As one of the fastest-growing economies in the world, India is undergoing development and redevelopment across sectors, a significant one being construction. Within this industry, the precast concrete market is expanding rapidly as a quicker and more innovative technology for replacing the widely used cast-in-situ method which poses challenges of on-time completion and high requirement for skilled manpower.
The adoption of precast technology is broader in Tier-II & III cities, and with the Make in India movement picking pace, precast adoption is set to increase in Tier-I cities as well. However, some issues including design and engineering complexities, improper communication, quality concerns, scheduling incapacity, and challenges related to space and transportation can cause consumers to not choose precast solutions.
Balaji Pipes, Odisha’s leading manufacturers of ISI marked R.C.C pipes, SFRC manhole covers and frames, and other precast products, established in 1983, addresses each of these challenges through strategic methods including utilization of advanced technologies, establishing clear lines of communication, implementing quality control techniques, innovative transportation techniques, and effective scheduling practices.
Certified Range of Products
Balaji has served as the primary supplier of major sewage projects in Odisha since 2003 because of the quality of its products and certifications which prove its adherence and commitment to industry best practices and standards.
“Our mission is to improve cost efficiency and hence productivity by keeping pace with the latest technological advances in the field of MSME sector. Our vision is to provide quality and affordable concrete products to our customers and adhere to delivery schedule stipulations. To ensure this, we have BIS certification for almost all classes and sizes of S&S joint R.C.C pipes (from 100mm to 1800mm dia) for both spun cast and vertical casting pipes”, shares Sampath Kumar Pinniti, Managing Partner.
Sasmita Mahapatra, Partner
For manufacturing the best quality products, the firm emphasizes selecting high-quality raw materials, gaining a strong foundation. In addition to being very particular about the raw material used, the firm also pays critical attention to the mix design of the concrete, ensuring that the mix composition is monitored, carefully designed, and strictly followed.
Furthermore, several quality checks implemented at various stages of the designing and manufacturing process help in identifying gaps early on. From concrete mix design to reinforcement placement, there are a number of checks, including a series of tests which finished products are subjected to as per Indian standards, to make sure the products are not defective.
“Our quality control engineers ensure that there are checkpoints at every stage of the manufacturing process including water curing which plays a vital role in the acquisition of strength of the precast products. We also offer pre-delivery inspections to our stakeholders on a regular basis. Each lot of material is inspected and tested in their presence before dispatch”, further shares Sampath.
Specialized Processes & Technology Implementation
Through the implementation of advanced technology and software, the firm overcomes forecast detailing challenges, by creating 3D models of the precast components. This helps in resolving design and engineering issues before manufacturing is started ensuring that resources and time are not wasted. This helps the firm deliver customized products which in turn has provided it a first-mover advantage and enabled it to meet deadlines much faster without compromising on quality, making it a dependable partner in the industry.
Additionally, the use of vibrated casting technology with batch-mixed concrete has enhanced Balaji’s capability of production, minimized its dependence on manual labor, and diminished raw material wastage thereby lowering the cost of production. The firm’s focus on technology integration has further enabled it to improve stakeholder communication and engagement by providing a central platform for information sharing and accessibility.
Balaji has served as the primary supplier of major sewage projects in odisha since 2003 because of the quality of its products & certifications
Beyond technology integration, the company has also incorporated a range of specialized processes for manufacturing which allow it to ensure that the manufactured products are free of abrasions and corrosion.
“We have followed methods like lowering the water-cement ratio of the concrete and increasing the concrete cover over the steel reinforcing bars. In some cases, we have reduced concrete permeability by using admixtures and corrosion inhibitors. In cases where our products have been used in coastal areas where the chances of abrasion and corrosion are very high, we have manufactured pipes with high-density polyethylene lining and have used sulfate-resistant cement for the manufacture of pipes. In specific cases, we have followed a multi-protection strategy like simultaneous use of epoxy-coated reinforcing steel and corrosion inhibitor”, further shares Sampath.
Journey & Future
With a legacy of over three decades of innovation, adherence to industry best practices, and continuous evolution that drives excellence and trust, Balaji Pipes has grown to become an industry stalwart, especially in the Odisha region. The company’s journey can be defined as one of growth across multiple verticals.
Over the past five years, the firm has grown at an exponential rate, with its turnover tripling. This has been made possible by the firm’s strategic move of striking just the right balance between sales volume and decent profit margins. Despite having its presence only in Odisha so far, the firm has also capably fulfilled some major orders in its neighboring states including Bihar, Chhattisgarh, and Andhra Pradesh among others.
In addition to these activities, Balaji Pipes has been associated with a lot of significant projects and has extensive experience in dealing with demanding contractors and project management consultants which has provided great insight and expertise into navigating industrial and administrative complexities in the business.
“Over the past 30 years, we have learned the art of delivering cost-effective and quality-driven products within the stipulated time frame. In the case of precast products you need to be flexible with regards to customization and a one-size-fits-all approach does not really work. You have to provide customized solutions to the customer keeping the project's economics in mind and not push or miss-sell your available products. So, it is only a customer-centric approach that will serve you in the long run. There are laborers in our workforce who have been working with us for the past 30 years and we have found a way to fit them into our scheme of things. So, a key learning has been to understand that your workforce is your primary asset and not technology”, lastly adds Sampath.
As the company plans its future endeavors, it is currently focused on greater technology integration and adoption of processes rather than just concentrating on turnover sales and volume. The firm is also targeting markets in certain parts of eastern India through the manufacture and sale of customized small module precast products. Recognizing the tremendous scope that the prefabrication industry promises in India, the firm aspires to become a frontrunner in its adoption. Moreover, the firm aims to not limit itself to specific types of precast products like pipes, manhole chambers, box culverts, or others. A substantial effort for the firm will be aimed at completing projects successfully and on time which will boost its reputation further, and allow profits to flow through seamlessly.
With a forward-thinking approach and a multifaceted plan for strategic expansion, Balaji Pipes is on the verge of becoming the most prominent name in the precast concrete industry across the nation in no time.
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