It sounds like a poorly done script for a fictitious movie, right?
This is actually a reality, however, thanks to China Wu Yi, a global construction firm operating a precast factory and supermarket in Athi River on the outskirts of Nairobi.
The facility, the first of its kind in the region, stocks segments of building parts and hardware, including beams, staircases and slabs, cutting construction time by nearly 40 per cent.
It also significantly cuts costs, reduces pollution and reduces material wastage.
Precast is a modular building system based on ready-made, factory-manufactured components and intelligent connections.
Approved by the Ministry of Lands, Housing and Urban Development in 2012, the building technique is expected to play a major role in the country's dream to cut the housing deficit, which currently stands at 2 million units.
Affordable housing is one of the four economic agendas rolled out by President Uhuru Kenyatta's regime, targeting at least 500,000 housing units every year since 2018.
In an exclusive interview with the Star, China Wu Yi general manager Qiu Wende said they have witnessed the building technique picking pace in the country since they started operations in 2016.
"The factory has engaged in several commercial and residential projects either fully or simply supplying interior wall panels, slabs, beams, columns and staircases," Wende said.
He believes that by delivering the technology, not only stable and safe houses are built, but also the value creation chain is kept inside the countries. Jobs are created and local resources deployed.
Compared to traditional cast-in-situ, precast uses less cement, water, steel and labor
WHY PRECAST
Precast housing uses prestressed steel strands and dry concrete c-50, saving concrete 40 per cent and reinforcement 60 per cent.
The technique also significantly cuts material wastage by 70 per cent according to precast building expert at China Wu Yi Brian Calisto.
"Compared to traditional cast-in-situ, precast uses less cement, water, steel and labour," Calisto said.
He adds that the technique cuts the number of builders on the site by almost 50 per cent, saving investors hugely on human resource costs.
His colleague, Mercy Wambui, quips that the technique respects time as it cuts the construction period by a third.
"Kenya is in urgent need of housing units. I believe if this technology is incorporated into the affordable housing project, Kenya will meet her goals faster," Wambui said.
She said it takes only a week to complete one floor, a task that traditionally takes almost a month.
It is also environmentally friendly as it significantly cuts on littering, noise and general safety at the construction site.
"Most of the work is transferred from the site to a safe and controlled, automated factory environment. This results in improved productivity and minimal logistics," she said.
Furthermore, the use of prefabs is highly adaptable. While the traditional building can be hard to extend without dismantling part of the house. the modular home allows room for an extension as most of the assembled parts can be reassembled in a different style.
It will not only cut on time, cost and material wastage but will also limit theft and corruption that sometimes impend public projects
COSTING
Construction expert Gilbert Muchemi gives a practical example of the effectiveness of the technology.
He said it will cost you between Sh3 million to Sh3.8 million to set up a three-bedroom house using the conventional method, depending on the location.
"This, without factoring in material wastage, theft and other miscellaneous expenditure," Muchemi told the Star.
On the other hand, construction of a similar project via precast takes at most three weeks and will cost at most Sh2.6million.
He adds that a 2-bedroom house costs at most Sh2 million, saving between 40-45 per cent, depending on the client’s requisition.
He, however, warns of high transportation costs and the lack of enough local experts.
China Wu Yi, which invested Sh10 billion in this technology, says most of its resources are sourced locally, save for machines that are imported from Germany.
"Our main raw materials are sand, concrete and cement, which we source locally. It perfectly demonstrates the 'buy Kenya build Kenya' mantra," Wende said.
The housing wing of the company offers jobs to thousands of locals either at the factory or when contracted to undertake projects.
Wende says the firm has transferred skills to many artisans, who are taking the new building technology to different corners of Africa.
"We hope to open more factories across the country once the demand for this technology picks. So far, we have partnered with several local universities and building institutions to orient upcoming engineers," Wende told the Star.
Although modular homes are widely accepted in developed countries, such as the US, UK and China, there is a great need to create awareness in the developing world.
According to experts at China Wu Yi, poor transport network, deficiency of experts and high cost of machines used are hindering the adoption of this technique, which holds the key to housing promise in the continent.
The firm exuded confidence that the country will quickly achieve its target on the housing agenda if the technology is adopted.
"It will not only cut on time, cost and material wastage but will also limit theft and corruption that sometimes impend public projects," he said.
Wende added that prefabs have helped Kenya deliver some top infrastructural projects in a record time, including the Standard Guage Railway and the recently unveiled Nairobi Expressway.
PROJECTS
China Wu Yi recently helped CBK pensioners fast-track the completion of Sh2.49 billion 27-story skyscrapers.
Located on Nairobi’s Harambee Avenue, it has six basement levels and space for a Kenya currency museum, offices and conference rooms, among other salient provisions.
Both traditional and prefab models were employed in the construction of the project, which took two years.
"While it took a whole month to erect a floor using the conventional building technique, we took a maximum of three weeks to do the same," Wanda said.
The iconic building boasts many unique features, including a 360-view area at the top, and it is solar-powered.
Its unique design gives the impression of two leaning towers facing the opposite direction, a design exemplifying two retirees.
During the official opening in late May, President Uhuru Kenyatta praised the constructors.
"With the addition of this skyscraper, our capital city of Nairobi skyline now acquires not just a new building, but one whose design is very bold and without question, very distinctive," Uhuru said.
The firm also played a key role in the renovation of the Uhuru Gardens, a national facility that President Uhuru Kenyatta said offers a platform where the past, the present and the future converge.
The museum has up to six compartments, all evoking memories of the country’s struggle to attain self-rule.
The firm constructed all pillars at the facility in a record two months.
