Diesel Engine Major’s New Facility Centre

Background
The customer wanted a strong, durable, leak proof and aesthetically pleasing roof for its third manufacturing plant in Phaltan. The scope of work included design, manufacture, supply, project management and installation of new roof for this upcoming project.

Leak-Poof Solution
Due to high end manufacturing operations, the customer was looking for 100 per cent leak proof solution. LYSAGHT FLEX-LOK® profile comes with on-site roll forming option and provides single length of the sheet from ridge to eve, wherein no fasteners are exposed to atmosphere and eliminates chances of roof leakage. This system provides excellent weather tightness and wind uplift resistance. Due to a large roof area, the overall quantity of sheets would be more if used in standard length and transportation would have be cumbersome. LYSAGHT FLEX-LOK™ sheets of 52-meter length were roll formed through on-site roll forming method for this project.

Timely Completion
Availability of finished goods at site due to onsite roll forming option eliminated transportation time and accelerated the installation work and enabled timely completion of work; the same was achieved through onsite roll forming method which could roll out upto 5000 sq. mtr. area of LYSAGHT® FLEX-LOK™ sheets on daily basis.

Quality Workmanship
With the use of machine seamed and on-site roll formed LYSAGHT® FLEX-LOK™ roofing sheets, Tata BlueScope Limited delivered a 100 per cent leak proof roofing, thereby exhibiting superior quality of workmanship.

 

The new age construction technology from LYSAGHT® team was put into place to enable the workforce to execute the job seamlessly. Due to safety trainings and regular supervision, the project was completed without any unsafe incidence. With the use of LYSAGHT® FLEX-LOK® on site roll formed sheets; the client was able to complete the project in time, resulting to substantial savings in overall project cost and time.

Ajay Rattan, GM – Sales (Construction & Engineering),
Tata BlueScope Steel

 

Against The Odds
Tata BlueScope Steel has the clean slate in this project of safely working at the height of 15 metre (50 feet) and maximum sheet length of 58 metres. It was an uphill task of facing strong winds, since the work was being carried out at a height was challenging enough for the TBSL team. This was met by adopting high safety standards and accurate supervision of the entire activity.

The new age construction technology from LYSAGHT® team was put into place to enable the workforce to execute the job seamlessly. Due to safety trainings and regular supervision, the project was completed without any unsafe incidence. With the use of LYSAGHT® FLEX-LOK® on site roll formed sheets; the client was able to complete the project in time, resulting to substantial savings in overall project cost and time.
Value engineering by LYSAGHT® team helped to optimize the steel usage by providing on site roll forming. Single length sheet of 58 meter from ridge to eve avoided any joints and eliminated any kind of leakage. This also helped savings in lap lengths thus reducing the input material and installation time.

As the customer was looking for leak-proof roof, Tata BlueScope Steel gave installation support of the best quality workmanship to achieve the goal of leak-proof roof, and the average sheet length of 50 meter was used in project. Project site was located at dry industrial area. Thermal stress developed in the roofing system due to high variation in temperature, however, LYSAGHT FLEX-LOK® specially engineered aluminium clips and thermal pads slide neatly onto base of clip which can reduce the thermal bridging effects. Frequent inspections were taken place to achieve the high quality of installation.

LYSAGHT® Flex-Lok™ 500 profile is made out of high end raw material such as COLORBOND® and ZINCALUME®. COLORBOND® material is environment friendly due to the use of lead free paint system and is a 100 per cent recyclable material (steel).

 

For our global client in India, we have delivered a landmark project, benchmarked against the company’s world-wide operations. Tata BlueScope Steel, with its value engineering, new age construction technology, followed by an on-time project completion undertaken with world class safety practices, has truly delivered a structure worthy of an International repute. Right from the beginning of the construction phase, TBSL team has been collaborating with the best quality workmanship for the entire installation process.

Sadik Khan, Venkatramanan Associates, Pune

Fact File
Customer: Diesel Engine Manufacturing Market Leader
Location: Phaltan, Maharashtra
Project Size: 72,000 sq. mts.
Profile Used: LYSAGHT® FLEXLOK™ 500, LYSAGHT® TRIMDEK® 1015
Contractor: B. G Shirke, Pune
Consultant: Venkatramanan Associates, Pune