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Precast concrete allows for elaborate and customised designs

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Aayush Patel, Director, Atul Projects India, discusses how precast concrete, when combined with automation and technology, has the potential to help India achieve its affordable housing goals.

What kind of precast concrete shapes do you use for residential buildings and commercial buildings?
We use a variety of precast concrete shapes to enhance structures in both residential and commercial construction. These include mouldings, rounded or modular features, grills, fins and projected pergolas for residential structures, all of which add to an appealing façade. Similarly, in commercial buildings, these components provide a professional and welcoming appearance that is consistent with the company’s identity. These adaptable precast concrete shapes play an important role in influencing the future of buildings by offering architectural projects with both aesthetic originality and durability.

What are the advantages of using precast concrete shapes as compared to other alternatives?
Using precast concrete shapes has various advantages over alternatives. One noticeable advantage is quicker construction due to off-site production, which saves significant time when compared to on-site curing. This technology allows for concurrent site preparation and assembly, which reduces labour needs. Furthermore, precast concrete allows for elaborate and customised designs that would be impractical otherwise. Precast elements, as opposed to cast-in-place concrete, are cured consistently in controlled factory settings, ensuring uniform quality. They also outperform steel constructions in terms of fire resistance and longevity. Precast concrete outperforms wood in terms of adaptability and durability. It reduces the need for substantial formwork and scaffolding, reducing waste and construction interruption.

Tell us about the quality standards you adhere to in selecting precast concrete shapes.
Our selection of precast concrete shapes is driven by strict quality requirements, emphasising precision work and achieving micro-finishes. In all aspects of our precast work, we prioritise exquisite craftsmanship and painstaking attention to detail. Our dedication to quality extends beyond surpassing basic criteria to achieving beautifully smooth surfaces on all of our goods. We ensure that each precast shape not only meets but exceeds industry requirements through a thorough review procedure, demonstrating our unwavering dedication to delivering the best level of workmanship available.

How do precast shapes help in the profitability of a construction activity?
Precast shapes add great value to construction activities by increasing profitability through faster processes and enhanced quality. These shapes are manufactured off-site under regulated conditions, decreasing material waste as well as labour and construction time. Various complicated shapes adapted to the project’s specifications can be achieved using Tensile Rubble Mould with grout and minimum diameter-wired reinforcement. This customisation lowers on-site modifications, optimising resource usage and eliminating costly errors. Furthermore, because of regular production circumstances precast shapes frequently display greater structural integrity and endurance. These elements work together to improve project efficiency, lower overall costs, and increase profitability in building endeavours.

What are the challenges you face in using precast shapes?
The use of precast shapes for multi-story elevations provides precise and diverse solutions for a variety of design objectives. However, it comes with obstacles such as extensive design and technical needs, communication barriers among multiple teams, assuring quality control, managing complex scheduling and sequencing, and dealing with limited on-site space and transportation restrictions. Overcoming these issues is critical for fully utilising the benefits of precast detailing in multi-story projects.

How do you incorporate sustainability in your construction process? How can precast concrete contribute towards affordable housing in India?
Sustainability is integral to our construction process, achieved through local material sourcing, energy-efficient designs, and waste reduction. We prioritise green certifications and eco-friendly practices to minimise our ecological impact from inception to completion. In the context of India’s affordable housing initiatives like Pradhan Mantri Awas Yojana and MHADA, precast concrete holds immense potential. Its modular approach, based on factory-made components, ensures consistent quality and accelerates construction timelines. This aligns with the urgent need for rapid and cost-effective housing solutions. By minimising material wastage and labour costs, precast concrete offers an efficient way to deliver affordable housing projects on time. Its adaptability to various housing designs makes it suitable for large-scale housing ventures. As a result, precast concrete significantly contributes to India’s affordable housing goals by providing durable, affordable and quickly deployable housing units to address the housing needs of the population.

What kind of innovations do you hope to see in the future in the precast concrete shape industry?
In the realm of precast concrete shapes, we anticipate witnessing significant innovations that revolutionise the construction industry. We hope to see advancements in sustainable materials, leading to eco-friendly precast products that minimise environmental impact. Automation and robotics could streamline manufacturing processes, enhancing efficiency and precision. Integration of smart technologies might enable real-time monitoring and maintenance of precast structures, ensuring long-term durability. Additionally, developments in modular design and customisation could allow for more versatile and aesthetically pleasing architectural solutions. These innovations would not only contribute to rapid and high-quality construction in metropolitan areas but also promote sustainability and creativity in the field.

-Kanika Mathur

Concrete

Star Cement launches ‘Star Smart Building Solutions’

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Star Cement has launched ‘Star Smart Building Solutions,’ a new initiative aimed at promoting sustainable construction practices, as per a recent news report. This venture introduces a range of eco-friendly products, including tile adhesives, tile cleaners and grouts, designed to enhance durability and reduce environmental impact. The company plans to expand this portfolio with additional value-added products in the near future. By focusing on sustainable materials and innovative building solutions, Star Cement aims to contribute to environmentally responsible construction and meet the evolving needs of modern infrastructure development.

Image source:https://www.starcement.co.in/

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Concrete

Nuvoco Vistas reports record quarterly EBITDA

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Nuvoco Vistas reported its highest-ever quarterly consolidated EBITDA of Rs.556 crore in Q4 FY25, with annual EBITDA at Rs.1,391 crore. Cement sales reached 19.4 MMT in FY25, with Q4 contributing 5.7 MMT. Revenue rose 4 per cent YoY to Rs.3,042 crore in Q4. Net debt reduced by Rs.390 crore to Rs.3,640 crore. The company received NCLT approval for acquiring Vadraj Cement, targeting 31 MMTPA capacity by FY27. Key marketing initiatives, expanding RMX and MBM businesses, and a focus on sustainability (457 kg CO2/tonne) drove performance. Nuvoco remains focused on premiumisation, operational efficiency, and market expansion.

Image source:nuvoco.com

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UltraTech Cement increases capacity by 1.4Mt/yr

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UltraTech Cement has expanded its production capacity by 1.4 million tonnes per annum (Mt/yr) through a combination of debottlenecking efforts and operational efficiency upgrades across several of its plants. The enhancements include an addition of 0.6Mt/yr in grinding capacity at the Nagpur facility in Maharashtra and a combined 0.8Mt/yr at the Panipat and Jhajjar units in Haryana. With these upgrades, the company’s total domestic grey cement capacity has risen to 184.8Mt/yr, while its global capacity now stands at 190.2Mt/yr.

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