Elematic For Precast Technology
Sales Head - India
Elematic India Pvt. Ltd.
Shridhar Rao, Sales Head - India, Elematic India Pvt. Ltd., in conversation with Civil Engineering and Construction Review:
Civil Engineering and Construction Review: In terms of management, how long does it take to produce a piece of precast plant?
Shridhar Rao: You asked a very good question; I will explain you the detailed process involved and how expertise plays vital role.
Management vision of long-term goals to be achieved using the Precast business is very important. Once the idea of establishing a precast concrete plant has emerged, starting a pre-study is the natural next step. The earlier experts are involved in the process, the better.
For this reason, Elematic offers Engineering services and has an internal Structural design team to help customers in their journey of implementing Precast in their projects.
Our experts, based on their extensive experience in designing precast production plants and the end use of the products, know what is crucial when pre-planning the plant and machinery. They can ask the right questions and find the most suitable solutions in the given conditions.
When Elematic team is involved in the process from the start, we can make sure that the solution really responds to the specific.
Construction companies, for example, often have a clear idea of what they need. They may plan to acquire an operating precast production plant or want to set on a new plant to expand operations from cast-in-situ to precast element manufacturing.
Some are looking for new business opportunities. They have recognized the potential in precast production and want to invest in it; they are getting into the concrete business and need more guidance. This is where our experts can provide their knowledge.
No matter what the need, Elematic’s experts make sure that everyone receives a tailored, relevant, and feasible solution.
You should also consider products, volume, and capacity but first you need to define what types of product – precast wall elements, floors, piles, or Acotec partition walls, for example – you will be manufacturing.
Will the focus be on one specific product or will the plant provide a wider selection? These factors will affect the optimal factory layout, machinery, and floor area needed.
Another essential factor in pre-planning is the plant’s capacity. It defines the machinery, storage and logistics needed.
For companies starting with the business, it is wise to think about possible needs for capacity expansion later. This enables future plans to be included in the factory layout from the very beginning.
CE&CR: What all must one think through when designing precast concrete buildings?
Shridhar Rao: Precast concrete is widely regarded as an economic, durable, structurally sound and architecturally versatile form of construction. Precast is still often misunderstood to be another variant of cast-in-situ construction, which leaves many of the benefits of precast technology under-leveraged.
To achieve the best results, a design should always use the specific demands of the intended structure as its starting point. This is one of the fundamental design principles of precast technology.
Elematic has an Engineering centre manned by Structural and BIM Experts in the field of designing precast buildings and can work with the client team in reaching the optimal solution.
Modern precast concrete buildings can be designed safely and economically, with a variety of layouts and with considerable variation in the treatment of elevations.
CE&CR: Why is precast concrete considered the most versatile and dynamic product, which has revamped the Indian construction industry?
Shridhar Rao: Good organization of the project team, and design routines are very important in precast concrete.
It is recommended that all information about the design, building information model (BIM) and production is made available to the client, architect, consulting engineer, service engineers and all other disciplines to give unified guidance to the entire team.
The best design for a precast structure is one that is conceived as a precast structure from the very start. It should not merely be adapted from a traditional cast-in-situ design.
The specific design philosophy of precast structures involves large spans, structural integrity and specific stabilizing systems. It also includes standardized solutions such as modular design, standardized products and internal standards for details and work procedures. Details that are too elaborate or vulnerable should be avoided.
We must not forget precast concrete production is an industrialized process. This is an advantage that affects every stage of the design and construction, enabling quick long-line production, the use of standardized components, the calculated positioning of details and uncomplicated documentation. The focus must be on careful design and planning, and information needs to be distributed well in advance.
CE&CR: How is Elematic India providing better machinery maintenance when it comes to precast concrete production?
Shridhar Rao: Elematic production lines are designed to generate the lowest possible operational costs and the best end products. All machinery in the production line meets the strict requirements of the EC Machinery Directive.
We have a team of 30 + after sales and Projects team who not only help establish Precast plant but also help run the production line, train the client team and help optimize end to end process of Precast production.
We also offer AMC and Service agreements that help run the plant 24x7 and help client team to run the factory without any breakdowns, plan spare parts and preventive maintenance so that production runs as desired.
CE&CR: The practice of precast concrete application is booming now. How important is Elematic India’s role in this boom?
Shridhar Rao: For Elematic India is one of the key potential markets and our investments in setting up a large support base out of India is proof of that.
Elematic’s ISO 9001:2015 certified fabrication plant at Alwar, Rajasthan, improves cost-efficiency of these heavy-duty products and significantly reduces their delivery time. In India, Elematic is the only turnkey solutions provider present in the country for over 10 years and has set up 33 precast installations, till date. This by the way represents more than 50% market share.
With a 100 people team in India, Elematic is truly a technology partner that can come on board, impart the knowledge and right practices in setting up Precast business, help client achieve their long-term vision of a successful Precast business
CE&CR: What is the role that computer-aided design BIM software plays in construction of precast concrete projects?
Shridhar Rao: Elematic has adopted BIM in a big way and help clients through its Engineering Design centre to visualise building engineering models in creating constructible model where correct and accurate quantity calculations information is crucial.
A software solution such as BIM allows customization according to the company-specific needs plus standardizing your workflow makes productivity gains achievable throughout the design build process, resulting in successful delivery at a record speed. Information on every single precast product is included in BIM, which makes it easy to monitor production and deliveries in the factory and on site.
The model must be accurate so that every detail of the concrete element, reinforcements, connection components, MEP as well as material and process information, can be included.
CE&CR: Are there any upcoming additions and/or new offerings envisioned for the sector?
Shridhar Rao: Recently we have launched the all-new Elematic Extruder E9 - the best-in-the-industry extruders, the machine sets a new benchmark for high-speed casting in hollow-core slab production with low production costs. Equipped with an advanced touch screen user interface, added intelligence and a smart concrete recycling option, the new Extruder will also offer a new kind of modern user experience and significant material savings.
The new fully automated Elematic EDGE wall line optimizes the whole precast wall production from building design all the way to the construction site. The line features advanced software, modern table circulation and state-of-the art production machinery, and its automated functions cover planning, monitoring and controlling the production process.
This year we introduced the Wall MES system, which is a part of Elematic’s new, advanced Plant Control solution for precast production. The Wall MES part of Plant Control will cover automatic production planning, work follow-up and quality control of precast wall production. The system can also take panel design information in directly from BIM systems such as Tekla Structures.
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