Godrej & Boyce uses 3D printing to build a fully functional office within 40 hours

Godrej & Boyce, the flagship company of the Godrej Group, has announced that its business, Godrej Construction, has constructed a 500 sq. ft. office in the company's own Greenfield campus at Khalapur in just 40 hours. This structure, known as 'The Cocoon', was created using prefabricated modules and innovative 3D Construction Printing (3DCP) technology.

3D printing in construction, also called 3DCP, makes use of robotics to deposit construction material in layers, creating walls, floors and roofs.

Anup Mathew, Senior Vice President and Business Head of Godrej Construction, said, "The Cocoon is a testament to our commitment to pushing boundaries, not only in terms of architectural design, but also in redefining construction timelines. The construction of 'The Cocoon' demonstrates effective team collaboration, combined with good project planning using tools such as Building Information Modelling (BIM), lean construction methods, and 3D Construction Printing."

The modular office is named after its unique structure and incorporates advanced engineering techniques, integrated with a modular construction process. The office has been thoughtfully designed to showcase the potential of 3DCP technology, featuring an unconventional curvilinear elliptical design that offers design flexibility. The layout of the office is column-free, providing maximum usable office space, and includes a prefabricated toilet unit.

The construction project involved the complete installation of 3D printed modules, civil works, waterproofing, flooring, external and internal painting, electrical works, lighting, AC installation, plumbing, drainage and sanitation fixtures, office furniture, and landscaping, all completed within 40 hours.

The office was constructed using a concrete mix design that included up to 20% of Recycled Concrete Aggregates (RCA) sourced from concrete debris, which was recycled at the Godrej & Boyce Recycled Concrete manufacturing facility in Vikhroli, Mumbai. The business continues to lead the way in pioneering green and innovative construction practices, achieving yet another milestone with this meticulously designed office space that maximizes utilisation.

As of today, there are at least three construction 3D printer manufacturers in India. In August 2023, India’s first 3D-printed post office located in Bengaluru’s Cambridge Layout was launched. It was completed in just 43 days at only ₹23 lakh. Its construction was carried out by Larsen & Toubro Limited with technological support from IIT Madras under the guidance of Professor Manu Santhanam, Building Technology and Construction Management Division, Department of Civil Engineering. L&T said the company plans to construct eight villas in Bengaluru using the technology.The company said the technology can be used to lower costs only when a large volume is to be constructed.

In April 2021, India’s first 3D printed home in Chennai was built within the IIT-Madras campus, made by a tech start-up called Tvasta. A 600-square foot, single-storey unit took three weeks to put together from printing to final construction, and the company said the cost was around ₹5.5 lakh, nearly a fifth of a typical 2-bedroom apartment in most parts of urban India. Simpliforge Creations is another 3D printing startup that has also partnered with Apsuja Infratech and the companies have collaborated to create a new-age gated community project in Telangana.