the Vollert plant in India
The expansion of the Vollert plant in India marks an important milestone in the company’s commitment to provide high-quality products to customers. With the increased production capacity, the company aims to expand its market share and strengthen its position in the construction equipment industry, and also serve as a manufacturing hub for South Asia and Southeast Asian markets.

Vollert India, based in Sikandrabad (near Greater Noida) since 2017, has expanded its production capacity of precast machinery and components to meet the increasing demand from India’s fast growing infrastructure sector. The inauguration of the expanded factory took place recently in the presence of Group CEO Hans-Jörg Vollert, and Head of India Operations Krishan Mohan Sharma. Present at the event were the company’s customers, channel partners, suppliers, VDMA, representatives from the media, and the Vollert staff.

While addressing the large gathering, Hans-Jörg Vollert highlighted the importance of the expansion project and thanked everyone for contributing to the company’s success. He said, “It is a great honour for me to open our extended facility in Sikandrabad. We started our India operations through sales in 2011 and when our products began to see a lot of demand, we set up this factory in 2017, which has now become a manufacturing hub for our locally produced products. From here, we will not only serve the Indian market but also countries in the South Asian and South-East Asian regions. This shows how important this manufacturing hub is for the Vollert Group.”

the Vollert plant in India

From catering largely to the residential segment of users in India, Vollert is now eyeing the country’s infrastructure segment like roads and high-speed rails, given the Indian Government’s focus on infra development and its acceptance of precast construction. The Indian construction industry is also evolving and imbibing new construction technologies like the well-proven precast, for speedier and better-quality construction.

“Since business is picking up again post the Covid pandemic, we decided to expand our workshop to serve the needs of our increasing base of customers. We have enabled state-of- the-art and cost-effective production with optimized workflows. The new installation is already operating full steam - producing high quality precast moulds, and soon this unit will also start catering to our customers in other parts of Asia. However, our journey does not end here; we will continue to make more investments during this financial year. We have also planned to set up a blasting and a paint booth at our Sikandrabad facility,” informed Hans-Jörg Vollert.

The new plant is equipped with state- of-the-art machinery and technology, which will improve efficiency and reduce production time and carbon emission. It will also create employment opportunities for the local community, as the company plans to hire additional staff to operate the facility.

the Vollert plant in India

The facility produces stationary moulds, tilting tables, beam and column moulds, and special formwork. Local production allows Vollert to offer a competitive price/ performance ratio compared to imported goods since there are no high custom duties to pay, plus the products are produced and delivered to project sites without any delays.

“India is now our focus hub from where we are not just serving the country’s growing demand but also the markets of South Asia and Southeast Asia. We have an ambitious target of growing 10 to 20% in the next two years here,” he informed.

the Vollert plant in India
Said Krishan Mohan Sharma, “Since India is a cost-conscious market, we have to indigenize the solutions; we have to design and localize products, especially when clients want customized products.”

He opined that construction processes in India are still conservative and to change them could take ages. “No doubt, there is some reluctance in India, but there are also customers who understand the benefits of precast construction,” he said.

No doubt, with precast, there are issues of logistics and need for skilled manpower, but the benefits that accrue are far more.”

The company is spreading awareness on precast technology through social media channels, seminars and conferences with architects, real estate developers, consultants, and civil engineers, to demonstrate its benefits of reduced carbon footprint, better-quality construction, and time and cost savings through speedy construction.

However, despite the promising outlook of precast in India, Vollert is faced with the challenge of finding manpower skilled in precast construction. The company is therefore placing a lot of emphasis on training and upskilling its employees to ensure they have the necessary skills and knowledge to meet the demands of the job.

“Our HR undertakes a quarterly training program with a proper TNI (Training Need Identification) in place. The initial training and induction of key members takes place in Germany. We also train our vendors and employees through different modes including video conferencing on regular basis,” informed Sharma.

He added, “Another challenge is the lack of infrastructure; for instance, we procured 4-meter-wide plate for a project of Thailand based customer but there were no proper approach roads with wide enough toll gate for transporting the material. Our requirement is for roads that can cater to even 6-meter-wide products and on which we can transport entire structures from factory to site. If the road infrastructure is good, our transportation costs will also come down.”

the Vollert plant in India

Handling of precast elements is another challenge. PPVC’s (prefabricated precast volumetric concrete) are three- dimensional modular units produced in controlled factory conditions prior to their transportation to project sites. Modules can be brought to sites either as a basic structure or with all the internal and external finishes and services installed

- ready for assembling. “The challenge here is that due to the heavy weight of the components, we require huge cranes for lifting and installing them. In fact, logistics, and the right tools and lifting equipment are a must in the precast industry. This may increase the initial cost of construction, but the pay back is fast and good.”

According to Hans-Jörg Vollert, “Precast is the most effective and quality-oriented way of offsite construction. However, getting and retaining labor on site is a hassle as one has to provide them accommodation, food, and basic facilities. Precast, in general, came to India 10 years ago but there was no awareness about this technology. In developed countries like Singapore, Turkey, and America, 40% of the buildings are precast built, whereas in India it is only 3%. But there is now a growing acceptance and inclination towards precast construction here as India is one of the fastest growing markets due to the impetus being given to infra development by the Government. We have clear cut approvals from the Government that precast technology is authorized and has passed quality tests. This has boosted our confidence and that of the developers too.”
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
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
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
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
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
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
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 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 ...

India an Important Market for TOPWERK
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

Read more ...

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 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 ...

Prensoland Modern Precast Floors Appearance of the iHCS
Pre-stressed concrete hollow core slabs used for building floors are unidirectional members; they are laid one next to the other until the complete carpet area is covered. In the presence of lateral loads like wind, or due to seismic episodes, they behave

Read more ...

Brimax AAC: An Indian Lighthouse Project from HESS AAC SYSTEMS, Netherlands
Brimax AAC Products LLP contracted Hess AAC Systems to supply a new AAC plant in Vadodara, India, with a capacity of 680 cbm/day (expandable up to 900 cbm/day with reinforcement for panel production). This order strengthens Hess´ position as

Read more ...

Vollert India Expands Production Capacity to Cater to Infra Development Sector
Vollert India, based in Sikandrabad, near Greater Noida (UP) since 2017, is strengthening its commitment to India; it is now expanding its production capacity of precast machinery and components to meet the greater demand from India’s fast

Read more ...

Elematic Precast Technology Solutions for Building, Industrial and Infra segments
Elematic offers a comprehensive range of precast technology solutions for the Building, Industrial and Infra segments. Elematic precast technology enables clients to automate the production of walls, slabs, columns, beams, and stairs, providing an efficient

Read more ...

Advanced Concrete Curing Systems from Kraft Curing
Kraft Curing Systems GmbH is offering advanced concrete curing systems that optimize the hardening process of concrete. Kraft Curing’s Advanced Concrete Curing System provides numerous solutions, from vapor-based (steam) systems mainly for the precast

Read more ...

Why Automating Production is the Solution
Automating the production processes will lead to reduced wastage, fewer errors, more precision, greater safety, and higher quality of the end-products, and in a shorter period of time. First, we need to understand where we stand today as regards industrialisation

Read more ...

Elematic India confident of the future of Precast Business
Elematic India sees growing demand for its precast plants in India due to the growth in precast construction across segments. What gives the company an edge is its ability to support the customer through the entire value chain. Says Sridhar Rao, Sales

Read more ...

F.B.I. Tasbud Partners With Progress Group
Progress Group is helping companies like Tasbud stay ahead in a changing market with automation and software integration. Automated machinery to produce precast elements as well as the reinforcement and the integration of the fitting software are

Read more ...