Introduction: In a sector where speed often competes with structural integrity, Mount Roofing & Structures Pvt Ltd achieved a rare feat — delivering a 1.2 lakh sq. ft. pre-engineered solar PV manufacturing facility in Sira, Tumkur with clockwork precision and zero margin for error. This case study unpacks the project’s scale, its structural complexity, and the rigorous engineering that drove its success.
India’s clean energy transition is calling for industrial spaces that match the pace of innovation. In response, a state-of-the-art solar PV module manufacturing facility was commissioned at Sira, Karnataka. Mount Roofing took on the engineering and fabrication responsibilities for this high-priority industrial asset, executing one of its fastest projects to date with remarkable efficiency.
The client’s requirement was clear — create a high-clearance, column-free structure that allows seamless operations for solar module production, with rapid turnaround and durable envelope performance. Steel was the natural choice, offering the speed, scalability, and precision required to meet these functional and time-sensitive objectives.
STRUCTURAL FRAMEWORK & MATERIAL STRATEGY
The architectural concept revolved around a clean-span industrial shed, engineered with wide portal frames to maximise uninterrupted floor space. The structural engineering approach prioritised robustness without compromising execution agility.
Structural Framework:
- Primary Members: Built-up I-sections designed for long-span stability and wind-load resistance.
- Secondary Members: Cold-formed Z-purlins and C-sections ensuring lightweight yet rigid support for roofing and wall systems.
- Total Steel Tonnage: Over 450 MT of structural steel fabricated and delivered in calibrated phases.
Envelope & Cladding:
- Roofing: 12,000 m² of high-performance Sandwich PUF Panels ensuring thermal efficiency in a high-heat zone.
- Wall Sheeting: Approx. 4,000 m² of PPGL cladding for weather resistance and durability.
- Just-in-Time Delivery: All 1.2 lakh sq ft of roofing panels were manufactured and delivered to site within 24 hours was a logistical triumph that supported rapid installation cycles.
INNOVATION IN FABRICATION AND EXECUTION
What set this project apart was not just its scale but the speed and synchronisation of operations. Facing a compressed timeline, Mount Roofing employed several tactical innovations to align fabrication with on-site progress.
Key Execution Highlights:
- Multi-Zone Fabrication: Steel components were fabricated in parallel streams and dispatched in a zone-wise manner to match site erection sequences.
- Digitally Tracked Installation: Site teams used real-time digital tracking to monitor crane movement, pre-labelled component assembly, and erection timelines.
- 24/7 Site Operation: Dedicated shift-wise teams operated round the clock, coordinating hourly erection targets with safety supervision at all times.
- Pre-Labelled Dispatches: Every component was mapped and labelled according to its position in the erection sequence, eliminating on-site confusion and idle time.
OVERCOMING CHALLENGES WITH PRECISION PLANNING
Despite logistical and climatic hurdles, including unpredictable monsoons and high wind conditions, the Mount Roofing team ensured there were no delays in the schedule. Site operations maintained strict safety compliance while continuously liaising with transport teams and crane operators to eliminate downtime.
The team’s ability to manage material flow, sequencing, and on-site execution within a highly compressed timeframe became the defining highlight of the Sira project.
