The Electrical Control Room (ECR) Building for CO ETP at Tata Steel’s Kalinganagar plant stands as a benchmark in innovative steel construction. This G+3 storied structure, spanning 37.25 m x 38.5 m, integrates advanced design principles with efficient material usage. Built with steel structures and reinforced concrete floors supported by metal decking, it showcases functionality and optimisation.
Material Specifications
The structure utilises 695 MT of structural steel, with 65 per cent comprising Tata Structura Hollow Sections of grade Yst355. Additionally, the design incorporates 3120 sq m of 100 mm thick rock wool-insulated sandwich panels and 6200 sq m of metal deck sheets, specifically the 1.0 mm BMT LYSAGHT SMARTDEK 51 by Tata BlueScope Steel. These carefully selected materials balance economic efficiency with superior performance, showcasing an intelligent approach to construction.
Innovative Design
A key highlight of the project is its extensive use of hollow sections, setting it apart from conventional construction practices. The main columns are constructed entirely from large-diameter SHS 400 hollow sections (Yst355), while the secondary beams use 400 x 200 Tata Structura sections. This marks a significant shift from the traditional rolled or built-up I-sections.
The strategic use of hollow sections led to a 20 per cent reduction in steel usage compared to standard joist sections, offering substantial economic and structural benefits. Moreover, employing higher-grade steel improved the building’s strength and durability. Prefabrication of components also contributed to time efficiency, significantly reducing the fabrication period for columns and beams.
Quality Control Measures
The construction process prioritised stringent quality control through the use of bolted connections. By prefabricating all connections in a controlled environment and assembling them on-site, the project eliminated the need for on-site welding. This approach not only reduced labour dependency but also minimised the risk of errors, ensuring consistently high-quality standards throughout the build. This meticulous approach highlights the careful planning and precision that defined the execution of this project.
Challenges and Solutions
The project, while successful, came with its share of challenges. Transitioning to the use of hollow sections demanded a complete rethinking of connection designs typically suited for I-sections. This led to the development of entirely new methods for site assembly. Furthermore, the distinctive nature of the design extended the project timeline to two years, compared to the usual nine to twelve months for similar builds. However, these obstacles were overcome with innovative solutions, setting a benchmark for future steel construction projects.
Quote
“Structural hollow section is a potential structural element for optimal use of steel if fitted strategically on the overall structural system. This achievement underscores Tata Steel’s leadership in advancing steel as a sustainable and efficient building material. By tackling challenges head-on and pioneering new approaches, the ECR building embodies the company’s dedication to innovation.”
– Sanjib Kumar Das, Head – D & E Structural, Engineering & Project, Tata Steel Ltd
Fact File
Project: Electrical Control Room (ECR) Building at Tata Steel’s Kalinganagar plant
Owner: Tata Steel Ltd
Engineering: Tata Steel – Engineering & Projects
Fabrication & Installation: Larsen & Toubro
Tonnage: 695 MT
Tata Structura Qty. Used: 451 MT
