Start Your Precast Factory?
Feasibility Study
Execution
Hand Holding
Everything you need to build your factory — minus the confusion.
Projects that used to take 12–18 months are now being completed in just 6 months. Buildings are going up faster, with fewer resources, lower labor dependency, and no weather delays.
But here’s the best part — builders are saving capital while boosting their profits.
Sounds like a dream?
It’s already happening. At Modular Pulse, we help you set up and scale your precast business from scratch, giving you clarity, direction, and real-world guidance at every step.
From Planning to Performance:
A Structured Path to Precast Success
Our streamlined 3-step process is designed to help you plan, build, and run a high-performing precast facility with confidence.
STEP 1
Planning & Cost Analysis
We start by analyzing a typical project to model production needs, estimate costs, design the factory layout, and calculate ROI—laying a solid foundation for your investment.
STEP 2
Execution & Operations Setup
Next, we guide you through factory setup, trial production, quality control, and team training—ensuring your facility runs efficiently from day one.
STEP 3
Ongoing Support & Optimization
Post-launch, we offer tailored support to help your team operate independently, convert future projects to precast, and continuously improve performance.
STEP 1
Project-Based Factory Planning and Cost Analysis
We begin by selecting one typical project provided by the client. This project will represent the kind of work the client expects to manufacture regularly in their new precast facility.
i. Conversion and Cost Estimation
We take the architectural and structural drawings of the selected project and convert them into a precast design.
A detailed cost estimation is then prepared, assuming the project is manufactured in the upcoming precast facility.
The cost analysis is done in close coordination with the client, using their preferred local raw material rates, labour wages, and overheads.
Project timelines are incorporated based on client input, which helps determine how many such projects are expected annually.
ii. Factory Size and Panel Optimization
Using the number of projects and the required timeline, we calculate the optimal factory size.
We extract all panel sizes, volumes, and unique design elements from the sample project.
These panel dimensions are also shared with the architect, ensuring future projects are designed with repeatability and precast efficiency in mind, without compromising on architectural uniqueness.
iii. Factory Design and Equipment Planning
Based on panel geometry and production volume, we design a factory layout that optimises for flow, space, and man hours per cubic meter.
A complete list of required machinery and tools is prepared, along with recommendations for sourcing (both new and high-quality used equipment).
We assist in procurement and setup planning to ensure seamless commissioning.
iv. Financial Integration
The total investment cost for the factory setup is added into the cost estimation model.
We calculate per Sqm. and per Sqft. cost of the precast elements, factoring in depreciation, financing, and operational expenses.
This gives the client a complete financial picture, linking capital expenditure to production cost and profitability.
STEP 2
Execution. Support, Operations Setup, Sales Enablement & Quality Control
Once the planning phase is complete, we transition into execution—ensuring that your factory is not just built right, but also runs efficiently and profitably from day one.
Factory Commissioning, Trial Runs, and Performance Monitoring after the factory setup and training systems are in place, the focus shifts to commissioning, pilot production, and ensuring that the factory achieves its intended performance benchmarks.
This step is critical to bridge the gap between setup and steady operations.
i. Final Commissioning and Trial Run Supervision
We will assist in supervising the final commissioning of the factory equipment, including setting up production lines, verifying utility connections, and ensuring correct machine calibration.
Trial runs will be conducted using the optimized mix designs developed in Step 2. These trials help ensure production output meets quality benchmarks and volume targets.
Our team will monitor initial production cycles, identify any bottlenecks, and fine-tune the process parameters for optimal efficiency and minimal wastage.
Quality Assurance and Process ValidationWe will evaluate the product quality, dimensional accuracy, surface finish, and curing consistency during initial batches.
A set of quality control checklists and reporting formats will be implemented to maintain long-term consistency.
Any deviations from expected outcomes will be addressed through process adjustments or equipment alignment.
ii. Process Flow Optimization
Based on real-time performance during trial production, we will review:
Movement of materials and elements across the factory floor
Labor productivity and workstation utilization Curing and demolding efficiency
Using this data, we’ll help refine the workflow layout and man-hour allocations to reduce time, energy, and material consumption per cubic meter or square meter of precast output.
iii. Final Team Training and Role-Based Task Allocation
A final hands-on training session will be conducted for all key roles (plant manager, production engineer, quality inspector, batching operator, installation supervisor, etc.).
Clear task allocation matrices and shift planning formats will be handed over to ensure efficient management of labor and production targets.
Using this data, we’ll help refine the workflow layout and man-hour allocations to reduce time, energy, and material consumption per cubic meter or square meter of precast output.
iv. Product Performance Testing and Feedback Loop
We will supervise the testing of final precast elements for compressive strength, durability,
and performance against industry standards.
If needed, third-party testing agencies can be engaged for independent validation.
A feedback loop will be created where learnings from each batch are used to improve the next cycle, ensuring a culture of continuous improvement.
v. First Project Execution Support
We will assist in the planning and execution of the first actual project using precast
elements from the factory. This includes:
Casting schedule planning based on project timelines
Coordination with the erection/installation team
On-site installation guidance and logistics planning
The goal is to ensure a successful transition from trial to real-time production and installation, giving the client a replicable model for all future projects.
vi. Operational Handover & Sustainability Plan
After stabilizing operations, a full handover report will be created, outlining:
• Production KPIs
• Maintenance schedules
• Staff responsibilities
• Suggested upgrade timelines
We also provide a long-term roadmap to help scale production, introduce new product lines,
or move toward automation as demand grows.
STEP 3
Handholding & Post-Commissioning Support
Fee: Custom (based on level of support required) This phase is tailored to match the specific needs of your team and project pipeline, ensuring a smooth transition from commissioning to full-scale operational success.
After the factory is commissioned and initial production is established, this phase focuses on ensuring that your team can independently run the facility, convert future projects to precast with confidence, and deliver high-quality results consistently.
We recognize that every client’s internal team and project pipeline are different— some may need full hands-on involvement, while others may only need advisory-level support. Hence, this phase is fully customizable based on the client’s goals, capacity, and complexity of projects.
i. In-House Team Training and Capacity Building
On-site or remote training sessions will be conducted across core departments including:
Production: daily operations, batching, curing, demoulding
Quality Control: material testing, defect checks, rejection management
Design Team: understanding precast design logic, how to read production drawings, suggest optimizations to architects
Project Managers: planning site logistics, crane management, and erection sequencing.
We will provide your team with role-specific SOPs, training videos, and trouble shooting guides to reduce reliance on external experts.
ii. Project-Specific Conversion Support
We offer direct consultation for converting your upcoming live projects into precast-compatible designs.
This includes:
Reviewing architectural drawings
Advising on penalization logic and connection strategies
Defining erection sequences
Creating basic colour-coded layouts for developer or architect coordination
The goal is to enable your design and execution teams to integrate precast smoothly into your ongoing projects with maximum efficiency and aesthetic value.
iii. On-Ground Handholding for Live Projects
For high-stakes or complex projects, we provide full handholding, which may include:
Supervising production of key elements in the factory
Quality audits and process adjustments during manufacturing
Site visits to assist during first-time erection and installation
Coordination between your team, contractors, and suppliers to ensure timely delivery and execution
This ensures that your first few projects serve as successful proof of concept, reinforcing confidence across your client base and internal teams.
iv. Business and Sales Strategy Support (Optional)
If needed, we can continue to support your business team with:
Technical sales presentations for developers and contractors
Marketing material showcasing the benefits and speed of precast
ROI calculators and cost breakdowns for client pitches
Help with responding to tenders or government precast mandates
v. Scope Flexibility and Fee Customization
Since every factory and team requires a different level of support, the fee for this phase is customized.
You can choose from:
Advisory Support (light-touch, remote guidance)
Hybrid Support (remote + key in-person visits during milestones)
Full-Time Support (end-to-end involvement across multiple projects)
hello@modularpulse.com
+91 73873 22342
Apna Bazaar, Vasco Da Gama,
Goa, 403802
GST No: 30ACCFM2251R1Z7
© 2025 Modular Pulse