction lifecycle of such buildings, along with the compulsions of architectural, structural and services, design decisions

Read more ...

Saurabh Purandare, Director, & Khaja Rasool, Structural Engineer, Innovela Building Solutions, Pune, discuss an out-of-the-box construction approach for meeting today’s call for shorter timelines and reduced cost in construction, while ensuring the highest

Read more ...

R. Siva Chidambaram, Scientist, ASCD Division, CSIR-Central Building Research Institute, Roorkee, discusses the importance of shear resisting key based precast joints and the influence under cyclic loading. The hysteresis behaviour and energy dissipation show

Read more ...

N. Gopalakrishnan, Director, CSIR-Central Building Research Institute, Roorkee, emphasizes the importance of structural integrity of precast connections to enhance the static and cyclic behavior of the joints, and gives reasons

Read more ...

PT. Modern Panel Indonesia, a subsidiary of Modernland, one of Indonesia’s leading developers, is creating a new housing project using tested, earthquake-safe precast elements. The prefabricated elements are produced

Read more ...

×
Sign-up for Free Subscription
'India Construction Week'
Weekly e-Newsletter on Construction Industry
Get the latest news, product launches, projects announced / awarded, government policies, investments, and expert views.
Click here to subscribe.