Thought starter:

Looking at this, we chanced upon an idea – can we make functional, strong, inexpensive houses for the masses using all our knowledge in building prefab structures which use factory made panels and slabs?

And there was no looking back!

Challenges:
There were two major challenges. One: the strength requirements were of a different kind in a permanent structure and we had to look beyond using plastic and concrete (which were largely used in prefabs). And two: we believed that the new technology should reduce dependence on human skills as it was critical to bring down the cost of construction.

Action:
Over the years we had developed a knowledge base of optimizing benefits from all
materials. We added galvanized steel to plastocrete (plastics & concrete) and developed a polymer system that was strong enough for such projects. We believed in functionality and scale, so developed standardized plans that would ensure quick construction reducing cost and dependence on human skills.

Results:
These buildings take one-fourth the time to get completed, are strong enough to withstand high windspeeds (150km/hr) & earthquakes, cost half as much, do not require any maintenance, look good and are eco friendly.

The first project is coming up on the outskirts of Ahmedabad and we have extremely healthy order bookings from various governments, municipal bodies and corporates.

However, there was one area where the most efficient electricity boards had limitations. The electric meters of the day were not tamper proof. There was a simple solution to this problem – tamper proof meter boxes, but the scale of implementation demanded a unique approach.

In a typical Sintex way of working, we took that approach.

Challenges:
The challenge was in breaking the inertia of electricity board and companies and convince them to adapt to the new meter boxes.

Action:
We developed these tamper proof meter boxes on our own. They were also fire proof, corrosion proof and shock proof. We identified a progressive and efficient electricity company for the pilot – Ahmedabad Electricity Board (AEC), which was happy to check it out and implemented it.

Results:
AEC, which was already an efficient electricity company made an additional gain of 4% in revenues by reducing their T&D losses. It was easier for us to convince other electricity boards after the pilot. Rajasthan Electricity Board (REB) has already placed an order and we are in advance talks with other boards as well.

The conventional processes have their limitations and could only install 800 to 900 classrooms per year which were insufficient to fulfill Government’s requirement of 42,000 classrooms.

Sintex required no second invitation to utilize its expertise and experience to install 4000 to 5000 classrooms per year to make the vision of Government a reality.

Challenges
The main challenge was to install such structures on raw ground. Keeping in mind the seismic conditions of the land in Gujarat, these structures needed to be earthquake proof, non-fatal, durable and strong. Another challenge was to install them quickly so that more and more students could benefit from the program.

Action
Through our research and experience Sintex had developed a strong know how on the use of plastics. With little modification we were able to strengthen the structures made of plastics. As a result of which Sintex engineered 10,000 prefabricated schoolrooms for the most remote areas of Gujarat that not only can be installed on raw ground within a week,