India’s evolving and advancing infrastructure ecosystems is paving the way for innumerable developments within the civil engineering applications of the construction sector. Irrespective of whether it is urban/rural or metro development, steel, cement, road, power, irrigation, communication, oil & gas storage as well as underground facilities, railways, health, or even the IT sector, the demand for the formwork solutions, innovative scaffolding & its manufacturing is growing exponentially. The rising investments matching with the pace of infrastructure development and the governmental incentives to enhance & upgrade the existing facilities are the significant factors propelling the growth of this expanding sector.
Nevertheless, the industry faces numerous challenges in finding reliable agencies and skilled manpower who can offer high-quality and cost-effective solutions to expedite construction activities for high-rise structures including silos, chimneys, enzyme towers, bridge piers, adit (access tunnels), ventilation shafts, underground water conducting systems/powerhouses, space for underground parking of defence/strategic equipment, nuclear warfare development & safety measures, dams including its spillways, formworks for CFRD’s ( Concrete faced rock filled dams), etc. It was necessary to address these challenges of the industry which was retarding its growth in the country.
In the past, most organizations like HCC, Afcons Infrastructure, Patel Engineering, Gammon India, NCC, Jaiprakash Associates, etc. had their in-house manufacturing units like ACROWS for shuttering & scaffolding, etc. Others had to rely upon costly imports in the absence of appropriate indigenous facilities. NHPC had to import continuous hydraulic tunnel form works for their 3.81 m dia tunnel of Loktak H. E. Project Manipur in 1980 from ICOMA, Italy. Similarly, tunnel forms were imported for Chamera H E Project from EQUIFAB Canada and later from CIFA Italy. Looking at the opportunity available to reduce the costly imports and to help the country to save foreign exchange, Mumbai-based entrepreneur formed a company “CONSTRO SYSTEMS & ENGINEERS PVT LTD” about three decades ago to fulfill the demand of the market. The hurdles for many small and medium-sized contractors engaged in the construction business needed to be removed. Fortunately, the Konkan Railway Project also came on the anvil in 1992 and therefore a large market was available for the company for the sale of such facilities in Maharashtra per-se. There after MSRDC commenced many projects in the state paving the way for the company to grow faster.
Today CONSTRO SYSTEMS & ENGINEERS take pride as a trusted solution & services provider in a pro-active manner to the global construction industry. The outstanding problems of the industry have been largely addressed & many hurdles removed; people shouldn’t look for import of these items anymore.
Inception Saga
Established as a small-scale industry to manufacture, supply & operate Slip Forms in 1987, Constro Systems & Engineers is a leading manufacturer and service provider to all the sectors engaged in the field of infra structure development as described in the preamble.
The company delivers slip-form construction services that include RCC Bridge Piers, Silos of cement plants, RCC Chimneys of any height, RCC Shafts, Lighthouse construction, Jack well construction, and similar structures in the construction sector. The company has been supplying a wide range of shuttering for rail, road & hydro tunnels from 2 to 19 m dia. for more than 30 years. Initially, the company supplied such services for the major bridges & tunnels of the prestigious 760 km long Konkan Railway Project about 30 years ago. Thereafter company manufactured & supplied a wide range of pier shuttering for other Railway, MSRDC, Metro & Hydro Projects.The shuttering for circular, rectangular, or even tapering piers, dis-piers with staircase, and supporting arrangements were designed, manufactured & supplied to withstand pouring heights of 6, 9, or even 12 meters with high-quality of workmanship.
The slip-form technique is an economical & rapid construction method. The company has an experienced team of Slipform in Mumbai who assist the client in the field construction work anywhere in the country or even in neighbouring countries like Bhutan, Nepal, Bangladesh, UAE, South Africa, etc. We are in possession of competent teams to provide complete & innovative solutions for planning & design, matching the construction sche-dules/programming of the clients. Time-bound manufacturing, supply, and execution at the site are necessary to make any project successful.
We also undertake the civil works at the site wherein the client has to provide basic facilities of boarding, lodging, water & power, access, etc. The ultimate slip form technology is breaking the ground efficiently and we are equipped to serve & meet customer needs with better service each day says Suresh Satri Managing Director of Constro System & Engineers Mumbai.
Founding upon a team of experienced & qualified design engineers, equipped with all requisite technical facilities, resources, and skilled manpower, Constro Systems and Engineers have a proven record of navigating through many projects of complex nature globally by nurturing it with cost & time-effective technical solutions. The company is in possession of about two lac sq. ft manufacturing unit at Wada (Palghar), a 30,000 sq. ft factory at Shilphata (Thane), and a 15,000 sq. ft machining unit at Rabale (Navi Mumbai). All the factories are divided into multiple sheds, equipped with modern & advanced machines to ensure quality production and following proper specifications.
With a track record of successfully delivering cutting-edge solutions that align with the needs of the construction project across borders, Constro Systems has carved a distinctive reputation for itself in this niche market
Moreover, the company has earned the reputation and trust of clients for using the best & tested materials during fabrication & manufacturing of the formworks and allied components. This aspect has been very conducive to winning large clients not only from India but from overseas too. For this capability, Constro Systems bagged an elite project in Bangladesh too.
The company has designed, manufactured, and supplied mobile formworks for kerb lining innovating it for the first time in India for the 10.15 m dia horse shoe shape, head race tunnel of 1500 MW Nathpa Jhakri H. E. Project in Himachal Pradesh. It can be termed as a horizontal slip form to enable the casting of footing /bottom stopper while placing the concrete for the overt lining. Similarly, hydraulically operated screeds were innovated & manufactured to pour invert concrete even @ 100m/day. The company manufactured & supplied 14.7 m dia hydraulically operated overt forms for the lining of twin diversion tunnels of the KOL DAM Project of NTPC in Himachal Pradesh in 2003.
The shuttering for bridge girders, cantilever beams, and pier caps is designed and manufactured for building bridges & tall structures. All this work is done with utmost precision, finesse, and maintaining strict quality control. The safety of the structures is maintained during concrete pouring activities. The company also undertakes the concreting & reinforcement fixing jobs at the sites on a turnkey basis; the client has to provide basic facilities of boarding, lodging, water & power, access, etc. besides the availability of concrete with equipment for the pouring.
Furthermore, the company has evolved highly economical & efficient methods of pouring invert & overt lining in the tunnels simultaneously and continuously; using a self-propelled hydraulic formworks system (with or without reinforcement). These formworks have been successfully used for the lining of one of the major water supply tunnels of Bombay Municipal Corporation where a progress of about 100m/20 days has been achieved.
In-House Capabilities
Slip Forming is a proven & most economical method in the construction of structural components of any project. It facilitates quick construction of high-rise structures whether residential or in the industrial sector thereby increasing productivity to a large extent. This technique is economical & suitable for structures taller than 10 to 275 meters in height allowing further new constructions to be available swiftly in the sequence.
Across all its areas of focus, the company stands out for its customer-centric approach to designing every product from scratch by understanding the needs of distinguished clients and leveraging its in-house designing & drawing capabilities to curate something that perfectly matches those needs.
The company has executed different types of slip-form works within India as well as overseas in the countries including South Africa, U.A.E & Bhutan. We have developed cement silos using this technique, bridge piers (straight & tapered), ESR water shafts, under ground surge shafts for hydropower, clinker silo & multi competent silo including carrying roof girders for casting slabs at the top level with specially designed slip form system and concrete lining of gate shafts (elliptical). Surge shafts with gate groove and pressure shafts with single side form work.
What elevates the firm's standing even more in the sector is its cost-effective & rapid production and manufacturing capabilities. By adopting automation and integrating automation systems wherever possible. The firm decreases lead times, which helps it support the customer’s construction time lines.
As Constro, client satisfaction is what we always strive to achieve. For these highly professional & qualified engineers are employed whose excellence in this field collectively allows us to make a strong introduction to formwork, scaffolding, and slip form construction technology. Later follow up with construction work based upon predefined parameters of the firm. This practice of employing an intellectual set of people and designing the project with optimum use of resources before starting the actual work is a differentiating factor of the company. This is a key factor that attracts clients from across the length & breadth of India towards us.
Journey And Future Road Map
From the time its business got off the ground, Constro Systems has been working tirelessly in this domain, taking on new challenges head-on, and continuing to improve its capabilities to drive business excellence, becoming one of the most impressive and prominent players in the sector. Starting from Mumbai, the company has increased its geographical reach to the farthest corners of India and captured numerous opportunities in overseas locations time and time again. With an unshakable dedication to continually enhance its offerings and incrementally add value to the clients, Constro has envisioned a vibrant future with robust capabilities.
The firm has recently added a plasma CNC machine which will simplify plate cutting and turning processes. Additionally, it aims to standardize its press shop in the near future and increase its size, and thereby capabilities to scale with the company’s growth. Moreover, Constro is making headway into manufacturing its own hydraulic and machining components, with which it aims to enhance profits and timelines further.
With this overall expansion plan, Constro stands poised to emerge as an industry leader in the near future.
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