That’s exactly what unfolded at Project A, an industrial textile facility located in Andhra Pradesh, India, covering a built-up area of 18,000 square metres. The project encountered design-stage challenges concerning its internal road infrastructure, putting the team at a critical decision point. With the timely intervention of AN Prakash Construction Project Management Consultants (ANPCPMC), a technically sound and cost-effective solution was implemented—one that adhered to IS 456:2000 guidelines and resulted in substantial savings through intelligent reinforcement optimisation.
Project Overview
Project Name: Project A
Type: Industrial (Textile Manufacturing Facility)
Built-Up Area: 18,000 sq.m
Location: Andhra Pradesh, India
Scope of Work:
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Production block
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Administrative block
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Boiler and pump rooms
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Security, temple, and compressor unit
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Canteen facilities
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RCC internal roads with stormwater drainage
Challenge: Inadequacy of Bituminous Roads
Originally, the project design specified bituminous roads for internal circulation. However, previous experiences on adjacent developments revealed common failures:
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Potholes and surface deformation
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Inadequate drainage performance
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Sub-base failure due to site-specific soil conditions
Given these conditions, ANPCPMC recommended a switch to Reinforced Cement Concrete (RCC) pavement to ensure longevity, structural integrity, and maintenance efficiency.
Technical Evaluation and Design Optimisation
Initial Design Proposal
The structural consultant initially proposed reinforcement of:
- 12 mm diameter bars @ 150 mm centre-to-centre (both ways)
While structurally viable, this detailing significantly increased the project’s steel consumption, thereby escalating costs unnecessarily.
ANPCPMC’s Value Engineering Approach
After an in-depth technical review, the ANPCPMC team suggested a revised solution based on IS 456:2000, which recommends a minimum reinforcement of 0.12% of the gross cross-sectional area for RCC pavements.
Revised Detailing:
- 8 mm diameter bars @ 200 mm c/c (both ways)
This recommendation was supported with detailed structural calculations and design justifications, and the proposal was:
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Validated by the structural consultant
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Approved by the client for execution
Key Benefits of the Revised Design
1. Significant Cost Reduction
- Steel optimisation alone saved ₹63,47,845
- Reduced procurement, handling, and labour cost
This achievement demonstrates the power of cost-efficient reinforcement strategies in delivering substantial project savings.
2. Compliance with IS Standards
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Fully compliant with IS 456:2000
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Maintained required structural strength and durability
3. Faster Execution
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Lighter reinforcement allowed easier bar bending and placement
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Improved construction speed without affecting concrete curing or quality
4. Sustainability and Efficiency
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Reduced steel consumption contributes to a lower carbon footprint
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Efficient use of materials reflects responsible project management
Construction Methodology
The RCC pavement was executed using:
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200 mm thick M25 grade concrete
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600 mm wide stormwater drains
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110 mm dia. pipes for effective drainage
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Soling using 150 mm boulders and 100 mm wet mix base
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Kerb stones of 0.10 m thickness and 0.15 m height
The visual comparison of the original vs optimised rebar layout, as seen in the engineering drawings on page 2 of the case study, highlights the clarity and precision with which ANPCPMC carried out the redesign and implementation.
Strategic Role of Project Management Consultants
This case reinforces the importance of involving Construction Project Management Consultants (CPMC) not just for monitoring and execution, but also during the design coordination and value engineering stages. ANPCPMC’s proactive approach enabled:
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Seamless collaboration with design consultants
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Effective change management
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Clear communication with the client on technical and commercial fronts
Conclusion: Building Smarter with Expert Guidance
Project A exemplifies how expert intervention at the right stage can generate substantial financial, structural, and operational benefits. Through careful analysis and adherence to Indian Standards, ANPCPMC ensured that the client received maximum value for every rupee spent.
As the infrastructure sector in India continues to evolve, such proactive, data-driven, and standards-based solutions are critical to achieving sustainable and cost-effective construction outcomes. The importance of sharing optimization learnings across projects cannot be understated in building industry-wide expertise.