B. G. Shirke Construction Technology Private Limited (BGSCTPL)
R.B. Suryavanshi, Sr. Chief Executive
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B. G. Shirke Construction Technology Private Limited (BGSCTPL), formerly known as B. G. Shirke & Company, was established in 1944 by its Founder Chairman, Mr. B. G. Shirke. BGSCTPL is a multi-disciplinary civil, mechanical and electrical engineering consortium with seven international technology tie-ups and over 12000 employees, is a vibrant, dynamic and integral part of modern India, significantly contributing to industrial, economic and social progress. BGSCTPL also plays an active role in protecting and preserving the country’s eco-systems – its forests and waterways-and its production of food grains and seeds.
Shirke also pioneered and patented the ‘3-S’ system in India – a system using pre-cast structural components, such as dense concrete hollow core columns, dense concrete partially pre-cast beams, lintels, staircases, etc., and Siporex slabs, to achieve |
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strength, safety and speed.
The Company has so far executed more than 2,00,000 dwelling units using ‘3 S’ system, both in India and Overseas, in all types of climatic conditions and heavy rainfall areas. At present, it executes very large housing, industrial and commercial projects in India on Turnkey Lump sum Basis by the use of proven prefab products and/or also by the conventional methods and materials. It also undertakes projects on turnkey lump sum Basis including Planning, Designing and Execution. ‘3 S’ system of building construction has been used successfully for high-rise residential buildings up to 25 storeys.
Of late, to move with times, BGSCTPL has diversified in infrastructure developments and completed two road projects on NH-4 between Pune-Satara-Kolhapur, part of a “Golden Quadrilateral” and one road project at Panvel. BGSCTPL has developed expertise in construction of Highways, Bridges and Marine Structures as well.
BGSCTPL is-IMS registered organization, which covers ISO 9001:2008, ISO 14001: 2004 and OHSAS 18001:2007 for Quality, Environment, Health and Safety. The organisation has won many accolades and awards and also has been recognised for its service in Government sector projects.
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Built Expressions, in an exclusive one to one interview with Mr. R.B.Suryavanshi, Sr. Chief Executive, BGSCTPL, talks at length about their involvement in building construction using Precast Technology. Suryavanshi, with vast civil engineering knowledge at his command explained the knowhow. Excerpts of the interview as below;
Built Expressions also visited Shirke project site at Kengeri, Bangalore, to know as to how the technology gets implemented in actual execution. Mr. Jagadish Halyal, Dy. General Manager ( QAQC), gave an insight into the whole fabrication and construction process including the meticulous planning that is |
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required while erecting the precast elements.
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BE: With many years of experience in the precast industry, your organisation today is one of the leaders in Precast Industry. Brief us about the changing technological trend witnessed in the precast industry?
S: This is quite true. Our Founder Chairman, Padma Shri BG Shirke, was fully convinced that the conventional outdated methods and materials, apart from being costly and scarce, have totally outlived their technical and commercial usefulness inasmuch as they have no capacity to touch even the fringe of the demand and supply situation. Realizing this about 60 years back, he decided to completely transform civil engineering into its total industrialization by innovating, developing and introducing new products, having scientific objective quality controls and capable of being modularly planned for economy and standardized, which can cope up with future challenges for solving India’s acute and nagging problem of housing shortage and slum proliferation. With this objective in view, B.G. Shirke Construction Technology Pvt. Ltd. has done a yeomen’s service in the context of implementing “Prefab building Technology” for mass housing by promoting the concept of “Total Industrialization of Civil Engineering”. Our ‘3-S’ Prefab system has been extensively used in various mass housing schemes of Government/Semi-Government Corporations involved in providing mass housing and proved to be very efficient in all types climatic, rainfall and seismic conditions for the past four decades. Having acute shortage of houses throughout the country and the most imperative need to fulfil the same in a short span, the only sure solution is to adopt extensively tried, tested and proven proved prefab technology for fast track and quality construction. Our prefab technology has been widely accepted by many Government and Semi-Government Organizations.
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BE: Can you briefly explain your expertise in designing and detailing of precast building structures?
S: We have our own in-house expertise required to complete the project in all respects right from the planning stage to the handing over. Our team of engineers are having vast experience in designing the precast structures. Connections are done with in-situ Self-Compacting Concrete (SCC) of appropriate grade. Moment resisting connections through reinforcing bars anchored into the in-situ SCC of adjoining member and not merely with the shear connectors. Framed Structure is having structural integrity and not like a tower built from a pack of stiff cards. The structure and various elements are designed for the forces and moments resulted under the effect of intended design loads. In the structural design, dead, imposed and wind loads and forces, such as those caused by earthquake, and effects due to shrinkage, creep, temperature, handling, lifting, erection, etc, are accounted for, as per the relevant Indian Standards. Details of connections of ‘3-S’ elements – Perfection through continuous R&D; Connections through in-situ Self-compacting concrete - Ensuring monolithic continuous resilient durable behaviour of the structure. All connections designed for appropriate loads / moments- Under the effects of Dead, Live, Wind, Seismic loads. Joint detailing through Secured embedded reinforcement of appropriate diameter and length. Design has been tested and evaluated by IIT, Mumbai, CBRI, Roorkee etc.
BE: Which are the signature projects in India and abroad that you are currently involved with?
S: Few of our ‘3-S’prefab projects under execution are:
- Client : MHADA ( Maharashtra) S+24 Storey buildings at Mazgaon, Kurla, Worli, Lower Parel, Sewari, Prabhadevi, Kandiwali, Goregaon, Byculla, Dindoshi, Versova, Malavani and Sion with 52,98,760 SFT, Design and Build Turnkey Contract.
- Client: CIDCO – S+7 to S+14 buildings at Ulwe and Kharghar.
- Client : BDA, Valagerahalli, Kengeri, Karnataka, S+7 storey buildings with 6, 23,347 SFT, Design and Build Turnkey Contract.
- Client : BDA, Doddabanahalli, Karnataka, S+16 storey buildings with 7,11,000 SFT, Design and Build Turnkey Contract.
- Client : DDA (DELHI) - ROHINI, NARELA & DWARKA with 64,92,888 SFT, Design and Build Turnkey Contract.
- Client : UDA (Sri Lanka) - Colombo 6,09,000 SFT, Design and Build Turnkey Contract.
We have also constructed many projects with our tried, tested and proven prefab 3-S technology in gulf countries, like Dubai, Iraq and Saudi Arabia.
Q: With reference to India, what standard practice you adopt?
S: Manufactured precast components are erected, aligned and connected using Self-Compacting Concrete of appropriate grade along with embedded reinforcement. We adopt SUSTAINABLE & GREEN TECHNOLOGY due to Judicious use of construction materials, reduction in wastage of materials, using more durable materials, use of energy efficient building materials, use of products that contribute to a safe, healthy built environment, use of construction system minimizing air, water and noise pollution during construction, use of fly-ash, M-Sand and GGBS, very minimal requirement of water for construction, non-generation of construction debris, elimination of use of timber/ wooden scaffolding, Judicious use of scare natural resources, use of eco-friendly AAC products for walling, flooring and roofing.
BE: Please tell us about the various services your organisation can offer?
S: B.G.Shirke Construction Technology Pvt. Ltd. is a multi-disciplinary civil, mechanical and electrical engineering company, serving India since 1944 having dedicated team of about 11,000+ workforce, out of which there are more than 600 highly qualified and experienced engineers. We have pioneered and patented ‘3-S’ prefab building system way back in 1972. We are manufacturers of state of art building materials including Polynorm pressed metal door/window frames and shutters. We execute all types of building and infrastructure development projects, including planning, designing and construction along with all other allied services on turnkey basis. We are diversified into Power and Telecom sector – Transmission Lines & Microwave Towers, Oil & Gas, Post Harvesting System – Grain Storage Silos and Material Handling, Hospitality and Recreation etc.
BE: What are the various components involved in the construction of a precast building?
A: ‘3-S’ is the brand name of Prefab Building Construction System fully developed and perfected by B.G. Shirke Construction Technology Pvt. Ltd. after years of strenuous R & D supplemented by extensive field trials. Structural components, like Slabs, Columns, Beams, Staircases, Lintels, Chajjas etc, are precast in casting yard, having factory like condition. ‘3-S’ PREFAB components are erected, aligned and connected; using SCC i.e. Self-Compacting Concrete of appropriate grade along with secured embedded reinforcement. The slabs are made of “Siporex”, which is a light weight autoclaved cellular concrete and is being used for structural as well as non-structural applications.
BE: What kind of turnkey solutions do you provide?
S: We undertake mass housing projects on turnkey lump-sum basis as per client’s requirements and specifications. We prepare the architectural plan, layout, structural designs, electrical, plumbing, vertical transport system, fire fighting, internal roads, storm water drains, water supply etc. The whole thing is done in-house.
BE: How sustainable precast concrete elements are? And how do they contribute to support the green movement?
S: Construction Sector as a whole is a major contributor to the formation of ‘Green House Gases’ in the atmosphere i.e. ‘Global Warming’. ‘3-S’ Prefab Building System is an eco-friendly technology, which effectively addresses this burning issue and reduces Global Warming. It reduces air pollution at construction sites because the site activities are minimal. Use of fully “Cured” and “Matured” components considerably reduces water consumption. High thermal insulation results in achieving energy efficiency. The requirement of raw materials as well as energy in manufacturing is considerably reduced. Production utilizes fly-ash and GGBS to a great extent. Manufacturing process is non-toxic and environmental friendly, which does not give off any harmful emissions during production. No waste is generated in the production process. Use of wood for shuttering and doors/windows is eliminated. Pressed metal frames and shutters are used. Use of good soil is avoided due to Siporex walling material.
BE: What are the factors to be considered when deciding to implement precast concrete construction?
S: The various factors, such as Energy efficiency, improved internal building environment, durability, low maintenance, use of local labour and raw materials, acoustic performance, fire resistance etc, are considered in our precast construction.
BE: India is facing in general acute construction labour shortage. How is this problem addressed by precast technology?
S: Most of the precast components are manufactured at site in a factory like condition. Columns, beams, stairs, lintels and chajjas are cast horizontally by the use of Ready Mix Concrete. Minimal labour is required for moulding, de-moulding and placing concrete. The reinforcement cage making is done using bar bending machines. Shifting and erection of precast components is done using mobile and tower cranes. A few trained erectors are required to complete any volume of work. The “Siporex” slabs and blocks are made of AAC (Autoclaved Aerated Lightweight Concrete), which help in speed of construction. The construction time for completing the project is considerably reduced due to prefab construction and hence more number of houses can be built in a given time.
BE: What are the advantages of your ‘3-S’ prefab technology?
S: ‘3-S’ means Strength, Speed and Safety. All structural units have scientific objective quality norms and are manufactured in factory under rigid quality controls. This results in uniform assured quality. The construction materials and methods are in line with requirements of ‘GREEN BUILDING” conserving natural resources. Use of timber is completely eliminated for shuttering & scaffolding works. Use of scare commodities, like water and river sand, is reduced substantially. Fly-ash and GGBS is used to the maximum possible extent. The technology helps in achieving ecological balance. Due to use of prefab components, construction time is reduced substantially, resulting into early completion, accrual of client investment and saving in escalation. 3-S prefab buildings require very minimal maintenance owing to scientific objective quality construction. Mechanized and standardized prefab products assure perfect and accurate shape / size of entire structure, uniform cover, dense concrete, correct placement of reinforcement, high strength etc. Prefab construction activity results in much lesser pollution with respect to air, noise and water at construction sites. It is extensively tried, tested and proven to perform in various climatic conditions, seismic zones and rainfall areas. We can build any number of stories. It is suitable for Residential / Commercial Buildings. Any type of layout and plans of buildings can be achieved like EWS / LIG / MIG / HIG housing. Any type of alterations / additions in future can be made. Any aesthetic elevation and type of surface finish can be achieved. Concealed services (Plumbing /Electrical/ Sanitary) are possible. It is Energy efficient GREEN BUILDING Construction. It is a better Substitute for conventional system. The buildings are safe & durable.
About Author: Shri R.B.Suryavanshi, working with B.G.Shirke Construction Technology Pvt.Ltd., Pune, as Sr. Chief Executive, since last 50 years.
R.B.Suryavanshi