Factory construction and maintenance in India are evolving rapidly as manufacturing scales up. Construction chemicals are critical in ensuring durability, preventing corrosion, and minimising downtime. At the 7th CC-KLI event by Asian Paints in Bharuch, experts explored innovative solutions shaping the future of factory resilience.

Factory construction and maintenance procedures are transforming rapidly as India positions itself as a worldwide centre for manufacturing. Sustainability, durability, and efficiency are now urgent needs rather than lofty goals. The 7th edition of the Construction Chemicals Knowledge Leadership Initiative (CC-KLI), organised by Asian Paints at Bharuch, is at the vanguard of this development.

The event brought together leaders from various industries, including academia, pharmaceuticals, automobiles, and civil construction, to talk about innovative methods for tackling the difficulties of factory construction and the increasing demand for repairing and adapting old buildings. Vishal Tiwari, General Manager, Project Sales at Asian Paints, explained, “This is a platform to share knowledge and drive industry transformation; it is not about Asian Paints products.”

Building resilient factories

Factories are the hubs of economic development, not just structures. Significant financial losses might result from a single day of production halts that affect whole supply chains. Vishal Tewari, General Manager, Project Sales, Asian Paints Ltd, emphasised that “maintenance is the biggest pain point in factories.” Given that factories are profit-making organisations, minimising downtime time is essential. When they cease, the losses happen right away.

Biral Shah, Project Director, VMS Engineering and Design Services discussed the role of smart technologies in creating sustainable structures. “Smart technologies, such as sensors and data analytics, can help us perform preventive maintenance and make informed decisions. However, we must balance data with human judgment,” she said. Shah also highlighted the importance of specialised contractors in the construction ecosystem, a practice common in the US but still evolving in India. Construction and maintenance solutions must prioritise speed, durability, and little disturbance to meet these operating realities. Asian Paints provides complete factory maintenance solutions that include waterproofing, corrosion prevention, concrete repair, flooring, and more through its Total Assure and Meta programs..

Understanding the repair and rehabilitation crisis

In his keynote speech, Dr. Prakash Nanthagopalan, professor of civil engineering at IIT Bombay, revealed an alarming fact: India spends over 4 percent of its GDP on structural upkeep and repair. He disclosed that approximately 40 percent  of the nation’s cement production and 30% of its steel are used for repairs. This figure highlights the industry’s need to move away from reactive repair and towards proactive, durability-driven building.

Dr. Nanthagopalan underlined that steel is frequently the weak point in reinforced concrete constructions. Concrete is a durable material that can endure for centuries. The life of the structure is determined by the steel inside. “The entire system is compromised when steel corrodes,” he said.

Corrosion: The silent predator

India’s varied terrain presents different corrosion hazards, including carbonation-induced corrosion in landlocked industrial centres like Delhi and chloride attacks close to coastal areas. It is a common misconception that people are immune to chloride corrosion because they live 50 km from the shore. However, Dr. Nanthagopalan warned that chlorides move through the atmosphere as well.

The first line of defence for embedded steel is strong cover concrete, which is necessary to combat this. Dr. Nanthagopalan emphasised the need for careful craftsmanship, saying, “Choosing the thickness of the cover is not a snap decision. Due to variations, a structure’s lifespan can be shortened from fifty years to just five.”

The role of construction chemicals in enhancing durability

Modern building materials are essential for prolonging the life of manufacturing buildings. For example, slag-based cement was suggested as a remedy. According to Dr Nanthagopalan, “Slag not only lowers concrete porosity but also binds chloride ions, preventing them from reaching steel reinforcements.”

Alternative options included fibre-reinforced polymer (FRP) bars, stainless steel reinforcements, fusion-bonded epoxy-coated rebars, galvanic cathodic protection systems, and impressed current cathodic protection, which were also displayed during the exhibition. Every option has special benefits, but they all require careful implementation. Dr. Nanthagopalan cautioned, “A poorly handled epoxy-coated rebar can be more problematic than a standard steel bar.”

Smart practices in factory construction

The panel discussion moderated by Dev Dave, Specialist Specifications, Asian Paints Ltd and Ram Duggirala, Specialist Waterproofing, Asian Paints Ltd focused on smart construction practises and how they can address modern-day factory challenges. Industry veteran P.S. Patel, Chairman and Managing Director of PSP Projects Ltd., looked back on his 40 years of experience, seeing how factory construction changed from crude methods to precision driven by technology. “When I started in 1985, proprietors and their families were in charge of the building. Technology sets the standard nowadays,” Mr. Patel said.

Manufacturing is undergoing a transformation thanks to innovations like sensor-based monitoring systems, nondestructive testing (NDT), Building Information Modelling (BIM), and digital project management tools. “You cannot enhance what you cannot measure,” Mr. Patel  underlined. Thanks to real-time data, we can detect possible structural problems before they worsen.”

Despite advancements, on-ground execution often lags. Binding wires, for instance, emerged as an overlooked yet critical detail. “The knot of the binding wire should face inward. When it faces outward, it compromises cover thickness and exposes steel to corrosion,” Mr. Patel noted.

Similarly, improper curing practices frequently undermine concrete strength. “Curing is not about pouring water aimlessly. It is about ensuring that the water mixed during concrete production stays within the matrix,” explained Dr. Nanthagopalan. Covering fresh concrete with plastic sheets can often outperform traditional water curing.

Retrofitting aging factories

India’s industrial boom in the 1980s and 1990s led to thousands of factories, many ageing. Structural retrofitting has thus become a priority. “Retrofitting is no longer a patchwork affair. It is an engineering solution requiring scientific assessments and tailored interventions,” noted Anshul Shah, Director at Ducon Consultants.

Electrochemical repair methods, such as cathodic protection, are increasingly being adopted. Galvanic anodes, for example, sacrificially corrode to protect steel reinforcements. “Selecting the right anode is crucial. The GAP test, developed by IIT Madras, can help ensure compatibility,” advised Dr. Nanthagopalan.

Preventive maintenance is often neglected in India’s factory landscape. Dr. Nanthagopalan likened structural health monitoring to personal health: “We don’t wait for a heart attack to check our health. Structures deserve the same proactive attention.”

Periodic inspections using cover meters, rebound hammers, and ultrasonic pulse velocity (UPV) tests can reveal early signs of distress. “Timely intervention can prevent catastrophic failures and prolong structural life by decades,” he asserted.

Material selection is critical to extending the lifespan of factory infrastructure, particularly in aggressive environments like industrial zones and coastal areas.

During the seminar, slag cement was repeatedly cited as a preferred solution. Unlike ordinary cement, slag cement reduces concrete porosity and binds chloride ions, preventing them from reaching steel reinforcements.

Other materials discussed included corrosion-resistant steel, epoxy-coated reinforcement, and fibre-reinforced polymer (FRP) bars. While effective, these materials require skilled handling during installation. Procurement teams must evaluate the material and the contractor’s capability to execute the installation correctly.

Factory downtime is a financial liability

Unlike other types of construction, factory operations are directly tied to the structural health of the building. A damaged floor, corroded roof, or cracked column can halt production lines, causing significant operational and financial losses.

Factory floors face sustained mechanical stress from heavy machinery, vehicle movement, and chemical spills. Ordinary concrete often deteriorates under these conditions.

“Factory floors are subjected to extreme loads and wear. They need industrial-grade flooring systems designed specifically for heavy usage,” said Maitrey Talati, Managing Partner at Shah & Talati Design and Engineering.

Fast-curing repair materials and modular repair techniques are becoming increasingly important in factory settings. These solutions allow for repairs with minimal downtime, ensuring production resumes quickly. Procurement professionals must prioritise suppliers and contractors who understand the urgency of factory operations and can deliver rapid, durable repairs.

Monitoring systems for predictive maintenance

Another development gaining traction is using sensor-based monitoring systems for structural health assessment. These sensors detect real-time stress, cracks, and moisture infiltration, enabling early intervention before structural issues escalate.

“Structural monitoring systems provide data on hidden vulnerabilities, allowing factory managers to address them before they disrupt production,” said Anshul Shah, Director at Ducon Consultants.

Procurement professionals should explore including such monitoring systems as part of initial project specifications or retrofitting plans.

A call for collaborative innovation

The Bharuch edition of CC-KLI underscored the importance of industry-academia collaboration. Factory construction professionals, manufacturers, and researchers must work together to close the gap between knowledge and practice.

“Factories are economic engines. Their longevity and performance directly impact national growth. Our collective responsibility is to build faster, smarter, and stronger,” said Mr. Patel.

As India continues its march towards industrial prominence, the factories of the future will be defined by the confluence of smart construction practices, cutting-edge materials, and a culture of maintenance.