The Manufacturing Facility for Furniture in Navi Mumbai, Maharashtra, transformed a 40 year old RCC structure into a state-of-the-art, efficient, and sustainable production hub. Located in a dense urban area, the redesign incorporated a simple roofing system with north-facing skylights aligned to the site’s east-west orientation, flooding the interiors with natural light and enhancing functionality, workflows, and user comfort.
Inspired by the nearby Parsi mountains, the facility’s roof design establishes a visual connection with its natural context. Additionally, the design includes a cantilevered boardroom that doubles as an entry canopy, combining aesthetic appeal with practical functionality. Spatial planning of this structure features a high-bay area at the centre, equipped with automated cranes for loading and heavy activity, and low-bay areas on the sides for functions like the paint booth, ensuring an optimised workflow.
Kush Patel and Ruchita Jagzap, Co-founders of Raagin Karman, mention how efficient lighting, thoughtful spatial planning and functional design elements have enhanced the manufacturing process.
Construction Conundrum
The client, a leading manufacturer of contemporary ergonomic furniture, sought to establish a modern factory in Mumbai to support large-scale turnkey contracts. Initially, they anticipated only minor refurbishments to the ageing RCC factory shed on-site. However, site analysis revealed significant challenges, including an inadequate 5 m x 20 m column grid, poor lighting, structural deterioration, and an inefficient layout, making repairs impractical. This prompted the creation of a new, purpose-built facility designed for functionality, sustainability, and innovation.
Steel was chosen for its durability, flexibility, and resistance to Mumbai’s heavy rains, ensuring a future-ready design with long-term cost advantages. Timely completion of the roofing before the monsoon was critical to avoid delays and align with the client’s vision of an efficient, high-quality production hub.
One of the obstacles was the existing structure’s lower elevation compared to the surrounding road level, necessitating the filling of the site. This RCC Structure was demolished as its large size columns and small span column-grid left limited space for machinery installation. The original design had a 5 m span, but a 9 m span was required to optimise the layout with fewer columns. The debris was recycled to fill the site, and steel was reused, which contributed towards making the project sustainable. Considering the tight timeline and the commitment to sustainability, a decision was made to demolish the old structure and build an efficient one.
PEBs provided a lightweight, sleek structure, and aided in simultaneous construction of the steel frame and plinth, ensuring an efficient progress. In contrast to traditional construction, which often faces waste management challenges, PEBs effectively eliminate this issue. Convincing PEB vendors to design cantilevers was initially difficult due to their concerns about large member sizes, such as 1.5 m deep girders. After extensive discussions and alternative design proposals, the vendors were ultimately convinced.
Another significant challenge came with the early delivery of 28 machines in 11 containers. To manage this, the client opted for direct delivery to the site instead of the container yard. The 5,000 sq m site was still under construction, so a system was developed to efficiently move and relocate the containers without disrupting the ongoing work.
Initially, a KALZIP clip-lock roofing system was to be used, but long lead times necessitated a switch to the conventional clip-lock system. Installing a sandwich roof for insulation would require more time relatively, to address this roofing was executed in phases: enclosing the outer shell first, followed by insulation from below. This unconventional method allowed for quicker completion while ensuring effective insulation.
Powerful Precision
The project management team played a vital role in ensuring smooth execution, managing manpower effectively, and maintaining a rigorous schedule. Weekly meetings were held to align all stakeholders, streamline project detailing, and address client’s concerns. Despite limited space around the standalone building, efficient organisation of waste and materials helped keep the site operations seamless. The client had purchased 28 advanced, automated carpentry machines from a single German vendor, who deployed their team to assist. This project also turned the facility into a showcase.
The ducting system for the dust collector was imported from Italy, requiring precise ‘zero-zero’ drawings for fabrication and seamless coordination. The involvement of detail-oriented stakeholders, including the client, vendors, and manufacturers, fostered a precision-driven approach, ensuring the project met the highest standards of quality and efficiency. The design emphasises natural light and ventilation to enhance energy efficiency and worker comfort. The east-facing glass facade provides ample daylight, eliminating the need for ambient lighting to 20 per cent task lights during the day.
A 1.5 m overhang with perforated copper-coloured steel sheets ensures ventilation, rain protection, and fresh air circulation. High-velocity, low-speed (HVLS) fans improve air circulation, creating a comfortable environment for carpenters. This approach reduces reliance on artificial lighting and mechanical ventilation, significantly saving energy.
Astonishing Approach
Below the site lies an underground tank with a 12 m x 6 m pump house and a 1.5 lakh-litre storage tank for firefighting. To avoid the need for pillars or columns in this space, a drop-off zone with a canopy was crafted, creating a designated area to welcome and see off visitors. An office and conference area were incorporated, supported by a cantilever design extending into the factory. The entire box structure ensures stability and eliminates any floating perception, making the facility more reliable and robust.
To reduce weight and enhance aesthetics, dry terracotta cladding was used, offering thermal insulation, an earthy appeal, and branding alignment with the client’s orange-themed identity. Advanced Hunter Douglas panels ensured precision and durability, with a robust substructure for safety. High-tech materials and processes defined the construction. The terracotta cladding, copper sheets, and nut-bolt assembly allows for dismantling and reuse, promoting sustainability.
Automated equipment like beam and welding lines facilitated manufacturing, while hydraulic lifts and advanced cranes expedited erection and enabled maintenance without scaffolding. This approach met tight timelines and ensured precision. The glass facade, supported by maintenance cranes, highlighted functional efficiency, eliminating traditional scaffolding for cleaning or roof work.
The facility is located on a MIDC plot with no scope for significant expansion, the design accounted for potential linear additions by maintaining uniform sections across the factory, office, and display areas. However, surrounding plots’ irregular layouts and roads limit the possibility of meaningful extensions. While future growth would require separate structures, the current layout supports functional and aesthetic coherence within the available space.
Fact File
Project: Manufacturing Facility for Furniture, Navi Mumbai
Client: Narsi & Associates
Architect: Raagin Karman
Structural Consultant: Saunrachana Strucon Pvt Ltd [SSPL]
Project Management: RVSA Consultants Pvt Ltd
Fabricator: Phenix Construction Technologies
Supplier: JSW STEEL
Tonnage: 330 MT
Current Status: Completed
Quote
“We believe that factory buildings deserve the same level of architectural consideration as any other typology. With a large number of workers spending good 8-10 hours a day in these spaces, it is vital to prioritise their comfort and productivity. By focusing on key elements like natural daylight, ergonomic design, and timely project execution, we not only enhance the quality of their daily experience but also ensure that our clients benefit from seamless, uninterrupted operations. The positive feedback from workers, such as reduced eye strain from improved lighting and a more conducive environment for higher performance, drives us to go beyond mere aesthetics. Our goal is to create spaces that truly make a difference in people’s lives, ultimately contributing to the progress of the industrial sector and our country.”
– Ruchita Jagzap, Urban Designer & Co-founder, Raagin Karman
“I focus on design efficiency, this one stands out for its creativity and efficiency, blending functional design with impactful innovations like curved edges, enhanced ventilation, and north light. We completed it on time, which enabled the client to secure major projects like the Lok Sabha interiors. Unlike typical factory sheds, it balanced cost and design value, won awards, and inspired neighbouring factories too. It’s deeply rewarding to see our work influence architecture and enrich lives while setting a new benchmark for factory design in India.”
– Kush Patel, Principal Architect & Co-founder, Raagin Karman
– Vanshika Raigaga
