HILTI India Pvt Ltd, a renowned multinational corporation, has embarked on an innovative journey to establish a DGNB-rated Green Building, demonstrating a commitment to sustainability, accessibility, and usability. This project stands as the first of its kind in India, meeting the rigorous standards set by the German Sustainable Building Council (DGNB), and is a testament to the integration of high standards in construction and design.
Dr CN Srinivasan, Managing Director of CR Narayana Rao (Consultants) Pvt Ltd, sheds light on the distinctive and innovative aspects of the HILTI India Pvt. Ltd. project.
According to Dr. Srinivasan, HILTI’s facility not only addresses high standards in sustainable construction but also prioritises a high-quality, consistent work environment that benefits employees and optimises productivity year-round. This integration of sustainability, innovation, and human-centric design reaffirms HILTI’s leadership in the industry, setting a strong example for future sustainable building projects across India.
A Benchmark
The stringent DGNB requirements naturally directed the project toward using structural steel—marking a significant milestone as the first DGNB-rated steel building in the country. The adoption of structural steel aligns with HILTI’s emphasis on sustainability and engineering excellence. This approach highlights the flexibility of steel as a material, which supports innovative design while fulfilling strict quality and environmental standards.
HILTI’s facility embodies the ‘Form Follows Function’ design principle, balancing functionality, sustainability, aesthetics, and efficient engineering across both administrative and manufacturing spaces. The focus on safety is evident in meticulous planning that prioritises ease of movement, wide passages, and barrier-free accessibility, ensuring inclusivity for all users.
Project Highlights
The campus features a main plant area measuring 120 x 105 m, incorporating a north light structure equipped with insulated roof and wall cladding. This innovative design also integrates double-skin cladding and insulated roofing to enhance energy efficiency. The manufacturing and administrative areas are thoughtfully designed, combining advanced technology with sustainable practices:
– Column-Free Areas: These spaces provide a more efficient working environment, enabling unobstructed movement and optimised layout.
– Adequate Ceiling Height: Ensures human comfort and accommodates essential services.
– Fire Protection: Comprehensive fire safety measures for all steelwork.
– Barrier-Free Accessibility: Wide, accessible passages facilitate safe and efficient movement for both able-bodied and differently-abled individuals.
A Refined Approach
Embarking on this project was a first-time endeavour that required a dedicated, ‘on the toes’ approach due to the strict time constraints and the limited number of design iterations allowed. A strong emphasis was placed on achieving a ‘Right First Time’ methodology, avoiding wasteful cycles that could consume valuable time and resources.
Key design features included a clean soffit with no perching points for birds, ensuring minimal maintenance and reduced exposure to solar radiation, thereby lowering power costs. The high reflectivity of the ceiling further enhanced the uniform quality of light distribution, contributing to energy savings by reducing the need for artificial lighting.
The achievement of maximum column-free spaces was possible through the use of steel frames as the primary structural system. This not only facilitated flexibility but also allowed for adaptable process floor layouts and machine arrangements. This outcome was the result of continuous iteration and close coordination across all design disciplines, reflecting a meticulous and collaborative effort.
Key Design Aspects
The design of HILTI India Pvt. Ltd.’s manufacturing unit showcases a comprehensive integration of sustainable and functional design elements, underlining its leadership in eco-efficient building practices. This project highlights various innovative structural and architectural features that make it a model of sustainable development.
The building incorporates double skin cladding, which enhances insulation and energy efficiency, along with insulated roof cladding that minimises heat transfer, contributing to reduced power consumption. Spot cooling is strategically implemented where needed, ensuring targeted climate control. Additionally, the design harnesses wind flow for ventilation while employing dust control measures to maintain air quality.
Noise control features are integrated to ensure a quieter, more comfortable working environment, while dedicated utility corridors are placed at both roof and floor levels for streamlined maintenance and operational efficiency.
The 120 x 105 m main plant, featuring a north light structure, maximises natural light and provides airtight insulation in both the roof and walls for enhanced energy performance. The plant’s height reaches 12.75 m at the ridge, and approximately 1,000 MT of steel were used in its construction. To further optimise daylight and thermal regulation, high-performance laminated glass is used within the north light frame structure.
Radiant and slab cooling systems were implemented at the Vadodara manufacturing unit to enhance energy efficiency. These systems are designed to reduce operational expenses (OPEX) by 35-40 per cent, thanks to their ability to distribute temperature evenly and maintain lower air velocity. This results in a consistent indoor climate that is draft-free and quiet, promoting a comfortable working space for employees.
This meticulous approach underscores HILTI’s commitment to innovation and sustainability, setting a benchmark for future industrial projects that seek to blend functionality with environmental responsibility.
Advanced Energy-Efficient Solutions
A key aspect of the HILTI project is its focus on operational efficiency. The building utilises radiant and slab cooling systems, capable of reducing operational expenses by 35-40 per cent. These systems maintain a consistent, draft-free, and quiet environment, enhancing occupant comfort. Additionally, high-performance laminated glass minimises heat transfer while providing optimal daylighting.
Sustainable Infrastructure
The project incorporates several energy-saving features that underscore its strong commitment to sustainability. Spot cooling for dust control is utilised to maintain high air quality while reducing energy consumption. This targeted cooling method ensures efficient use of energy by cooling only specific areas as needed.
Additionally, wind harnessing techniques are employed to leverage natural wind flow, further enhancing energy efficiency and reducing reliance on mechanical ventilation. The inclusion of a syphonic drainage system is designed for effective rainwater management, promoting sustainable water use and contributing to the overall eco-friendly nature of the facility.
These sustainable measures have created a measurable, high-quality working environment that remains consistent across all seasons, resulting in significant benefits. The improved inside ambiance and a fatigue-free work environment have directly enhanced worker productivity, showcasing the positive impact of thoughtful, sustainable design on operational efficiency and employee well-being.
Aligning with its commitment to long-term sustainability, HILTI has ensured that the manufacturing facility will include products designed to enhance the lifespan of the structure. This approach allows for future process upgrades through retrofitting, upholding the company’s quality philosophy and contributing to the durability of the building.
Holistic Planning
To prevent conflicts in the movement of people and materials, careful internal planning was implemented. The wide, accessible corridors are designed to accommodate heavy foot and material traffic without hindrance. The project places significant emphasis on airtight cladding to maintain the integrity of conditioned spaces, further optimising energy usage.
This landmark project is more than just a building; it is a testament to innovation in design and sustainability. By choosing structural steel and adhering to DGNB guidelines, HILTI India Pvt. Ltd. has set a new benchmark for sustainable construction in India. The project not only showcases the versatility of steel but also serves as a blueprint for future developments aimed at achieving high standards in functionality, environmental responsibility, and human-centric design.
HILTI’s commitment to quality, showcased in this project, reinforces its reputation as a leader in sustainable construction. This initiative, realised with the involvement of CRN, has demonstrated that structural steel can be the backbone of pioneering green buildings, opening doors to a new era in Indian construction.
Quote
“HILTI’s unique combination of being German at Head — strict on safety, quality, timelines, and sustainability—and Indian at heart — inclusive and adaptable —has driven their projects to run seamlessly. The consulting team enjoyed financial freedom, allowing quick, effective troubleshooting. The strong teamwork among vendors made review meetings productive and enjoyable, contributing to smooth project management and overall success.”
Dr CN Srinivasan, Managing Director, CR Narayana Rao (Consultants) Pvt Ltd
Fact File
Project: HILTI India Manufacturing Facility, Gujarat
Client: HILTI India Pvt. Ltd.
Architect & Consultant: CR Narayana Rao (Consultants) Pvt Ltd
Fabricator: Kirby Buildings Systems Ltd
Tonnage: 1,000 MT
Status: Completed
