India an Important Market for TOPWERK

Sachin Shetty, India Head – Operation & Sales, and Rajesh Jha, India Head - Sales & Market Development, TOPWERK INDIA
Sachin Shetty, India Head – Operation & Sales, and Rajesh Jha, India Head - Sales & Market Development, TOPWERK INDIA, discuss the potential of precast concrete construction in India, localization of non-critical components to bring down cost, and the possibilities of digitalization in increasing production, monitoring quality, and enhancing work efficiencies.

How do you see the mindset of the Indian construction industry changing towards precast technology?

Precast Technology is a relatively new technology in the Indian construction industry. There have been a lot of debates and discussions about the benefits of this technology over traditional ways of construction. In India, this alternative technology has been under discussion for differing compulsions such as labour availability, construction quality, cost, productivity, volume of work, etc. These factors have resulted in an inflection point, wherein it is increasingly becoming imperative to change the traditional ways of construction.

The global Precast Concrete market size surpassed USD 116 billion in 2020 and is anticipated to grow at over 5.6% CAGR from 2021 to 2027. The market revenue is likely to be valued at USD 134 billion in 2023 and is forecasted to exhibit a revenue growth of USD 234 billion by 2033. Rapid urbanization and infrastructural growth have continuously encouraged urban construction projects, stimulating industry growth.

What growth prospects do you see in the precast industry in India?

The traditional construction methods in India need to be improvised by using 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 utilization 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 done in precast, including segmental box girders or U-girders, piers, and pier caps, etc.

The efficiency of precast concrete construction technology has been proven since the last 50 decades in developed countries and regions. In India, which is a developing country, 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.

Sachin Shetty, India Head – Operation & Sales, and Rajesh Jha, India Head - Sales & Market Development, TOPWERK INDIA

What are the benefits of using precast over conventional construction systems and how does precast support the green movement and cost-effectiveness?

Precast concrete is often stronger than cast-in-place concrete. Not only are precast concrete products already reinforced with steel rebar, but the controlled curing process also ensures that the concrete will be set correctly under ideal conditions for maximized strength. Precast concrete can also be stress-tested before being delivered to the job site. There are many advantages of using precast concrete:
  • Cost-effective
  • Superior quality
  • Reduces overall construction time
  • Can use prestressed concrete
  • Enhances safety at construction site
  • Highly durable
  • Promotes sustainable construction
  • Enhances project efficiency
  • Increases project control
  • Versatile
  • Aesthetically pleasing
  • Safe construction
Precast concrete is truly a sustainable green product; it is highly durable, and uses an extremely low water-cement ratio. Due to their sustainability and the above-mentioned benefits, precast concrete products are being chosen for builders keen on LEED-certification for their projects. The carbon that is produced during the manufacture of cement is offset by the minimal maintenance costs, lower heating and cooling costs, and the concrete re-absorbing up to 40% of the carbon over the structure’s life. Cement consumption is reduced by a third per m3 of concrete because the compaction process in the plant is much more effective. Even steel consumption is lower because it is prestressed before concreting, so about 10 to 15 kg less steel is needed per sq.m. of the hollow core.

Sachin Shetty, India Head – Operation & Sales, and Rajesh Jha, India Head - Sales & Market Development, TOPWERK INDIA

Despite its advantages, precast technology is still not popular in India. What needs to be done to make it more attractive to developers, builders, and consultants?

The application of Precast Technology is very effective in executing large-scale construction projects like housing, commercial, institutional buildings, etc. It is also very efficient with respect to saving time, lesser requirement for manpower, better construction quality, less wastage of materials, flexibility in executing the design parameters for facades etc.

However, 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 distance of the construction site from the component manufacturing units, entailing transportation costs, 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.

What competitive edge does TOPWERK have over its competitors in India?

TOPWERK GROUP has been actively involved in the Indian market since 2007. In our long-standing engagement, we have succeeded with twenty-nine installations with different product houses under the TOPWERK GROUP roof.

HESS GROUP, which produces machines and plants for the production of concrete blocks, pavers, tiles, flagstones, and other architectural products has established fourteen installations in the country. HESS AAC SYSTEMS has established five installations in the country. PRINZING PFEIFFER has seven installations. They specialize in machines for the production of pipes, manholes, and precast concrete elements. Also, we have three installations from SR SCHINDLER. They provide finishing lines for concrete blocks and presses for concrete slabs.

At TOPWERK, we prioritize customer satisfaction. We do this among other things by providing local service support and spare parts to all our installations. Furthermore, we are committed to localizing several components. For this, we collaborate with approved vendors who provide value-for-money products, ensuring that there is no compromise on quality.

Overall, our broad spectrum of offerings enables us to meet diverse needs. This diversified portfolio is the key to our success and the satisfaction of our customers in the Indian market and all over the world.

How is your company addressing cost issues in the price-sensitive market of India?

The TOPWERK GROUP is reputed for the durability and reliability of its plants and machinery. Following the same tradition, we maintain a fine balance between quality and pricing for the Indian market. Our local vendors provide cost-effective products of high quality. These undergo three levels of quality checks: the first is by the vendor, the second by our company, and the third from an international rating agency. Our quality control and project engineers monitor day-to-day progress at our production unit. We are also offering service and spares locally and with our company in China, TOPWERK Langfang, we have the possibility to offer localized products for the international market - for example railway sleeper plant solutions or the hermetic press Uni500 C.

Sachin Shetty, India Head – Operation & Sales, and Rajesh Jha, India Head - Sales & Market Development, TOPWERK INDIA

How is IoT/Digitalization in production units and machineries helping in controlling cost and improving the efficiency, productivity, and safety of construction machinery?

The digital revolution is changing the way we live, work, and communicate fundamentally and with increasing speed. The TOPWERK GROUP actively designs new working conditions for the building materials industry together with our customers. The focus here is on ensuring product quality and automating the manufacturing and production processes. Our goal is not only to meet the highest demands worldwide but to exceed the expectations of our customers.

We at TOPWERK want to use the positive effects and the new possibilities of 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. In order to maintain and expand our status as an innovative industry leader, the company started series of projects to continuously increase the degree of digitization of our machines and systems.

Smart Vision solution from HESS GROUP: With this digital innovation, 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, you have the option of having your maintenance instructions 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: Web based visualization of the production statistics for pipe and manhole machines is currently being developed. Through this, 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 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; it is currently being developed. With this function, you can quickly get an overview of the status of your machinery which will help you to optimize various 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. The aim is to minimize machine downtime and reduce overall cost.

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.

How is establishing a local sales and service center in India helping the company in intensifying contact with its existing and new customers? How important is this move in the Group’s global growth strategy?

TOPWERK GROUP has a worldwide presence with a total of 14 subsidiaries with TOPWERK INDIA as one of the important establishments. This way we are closer to our existing and potential customers in the SAARC region. We are in direct day-to-day communication with customers and offer local service and spare parts support. As stated earlier, we have started localization of non-critical items to bring down the manufacturing cost and avoid imports and transportation costs. We are providing engineering services and software/hardware support to our group companies and have plans to export some accessories to our worldwide customers.

For more information regarding the TOPWERRK GROUP follow us on LinkedIn
NBM&CW JULY 2023

No comments yet, Be the first one to comment on this.

×

Terms & Condition

By checking this, you agree with the following:
  1. To accept full responsibility for the comment that you submit.
  2. To use this function only for lawful purposes.
  3. Not to post defamatory, abusive, offensive, racist, sexist, threatening, vulgar, obscene, hateful or otherwise inappropriate comments, or to post comments which will constitute a criminal offense or give rise to civil liability.
  4. Not to post or make available any material which is protected by copyright, trade mark or other proprietary right without the express permission of the owner of the copyright, trade mark or any other proprietary right.
  5. To evaluate for yourself the accuracy of any opinion, advice or other content.
Curetec's Concrete Curing System: Faster production times & Energy savings

Curetec's Concrete Curing System: Faster production times & Energy savings

Curetec continues to push the boundaries of energy-efficient technologies, with its advanced energy-saving Concrete Curing System, providing faster production times, and ensuring superior concrete quality.

Read more ...

Prefabrication for Affordable Housing Projects: Trimble Solutions

Prefabrication for Affordable Housing Projects: Trimble Solutions

Harsh Pareek, Regional Sales Director, India and SAARC, Trimble Solutions, highlights the transformative potential of prefabrication in the affordable housing sector, paving the way for a more efficient and sustainable future in construction.

Read more ...

Concrete 3D Printing Technology: Potential & Problems

Concrete 3D Printing Technology: Potential & Problems

A. V. Rahul, Assistant Professor & Divya S. Kurup, Research Scholar, Department of Civil and Environmental Engineering, IIT Tirupati, discuss the progress being made in 3D Concrete Printing, applications worldwide, and the ongoing

Read more ...

Innovative Construction Technologies for PMAY-U Light House Projects

Innovative Construction Technologies for PMAY-U Light House Projects

Urban India is undergoing a rapid transformation, driven by initiatives like the Pradhan Mantri Awas Yojana - Urban (PMAY-U), which aims to provide housing for all. To meet this ambitious goal, it's crucial to shift from traditional

Read more ...

3D Concrete Printing: A Look at Challenges & Future of Construction

3D Concrete Printing: A Look at Challenges & Future of Construction

Construction industry is the economic backbone of a country. The productivity of the projects in the construction industry is significantly influenced by formwork systems that consume huge project resources such as time, cost, material and

Read more ...

Boosting Precast Construction with Augmented Reality

Boosting Precast Construction with Augmented Reality

Blending virtual information with the real-world view, AR has become an effective tool in construction management to improve project planning, execution, and delivery. Bhavin Lakhani, Project Controls Specialist Lead, PMP, and CCM

Read more ...

3DXB Group Sets Guinness World Record for Largest 3D-Printed Villa in Dubai

3DXB Group Sets Guinness World Record for Largest 3D-Printed Villa in Dubai

3DXB Group, a leading innovator in 3D printing solutions for the construction industry, unveiled its achievement in making the world’s largest 3D-printed villa in Dubai. This groundbreaking project signifies a pivotal moment in the UAE

Read more ...

Rapidcast Boundary Walls: Best Quality Concrete Precast Textured Walls

Rapidcast Boundary Walls: Best Quality Concrete Precast Textured Walls

Rapidcast LLP brings to you for the first time in India the best quality concrete precast elements such as RCC precast compound walls and RRC precast stormwater UDrains. The new generation Rapidcast boundary wall/fence is a high quality precast

Read more ...

Elematic's Large Precast Concrete Plant for My Home GRAVA Project

Elematic's Large Precast Concrete Plant for My Home GRAVA Project

Hyderabad is witnessing the construction of Asia's tallest towers with a planned built-up area totalling 3.7 million sqm. The two 180-meter towers, each comprising 43 storeys, will be accompanied by six more similar towers. With each tower

Read more ...

Benefits of Shear Keyed Surfaces in Precast Building

Benefits of Shear Keyed Surfaces in Precast Building

Depending on the finish of the concrete surface, different coefficients are assigned by international codes in the calculation of shear resistance. The American Concrete Institute Code ACI318, Nov.19, states the following: Chapter 16.2.1.1 – Transfer of forces by

Read more ...

Revolutionizing Precast Industry with Advanced Tracking of Precast Concrete Elements

Revolutionizing Precast Industry with Advanced Tracking of Precast Concrete Elements

The precast concrete industry is undergoing a transformative change with innovative software solutions that offer enhanced tracking of precast concrete elements. One of these pioneering software solutions is StruSoft’s Impact Precast, which aims

Read more ...

Emerging Trends & Growth of the Prefab Industry

Emerging Trends & Growth of the Prefab Industry

Prefabricated technologies are becoming increasingly popular in the construction industry, particularly for large-scale construction. As prefabricated structures continue to evolve and improve, they are being used to construct warehouses, factories

Read more ...

Precast RCC Structures versus Pre-Engineered Steel Structures

Precast RCC Structures versus Pre-Engineered Steel Structures

A comparative study on Industrial Building Adopting Structural Frames as Precast RCC and Structural Steel Frames with Prestressed Precast Hollow Core Slabs as Flooring Slabs, presented by C. A. Prasad, Director, METEY Engineering Consultancy, Hyderabad

Read more ...

My Home Mega Project Shows Potential of Precast Construction Technology in India

My Home Mega Project Shows Potential of Precast Construction Technology in India

Storey by storey, Asia’s tallest precast towers with a total planned built-up area of 3.7 million sqm are rising towards the sky in Hyderabad. These two 180-meter towers of 43-stories each will be followed by six more similar towers. With each tower

Read more ...

Mekuba: A Leader in Mould Releasing Agents for Concrete

Mekuba: A Leader in Mould Releasing Agents for Concrete

With over 47 years of experience in the petrochemicals industry, and an expert in the formulation and production of mould-releasing agents, Mekuba Petro Products is growing rapidly in the construction chemicals segment with a daily production

Read more ...

Dextra Groutec Coupler - A Unique Solution for Reliable Joints in Precast

Dextra Groutec Coupler - A Unique Solution for Reliable Joints in Precast

Dextra has added yet another customer-centric, innovative, and custom engineered product - the Groutec Coupler - an efficient product that has been qualified and tested successfully on several major infrastructure projects in the recent past. With the

Read more ...

Vollert: Building A Stronger India with Precast

Vollert: Building A Stronger India with Precast

Vollert India has recently expanded its production capacity in Sikandrabad (UP) India. As a global leader in precast concrete components, systems, and machine solutions, Vollert’s investment in India indicates a growing interest among German companies

Read more ...

Precast India Connector - Helping Precasters Overcome Cost & Time Overruns

Precast India Connector - Helping Precasters Overcome Cost & Time Overruns

Precast India Connections, a new entity of Precast India Infrastructures, has innovated and patented a method of achieving a Dowel-Sleeve connection that functions even in the horizontal direction. Kapilesh Bhate, MD, Precast India Connections, shares

Read more ...

To get latest updates on whatsapp, Save +91 93545 87773 and send us a 'Saved' message
Click Here to Subscribe to Our eNewsletter.