Starworth Group Focuses On Exclusive Living In The Heart Of Bangalore

 

 

Starworth is one of the fastest growing construction companies in India with 18 residential projects and more than 15 years of expertise. The project Provident Park Square in Bangalore is now the first to rely entirely on precast concrete elements as a construction system. From October 2021, the new owners will be offered architecture and luxury in a unique residential environment.

 

Starworth Infrastructure and Construction (SICL) was conceived in 2001 as an internal construction and development service provider for the Indian Puravankara Group. In the early years, the company realised some of Bangalore‘s most famous construction projects such as the Purva Riviera and Purva Venezia. In order to take on external construction contracts and act as a back-end service provider for the Puravankara Group, SICL was spun off as an independent construction company in 2009.

Having specialised and highly experienced in the traditional cast in-situ construction method for almost
20 years, with almost all construction progress taking place directly on site, Starworth faced a fundamental reorientation of the construction system in 2018. “The industrial pre-production of precast concrete elements is now the practice in all leading industrialised countries. With this construction system, which is still relatively new for India, one can achieve real quantum leaps in terms of architecture, construction quality, cost efficiency and the time factor,” explains Raj Pillai, Managing Director, SICL.

“The Provident Park Square construction project in the heart of Bangalore, initiated in 2018, was the starting signal for Starworth to rely completely on this construction technology for the first time.”  India is currently taking major steps to introduce this global standard in construction technology. The government’s ‘Housing for all by 2022’ project requires affordable housing that can be built quickly.

 

 

Provident Park Square As Lighthouse Construction
Project In India

“Provident Park Square is an exclusive residential project located in the prime area of Judicial Layout on Kanakapura Road in Bangalore,” says Pillai. “Park Square extends over 20 hectares, has excellent transportation links and consists of several residential building complexes with apartments from 517 sq. ft. to 1,300 sq. ft., and luxurious in-home features. It is the ideal choice for families and singles that are looking for a high quality of living and at the same time a luxurious living experience.” A luxury clubhouse, a shopping mall, cafés, children’s playgrounds as well as attractive sports facilities such as tennis, cricket and futsal courts and many green parking areas make Park Square truly exemplary for a new urban architecture in India. This stems from Starworth’s vision to offer modern, high quality living space in an exclusive ambience to the Indian families of today. Already today, almost 2 years before the completion of the building, all apartments are completely sold.

 

 

“From the beginning, it was clear that Park Square could not be realised with traditional building methods. We wanted to make the construction periods transparent and plannable and thus, realize the project in 2-3 years,” says Pillai. Thanks to industrialised processes, the precast construction technology not only allows construction defects to be minimised but also construction costs to be significantly reduced. More importantly, the duration of construction is considerably shortened.

“To get an idea for the building speed: One floor has
8 apartments and consists of 210 to 220 individual components. With a production and crane capacity of 150 to 200 walls and floor slabs per day, floor cycle times of 3 to 5 days can be achieved - with conventional construction methods, 10 to 15 days are required,” describes Christoph Müller-Bernhardt, Executive Sales Director India, Vollert.

In addition, the architecture of Provident Park Square was also supposed to be extraordinary and special. “We are working with the Building Information Modelling (BIM) planning method to achieve this,” describes Pillai. The 16+ residential building complexes in Provident Park Square will initially be created virtually in 3D. All important data of the walls and slabs to be produced will then flow directly into the production engineering processes as well as into the preliminary planning of the construction site processes. The BIM construction details are also accessible at all times on a digital data platform for architects, structural engineers or electrical engineers.

 

 

Solid Concrete Elements and Special Precast Parts
such as Columns and Stairs are Produced Directly Adjacent
to the Construction Site for the Provident Square Park Construction Project.

 

 

Vollert’s ‘On-Site’ CSP Concept Convinced

Several factors are significant during a project - the return-on-invest should be achieved in a relatively short time;  the proximity to the construction site is very important in the preliminary planning phase, to keep the transport distances for the construction project short and minimize delays due to the factors such as weather, among others; the plant layout should be expandable for higher capacities and an option should be available to relocate the complete plant technology to another city for the next residential project after project completion.

With the German concrete plant specialist Vollert, an experienced technology partner was chosen after intensive discussions. “The chemistry was right from the start,” says Müller-Bernhardt. “Highly professional and extremely motivated, we planned the plant concept with an annual capacity of
300,000 m2 of solid concrete elements and special parts such as columns and stairs, in close dialogue with Starworth. Various production technology concepts such as a purely stationary tilting table production or battery moulds were discussed, and the advantages and disadvantages weighed up. Technology ‘made in Germany’ is definitely no longer a vision of the future for India,” explains Daniel Borchardt, the responsible Project Manager at Vollert. Here, plant suppliers offer novel concepts, in which state-of-the-art machine solutions can be combined with different degrees of automation. “At Starworth, we decided on the Central Shifter Plant (CSP) concept from Vollert,” continues Borchardt.

A VArio SHIFT central shifter platform is the heart of the system and makes the plant processes as flexible as possible. It combines the advantages of the circulation principle with those of a stationary production line. Individual work processes such as time-consuming reinforcement operations, concreting or curing times of varying lengths are carried out independently of each other. Even differently reinforced and complex precast concrete parts can be produced in parallel. The central shifter platform transports the shuttering pallet over a travel length of 110 m along the longitudinal side to the circulation position where it is needed at any given time. Cross-lifting trucks then move it to 8 transfer positions, either crosswise to the left or right to the respective processing station. This means that there are no downtimes or waiting times, and everything runs completely independently of the cycle time. There are also several buffer places for the intermediate storage of semi-finished walls or floor slabs.

 

 

1st Expansion Stage

In the first expansion stage, Starworth is relying on a semi-automated concept. The 22 shuttering pallets, produced at Vollert India in Sikandrabad, are in 2-shift operation in permanent circulation between the 32 cleaning, reinforcement, concreting, curing and buffer stations. Up to 500 m2 wall and slab elements can be produced per shift. Up to 200 mm thick solid concrete elements as well as architecturally special facade elements are produced in parallel. After manual positioning of the shuttering profiles, the reinforcement grids and built-in parts, the concrete required is precisely applied by means of a crane-guided and electrically operated concrete dosing bucket.

A Smart Compact vibrating station compacts the concrete at low frequency via 10 synchronized external vibrators. After the curing process on an intermediate buffer station, the central shifter platform moves the finished wall or slab element to the final loading position. Vertical lifting of the solid concrete elements is carried out by a VArio TILT high-performance tilting station. This takes place up to a maximum tipping angle of 80°. A hydraulically movable support beam travels against the precast concrete element and thus, prevents slippage during the tipping operation. Loading takes place directly into transport racks.

 

1st Expansion Stage

In the first expansion stage, Starworth is relying on a semi-automated concept. The 22 shuttering pallets, produced at Vollert India in Sikandrabad, are in 2-shift operation in permanent circulation between the 32 cleaning, reinforcement, concreting, curing and buffer stations. Up to 500 m2 wall and slab elements can be produced per shift. Up to 200 mm thick solid concrete elements as well as architecturally special facade elements are produced in parallel. After manual positioning of the shuttering profiles, the reinforcement grids and built-in parts, the concrete required is precisely applied by means of a crane-guided and electrically operated concrete dosing bucket.

A Smart Compact vibrating station compacts the concrete at low frequency via 10 synchronized external vibrators. After the curing process on an intermediate buffer station, the central shifter platform moves the finished wall or slab element to the final loading position. Vertical lifting of the solid concrete elements is carried out by a VArio TILT high-performance tilting station. This takes place up to a maximum tipping angle of 80°. A hydraulically movable support beam travels against the precast concrete element and thus, prevents slippage during the tipping operation. Loading takes place directly into transport racks.

 

 

“Already today, 6 months after the commissioning phase, and the first walls and slabs produced, the construction progress for the Provident Park Square is above the planned figures,” sums up Pillai. “The new construction system has convinced us. With Vollert as our know-how and technology partner, we have developed a sustainable and future-proof construction system. This means that the costs are 15 to 20% lower than conventional construction methods, even if the initial investment costs appear high. We get dimensionally stable slabs and walls, and have shorter construction times,” says Pillai. “In addition, the CO2 footprint is reduced by 25% and water consumption by 50%. The residential buildings have excellent thermal performance, are weather and fire resistant, and earthquake-proof.”