Rais Khan, CEO, Dynamic Precast, talks about catering to the changing demands of designers and architects with innovative solutions in precast shapes to take India’s construction industry onto the next level.
Tell us about the process of casting concrete in shapes.
In precast, with the help of mould, concrete and steel skeleton, any shape can be cast as required. It may be a designer flower pot, fountain, pole, pillars, drain, covers, garden benches, paving tiles, column, beam, roof, boundary wall or even a complete house. For precasting, the mould could be of cement, wood, Fibre Reinforced Plastics (FRP), aluminium and mild steel.
Concrete mix is prepared in a mixer and then poured in mould, and it vibrates on a vibrating table or by surface and needle vibrator. Demoulding process is done after some time or after complete setting in 24 hours.
Are concrete shapes made with a variety of concrete grades?
Yes. It depends on the product’s quality. As per standard of BIS precast products, cast in different concrete grades from M-10 to M-50 grade.
What are the standard sizes and shapes of precast made by your organisation?
We make paver blocks and chequered tiles as well as cable covers, which are smaller products. Other products are kerbstone, dividers SFRC frame cover, gratings of different sizes, drain with covers of any size, precast and prestressed wall panel with columns, hollow core slabs in heavy and light duty in imported semi-automatic plant, precast toilets, house, prestressed electric poles and spun pipes with septic tank, etc.
Explain the moulds used to make these shapes. Do you customise moulds if the requirement arises?
Always! As our products are for roads, infrastructure and housing, customers have different choices for size, shapes and shades. For that we customise the size and shape of moulds as per choice and selection of the customer. All designers and architects want innovation in their projects. We create as per their requirement.
What are the quality standards followed while making precast shapes?
We have a Quality Manual Plan in our system. Presently, a testing laboratory is active in our manufacturing premise. Regular tests for raw materials and concrete and quality checks are done here using tools, equipment and calibrated testing machines.
Quality checks in our factory starts from system update, raw materials, measurements and weighing process, compaction and ultimately in finished goods. The required curing process used for these products is standard. Channels and sections are not compromised with quality aspects. Quality fabrication is an important part, where we follow the standards.
How does automation and technology contribute towards this process and does that make it less labour intensive?
Automation and technology are very important for the precast industry. Today, there are labour crises in each industry, but in the precast industry, it is too much because of its heavy elements and mostly working in open areas.
While we have a lot of shaded areas in our production premises and many mobile and lifting equipment, it’s necessary to make the system more and more automated.
What are the major challenges you face in the process of making precast shapes and in their transportation?
Major challenges in this industry that we face are in making proper mould to make good quality products or elements as per required by the customer. Secondly, availability of proper raw materials and procurement of subsidiary materials are useful for quality. No doubt packing and transportation of finished products are tough jobs in the precast industry.
How do precast shapes help in the profitability of a construction activity?
In the construction industry, precast elements and products have a big contribution in speedy completion of projects. Projects get finished before time because of precast and prestressed elements. Columns, beams and slabs have a bigger role to play in fast construction and economic growth. In India, acceptability for precast housing is quite slow, but only this industry can fulfil the requirement of infrastructure and housing sector in the country.
What kind of innovations can be seen in the near future in your industry?
The market is moving towards a precast, prestressing system. Systems and equipment are becoming available in the market. High grade concrete and PC wire will change the scenario of this industry. We are preparing for mass housing elements for the middle and low class on a priority basis, especially in towns and rural sectors.
-Kanika Mathur
