Concrete

Prefab Concrete: Moulding a Success Story

Published

15 years ago

January 6, 2011

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The Indian prefabricated component industry although is in a nascent stage, is fast catching attention of builders and construction companies. Even a fraction of upcoming investments in real estate and infrastructure project is spent in using prefabs would add about Rs 20,000 crore of business to the industry in next five year, from the current level of less than Rs 2,000 crore, that’s 10 times, finds FIRSTINFOCENTREHistorically, houses have been built in one place and reassembled in another and possibly the first recorded prefab house was the manning portable cottage constructed by a London carpenter, H Manning. He constructed a house that was built in components, then shipped and assembled by British emigrants. Another interesting building was the prefabricated hospital that the British Army deployed in 1855 during the Crimean War designed by Isambard Kingdom Brunel with innovations in sanitation, ventilation and ria flushing toilet.The world’s first prefabricated, pre-cast panelled apartment blocks were pioneered in Liverpool. A process was invented by city engineer John Alexander Brodie, whose inventive genius also had him inventing the football goal net. The tram stables at Walton in Liverpool followed in 1906. The idea was not extensively adopted in Britain, however was widely adopted elsewhere, particularly in Eastern Europe.Prefabricated homes were produced during the Gold Rush in the United States, when kits were produced to enable Californian prospectors to quickly construct accommodation. Homes were available in kit form by mail order in the United States in 1908."Prefabricated" refers to building built in components (eg, panels), modules (modular homes) or transportable sections (manufactured homes). Modular homes are created in sections, and then transported to the site for construction and installation. These are typically installed and treated like a regular house. Although the sections of the house are prefabricated, the sections, or modules, are put together at the construction much like a typical home.In India, the prefabricated or precast material industry is in a nascent stage. It is worth Rs 1,500 crore in infrastructure construction and less than Rs 500 crore in case of prefabricated homes. People are experimenting with them and some contractors specialise in them although there are certain drawbacks to the support system in urban area. At present, precast technology are more in vogue in rural India and not so favourable for elite housing as aesthetics may be compromised.However, of late, many builders have taken up prefabrication to meet demand. Earlier used in large projects, this system is gradually being preferred in most aspects of construction. Facing a shortage of labourers, builders are resorting to new ways to meet the unprecedented construction demand in one of the fastest growing property markets in Asia. Prefabricated building systems that have been traditionally used in India to build bridges, metro rails and industrial units so as to save money and time are now finding their way into constructing homes.Says a structure consultant, that using prefabricated materials has made construction work easy and it also brings down the construction time by as much as 50 per cent. Though using such materials is more common abroad, prefabricated structures are used in India in only large construction projects.Use of prefabricated materials has more or less become a norm in building construction in markets overseas. The trend has just started in India, because of the construction boom and western architectural influences.Now, more and more builders are opting for prefabricated materials to put together large structures without employing large labourers. Prefabricated materials are essentially ready-to-fit materials manufactured at a factory outside the construction site. They are later assembled at the construction site by masons and joiners.In prefabricated housing construction, only the foundation and floor slabs are constructed the conventional way, which involves brick work, timber work, cement and sand to the building site. Sections of walls and roof are fabricated at a factory-with or without windows and door frames attached – and transported to the site, where they are just assembled and bolted together.Prefabrication saves time and as a result cost. For instance, casting of a super structure, where the structure of a building above the ground level takes 7-28 days if the casts are made at the construction site. But if the casts are made at a plant outside the construction site, it takes just seven days.Although prefabrication is being used on a growing number of projects, most construction work is still site-based.Players in Prefabricated componentsThe cement prefabricated component industry is largely fragmented with large number of small players dominating regional business. Many producers still continue with conventional methods of production that meet local demand and specifications. Few organised players using modern technology are emerging with modest investments in plant and machinery. Couple of them also have technical tie-up with foreign specialists. Among the major players having pan-India presence is NCL Industries.NCL Prefab a division of NCL Industries, was set up in 1979. The company’s manufacturing unit is located at Jeedimetla, Hyderabad. NCL has developed its prefab housing systems by using Bison Panel. These systems are mainly used in farmhouses, dwelling houses, row houses, project houses, custom-made houses, rest houses, guest houses, hill resorts, store sheds, penthouses, security cabins, mobile check-posts, industrial sheds, disaster housing, defense barracks, school buildings and many more. Office quarters for Reliance Petroleum staffs, guest houses for Sanghi Industries in Hyderabad, office building for Arvind Mills in Ahmedabad, hill resort at Kodaikanal and a four-storey school building in Pune are some of the projects undertaken by the company using this technology.The company feels that the prefab business has really caught on, as most construction companies, army, as well as paramilitary forces, have started using them on a regular basis. While announcing the 2010-11 third quarter results K Ravi, MD of NCL Industries, stated the that company will take up construction of prefab structures in a joint venture with Austria’s VST namely, NCL VST Infra Limited. The idea is to introduce the prefab technology in India, particularly for high rise buildings. The cost of the project is estimated at Rs 21 crore and the first unit will come up in Hyderabad. Later on it will spread the technology throughout the country.The current technology limits the operations to cater to ground floors and manufacturing normal prefab shelters. Using new technology known as the formation; the shuttering material will remain in the building.Prospects and challengesThe current cement prefabricated component industry size estimated at Rs 2,000 crore, although in a nascent stage, is fast catching attention of builders and construction companies. The size has potential to grow 10 times even if a fraction of upcoming investment in real estate and infrastructure projects is spent in using prefabs. The potential sectors which can use prefabricated component are roads and bridges, railways, airports, ports, warehousing and storage housing and commercial complexes. As of end-May 2011, total investment in pipeline in these sectors was about Rs 32,400 billion. Even 0.6 per cent of this can bring in additional business of Rs 200 billion for the prefab industry. High potential segments are roads and bridges, railways, airports and ports. These four can generate more than Rs 150 billion of business alone. However, much would depend on quality of products offered, meeting specifications and timely delivery as these projects are time and cost conscious.NCL’s improved prefab systemsThe wall panel height is increased to 9 feet & 10 feet.Expanded polystyrene sheets are sandwiched between double skin panels for better thermal comfortEach panel is lipped on all sides with appropriate GI sections for easy interlocking. The lipping provided is helping to avoid damage of the edges during transport False ceiling is introduced for all most all the modelsThe roofs are provided with GI corrugated sheets or pre-painted sheets with appropriate ridge elementsDesigned eve plates are introduced at the edges of the roofs to add elegance to the sheltersElectrification for lighting and air conditioning is stream lined in the systemThe system of erection is simplified using minimum components

Concrete

FORNNAX Appoints Dieter Jerschl as Sales Partner for Central Europe

Published

2 weeks ago

February 5, 2026

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FORNNAX TECHNOLOGY has appointed industry veteran Dieter Jerschl as its new sales partner in Germany to strengthen its presence across Central Europe. The partnership aims to accelerate the adoption of FORNNAX’s high-capacity, sustainable recycling solutions while building long-term regional capabilities.

FORNNAX TECHNOLOGY, one of the leading advanced recycling equipment manufacturers, has announced the appointment of a new sales partner in Germany as part of its strategic expansion into Central Europe. The company has entered into a collaborative agreement with Mr. Dieter Jerschl, a seasoned industry professional with over 20 years of experience in the shredding and recycling sector, to represent and promote FORNNAX’s solutions across key European markets.

Mr. Jerschl brings extensive expertise from his work with renowned companies such as BHS, Eldan, Vecoplan, and others. Over the course of his career, he has successfully led the deployment of both single machines and complete turnkey installations for a wide range of applications, including tyre recycling, cable recycling, municipal solid waste, e-waste, and industrial waste processing.

Speaking about the partnership, Mr. Jerschl said,
“I’ve known FORNNAX for over a decade and have followed their growth closely. What attracted me to this collaboration is their state-of-the-art & high-capacity technology, it is powerful, sustainable, and economically viable. There is great potential to introduce FORNNAX’s innovative systems to more markets across Europe, and I am excited to be part of that journey.”

The partnership will primarily focus on Central Europe, including Germany, Austria, and neighbouring countries, with the flexibility to extend the geographical scope based on project requirements and mutual agreement. The collaboration is structured to evolve over time, with performance-driven expansion and ongoing strategic discussions with FORNNAX’s management. The immediate priority is to build a strong project pipeline and enhance FORNNAX’s brand presence across the region.

FORNNAX’s portfolio of high-performance shredding and pre-processing solutions is well aligned with Europe’s growing demand for sustainable and efficient waste treatment technologies. By partnering with Mr. Jerschl—who brings deep market insight and established industry relationships—FORNNAX aims to accelerate adoption of its solutions and participate in upcoming recycling projects across the region.

As part of the partnership, Mr. Jerschl will also deliver value-added services, including equipment installation, maintenance, and spare parts support through a dedicated technical team. This local service capability is expected to ensure faster project execution, minimise downtime, and enhance overall customer experience.

Commenting on the long-term vision, Mr. Jerschl added,
“We are committed to increasing market awareness and establishing new reference projects across the region. My goal is not only to generate business but to lay the foundation for long-term growth. Ideally, we aim to establish a dedicated FORNNAX legal entity or operational site in Germany over the next five to ten years.”

For FORNNAX, this partnership aligns closely with its global strategy of expanding into key markets through strong regional representation. The company believes that local partnerships are critical for navigating complex market dynamics and delivering solutions tailored to region-specific waste management challenges.

“We see tremendous potential in the Central European market,” said Mr. Jignesh Kundaria, Director and CEO of FORNNAX.
“Partnering with someone as experienced and well-established as Mr. Jerschl gives us a strong foothold and allows us to better serve our customers. This marks a major milestone in our efforts to promote reliable, efficient and future-ready recycling solutions globally,” he added.

This collaboration further strengthens FORNNAX’s commitment to environmental stewardship, innovation, and sustainable waste management, supporting the transition toward a greener and more circular future.

Concrete

Budget 2026–27 infra thrust and CCUS outlay to lift cement sector outlook

Published

2 weeks ago

February 2, 2026

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Higher capex, city-led growth and CCUS funding improve demand visibility and decarbonisation prospects for cement

Mumbai

Cement manufacturers have welcomed the Union Budget 2026–27’s strong infrastructure thrust, with public capital expenditure increased to Rs 12.2 trillion, saying it reinforces infrastructure as the central engine of economic growth and strengthens medium-term prospects for the cement sector. In a statement, the Cement Manufacturers’ Association (CMA) has welcomed the Union budget 2026-27 for reinforcing the ambitions for the nation’s growth balancing the aspirations of the people through inclusivity inspired by the vision of Narendra Modi, Prime Minister of India, for a Viksit Bharat by 2047 and Atmanirbharta.

The budget underscores India’s steady economic trajectory over the past 12 years, marked by fiscal discipline, sustained growth and moderate inflation, and offers strong demand visibility for infrastructure linked sectors such as cement.

The Budget’s strong infrastructure push, with public capital expenditure rising from Rs 11.2 trillion in fiscal year 2025–26 to Rs 12.2 trillion in fiscal year 2026–27, recognises infrastructure as the primary anchor for economic growth creating positive prospects for the Indian cement industry and improving long term visibility for the cement sector. The emphasis on Tier 2 and Tier 3 cities with populations above 5 lakh and the creation of City Economic Regions (CERs) with an allocation of Rs 50 billion per CER over five years, should accelerate construction activity across housing, transport and urban services, supporting broad based cement consumption.

Logistics and connectivity measures announced in the budget are particularly significant for the cement industry. The announcement of new dedicated freight corridors, the operationalisation of 20 additional National Waterways over the next five years, the launch of the Coastal Cargo Promotion Scheme to raise the modal share of waterways and coastal shipping from 6 per cent to 12 per cent by 2047, and the development of ship repair ecosystems should enhance multimodal freight efficiency, reduce logistics costs and improve the sector’s carbon footprint. The announcement of seven high speed rail corridors as growth corridors can be expected to further stimulate regional development and construction demand.

Commenting on the budget, Parth Jindal, President, Cement Manufacturers’ Association (CMA), said, “As India advances towards a Viksit Bharat, the three kartavya articulated in the Union Budget provide a clear context for the Nation’s growth and aspirations, combining economic momentum with capacity building and inclusive progress. The Cement Manufacturers’ Association (CMA) appreciates the Union Budget 2026-27 for the continued emphasis on manufacturing competitiveness, urban development and infrastructure modernisation, supported by over 350 reforms spanning GST simplification, labour codes, quality control rationalisation and coordinated deregulation with States. These reforms, alongside the Budget’s focus on Youth Power and domestic manufacturing capacity under Atmanirbharta, stand to strengthen the investment environment for capital intensive sectors such as Cement. The Union Budget 2026-27 reflects the Government’s focus on infrastructure led development emerging as a structural pillar of India’s growth strategy.”

He added, “The Rs 200 billion CCUS outlay for various sectors, including Cement, fundamentally alters the decarbonisation landscape for India’s emissions intensive industries. CCUS is a significant enabler for large scale decarbonisation of industries such as Cement and this intervention directly addresses the technology and cost requirements of the Cement sector in context. The Cement Industry, fully aligned with the Government of India’s Net Zero commitment by 2070, views this support as critical to enabling the adoption and scale up of CCUS technologies while continuing to meet the Country’s long term infrastructure needs.”

Dr Raghavpat Singhania, Vice President, CMA, said, “The government’s sustained infrastructure push supports employment, regional development and stronger local supply chains. Cement manufacturing clusters act as economic anchors across regions, generating livelihoods in construction, logistics and allied sectors. The budget’s focus on inclusive growth, execution and system level enablers creates a supportive environment for responsible and efficient expansion offering opportunities for economic growth and lending momentum to the cement sector. The increase in public capex to Rs 12.2 trillion, the focus on Tier 2 and Tier 3 cities, and the creation of City Economic Regions stand to strengthen the growth of the cement sector. We welcome the budget’s emphasis on tourism, cultural and social infrastructure, which should broaden construction activity across regions. Investments in tourism facilities, heritage and Buddhist circuits, regional connectivity in Purvodaya and North Eastern States, and the strengthening of emergency and trauma care infrastructure in district hospitals reinforce the cement sector’s role in enabling inclusive growth.”

CMA also noted the Government’s continued commitment to fiscal discipline, with the fiscal deficit estimated at 4.3 per cent of GDP in FY27, reinforcing macroeconomic stability and investor confidence.

Concrete

Steel: Shielded or Strengthened?

CW explores the impact of pro-steel policies on construction and infrastructure and identifies gaps that need to be addressed.

Published

3 weeks ago

January 31, 2026

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Going forward, domestic steel mills are targeting capacity expansion
of nearly 40 per cent through till FY31, adding 80-85 mt, translating
into an investment pipeline of $ 45-50 billion. So, Jhunjhunwala points
out that continuing the safeguard duty will be vital to prevent a surge
in imports and protect domestic prices from external shocks. While in
FY26, the industry operating profit per tonne is expected to hold at
around $ 108, similar to last year, the industry’s earnings must
meaningfully improve from hereon to sustain large-scale investments.
Else, domestic mills could experience a significant spike in industry
leverage levels over the medium term, increasing their vulnerability to
external macroeconomic shocks.(~$ 60/tonne) over the past one month,
compressing the import parity discount to ~$ 23-25/tonne from previous
highs of ~$ 70-90/tonne, adds Jhunjhunwala. With this, he says, “the
industry can expect high resistance to further steel price increases.”

Domestic HRC prices have increased by ~Rs 5,000/tonne
“Aggressive
capacity additions (~15 mt commissioned in FY25, with 5 mt more by
FY26) have created a supply overhang, temporarily outpacing demand
growth of ~11-12 mt,” he says…

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