Volvo Truck Factory, Bangalore

volvo-truck

Volvo India Pvt. Ltd. had planned to expand their facility located at Yalachahally, Tavarekere Post, Hosakote, Bangalore. The total construction area for the proposed industrial expansion was 25000 sq. mtr. with pre-engineered steel building concept. Frame members are designed in accordance with Indian Standard IS 800. Cold formed members are designed in accordance with the Indian Standard IS 801.

The Expansion
The total construction area for the proposed industrial expansion was 25000 sq. mtrs. The critical challenges were to ensure high quality work, while maintaining high standards of safety, and no disturbance to ongoing production activities. This needed teamwork of the highest order between all the stakeholders, viz., Client project team, Design Consultants, FABS as PMC, Contractors and Client Production team. Indeed, one of the key driving forces for success was the strong support from Volvo, both, in the form of motivation as well as direction-setting for all the stakeholders.

Each aspect of the project plan and execution methodology was reviewed through a robust mechanism of team review meetings to ensure all stakeholders were on board before selection of technology/systems/materials was finalized. The PEB and roofing system too underwent this screening process before being ordered and installed.

The PEB Route
The PEB design was taken through a strict process of review with experts, site confirmation and sign-off with all stake-holders including manufacturing teams to ensure that all critical loads, including special overhead crane requirements, were adequately provided for. The size and assembly plan of the PEB components used for steel column, roof truss, purlin and roof sheets/wall cladding were oriented to suit the site constraints and factory inspections ensured compliance with project expectations.

One of the most critical challenges was to connect the new buildings with the existing structures – the PEB transition from old to new structures underwent very detailed reviews by the project team before being finalized, especially since the production activities could not be allowed to halt for project work. The final connections between buildings and services were done as part of a special shut-down process using work holidays, round-the-clock shifts, etc. and this was meticulously planned right down to the smallest detail, including tea/snacks timings for the shift work teams.

The Structural Outline
Frame members are designed in accordance with Indian Standard IS 800. Cold Formed members are designed in accordance with the Indian Standard IS 801. These Pre-fabricated structure at various sizes brought in to site then assembled and erected with bolt & nut system.

Built Up Primary Members: Grade 50 confirming to ASTM A572 materials having min. yield stress of 345 N/mm2. HOT ROLLED Members: IS 2062 Grade A.

The secondary member is the light gauge cold formed sections having min. yield stress of 345 N/mm2. The existing Volvo building was expanded with area of 15,000 sq. mtr. steel building. There are other standalone steel building units with area of 10,000 sq. mtr. steel building considered with 6-meter clear height with overhead crane load.

A FAB(S) Coordination
Material receipt, handling and storage plans were worked out in advance. Close coordination was achieved with the supporting vendors like civil, plumbing, etc. through a system of detailed site reviews and action plans to ready the site for receiving the PEB components. Safety was of utmost priority, and all the site teams were taken into confidence on the expectations and detailed “safe work method statements” were drawn up.

n-sridhar

“The size and assembly plan of the PEB components was oriented to suit the site constraints and factory inspections ensured compliance with project expectations. Close coordination was achieved with the supporting vendors like civil, plumbing, etc. through a system of detailed site reviews and action plans to ready the site for receiving the PEB components. Safety was of utmost priority, and all the site teams were taken into confidence on the expectations and detailed “safe work method statements” were drawn up. Before starting erection of the PEB components, the PEB installation vendor team was given a thorough induction into the safety and quality requirements.”

N. SRIDHAR, Operations Head
Facilities And Building Solutions Pvt. Ltd.

Before starting erection of the PEB components, the PEB installation vendor team was given a thorough induction into the safety and quality requirements. On arrival of the PEB components at site, all the above plans were put into action and monitored closely in order to achieve safe assembly and erection of the PEB structure as per design intent. This included a variety of quality tests at key stages to ensure that the work was done “first-time-right”. Success in achieving all this required strong teamwork and positive intent from all stakeholders and we were happy that the project received this in full measure.

Sticking to Safety
Safety and Quality were key focus areas on all the project works and the PEB system presented unique challenges. Volvo adopted a strict zero-tolerance approach to these two subjects and FABS was an enthusiastic partner in this. Safety system tools like Job Safety Analysis, Safe Work Method Statements, Work Permits, Induction and Training, Motivation & Rewards, etc. were implemented to ensure a safe work environment.

Similarly, for achieving the required quality of work, the work teams were given detailed inductions and expectations were clearly set out and then monitored closely to minimize rework or errors. The project won a Global Safety Award within the Volvo factory system, measured across all their factories across the globe. FABS is very proud to have contributed to this project achieving such a prestigious Award.

Some of the complexities faced during the making of the project was the merger of old and new buildings without affecting the existing operations, and to match the profile of existing building with new buildings.

Salient Features

  • Natural Ventilation with Louvers at Monitor & Wall
  • Sky Light provided 5% of total area
  • Screw less Double Lock Standing Seam roof
  • 50mm thick (48 Kg/Cum) Insulation with liner sheet.

Structural Uniqueness

  • The existing Volvo building was expanded with area of 15,000 sq. mtr. steel building
  • Steel building considered with 7.5 mtr clear height with all overhead crane load
  • 2 MT crane to be supported on rafter @ every 6m span
  • 24 mtr span considered without intermittent column

Steel Sections

  • Built-up members: Grade 50 confirming to ASTM A572 materials having min. yield stress of 345 N/mm2
  • Hot Rolled members: IS 2062 Grade A