R+D Studio, based in Gurugram, is pioneering sustainable construction by utilizing recycled materials in projects ranging from military bunkers to eco-friendly anganwadis. Architect Shridhar Rao and his team have developed hollow blocks made from recycled foundry dust and plastic waste. These blocks, inspired by sandbag building techniques, are three times stronger than conventional bricks and weigh 7.5 kilograms each.
“After stabilizing our innovative product, we sought partners for collaboration. During discussions with the Armed Forces, we recognized a pressing need for thermally insulated and quickly deployable dry construction systems in challenging terrains,” Rao explained. This led to the creation of a Permanent Defence Bunker for the Indian Army, constructed using 1,800 of these blocks, which is currently operational at an altitude of 14,000 feet near Razdan Pass in Jammu & Kashmir.
The hollow blocks are crafted from a proprietary composite known as Green Banana, along with metal and bulletproof glass. Rao elaborated on how the project evolved through multiple visits and discussions with military personnel. “We established a dedicated division within Green Banana focused on specialized materials for defense applications,” he stated.
The construction of these bunkers employs a unique lock-and-pop technique, allowing for quick assembly without the need for mortar or concrete. “The entire system is packaged as a kit, enabling any regiment to assemble the structure in less than 48 hours, regardless of their location,” Rao noted. The blocks, when filled with materials like sand or soil, can also be made bullet-resistant, and they have undergone rigorous testing for snow load and freeze-thaw cycles. “We have observed nearly three winter cycles without any required repairs,” he added.
In addition to military applications, R+D Studio has also designed modular toilets and anganwadis in Vadodara and Telangana. For the anganwadi projects, durability was a key focus. “The boundary walls of public infrastructure must be long-lasting. We designed the anganwadi walls to require minimal maintenance over a decade, surviving floods, heat waves, and harsh winters,” Rao mentioned.
The firm is set to develop modular green anganwadis and tourism cottages for the Gujarat government, expected to launch in early 2026. These structures will utilize dry construction methods and have lift-and-shift capabilities for easy relocation. “The designs incorporate efficiency in light, water, and materials from the outset,” he said. Once operational, these solutions will serve as both climate-friendly infrastructure and high-performance sustainable enclosures meeting security, aesthetic, and cost requirements.
The innovative interlocking construction technique used for the Army bunkers has also facilitated the creation of office spaces through collaborations with Villgro and Habitat for Humanity, executed via their partner Uppigo. “This mortar-free approach has broadened our scope to develop modular lift-and-shift solutions for a variety of industrial and retail applications,” Rao stated, emphasizing the adaptability of these designs for emergency housing and disaster relief. “Our green anganwadis are also designed to function as emergency shelters during crises,” he concluded.
