Indian real estate company 3D prints office in 40 hours

Godrej Construction, a subsidiary of Godrej & Boyce, has built a fully functional office in just 40 hours using 3D construction printing technology.

This 46 square meter office, called “The Cocoon”, was constructed using prefabricated modules and sustainable materials, including up to 20% recycled concrete. The project also integrated lean construction methods and Building Information Modeling (BIM).

The office, named ‘The Cocoon’ due to its curved elliptical design, was created using innovative 3D construction printing technology (3DCP) from prefabricated modules and assembled within 40 hours.

Anup Mathew, Senior Vice President and Business Head, Godrej Construction said, “‘The Cocoon’ is a manifestation of our relentless pursuit of pushing boundaries, not just in terms of architectural design, but also in redefining construction timelines. Construction of ‘The Cocoon’ is a good demonstration of an effective team collaboration integrated with good project planning using tools like Building Information Modelling (BIM), Lean Construction methods, and 3D Construction Printing. At Godrej Construction, we are committed to delivering innovative and sustainably designed solutions tailored to the needs of our customers in the built environment.”

The construction included the installation of 3D printed modules, civil works, waterproofing, painting, electrics, air conditioning and more, all in under 40 hours. The office was constructed using a concrete mix that contained up to 20% recycled concrete aggregate (RCA) sourced from Godrej & Boyce’s recycled concrete plant in Vikhroli, Mumbai.

“The Cocoon was conceived to challenge the timelines in construction and the senior management challenged the team to see how much the construction can be speeded up. So the team started with two months, and planned further to bring it down to a month, 15 days, a week and finally 40 hours,” said Abhijeet Gawde, Head of Business Development & Marketing, Godrej Construction.

“We had the option of making it rectangular and build it with beams and columns, but it would have taken longer. So, we decided to make column-less structure with a curvature, and elliptical design which will look more aesthetic. 3D construction printing technology allows you to make complex designs,” he said.

“We have processed nearly 30,000 metric tonnes of construction debris so far. We manufacture and supply paver blocks, solid blocks, AAC blocks, box culverts using recycled concrete aggregates to real estate developers as well as infrastructure companies and projects,” said Gawde adding that the company has supplied over 450 box culverts made with 10% recycled concrete aggregates for big infrastructure projects like the Coastal Road, and its solid blocks and pavers were used in the construction of Mumbai Metro 2A and 7 lines.

The construction of “The Cocoon” not only demonstrates Godrej Construction’s ability to deliver innovative and sustainable solutions, but also highlights the transformative potential of 3D construction printing technology in the construction industry. This project marks a significant step towards more efficient and environmentally friendly construction processes and sets new benchmarks for the future of construction.

 “With increasing urbanisation, and many infrastructure and real estate projects underway, it is the need of the hour to reduce the emissions by using sustainable construction materials. A report by Centre for Science and Environment had said only 1% of construction debris and waste is recycled in India. So, more companies need to step forward and set up recycling plants.”