Design Finalization & Approvals
The manufacturing process begins after final approval of
architectural drawings, shop drawings, and pattern detailing.
All dimensions, profiles, finishes, and fixing details are frozen at this stage.
Pattern Development
Approved pattern drawings are converted into
physical patterns using suitable substrates such as wood,
POP, clay, plywood, or metal to achieve high precision.
Mould Making
High-quality moulds are prepared from the approved patterns.
The mould material and technique are selected based on
element complexity, repetition, and surface finish requirements.
Material Selection & Mix Design
Carefully designed mix formulations are prepared using
cement, graded aggregates, alkali-resistant glass fibres,
polymers, admixtures, or UHPC components as per project specifications.
Casting / Spray-Up / Hand Lay-Up
Elements are manufactured using appropriate techniques such as
spray-up, premix casting, or hand lay-up, ensuring uniform thickness,
strength, and surface consistency.
Embedding & Reinforcement
Necessary MS / GI / SS inserts, anchors, frames, and reinforcements
are embedded during casting to ensure structural integrity
and safe installation.
Curing & Strength Development
Cast elements are cured under controlled conditions to achieve
optimum strength, durability, and dimensional stability.
De-moulding & Surface Finishing
After adequate curing, elements are de-moulded and finished.
Surface treatments such as
sanding, texture matching, pigmentation, or coatings
are carried out as per approved samples.
Quality Control & Inspection
Each element undergoes strict
dimensional checks, surface inspection, strength verification,
and finish approval before dispatch.
Packing & Dispatch
Approved elements are carefully packed using protective materials
to prevent damage during transportation and are dispatched
as per site sequence requirements.
