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Precast to accelerate the growth trajectory

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It would be interesting to see how the industry will adapt itself to the move towards precast. One needs to carefully explore the possibility of the adaptation of precast into an existing project. The bigger question here is whether the migration in the design approach is possible or not.

The pandemic that shook the world in no time has disrupted business across segments. Cement, infrastructure, construction all came to a grinding halt. Most of the sector players will have numbers highlighting the severe depression created by the pandemic in their balance sheets. However, there are segments with these sectors that would have greater opportunities smiling at them when the country returns to the business as usual. One such segment, the experts say is the precast. Precast concrete which is one of the most sought after segment in construction because of the various benefits, is expected to pick up momentum. Till now, this segment has had slow growth. Owing to the new derived situation (demand dip, labour shortage, cost-effective ways to run business) put together will lead to construction segment increasing its dependency on precast.

The precast being dynamic – offers increased durability, increased load-bearing capacity especially when the concrete is pre-stressed with cable reinforcement, safer and faster as the casting is done offsite and is cured in a precisely controlled environment. It has the capacity for volume delivery as well. Above all, precast bring down the cost significantly in construction in comparison to the conventional standard concrete. Taking all these into consideration, it is natural for the construction industry to lean towards precast concrete.

Anil Banchhor, Managing Director & CEO, RDC Concrete (India), elaborated on the opportunities emerging for precast concrete. He said, "In the precast segment, post-Covid-19, the opportunity is more because precast requires fewer workers. Many companies would move towards precast construction. The precast industry is slowly maturing, and the growth though was slow. Some residential buildings, especially the low-cost housing, is shifting to precast. Apart from this, there is a lot of scopes for hospitals as the government will be spending a lot in hospital infrastructure. Also, commercial buildings will start moving to precast like hotels, offices etc. will move to precast. This opportunity is better for precast industries."

Devendra Pandey, an industry expert, pointed out, "Demand of concrete would be dependent on so many factors beyond our control currently. But our ability to support the change in technology would impact a shift in the customer bases. Overall concrete Demand will remain proportionately similar, but there will be a shift from the current customer segments towards the precast segment. The percentage of precast supply will definitely increase."

Global market
According to a study published in mid-2019 by ReportLinker, a market research solution company,"The precast Concrete market worldwide is projected to grow by $47.8 billion, guided by a compounded growth of 5.4 per cent. And the projection is the precast market would touch $54.1 billion by 2025. With a healthy forecast and leveraging on the emerging opportunity in floors and roofs, the said numbers appeared to be attainable. Floors and roofs segment expected to clock a 6.4 per cent growth. The shifting dynamics will support growth by adding significant momentum to the global growth of precast concrete."

The report also gave a breakup of the contribution of regional market to this projected growth in precast."The US will maintain a 4.7 per cent growth momentum. Within Europe, which continues to remain an important element in the world economy, Germany will add over $1.9 billion to the region’s size and clout in the next five to six years. Over $5.3 billion worth of projected demand in the region will come from other emerging Eastern European markets. In Japan, floors and roofs will reach a market size of $3.2 billion by the close of the analysis period. As the world’s second-largest economy and the new game-changer in global markets, China exhibits the potential to grow at 7.8 per cent over the next couple of years and add approximately $12.6 billion. Several macroeconomic factors and internal market forces will shape growth and development of demand patterns in emerging countries in Asia-Pacific, Latin America and the Middle East."

India market
India also was upbeat with investment flowing into the country with an optimistic outlook for 2020-2021. One such investment was the announcement of Rs 700 crore investment by the South US-based design and technical construction company Katerra. This investment, the company made in India to set by its second facility near Hyderabad. According to the officials of Katerra, the said facility will manufacture 8 million sq ft of prefabricated building components and fittings every year with robotic assembly line production. The plant was initially expected to be complete by March 2020.

Precast in India, currently, has only specific types of projects. Precast wasn’t a major defining driver in the construction segment till now, but, it would be in the future says, industry players. If the construction sector adopts precast concrete at a faster pace, then it is going to be successful in averting some post-lockdown impacts. There are low-cost housing projects that have already been using precast technology. With the use of precast, the floor casting cycle time can be reduced to 3-5 days, which is remarkable. The benefit of time reduction would enable faster adaptation of precast concrete and increase the Demand in the future.

Pandey continued on the challenging the precast segment would need to address post covid 19 by saying, "This is an interesting challenge. One needs to carefully explore the possibility of the adaptation of precast into an existing project. The bigger question here is whether the migration in the design approach is possible or not. It would be difficult for the real estate players and owners to make that decision to migrate into precast in an ongoing project. Existing projects may transition first by starting to use precast wall segments, manholes made out of precast concrete, precast staircases, and so on. Even in existing building design, more precast products can be used compared to the percentage earlier. I feel it would be easier for new projects into precast technology and the change is definitely coming. There is also the possibility of composite construction becoming popular compared to the traditional reinforced concrete format, which is designed using structural steel and concrete together."

Trends in precast
Many of the companies in the recent past have created a portfolio of value-added concrete products that are helpful for the construction industry in terms of technology adaptation towards this changing dimension.

Post-tension slabs: These are currently used in buildings, metro construction, bridges on national highways and cities. There is a lot of post-tension work going on.

However, this segment will emerge and mature. The customer requirement will also change accordingly. Faster curing and early development of strength of concrete will become crucial. There could be more Demand for self-curing concrete so that stocking of elements can be reduced. In short, the technical requirements of the precast project itself will start changing. That will require technically efficient producers who will be able to supply the needs in a timely manner.

Prashant Jha, Chief RMX, Nuvoco Vistas Corp, further elaborated on the trends that are witnessed in the segment.

Large-panel systems: The designation "large-panel system" refers to multistory structures composed of large wall and floor concrete panels connected in the vertical and horizontal directions so that the wall panels enclose appropriate spaces for the rooms within a building. These panels form a box-like structure. Both vertical and horizontal panels resist gravity load. Wall panels are usually one story high. Horizontal floor and roof panels span either as one-way or two-way slabs. When adequately joined together, these horizontal elements act as diaphragms that transfer the lateral loads to the walls.

Frame systems: Precast frames can be constructed using either linear elements or spatial beam-column sub-assemblages. Precast beam-column sub-assemblages have the advantage that the connecting faces between the sub-assemblages can be placed away from the critical frame regions; however, linear elements are generally preferred because of the difficulties associated with forming, handling, and erecting spatial elements.

Slab-column systems with shear walls: These systems rely on shear walls to sustain lateral load effects, whereas the slab-column structure resists mainly gravity loads. There are two main systems in this category: lift-slab system with walls, and prestressed slab-column system.

Modular system: In the case of smaller single units, this system is helpful. Some of the advantages are; a) Entire unit is cast in a factory and installed at site b) Suitable for toilet blocks or individual rooms c) Monolithic casting guarantees waterproofing at junctions.

Way forward
In the last Union Budget 2020, the government has announced infrastructure projects to the tune of Rs 103 trillion. Besides, the government also provided about Rs 1.70 trillion for transport infrastructure and highways construction. This allocation is expected to strengthen the demand for rural housing and infrastructure gradually. The emphasis given to infrastructure development, 100 new airports and a focus on roads will go a long way to revive concrete Demand.

However, the current infra projects will continue, but at a slow pace initial two to three months, primarily because of the shortage of migrant workforce. Every company would look at completing the projects as fast as possible to tide over the lost time. Most of the infra companies have labour camps attached, however, whether the migrant workers will stay or go back to their villages after lockdown determines the pace of the undergoing infra projects.

Pandey signed off by saying,"We can expect a slow start and a very steep rise in the Demand that is one view, while the other view is a little conservative. Looking at the slower pace of the market, it’s a bit hard to project at the moment. We remain cautious and observant. We are ready to serve the industry and the nation as the needs emerge."

However, there could be delays in rolling out the projects, completion of projects under implementation, with demand taking a long time to pick up. As per the latest report released by the rating agency Crisil in the first week of May says "there would be a delay of 12 months or more in the completion of Bharatmala phase 1." However, the report leaves an optimistic note that roads and highways would rebound faster despite sharp losses in the first quarter of FY21.

– RENJINI LIZA VARGHESE

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Economy & Market

RAHSTA Roundtable Sets Agenda for Smarter, Safer Highways

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Roundtable discussions focus on innovation for safer highways.

Held on 12 March 2026 at Courtyard by Marriott, Mumbai, alongside the Infrastructure Today Airport Conclave, the RAHSTA Roundtable brought together stakeholders from across the highways and infrastructure ecosystem to shape the agenda for the 16th RAHSTA 2026, scheduled for 8–9 July 2026 at the Jio Convention Centre, Mumbai. The session focused on key industry themes including road construction, technology, safety and long-term sustainability.

Opening the discussion, Pratap Padode, Founder, FIRST Construction Council, said the roundtable marked the beginning of a broader consultative process leading up to the July event. The aim, he noted, is to bring together industry stakeholders to refine the agenda for discussions on the future of roads, bridges, tunnels and allied infrastructure.

Padode noted that while central road project awards have slowed in recent years, states are increasingly driving the next phase of infrastructure growth. Maharashtra, with its long-term road development plans and agencies such as MSRDC and MSIDC, is expected to play a significant role in this expansion.

RAHSTA Expo 2026 as a specialised platform dedicated to road infrastructure, covering highways, tunnels, bridges and flyovers along with construction technologies, safety systems and maintenance solutions. He also highlighted the growing importance of rural connectivity and said the organisers are engaging with government bodies to highlight rural road development initiatives.

Tanveer Padode, CIO, ASAPP Info Group, presented insights from IMPACCT, the group’s infrastructure intelligence platform. He pointed to a strong project pipeline despite slower highway awards earlier in the year, noting that states such as Maharashtra, Odisha and Arunachal Pradesh are emerging as key drivers of new projects. The data also revealed that only a small group of contractors participates in large-value infrastructure bids.

Lt Gen Rajeev Chaudhary, former Director General, Border Roads Organisation and Chairman of the RAHSTA Expo Committee, emphasised the need for stronger collaboration across the ecosystem, including policymakers, contractors, technology providers and financiers. He also called for addressing systemic issues within the sector and encouraged greater participation of women in infrastructure leadership.

The discussion also explored the evolving economics of road development. Phani Prasad Mandalaparthy, Associate Director, CRISIL Intelligence, noted that the slowdown in project awards reflects a shift towards higher-value logistics corridors rather than simple road widening projects. However, private participation through BOT and TOT models remains limited.

From the contractors’ perspective, Sudhir Hoshing, Whole-Time Director, Ceigall, said companies are becoming more selective in bidding, favouring projects with clearer payment mechanisms and efficient processes. While NHAI continues to offer greater operational clarity, states such as Uttar Pradesh and Bihar were cited as relatively supportive environments for project execution.

Durability and sustainability also emerged as key themes. Himanshu Agarwal, COO – Road & Infrastructure, Zydex Group India, highlighted the need to prioritise lifecycle performance and resilient pavements, while participants discussed the potential of alternative materials such as plastic waste, steel slag and industrial by-products in road construction.

Dr LR Manjunatha, Vice President, JSW Cement, emphasised that India has abundant fly ash, slag and other industrial materials that can improve durability and sustainability if integrated into specifications and policy frameworks.

Technology and equipment challenges were also discussed. Dr Lakshmana Rao Mantri, Dy General Manager, Afcons Infrastructure, highlighted the shortage of tunnel boring machines (TBMs), which is delaying several underground infrastructure projects. Participants agreed that developing domestic TBM manufacturing capabilities will be critical for future infrastructure expansion.

The future of concrete pavements was another area of discussion. Dr V Ramachandra, President, Indian Concrete Institute, stressed that the debate should focus on lifecycle performance rather than material choice alone, noting that evolving design standards are improving the feasibility of concrete roads.

Prof Dharamveer Singh of IIT Bombay added that while India has made significant progress in infrastructure development, stronger capacity building and better execution practices are essential to ensure consistent road quality.

The discussion also touched upon technology adoption in the sector. Rushabh Mamania, Partner & CBO, Roadvision, highlighted the growing role of AI in road infrastructure, noting that AI-driven monitoring systems are already being deployed across large stretches of national highways.

Overall, the roundtable underscored that the future of highway infrastructure will depend not only on the pace of construction but also on durability, safety, technology integration and sustainable materials. The discussions offered valuable insights that will help shape the agenda for RAHSTA 2026 and guide future collaboration within the industry.

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Economy & Market

CTS Roundtable Charts Tech-Led Roadmap for Construction

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CTS Roundtable Maps Technology Roadmap for Construction

Ahead of the Construction Technology Show (Con Tech Show) 2026, industry leaders, technology innovators and academia came together in Mumbai to deliberate on how digitalisation, automation and industrialised construction can reshape the sector. The discussion made one thing clear: construction can no longer afford to treat technology as optional.

Held on 12 March 2026 at Courtyard by Marriott, Mumbai, alongside the Infrastructure Today Airport Conclave, the CTS Roundtable served as a precursor to the Construction Technology Show 2026, scheduled for 19–20 August 2026 at NESCO, Mumbai.

A platform to move from discussion to deployment

Opening the session, Pratap Padode, Founder and Editor-in-Chief, ASAPP Info Global Group, said construction technology has long remained close to his heart, especially given the sector’s traditionally slow pace of technology adoption. He noted that over the years, the Construction Technology Summit had steadily built interest, and the next step was now to expand it into a larger, more meaningful platform that could bring together technology providers, users, startups and innovators under one roof.

Padode said the vision for CTS is not limited to software alone. The platform aims to embrace all forms of technology that can improve construction efficiency, quality and execution—from digital tools and project management systems to lean construction, off-site fabrication and startup-led innovation. He also highlighted plans to deepen startup participation and create space for young companies to showcase emerging construction solutions.

Industry at a turning point

Moderating the roundtable, Naushad Panjwani, Chairman, Mandarus Partners, set the context by pointing out that the global construction industry, despite being a multi-trillion-dollar sector, continues to lag in productivity. He noted that while manufacturing has consistently improved efficiency, construction has remained slow to modernise.

Referring to both global and Indian trends, Panjwani underlined that the industry is now at a decisive moment. India, he said, is entering a major build cycle, and delivering the next phase of infrastructure and real estate growth through traditional methods alone is no longer viable. The goal of the roundtable, therefore, was not to debate technology in isolation, but to identify the most critical conversations that would bridge the gap between innovation and implementation.

His central message was clear: CTS 2026 must be shaped around themes that make CEOs, CIOs and CTOs feel they cannot afford to miss the event.

From BIM to AI, data to governance

A major theme that emerged through the discussion was the need for better data, better visibility and better decision-making. Dr Venkata Santosh Kumar of IIT Bombay echoed this, saying that the underlying data infrastructure itself needs attention. Construction projects, particularly remote ones, often face issues around connectivity, data collection and data use. Without this foundation, more advanced technologies cannot deliver their full value.

Chandra Vasireddy, CEO & Co-founder, Inncircles, expanded the discussion to governance, arguing that technology must help connect the many moving parts of a construction business. For him, the real value of digital transformation lies in creating better governance, clearer visibility and stronger business outcomes.

Tejas Vara of Inncircles stressed the importance of timely site data for leadership teams, especially in large and remote projects where decisions on materials, machinery and manpower often get delayed because information does not reach headquarters in time.

The role of AI also featured prominently. Rushabh Mamania, Partner and CBO, Roadvision said that while AI and machine learning are now common terms, vision intelligence and language intelligence have still not deeply penetrated the construction sector. He emphasised that startups in India are building relevant AI-led solutions and are already attracting international interest, showing that innovation need not be imported—it can be built locally and scaled globally.

Industrialised construction gains ground

The roundtable also placed strong emphasis on industrialised construction methods. Kalyan Vaidyanathan, CTO – Construction & R&D, Tvasta, called for greater focus on off-site fabrication and the broader industrialisation of construction. Bhargav Jog, General Manager, Dextra, highlighted precast technology and alternative sustainable materials as areas with immediate relevance.

Several participants agreed that modular, precast and pre-engineered approaches are no longer niche ideas. They are increasingly becoming practical responses to the sector’s challenges around labour shortage, timelines, quality control and predictability.

Anup Mathew, Sr VP & Business Head, Godrej, argued that the industry needs a fully integrated approach—from design and procurement to execution and asset management. Unless these are connected, technology adoption will remain fragmented and sub-optimal. He pointed to pre-engineered and modular systems as examples of how industrial thinking can compress timelines, improve quality and reduce dependence on difficult on-site conditions.

Adoption remains the biggest hurdle

While there was broad agreement on the promise of technology, the discussion repeatedly returned to one fundamental challenge: adoption.

Abhishek Kumar, COO, LivSYT, observed that the market is crowded with solutions, but many buyers still struggle to evaluate which technology suits which use case. According to him, the industry needs clearer frameworks to help users select, compare and adopt solutions, rather than expecting a single platform to solve every problem.

Dr Tenepalli JaiSai, Associate Professor, School of Construction(SoC), NICMAR University, noted that isolated technologies will not solve the productivity problem by themselves. What is required is an integrated Construction 4.0 approach, where digital, physical and cyber-physical systems work together rather than in silos.

That concern around silos was reinforced by Subodh Dixit, former Director, Shapoorji Pallonji, who said the issue is not just that technologies are disconnected, but that stakeholders are as well. Clients, consultants, contractors and partners often operate with different priorities. Unless these silos are broken, technology will struggle to percolate across the full project value chain.

Harleen Oberoi, Project Management, Tata Realty shared a practical perspective from the client side, saying that successful BIM implementation requires investment across the ecosystem, not just within one organisation. Trade partners, vendors and other stakeholders must also be trained and aligned if the technology is to deliver its intended results.

Beyond buzzwords

A notable takeaway from the session was that the industry is moving past the phase of treating technology as a buzzword. Participants repeatedly stressed that the real question is not whether technology should be used, but where it creates measurable value and how that value can be scaled.

The conversation also expanded beyond mainstream themes to include repairs and rehabilitation, construction and demolition waste, sustainability, circular economy, green sourcing, carbon measurement, design interoperability, generative design, robotics, and the role of horticulture and greener built environments.

Setting the agenda for CTS 2026

By the close of the session, the roundtable had surfaced a strong set of themes for the upcoming show: BIM and digital twins, AI and data platforms, industrialised construction, startup innovation, governance-led technology adoption, robotics, sustainable materials, and integrated project delivery.

More importantly, the session established CTS 2026 as more than an exhibition. It is shaping up to be a serious industry platform where users, technology providers, researchers and policymakers can collectively define the future of construction.

As Padode noted in his closing remarks, the conversation will continue through further consultations and possibly webinars in the run-up to the show. If the roundtable is any indication, CTS 2026 will aim not merely to showcase technology, but to push the industry towards meaningful adoption at scale.

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Concrete

Human Factor in Grinding Optimisation

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Ponnusamy Sampathkumar, Consultant – Process Optimisation and Training, discusses the role of skilled operators as the decisive link between advanced additives, digital control and world-class mill performance.

The industry always tries to reduce the number of operators in the Centre Control Room. (CCR) Though the concept was succeeded to certain extent, still we need a skilled person in the CCR.
In an era where artificial intelligence (AI) grinding aids, performance enhancers, and digital optimisation tools are becoming increasingly sophisticated, it’s tempting to believe that chemistry alone can solve the challenges of mill efficiency. Yet plants that consistently outperform their peers share one common trait: highly skilled operators who understand the mill as a living system, not just a machine.
Additives can improve flowability, reduce agglomeration, and enhance separator efficiency, but they cannot replace the nuanced judgement that comes from experience. Grinding is a dynamic process influenced by raw material variability, moisture, liner wear, ball charge distribution, ventilation, and separator loading. No additive can fully compensate for poor control of these fundamentals.

Operators see what additives cannot
When I joined the cement industry in 1981, not much modernisation was available then. Mostly the equipment was run from the local panel. Once I was visiting the cement mills section. The cement mills were water sprayed over the shell to reduce the temperature to avoid the gypsum disintegration.
The operator stopped the feeding for one of the mills. When I asked the reason, he replied that mill was getting jammed, and he added that he could understand the mill condition by its sound. I also learned that and it was useful throughout my career. In another plant I saw the ‘Electronic Ear,’ which checked the sound of the mill and the signal was looped with feed control!
Whatever modernisation we achieve, it is from the human factor that the development starts.
Additives respond to conditions; operators interpret them.
A skilled operator can detect subtle shifts, like a change in mill sound, a slight variation in circulating load, or a drift in separator cut point. It’s long before instrumentation flags a problem. These micro-observations often prevent major efficiency losses.
Additives work best when the process is stable
I would like to share one real time incident. The mill was running on auto mode looped with the mill outlet bucket elevator kilowatt. (KW)There was a decrease in the KW, and the mill feed was increased by the auto control (PID). After a while, the operator stopped both the feed and the mill. He asked the local operator to check the airslide between mill outlet and the elevator. They found the airslide was jammed and no material flow to the elevator!
The operator deduced the abnormality by his experience by seeing the conditions and the rate of increase of the feed by the auto control.
It’s always the human factor that adds value to the optimisation.

Grinding aids are multipliers,
not magicians.
They deliver maximum benefit only when:
• Mill ventilation is correct
• Ball charge is balanced
• Feed moisture is controlled
• Separator speed and loading are improved
• Blaine targets are realistic
Without these fundamentals, even advanced additives may become costly investments. The operator is responsible for ensuring process stability, whether using a ball mill or a vertical mill. After ensuring the system is stable, the operator observes it briefly before transitioning to automatic control. If there is any anomaly in the system the operator at once takes control of the system, stabilises and bring back to auto control.

Skilled operators adapt in real time
It will be interesting to note that the operators who operate from local panel start to operate from DCS also. They have the experience and the ability to adapt the changes. Operator checks each parameter deeply. Any meagre change in the parameters is also visible to him.
Raw materials change. Weather changes. Wear patterns change.
A skilled operator adjusts:
• Feed rate
• Water injection
• Separator speed
• Grinding pressure (in VRMs)
• Mill load distribution.
These adjustments require intuition built from years of experience, something no additive can replicate.

Human insight prevents over reliance on additives
Plants sometimes increase additive dosage to mask deeper issues like:
• Poor clinker quality
• Inadequate drying capacity
• Incorrect ball gradation
• High residue due to worn separator internals.


A knowledgeable operator finds root causes instead of chasing temporary chemical fixes.
The real optimisation sweet spot is reached when:
• Operators understand how additives interact with their specific mill.
• Additive suppliers collaborate with plant teams.
• Process data is interpreted by humans who know the mill’s behaviour.
This constructive collaboration consistently delivers:
• Lower kWh/t
• Higher throughput
• Better product consistency
• Optimum standard deviation.

Advanced additives are powerful tools, but they are not substitutes for human ability. Grinding optimisation is ultimately a human driven discipline, where skilled operators make the difference between average performance and world class efficiency. Additives enhance the process but operators
control it.

About the author:
Ponnusamy Sampathkumar, Consultant – Process Optimisation and Training, is a seasoned cement process consultant with 43+ years of global experience in plant operations, process optimisation, refractory management, safety systems and training multicultural teams across international cement plants.

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