Shapoorji Pallonji & Co. Pvt. Ltd. is one of the leading construction companies in India. In early 2014, the company put into operation the first carrousel plant in India and began producing precast concrete elements for the construction of 1,890 units under Residential Development, comprising 35 residential towers with up to 14 floors. EBAWE Anlagentechnik, a company in the PROGRESS GROUP, assisted Shapoorji Pallonji in this project and was responsible for the planning and installation of the plant.

Precast concrete elements for 35 residential towers with up to 14 floors
The precasting work for the New Haven Complex was started in early 2014. The project, planned by an American architect, will provide a total of 35 residential towers with 1,892 units spread over G+10 and up to 14 floors. In order to be able to meet the tight schedule and to maintain high quality, Shapoorji Pallonji Engineering & Construction as the main contractor opted for the EBAWE plant for the precast production. A modern carrousel plant has been installed close to the construction site to produce the precast concrete elements required for the manufacture of solid walls and slabs.

Shapoorji Pallonji Carrousel Plant
In order to be able to meet the tight schedule and the high quality requirements, Shapoorji Pallonji Engineering & Construction decided on the construction of a modern carrousel plant. Located close to the construction site for the New Haven residential complex, solid walls and slabs are produced in the production hall (centre of picture). To the left of this is the store for the solid slabs and to the right the store for the solid walls.

Carrousel plant constructed in record time
EBAWE Anlagentechnik, a company in the PROGRESS GROUP, which specialises in the planning and construction of carrousel plants, was awarded the tender for the design and implementation of the project. Shapoorji Pallonji specified that there had to be capacity to install a total of 62,655 solid walls and slabs during the construction phase. The construction company's target was to complete 70 units per month. The capacity required from the plant for this purpose was estimated at 1,000 sq.m. of precast concrete elements per day.

The carrousel plant was constructed in record time. Just six months from the start of the project production of the first precast concrete elements began. The carrousel plant itself consists of 30 pallets, which travel automatically from work station to work station.

Precast Technology for Highrise Precast Technology for Highrise Housing
Thirty pallets, which travel automatically from work station to work station, circulate within the carrousel plant At the end of the production process a transverse shift device transports the pallets to the tilting station in the outdoor area. A gantry crane removes the finished precast concrete element from the tilting station and places it in storage.

Manufacture of walls and slabs
The production process begins with the cleaning and oiling of the pallets. Next, a fully automated plotter precisely and accurately marks the positions of the shutters. The CAD data required for this, are transmitted directly to the plotter. Once the shutters are positioned and the made-to-measure mesh is inserted, the fresh concrete is applied. This is compacted by means of high frequency compacting equipment. Finally, in the curing process, a pallet stacker takes the elements to the curing chambers and removes them from there. At the end of the production process, tilting equipment brings the pallet into an almost vertical position. A gantry crane then removes the finished concrete elements and stores them in the two stores to the left and right of the production hall.

Haven Complex
The New Haven complex comprises a total of 35 residential towers with 1,892 units on up to 14 floors. A total of 62,655 solid walls and slabs are being installed.

The elements are then transported by HGV from the stores to the construction site and there five tower cranes are used to lift them and install them in their final position. A total of more than 1.7 million square feet of precast concrete are being produced for the New Haven Residential Complex in round the clock operation.

Complete software system controls all production processes
The entire plant is controlled by ebos®, a complete software solution developed by the PROGRESS GROUP. This solution, specifically developed and tailored to the needs of the precast concrete industry, addresses all aspects of the manufacturing process, from work preparation through production to process analysis.

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Currently, the construction work for New Haven is well under way. Once the residential complex is complete, this Green Township will offer its residents not simply an environmentally sustainable life-style surrounded by greenery, but also other amenities, such as a swimming pool, a gymnasium and shops.
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