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info@indesol.ae
Compared to traditional methods, modular construction offers several significant advantages:
- High construction speed – Buildings can be erected several times faster since module production and site preparation occur simultaneously.
- Quality and precision – Factory production eliminates human errors and ensures high precision in connections and easy installation.
- Cost efficiency – Reduced labor costs and minimal construction waste make this method more economical. Modules are fully finished at the factory, including glazing, built-in engineering systems, and interior and exterior finishes, simplifying and accelerating the construction process. The amount of finishing work required on-site is minimized.
- Minimal dependence on weather conditions – Modular elements are manufactured in controlled environments, eliminating the impact of external factors.
- Flexibility and versatility – Modular structures allow for the construction of residential buildings, hotels, office buildings, dormitories, medical centers, and other facilities for various purposes.
Using INDESOL modules enables buildings to be erected several times faster than traditional construction methods. The average construction time for an apartment building, office, or hotel is reduced to a few months, and in some cases, just a few weeks.
Thanks to the unique properties of foam concrete-filled modules, our technology is suitable for constructing:
- Multi-apartment residential buildings and private cottages.
- Hotel complexes and dormitories.
- Administrative and office buildings.
- Educational and medical institutions.
- Commercial and industrial facilities.
The INDESOL modular construction technology represents a step into the future, allowing for the rapid, reliable, and cost-effective erection of modern buildings. Thanks to the innovative approach of using lightweight steel structures filled with foam concrete, we are unlocking new possibilities in construction, making it more accessible and efficient.
In the context of growing demand for fast-built and reliable structures, modular construction is becoming a key trend that will shape the future of the construction industry.
If you are considering modular construction for your project, you can be confident in its efficiency and long-term benefits. This is not just a technology of the future—it is a reality that is already transforming the approach to construction today.
The key feature of the method developed by INDESOL is the use of a patented technology for filling lightweight steel structures with foam concrete. This groundbreaking solution, unparalleled worldwide, opens new horizons in modular construction. Thanks to this approach, we can:
- Manufacture modules on an industrial scale, significantly reducing construction time. The ability to prefabricate elements in a controlled environment ensures high quality and efficiency in assembly.
- Ensure durability and resistance to biological impacts. Buildings with foam concrete-filled walls have a lifespan of at least 100 years due to its strength and resistance to moisture, mold, and rodents. Unlike other materials, foam concrete does not shrink or degrade over time, maintaining structural stability throughout its service life.
- Achieve superior sound insulation. Thanks to its dense structure, foam concrete effectively absorbs sound both within a room and between separate rooms. This makes foam concrete an excellent choice for building residential homes, hotels, office buildings, and other facilities where silence and comfort are important. Using foam concrete helps reduce costs for additional soundproofing, making construction more economical and efficient.
- Construct buildings up to six stories high, expanding the application scope of our technology. The modules feature a specially designed profile that ensures high load-bearing capacity, guaranteeing structural integrity. Additionally, foam concrete enhances wall rigidity, improving their load-bearing properties and reducing susceptibility to deformations. The use of foam concrete increases structural strength by a factor of 10 compared to mineral wool insulation, allowing for taller buildings.
- Enhance the energy efficiency of buildings, reducing heating and cooling costs. Foam concrete with a density of D200 has a thermal conductivity coefficient of approximately 0.045 W/m·K. Moreover, it has excellent thermal mass properties, maintaining stable indoor temperatures. It retains both heat in winter and cool air in summer, contributing to a comfortable indoor climate year-round.
- Create a comfortable living environment, ensuring an indoor microclimate comparable to that of wooden houses. This provides a high level of comfort and well-being for residents.
- Guarantee strict environmental certification. The modules are environmentally friendly as they do not contain synthetic insulators such as mineral wool, polystyrene, or foam plastic. This compliance with the highest ecological standards makes our technology a sustainable choice for modern construction.
- Ensure high fire safety. Foam concrete is highly fire-resistant, significantly enhancing the safety of residential buildings. Its excellent fire resistance makes it an ideal material for fireproof structures, such as warehouses for flammable materials. Unlike heavy concrete, foam concrete does not crack or explode under intense heat exposure. As a result, the structural frame remains protected from overheating for a longer period. Tests show that 150 mm thick foam concrete can provide fire resistance for up to 4 hours. In trials conducted in Australia, a 150 mm thick foam concrete panel was exposed to temperatures of 1200°C on its outer surface, while the inner surface reached only 46°C after 5 hours of exposure.
- Optimize cost efficiency. Foam concrete is not only energy-efficient but also cost-effective due to its low material cost and ease of production. For example, producing 1 m³ of D200 foam concrete requires approximately 180 kg of cement, making it a more economical choice compared to alternative insulation materials.
Block-modular buildings are becoming an increasingly popular solution for organizations that value their time and budget. Their key advantage is the speed of construction: depending on the size and complexity of the project, the building process can take from 2 to 45 days. Additionally, the cost of such buildings can be 30–60% lower compared to traditional construction, making them an economically advantageous choice for businesses.
-80% Water
-90% Sand
-70% Electricity
-90% Defects
Currently, various types of mineral wool serve as the primary filler for lightweight steel frameworks. Below is a comparative analysis of foam concrete versus mineral wool, highlighting their differences in durability, and efficiency.
| Characteristic | Foam Concrete | Mineral Wool |
|---|---|---|
| Strength and Structural Rigidity | Foam concrete significantly increases the strength and rigidity of walls, enhancing their load-bearing capacity and reducing susceptibility to deformation. When using foam concrete, the structural strength increases tenfold, allowing for the construction of taller buildings. | Mineral wool does not have load-bearing capacity and requires additional structural elements to ensure rigidity. |
| Fire Resistance | Foam concrete is a non-combustible material and can withstand fire exposure for an extended period without losing its properties. | Mineral wool is also fire-resistant; however, at high temperatures, its binding agents can deteriorate, which reduces its effectiveness over time. |
| Thermal Insulation and Heat Accumulation | Good thermal insulation 0.045 W/m·K, accumulates both heat and cold, ensuring a stable indoor climate | Mineral wool provides good sound insulation initially, but if it shrinks or absorbs moisture over time, its soundproofing properties decrease drastically. |
| Sound Insulation | Due to its dense structure, foam concrete effectively absorbs sound, significantly reducing noise levels inside the building and improving acoustic comfort. | Mineral wool provides good sound insulation initially, but if it shrinks or absorbs moisture over time, its soundproofing properties decrease drastically. |
| Moisture Resistance and Vapor Permeability | Foam concrete is highly resistant to moisture and does not require additional waterproofing layers. It helps prevent condensation inside walls, maintaining a dry and healthy indoor environment. | Mineral wool loses its thermal insulation properties when exposed to moisture. It requires reliable waterproofing to prevent the accumulation of water, which can lead to mold growth and material degradation. |
| Durability and Resistance to Biological Factors | Buildings with walls filled with foam concrete have a lifespan of at least 100 years. Foam concrete is highly durable, resistant to moisture, mold, and rodents, and does not shrink or degrade over time, ensuring long-term structural stability. | Buildings with mineral wool insulation have an average lifespan of approximately 25 years. Mineral wool is prone to shrinkage, moisture accumulation, and the deterioration of binding agents. Over time, this leads to a decline in thermal insulation performance and the need for insulation replacement, increasing maintenance costs. |
| Environmental Friendliness and Safety | Foam concrete is an environmentally friendly material that does not emit harmful substances and is completely safe for human health. | Mineral wool may contain binding agents based on phenol-formaldehyde resins, which can release volatile organic compounds (VOCs) and potentially cause allergic reactions or respiratory irritation. |
| Ease of Installation | Foam concrete can be poured into walls, creating a monolithic fill without gaps or voids. This ensures uniform insulation, eliminates thermal bridges, and simplifies the construction process. | Mineral wool requires precise fitting and additional vapor barriers, making installation more complex. If the installation process is not followed correctly, its performance characteristics decrease significantly. Unfortunately, improper installation occurs quite often, leading to a loss of thermal insulation properties and an increased risk of condensation inside the walls. |
Foam concrete is a modern and efficient building material that combines numerous advantages compared to using mineral wool: cost-effectiveness, environmental friendliness, thermal and sound insulation properties, strength, and durability. Its use in construction allows for the creation of comfortable, safe, and energy-efficient buildings while reducing costs for both construction and operation.
Today, foam concrete is widely used in a variety of projects, from low-rise residential buildings to large industrial facilities. Its unique properties make it one of the most promising materials in the construction industry, ensuring a steady demand in the market.
Modern construction demands not only high precision and speed in design but also efficient resource management. One of the key tools that helps achieve these goals is Vertex BD software. INDESOL, a company specializing in the design and construction of modular buildings from light steel structures (LSS), actively uses this platform to optimize its processes. In this article, we will explore the benefits that Vertex BD brings to the company's operations.
Vertex BD supports Building Information Modeling (BIM) technology, allowing the creation of informational building models. BIM includes not only geometric data but also information about materials, lifespan, costs, and other parameters. For INDESOL, this means more effective management of a building's lifecycle—from design to operation. To learn more about the benefits of BIM, you can read the article on our website.
The use of Vertex BD software in INDESOL's operations not only improves design accuracy and speed but also optimizes resource utilization, reduces costs, and enhances the quality of the final product. This makes Vertex BD an indispensable tool for designing modular buildings from light steel structures, helping the company remain competitive in the modern construction market.
The adoption of advanced technologies such as Vertex BD and BIM underscores INDESOL's commitment to innovation and high-quality standards, making it a reliable partner for clients worldwide. To learn more about Building Information Modeling (BIM) technology, you can read the article on our website..
We have developed unique profiles and a specialized module fastening system designed specifically for our technology, which involves filling the modules with foam concrete.
Our technical solutions ensure reliability, ease of installation, and efficiency, significantly simplifying the construction process.
Explore sample modules commonly used in modular construction. These examples are for demonstration purposes only — each module can be tailored to meet specific design and functional requirements.
Finishing options:
Factory-finished modules – delivered fully completed with interior finishes such as painted walls, tile work, installation of plumbing fixtures, windows, and doors.
On-site finishing – available for clients who prefer or require final customization during assembly on the construction site.
Kitchen Module – a fully prepared space for kitchen installation.
Living Module – suitable for use as a bedroom, living room, or office.
Bathroom Module – includes a shower, toilet, and all required utility connections.
Staircase Module – provides vertical access between floors.
INDESOL modular homes help reduce construction costs by up to 60% thanks to fast on-site installation and factory-built volumetric units filled with lightweight foam concrete.
- Site preparation. Before delivering the modules to the construction site, it is necessary to prepare the site. This includes clearing the area, leveling the surface and creating the necessary infrastructure (roads, electricity, water supply, etc.).
- Delivery of modules. Finished modules are delivered to the construction site using special transport. It is important to ensure the safety of the modules during transportation and unloading.
- Building assembly. At the construction site, the modules are connected to each other using special fasteners and technologies. This process requires precision and professionalism to ensure the reliability and stability of the structure.
- Connecting utilities. After assembling the building, the necessary utilities are connected: electricity, water supply, sewerage, etc.
- Finishing work. The final stage is finishing work, which includes the installation of doors, windows, interior decoration of premises, etc. (if these works were not performed at the factory). Finishing work gives the building a finished look and ensures comfortable living or working.
- Building operation. After the facility is handed over, the modular building is ready for operation. It is important to comply with the operating rules, conduct regular inspections and maintenance of the building to ensure its durability and safety.
INDESOL has developed an advanced modular construction technology that has no equivalent in the world. At its core is a unique combination of foam concrete as a filler and a lightweight steel frame. This solution ensures exceptional structural strength, lightness, and outstanding thermal and sound insulation.
- Patented innovation: Every stage of production, from material selection to module assembly, is based on cutting-edge engineering solutions and protected by patents.
- Superior performance: Foam concrete provides high levels of insulation, while the steel frame ensures the necessary rigidity and durability.
- Eco-friendliness: The materials used have a low carbon footprint, reducing environmental impact.
- High construction efficiency: The light weight, ease of transportation, and full factory readiness of the modules significantly reduce building time.
- Maximum construction speed: The modules are pre-assembled and ready for installation, accelerating the building process.
- Energy efficiency: The high thermal insulation properties of foam concrete lower heating and cooling costs.
- Optimal balance of strength and lightness: The combination of a steel frame and foam concrete ensures reliability without unnecessary weight.
- Design flexibility: The technology is suitable for constructing buildings of any type, from residential homes to commercial and industrial facilities.
The INDESOL module manufacturing process is fully automated and adheres to strict standards. From material preparation to final inspection, advanced equipment guarantees impeccable quality and precision.
Thanks to an innovative method of integrating foam concrete with a steel structure into a unified system, INDESOL offers the construction solution of the future—meeting the highest industry standards.
Discover the potential of the INDESOL production platform — up to 1,000 m² of modular housing per day. A scalable solution for fast return on investment.
To visually demonstrate the innovation behind our method, below is a schematic of our core technological line.
Our company has developed multiple production lines tailored to different capacity requirements. Factors such as project complexity, degree of modular finishing, personnel qualifications, and other key parameters influence production output. This approach allows us to flexibly adapt manufacturing to specific client needs.
Currently, we operate the following production lines:
This multi-level approach enables us to optimize resources and achieve maximum efficiency at every stage of production.
Light Steel Section Manufacturing Area
Steel Frame Assembly Area
Section for Filling Modules with Foam Concrete
Section for Holding Modules until Foam Concrete has Completely hardened
Section for Final Preparation of Modules for Shipment
Light Steel Section Manufacturing Area / Steel Frame Assembly Area
Section for Filling Modules with Foam Concrete
Section for Holding Modules until Foam Concrete has Completely Hardened
Section for Final Preparation of Modules for Shipment
Light Steel Section Manufacturing Area
1.1AUTOMATIC PURLIN ROLL FORMING MACHINE
1.2HYDRAULIC DE-COILER
1.3PRODUCT SUPPORT FRAME
1.4SORTING TABLE
The multipurpose machine is classified as professional equipment for manufacturing light steel frames. It is specifically designed to meet all technical requirements and operational features necessary for assembling modular structures and panels, which are subsequently filled with foam concrete.
Our machine is driven by reliable reducers and includes the following components:
- DE - coiler,
- Feeding and leveling device,
- Punching system,
- Pre-cutting module,
- Profiling system,
- Hydraulic post-cutting unit,
- Output table,
- Hydraulic station,
- PLC (Programmable Logic Controller) for automated control.
It is equipped with an intelligent servo motor version, ensuring high precision and operational stability. The machine is compatible with design drawings from various architectural and construction software programs. Combined with modern digital industrial control software, it achieves high productivity, minimizes waste, and meets the strictest quality standards.
This equipment is designed for manufacturing light steel beams, trusses, wall panels, and floor slabs used in high-rise residential buildings, cottages, and apartment buildings. It is ideal for producing floor slabs for:
- 1-3 story residential houses and villas,
- 1-6 story apartment buildings,
- 1-8 story commercial properties.
This machine is the optimal solution for manufacturing floor slabs for high-rise buildings and supports CC and CU technologies. It enables the creation of a fully automated construction system characterized by high production speed, low cost, minimal waste, and flexible configuration options for various specifications.
- Material: Galvanized coil, zinc coil
- Width: 3 " to 13,8" (75mm to 350mm)
- Thickness: 0.8 - 4.5mm
- Height: single size 1 5/8" (41mm) Can be also customized to 1.25" or 2"
- Lip: 5/16" to 3/5" (8mm to 15mm)
- Tensile Strength: 355Mpa, 386Mpa,480Mpa
- Coil width: depends
Punches of other sizes can be added upon customer request.
1.1. Automatic Purlin Roll Forming Machine
1.2. Hydraulic De-Coiler
1.3. Product Support Frame
1.4. Sorting Table
Steel Frame Assembly Area
2.1ASSEMBLY TABLE
2.2SHEET FIXING TABLE
2.3MULTIFUNCTIONAL SHEET FASTENING BRIDGE
2.4BUTTERFLY TURNING TABLE
2.5INTERMEDIATE TABLE-TILTER
2.6INTERMEDIATE VERTICAL TABLE
2.7MODULE ASSEMBLY TABLE
Each company involved in the production of frame-panel houses has its own unique characteristics and requirements. That’s why we develop customized solutions in close collaboration with our clients.
Our steel frame assembly production line is designed with your specific needs in mind to ensure maximum efficiency, high precision, and full compliance with your product requirements. By integrating modern technologies and automated processes, we optimize the production cycle and minimize material waste.
The use of a CAD/CAM-controlled production line guarantees exceptional accuracy and flexibility in manufacturing wall structures with a metal frame. When designing the equipment, we take into account not only your production capacity requirements but also the specific structure of the elements being produced, as well as future scalability and modernization opportunities.
Our solutions help you enhance product quality, reduce manufacturing costs, and achieve maximum profitability.
Advantages
- All structural elements are manufactured on a single production line.
- High overall productivity.
- Flexible production of batches in various sizes.
- Enables the manufacturing of roof, floor, and ceiling elements.
- A unified system covering all stages, from assembly to positioning for foam concrete pouring.
- Can be adapted to meet individual customer requirements.
- Can be upgraded to achieve a higher level of automation.
- High quality and cost reduction due to a high level of prefabrication.
- Minimal setup time thanks to automatic machine adjustments based on element specifications.
- Precise results due to a high degree of accuracy.
- Reduces physical strain on employees.
Assembly Table
Sheet Fixing Table
Multifunctional Sheet Fastening Bridge
Butterfly Turning Table
Intermediate Table-Tilter
Intermediate Vertical Table
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Module Assembly Table
Section For Filling Modules With Foam Concrete
3.1Unit for preparing foam concrete mixture
3.2Mobile passing trolley for supplying modules for filling
3.3CONVEYOR FOR FEEDING MODULES FOR FILLING
3.4Mobile pass-through trolley for feeding modules after filling
The foam concrete module filling section is a fully automated production line designed for precise and uniform filling of modules and panels with foam concrete. The automated processes ensure consistent quality, optimize material consumption, and minimize production waste.
Key Features:
- Full Automation – The production and pouring of foam concrete are fully automated, eliminating human error and increasing overall efficiency.
- High Precision and Flexibility – The integration of CAD/CAM control systems ensures accurate dosing and even distribution of foam concrete, allowing for adaptation to various product types.
- Customization for Specific Requirements – The production line can be adjusted to meet the specific needs of each client, ensuring compatibility with unique product characteristics.
- Resource Optimization – Reduced waste and increased energy efficiency thanks to an intelligent process control system.
- Quality Control at Every Stage – Automated monitoring systems ensure stable foam concrete properties and uniform distribution throughout the entire product volume.
- Tailor-Made Foam Concrete Formulation – Our specialists develop a custom foam concrete mix based on the raw materials available in your region. We pay special attention to this aspect to achieve the best balance between high material quality and minimal costs. Additionally, we carefully select all chemical additives and components to ensure the durability, strength, and stability of the foam concrete.
Our advanced technologies significantly enhance the quality of the final product, reduce production costs, and ensure the reliability and durability of the structures.
Unit For Preparing Foam Concrete Mixture
Mobile Passing Trolley For Supplying Modules For Filling
Conveyor For Feeding Modules For Filling
Mobile Pass-Through Trolley For Feeding Modules After Filling
Section For Holding Modules Until Foam Concrete Has Completely Hardened
This line is designed to hold modules until the foam concrete has completely hardened, ensuring optimal conditions for the material to gain strength. This is a crucial stage of the technological process that directly impacts the quality of the final product.
Key Features:
- Hardening Time Control: The hardening time of foam concrete ranges from 6 to 12 hours, depending on the quality and characteristics of the raw materials used, as well as regional climatic conditions.
- Automated Transportation: The line includes a MOBILE PASSING TROLLEY, which automatically moves the modules between technological stages, minimizing manual labor and increasing production efficiency.
- Full Automation: The line is integrated into the plant’s overall software system, allowing real-time monitoring and control of processes.
- Minimal Labor Requirements: Due to its high level of automation, the line requires minimal personnel for maintenance, reducing production costs.
- Flexibility in the Production Process: The ability to adjust line parameters to accommodate various production conditions and product requirements.
The use of this line contributes to increased productivity, improved quality of foam concrete products, and reduced production costs.
Conveyor
Mobile Passing Trolley
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Section For Final Preparation Of Modules For Shipment
Purpose of the Line
The final module preparation line is designed for comprehensive processing of modules before they are shipped to the construction site. This stage is the final step in the production process and significantly enhances the quality and readiness of the modules for installation.
Main Preparation Processes
Module preparation for shipment includes:
- Puttying and finishing – eliminating minor defects and preparing surfaces for further finishing.
- Installation of windows and doors – mounting all necessary elements according to project documentation.
- Painting of walls – applying high-quality paint to ensure durability and aesthetics.
- Installation of plumbing and sanitary fixtures – fitting sinks, toilets, and other essential plumbing components.
- Ventilation and air conditioning installation – integrating HVAC systems to meet environmental and comfort standards.
- Assembly of sanitary units – pre-installing modular bathrooms and kitchens for quicker on-site assembly.
- Tile application – laying and securing tiles to designated surfaces for a finished look.
- Installation of electrical outlets and switches – ensuring safe and convenient access to power sources.
- Additional preparatory work – applying protective coatings, checking connection joints, and installing fastening elements.
Advantages of Factory Processing
Performing these preparation tasks at the factory offers several significant advantages over on-site work:
- High precision and quality – factory conditions ensure more accurate fitting and quality control of assembly.
- Minimized time spent on-site – modules arrive fully prepared, reducing installation time.
- Reduced labor costs and expenses – automation decreases the need for manual labor and minimizes installation errors.
- Protection from weather conditions – work is carried out in a controlled environment, eliminating external influences.
Automated Transportation System
The line includes an automated conveyor, which allows modules to be moved automatically, eliminating the need for manual transportation. This significantly improves production efficiency and reduces the risk of module damage.
Integration into the Production Process
The line is fully automated and integrated into the overall factory management system using modern software. This ensures:
- Synchronization with other production areas,
- Optimization of logistics and module tracking,
- Increased overall production efficiency.
Human Factor
The number of personnel required for operation depends on:
- Workers' qualifications – the higher the qualification and responsibility of the personnel, the more efficiently production processes are carried out, directly impacting the volume of output.
- Degree of module finishing – more complex finishing tasks require additional specialists, which can also affect production performance.
Using this line increases productivity, enhances the quality of finished modules, and significantly reduces costs on-site. Automated processes, integration with the overall production line, and strict quality control at every stage make this approach the most efficient solution for large-scale module production.
Conveyor
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with a Capacity of 500-1,000 м² per day
with a Capacity of 1000-2000 m² per day
with a Capacity of 2000-3000 m² per day
with a Capacity of 3000-4000 m² per day
