Integrated Fabrication Workflows for Pre-Engineered Steel Systems

Sunil Kumar Agarwal, Director at Kamdhenu Limited, in a conversation with Thiruamuthan, Assistant Editor at Industry Outlook, shares his expert insights on how India’s construction sector is embracing pre-engineered steel systems. Integrated fabrication workflows are redefining project execution by unifying design, analysis, and production into a seamless digital process that enhances precision, reduces errors, and minimizes costs. With AI, IoT, and digital twins, these workflows are enabling smarter, faster, and more sustainable construction.

Sunil Kumar Agarwal brings 33 years of steel industry expertise in production, marketing, and strategic expansion, driving the company’s nationwide growth through innovation and partnerships.

As pre-engineered steel systems gain momentum in India, how are integrated fabrication workflows enhancing speed, precision, and overall cost efficiency on projects?

Pre-engineered steel systems offer immense benefits such as enhanced quality of construction and significant reduction in construction timelines. The integrated fabrication workflow encompasses design and production into a single workflow, thereby streamlining the whole process. Such a system is ideal for the deployment of software tools and aids in analysis, planning and production stages to increase efficiency, reduce errors, and minimize costs compared to traditional construction. From 3D modelling to enhance structural integrity to precise fabrication and optimized workflow and material use, the integrated fabrication workflows deliver better buildings with significantly lower cost of construction and maintenance.

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Today, steel structures are becoming increasingly complex. Given this, what specific obstacles are companies encountering when aligning design software with automated fabrication machinery for smoother workflow integration?

The increasing complexity in steel structures with high performance requirements does presents challenges in aligning design software with the fabrication machinery. The use of proprietary data formats by different software companies and machinery producers often hinders interoperability and compatibility. Fabrication plants also tend to add customization to their machinery and software so as to cater to their specific requirements fragmenting the workflow. Even as software developers and machinery providers upgrade their products to the latest standards, the need for end users to incorporate specific design or quality cues from their real-world learnings will remain.

Amid rising modular construction demand, how are integrated fabrication workflows effectively reducing on-site assembly errors and minimizing rework in Indian projects?

Modular construction, as the outcome of an integrated fabrication workflow that seamlessly connects design, fabrication, and construction, significantly enhances on-site efficiency. By using precision-engineered components and optimized installation guides, it minimizes alignment issues and assembly inconsistencies. This coordinated approach not only reduces rework and material wastage but also ensures faster installation, improved quality control, and greater predictability in project timelines; key advantages in India’s fast-evolving construction landscape.

As digital twin technology sees wider adoption in steel fabrication, how is it improving quality control and enabling real-time workflow monitoring?

Digital twin technology creates a virtual replica that is continuously updated with real-time data. This allows for greater oversight into the manufacturing process with real-time monitoring and end-to-end visibility for greater coordination between the various teams involved in the process. With faster detection of issues, higher precision and the possibility of continuous process improvements, the digital twin technology is redefining workflow monitoring and quality control.

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With sustainability becoming a priority, how are integrated steel fabrication workflows helping reduce material waste and lower energy consumption in India’s pre-engineered sector?

The streamlining of designing, production and construction through the integrated steel fabrication workflow has resulted in better designs, greater quality controls, precision guided material use and minimized need for rework at the shop floor and construction site. The cumulative impact of all these is in better buildings, lower construction time and minimal material wastage for a more sustainable construction of buildings.

Looking ahead to AI and IoT adoption, how will these technologies transform the efficiency, accuracy, and automation of pre-engineered steel fabrication workflows?