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New Integrated Terminal Building, Aurangabad

Aurangabad is located in the Marathwada region of Maharashtra and is a very important tourist destination for both, domestic and international tourists. The city is also an industrial base, rapidly growing as an important commercial center in the region. All these factors put together provide immense potential for air travel to the city of Aurangabad.

The existing facilities at the airport provides only for handling of domestic air traffic. The runway is suitable for handling AB-320 class of aircrafts; the apron can accommodate 1 no. AB-320 and 1 no. ATR class Aircraft. The terminal building is suitable for 100 departing and 100 arriving passengers and with the growing air traffic becomes inadequate. A large number of foreign tourists come to Aurangabad, but, they reach via Mumbai or Delhi taking domestic flights, as facilities for handling of international flights is not available at Aurangabad.

Keeping in view the above situation, the Airports Authority of India planned the Development of Aurangabad Airport.

The Aurangabad Airport is a perfect example of the brand’s power to shine with excellence. The Airport was planned to be an important hub augmenting the nation’s connectivity. It was all the more vital as the city of Aurangabad was the gateway to the world-famous tourist destinations – Ajanta and Ellora Caves and other places of interest in the vicinity.

In addition, Aurangabad and its neighbourhood is also rapidly evolving commercial centre that has experienced a spurt in to be a prime catalyst for the economic development of the region, as it could facilitate better air connectivity that translated into faster mode of transportation of people associated with the businesses and the cargo required to be delivered.



I really feel privileged to get myself associated with the part of the great team involved in the work of Development of Aurangabad Airport. I had very good cooperation from the people not only associated with work also from general public with whom we have interacted for this work. Especially People of nearby villages adjoining Airport are very nice, cooperative and helpful in giving the land and understanding the specific requirement of Airport for the development. With all their help, Guidance of our senior officers from Mumbai & Delhi and with the active participation of our team of officers and staff of Aurangabad Airport we could successfully complete the work of New Terminal Building and Extension of Runway, so that Aurangabad can be placed as one of the best Airport in the map of International Airports.”
G. Prabaharan, General Manager (Engg-P), Airports Authority of India

Landmark Architecture
Vinay Hedaoo was selected as the structural designer for the modern structure and M/s KITCO was assigned the job of fabricators. This new Integrated Terminal Building at Aurangabad Airport was to be a glass and steel structure offering all kinds of passenger friendly facilities. Tata Structura hollow sections were chosen, as the brand was capable of meeting the requisites of the specific design and engineering. Tata Structura was used extensively to lend the structure an innovative, modern and classy finish that would turn it into a showpiece of creativity and a signature of exclusivity. Today, this landmark airport stands as a symbol of pride, not only for Tata Structura, but for the nation as well. Aurangabad Airport is not only a spectacular structure that represents sustainability, but also epitomizes world-class architectural splendour with its aesthetics.

Committed to Excel
Tata Structura has always stayed committed to its customers with its single-minded focus on delivering ‘the shags to come’. In course of fulfilling the commitment, the brand has adhered to its vision of excellence and innovation to emerge as a market leader steering the construction industry towards a future resplendent with possibilities. From airports, metros and railway stations to IT complexes, industrial clusters, commercial centres, malls, infrastructure and more – Tata Structure has successfully inspired the industry experts to redefine the skyline of tomorrow’s India. Tata Structura has empowered architects, engineers and designers to shape their dreams and fly unfettered on the wings of creativity.

Steel Work
Supplying, providing, fabricating, assembling and erecting at site tubular structure consisting of MS Pipe Rakers, purlins, and metal casing conforming to IS 1161 Grade 310 in the profile shaped as per the drawing with special plate connectors, pinion joints using SAW/MMAW/MIG welding process with cleaning the surface and applying a coat of epoxy primer, and including transportation, cutting, threading, machining, leads and lifts upto all heights, tools and plants and necessary scaffolding, etc. required for all operations involved to make structure of main terminal building. The tubular structure system with plate connectors, pinion joints, etc. is to be provided. The complete structure to be painted with one coat epoxy primer, including preparation of shop drawings had to be approved by the Engineer-in-Charge before start of work.

The above item includes supplying, providing, fabricating, assembling, and erecting at site tubular structure in the bended profile shaped as per the drawing with special plate connectors, pinion joints, using SAW / MMAW / MIG welding process with cleaning the surface and applying a coat of epoxy primer.

MS Pipes were used as per IS 1161 YST 310 Gr. / ASTM A106 Gr. B or equivalent standards. Bolts are high tensile bolts of minimum 10.9 grade having black phosphate coating as per IS 1363/1364 provided with a washer of sufficient thickness to avoid any threaded portion falling within the thickness of the parts bolted together if required.

The bended purlins in the profile as per drawing connected to the profiles MS Rakers with suitable arrangement, metal casing provided at the end of Rakers as per the drawings. The bending of the members wherever specified were in exact profile as per requirement.

Connector were used of high strength, manufactured out of similar grade of pipe material of required dimensions and holes for the bolts in the required position and direction. The item includes cleaning the surface and painting one coat of epoxy primer. The structure was properly bended, connected welded and aligned to get the required profile.

At Tata Structara, we believe in integrity at every step of the process which enables us to stand the test of public scrutiny which is of vital importance to us. We also believe that before we understand our product, first we must understand the people we work with, and our valued customers. Excellence has always been a significant part of our core values, which is why we are where we are today – at the core of your hearts and your structures. We work cohesively as a team to bring the essence of this excellence to you in the form of the hollow sections that revolutionize what you build and make a difference to your creative aspirations.
VINEET SARAF, Chief of Marketing & Sales, Tubes-SBU, Tata Steel

Tubular framework (in truss pattern as per design and drawings) got executed by specialized agencies having requisite experience in execution of similar works of similar magnitude as approved by Engineer-in-Charge. The structure was properly bended, connected, welded and aligned to the required profile, i.e. work was executed as per designs given and workshop drawing prepared by the agency and got approved by the Engineer-in-Charge.

Tubular structure system with plate connectors, pinion joints, etc. was provided in all respects to make the structure of the main Terminal Building. All components of tubular frame were cleared off the dusts/scales etc. completely before applying primer.

Welding was done in accordance with the following Indian Standards applicable:

  • IS 816 Code of Practice for use of metal arc welding for general construction in mild steel.
  • IS 820 Code of Practice for the use of welding in tubular construction.
  • Shearing, chipping or gas cutting prepared profile of fusion faces. In all cases, the faces dressed by chipping, filling or grinding and made regular.
  • The surface to be welded and adjoining metal for distance of at least 20mm must be clean free of rust, scale, paint etc.
  • Each bead of metal had the slag removed by light hammering and wire brushing before the next bead was deposited. The weld must show a good clean contour and on a cut specimen good fusion with parent metal. Before applying paint, the weld had to be carefully chipped and wire brushed.

The works included preparation of shop drawings giving complete information, necessary for the fabrication of the component parts of the structure including the location, type, size, length and detail of ail welds, and nuts, bolts, rivets etc. as per provided by the design drawings. The shop drawings were sufficient to ensure convenient assembly and erection at site. These drawings also included full details of all joints, connections, splices etc.


All connections were either bolted or welded as shown on the drawings. The contractor shall not redesign or alter any connection without prior approval of the Engineer-in-Charge. The components parts were assembled in such a manner that they were neither twisted nor otherwise damaged and prepared such that the specified cambers, if any, are provided. Drifting done during assembly did not distort the metal or enlarge the holes.

All steel work which is bolted together shall be in close contract over the whole surface. Where two bolted surfaces are to be in permanent contact after assembly, each shall be thoroughly scraped free of loose scales, dirt and burs and a heavy coat of red oxide, zinc chrome or other approved paint applied after cleaning and drying.

All bolts were provided with washers under the nuts and the washers shall be tapered on the inside of the flanges or RS joists and channels. Bolts and studs project not less than one full head through the nut after tightening. Unless otherwise specified, the ends of the bolts were burred after erection of prevent the removal of nuts.

High strength bolts were used in bearing of friction as shown on the drawings. High strength bolted joints were made without the use of erection bolts. Bolts shall be of a length that will extend not less than 10mm beyond the nuts. Bolts shall be entered into the holes without damaging the thread-members. They shall be brought tightly together with sufficient high-strength fitting up bolts which shall be re-tightened as all the bolts are finally tightened. Bolt heads shall be protected from damage during placing. Bolts that have been completely tightened hall be marked for identification. Bolted parts shall fit solidly together and shall not be separated by interposed compressible materials. The contract surface in high strength bolted connections shall be free of oil, paint, lacquer, loose scale or other coatings. The facing surfaces shall be machined flat. Final tightening of high strength bolts shall be by turn-of-nut method.

Anchor bolts were set by use of templates secured firmly in place to permit true positioning of the bearing plates and assembles. When in drawings anchor bolts are shown to be installed in sleeves, the sleeves shall be completely filled with grout.

Proper Bead Shape
Minimized penetration to prevent dilution of the weld metal with the alloy elements. Preheating, controlled interpass temperature and controlled heat input.

Welding was performed only by qualified and tested welders specifically trained and experienced for the type of job required to execute the welding work to the complete satisfaction of the Engineer-in-Charge. It was a criterion that the welder should have minimum five years of experience in the job of similar nature.

Use of standard weld symbols as adopted by IS:813 is mandatory. Prequalified jointed which are detailed, prepared and welded in accordance with the requirement of IS:816 shall invariable be used. Structural welding shall not commence until joints elements are bolted or tacked in intimate contract and adjusted to dimensions shown with allowance for any weld shrinkage that is expected. Welding sequence was planned and controlled to minimize undue stress increase or undue distortions on restrained members. Heavy sections and those having a high degree or restraint was welded with low hydrogen type electrodes.

Field Welding shall not be permitted unless shown on the drawings. Subsequent to fabrication, the overlapping or contracting surfaces or other closed sections (such as tubular, box section) which are inaccessible to painting shall be seal welded when the end of the tube is not automatically sealed by virtue of its connection by welding to another member the end shall be properly and completely sealed. Before sealing, the inside of the tube shall be made dry and free from loose scale.

Order of assembly of the tubular section shall consist of welding the tensile member to the main member first. Compression member shall be cut back to overlap the tensile member and then welded to both the tensile members.

As far as possible, the contractor delivered the fabricated steel work to the site in the same sequence as that which he wishes to follow for the erection. Dispatch was scheduled to avoid cluttering up of the site. The bolts required for erection was bagged according to size prior to dispatch.

All structural work was erected in accordance with IS:800, IS:806 and IS:1915 and as per the approved erection drawings. The contractor shall be responsible for setting out the works. The suitability and capacity of all plant and equipment used for erection shall be to the satisfaction of the Engineer-in-Charge. These shall be regularly serviced and maintained. Occupation safety practices shall be strictly adhered to and shall be to the satisfaction of the Engineer-in-Charge.

Individual places shall be plumbed, leveled and aligned. Drift-ins be used only to bring together the several arts. They shall not be used in such manner as to distort or damage the metal. Temporary bracing, but-line and staging shall be provided to ensure proper alignment and to adequately protect all persons, property and to withstand all loading to which the structure may be subjected during erection.

Attachment of such temporary steel work to the permanent steel work shall only be done with the approval of the Engineer-in-Charge. Temporary steel work shall remain in position until the structure is stable and self supporting and permanently bolted or welded to the satisfaction of the Engineer-in-Charge after removal of temporary steel work, the permanent structure shall be made good to the complete satisfaction of the Engineer-in-Charge.

No permanent bolting or welding shall be done until proper alignment has been obtained. Erection of the parts with any moderate amount of reaming, chipping or cutting shall be immediately reported to the Engineer-in-Charge. The steel work shall be rejected unless corrective action is approved by the Engineer-in-Charge.

Placement of joists shall not start until the supporting work is secured. Temporary bridging, connections and anchors shall be proved to assure lateral stability during erection. Bridging to steel joists shall be installed immediately after joint erection, before any construction loads are applied. Horizontal or vertical bridging shall be provided in accordance with the type of span of the joists. Ends of the bridging lines shall be anchored at top and bottom chords where terminating to walls or beams.

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