Karkas Monolit delivers facades that last: high-quality residential homes with precast technology

Karkas Monolit reshapes the traditional construction market in the Nizhny Novgorod region, Russia with modern precast technology. They stand out with a broad range of high quality products for easy construction of solid, durable concrete buildings, in particular with their colored, polished, long-lasting wall panels.

Every year, KM Precast’s factory – a part of Karkas Monolit construction company – in Nizhny Novgorod, Russia, produces 250 000 square meters of facade panels and 60 000 m2 of other precast wall elements on their Elematic circulation line.

In addition to the circulation line for sandwich and partition wall panels, the KM Precast factory has acquired Elematic equipment for manufacturing ventilation blocks, lift shafts and staircases. The products come in all types and sizes.

Ensuring a fast production speed and high-quality end products were decisive factors in choosing the machinery for the factory.

“Before signing up the contract on the circulation line we carried out a thorough market study. Elematic turned out to be one of the leading providers for precast concrete production equipment”, says Dovletbij Baybekov, General Manager at KM Precast.

The KM precast factory opened in November 2015, after a construction period of just 14 months.

“We like Elematic’s approach: They have tailored assembly solutions, top-quality equipment and efficient support. We are happy with the equipment and the support the company provides.”

The KM precast factory opened in November 2015, after a construction period of just 14 months.

“We like Elematic’s approach: They have tailored assembly solutions, top-quality equipment and efficient support. We are happy with the equipment and the support the company provides.”

Unlimited potential for tailor-made panels

Reliable manufacturing technology is vital, as KM Precast produces triple-layer panels with excellent insulating and ventilating properties along with high heat retention.

The triple-layer panels comprise of two concrete layers interlocked with heat insulation. The outer layer, when made of colored gravel, is manufactured using technology that exposes the color surface finish. In the process, the outer layer is polished until the surface is glossy and the gravel is exposed. The result is a finished product with mirror-smooth surface and marble-like patterns.

The inner layer, or the cladding panel, is made of gray concrete. In addition, KM Precast makes panels with graphic concrete. Graphic concrete technology allows designing customized facades of multi-layered panels. This technology offers unlimited potential for lasting, tailor-made drafts: You can reproduce famous art work or very fine, accurate patterns on the surface of the facade panel.

KM Precast’s panels stand out in the market, and the new possibilities with different surface treatments are of interest to housing agencies in the region, where traditional precast building constitutes the prevailing building stock. The panels retain their original look for decades and enable reduced overall heating costs.

Thanks to easy installation, precast concrete panels also evidently reduce construction time. On average, installing one panel takes less than 20 minutes, and a team of five workers can install up to 22 – 24 panels in a day.

Precast wall production at Karkas Monolit.

Ankudinov park: 27 high-rise residential blocks with KM Precast concrete panels

One of KM Precast’s biggest clients is KM Ankudinov park, also part Karkas Monolit group. The massive Ankudinov park housing project consists of 12 500 apartments in 27 high-rise residential blocks, ranging from 19 to 35 story high buildings.

Kadir Bag, Main Coordinating Officer at Karkas Monolit Construction Company, says the efficiency of the houses is by far better than any other houses in the area. “They are well-insulated and well-ventilated. Our clients are happy so we are happy”.

He stresses that the opening of the KM Precast factory greatly expedited the construction of Ankudinov park.

“The factory has allowed us to independently and profitably manufacture our unique product for our construction sites. Thanks to KM Precast, we have streamlined the Ankudinov park project without any loss in quality. Over the past 2 years, we have delivered more than 2000 move-in ready apartments, and we plan to complete the project within the next 6 years”, he notes.

Expansions on the horizon

In the near future, KM Precast’s plans include installing the Elematic Acotec line to manufacture light non-lifting partitions. This line covers the entire production process, from concrete mixing to product storage. Acotec panels are extruded from lightweight concrete, which makes them light and easy to install. The panels are 600 mm wide and floor-to-ceiling high. One panel can be installed manually by two people, cutting both construction schedules and costs.

To support the expansion plans, KM Precast has recently started working with PJSC PIK, a large Russian construction company and supplier of facade panels and internal walls.

Karkas Monolit factory in brief:

Production line: Circulation wall line

Year of delivery: 2014
Dimension of tables: 4.0 x 10.0 m table molds
Automation: concrete distribution system
Machinery: 3 x shuttle E9, shuttle washing station EB 460, Comcaster E9, transfer wagon E9, 6 x cross transfer, compaction station E9, tilting station E9, floating machine E9, bridge track EB872, cleaning machine, transport wagon E9
Accessories: FaMe side forms, Flex pro side forms and Push-button magnets. Lifting beam E9.

Production line: Special moulds

Year of delivery: 2014
Machinery: lifting beam, intermediate hopper EB 120, skip S5, 2-sided staircase element molds, lift shaft molds, ventilation duct molds, wagons E9, transport wagon EN 877.

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