Intro: Over the past decade, the exponential growth of e-commerce, cold-chain networks, manufacturing corridors, and data infrastructure has redefined how warehouses are conceived and executed. The metrics of success have changed from land and logistics to time, energy, and intelligence. To understand this transformation, SSMB brought together voices from across the ecosystem including developers, architects, structural consultants, PEB manufacturers, and material innovators to decode what’s driving the next wave of warehouse excellence in India.
India’s warehousing and logistics sector is expanding at an unprecedented pace from 350 million sq ft today to over 550 million sq ft by 2027. Steel has become the defining element of this growth, enabling faster build cycles, scalable footprints, and long-term durability for new-age industries.
As automation, cold-chain, and data-driven operations reshape spatial efficiency, the warehouse has evolved into a precision-engineered asset that is smarter, greener, and more adaptable than ever before.
This story explores how the convergence of design, fabrication, and technology is rewriting India’s industrial blueprint. Developers, architects, engineers, and PEB manufacturers are working in tandem to deliver speed with sustainability and performance with purpose.
Together, they represent the new face of India’s steel fraternity, building warehouses that don’t just rise quickly, but stand as enduring testaments to engineering foresight and material intelligence.
CHAPTER I: THE NEW GEOGRAPHY OF GROWTH
The modern warehouse is no longer a static shell built for storage, but an intelligent ecosystem designed for speed, scalability, and sustainability. At the heart of this transformation are developers like IndoSpace and Horizon Industrial Parks, who are reimagining how India builds, connects, and sustains its logistics backbone. For them, every square foot of steel and concrete must serve a purpose to enable faster movement, efficient operations, and lasting asset value.
STRATEGIC LOCATION, SMARTER GROWTH
India’s warehousing geography is being redrawn by the new logistics logic of connectivity over cost. “Every site choice begins with how efficiently goods can move and not just where land is available,” observes Pallav Srivastava, Managing Director – Projects & Development, IndoSpace. “We plan our locations around network strength rather than geography alone.”
This network-centric strategy has led IndoSpace to anchor its presence across high-velocity industrial corridors like Chakan, Bhiwandi, and Khopoli in the West; Delhi NCR and Rajpura in the North; and Narasapura, Coimbatore, and Oragadam in the South. These hubs, linked to ports, highways, and airports, form the backbone of India’s distribution engine.
For Mahendra Waghule, Head of Projects & Development at Horizon Industrial Parks, this shift marks a structural maturity in India’s logistics ecosystem. “The rise of e-commerce, 3PL, and omni-channel retail has moved demand closer to consumption,” he explains. “Developers are now positioning large-format, Grade-A parks on urban peripheries at places that offer speed-to-market and reduced lead times without compromising on quality or compliance.”
The emphasis, he adds, is now on integrated campuses rather than standalone facilities. Such developments combine warehousing, logistics, and value-add operations within a single park, reducing costs and enabling occupiers to scale quickly. IndoSpace’s own INLOGIS Chembur project, a compact, 1.5 lakh sq ft in-city distribution hub that exemplifies this shift toward flexible, high-throughput “last-mile” models designed for quick commerce and urban fulfilment.
“The next phase of India’s warehousing growth will depend on how well we balance speed, scale, and flexibility across dynamic demand cycles.”
— PALLAV SRIVASTAVA, IndoSpace
ENGINEERING SPEED, ENSURING SAFETY
In India’s fast-moving logistics economy, speed of delivery defines competitiveness, but the developers leading this transformation are clear that speed cannot come at the cost of safety or performance. Both IndoSpace and Horizon are pioneering project models that compress timelines without compromising long-term structural integrity.
“Speed in warehousing is valuable only when it is repeatable and safe,” says Srivastava. IndoSpace’s model begins with design clarity wherein structural grids, MEP layouts, and fire-safety systems are locked early to eliminate design drift. This preparation enables parallel procurement and execution, cutting down rework and ensuring consistency across multiple facilities. “Technology is the enabler,” he adds. “Digital scheduling, material traceability, and real-time quality checks keep the process predictable.”
Waghule echoes the same principle from Horizon’s perspective. “Speed and precision must go hand in hand,” he stresses. “Construction timelines directly impact client go-live schedules, but we never trade off safety or durability.” Horizon relies on standardised planning modules, pre-engineered components, and digitally coordinated design reviews. Each project undergoes real-time tracking and rigorous quality audits to maintain delivery discipline.
“Speed and precision must go hand in hand. You can fast-track only what you have first engineered to perfection.”
— MAHENDRA WAGHULE, HI Parks
THE RISE OF THE SMART TENANT
The warehouse occupier today is more informed, data-driven, and demanding than ever before. The “fit-for-use” mindset has given way to a “fit-for-performance” expectation, a philosophy that prioritises precision, sustainability, and adaptability.
“Customers today see warehouses as strategic assets,” explains Srivastava. “They expect floor flatness, racking precision, automation readiness, and sustainability built in from day one.” IndoSpace integrates these specifications at the design stage itself, ensuring that each facility is automation-compatible and ESG-ready before construction begins. From green certifications and solar rooftops to rainwater harvesting and energy-efficient lighting, sustainability is now embedded in IndoSpace’s design DNA.
At Horizon too, the design response is rooted in foresight. Their facilities feature FM2-grade floors for high racking systems, insulated panels for thermal efficiency, ridge ventilators and skylights for natural lighting, and drainage systems that prevent operational downtime. “Design precision builds long-term trust,” says Waghule. “It ensures that what’s promised on paper performs flawlessly on the ground.”
STEEL: THE BACKBONE OF MODERN PARKS
If there is one material binding this evolution, it is steel, the silent enabler behind India’s new-age logistics infrastructure. Both IndoSpace and Horizon have leveraged pre-engineered building systems to accelerate delivery, improve scalability, and optimise lifecycle performance.
At IndoSpace, the impact is quantifiable. “Off-site fabrication and pre-engineered components have reduced project timelines by 30–40 per cent compared to conventional RCC structures,” shares Srivastava. The ability to fabricate and prepare the site simultaneously means earlier occupancy and faster revenue generation. Modular designs also allow for phased expansion without disruption “we can add bays, modify layouts, or integrate automation with minimal rework,” he adds.
For Horizon, the advantage extends beyond time savings. “Steel has become the backbone of modern warehousing,” Waghule notes. “The versatility and recyclability of PEB systems make them an economic and environmental win. They reduce material waste, enable modular expansion, and align perfectly with net-zero objectives.”
Both developers report that steel construction also improves ROI by reducing maintenance costs, improving thermal performance, and extending the building’s usable lifespan. As India accelerates its shift toward high-performance logistics networks, these benefits are making steel the material of choice for scalable, sustainable growth.
LOOKING TOWARD 2030
By the end of this decade, India’s logistics hubs will look dramatically different. Warehouses will be taller, smarter, and greener that are designed for automation, powered by renewables, and integrated with data-driven systems. Developers are already reimagining their assets as digital twins having adaptive, self-monitoring spaces that optimise energy, safety, and performance in real time.
“By 2030, automation will be the norm,” predicts Waghule. “From drone-based inventory checks to AI-driven predictive maintenance, steel-based frameworks will continue to be the preferred base for that integration.” IndoSpace is on a similar trajectory, embedding renewable energy, water management, and energy-efficient design standards into every new park.
The ultimate goal is clear: to make India’s warehouses smarter, faster, and more sustainable, while also enhancing long-term asset value. “The most valuable warehouses of tomorrow,” says Srivastava, “will be those that combine automation, durability, and low environmental impact. They will not just store goods, they will store performance.”
The Developer’s Lens
- Location logic: From geography to network-driven site selection.
- Speed + Safety: Parallel design, digital coordination, zero rework.
- Smart tenants: Performance-first design with ESG built in.
- Steel as Strategy: PEB systems cutting timelines by up to 40%.
- Future Focus: Automation, renewable integration, and net-zero assets by 2030.
CHAPTER II: DESIGNING THE INTELLIGENCE OF SPACE
If developers define the “where” of India’s warehouse revolution, architects define the “how.”
The modern industrial facility is no longer a static shed. It is a high-performance organism, where material, climate, and brand converge in a single architectural language. For today’s architects, the challenge lies not in decoration, but in definition, shaping functional precision into spatial intelligence, and transforming anonymous boxes into expressive, sustainable assets.
DESIGNING PURPOSE WITH PRECISION
“Form follows function, but function itself has evolved,” begins Ar. Prashant Deshmukh, Principal Architect at Prashant Deshmukh Associates. “In modern warehousing, my approach is to design a structure that performs like a machine but still looks sharp doing it.”
For Deshmukh, architectural integrity begins with an uncompromising understanding of operational flow of zoning, safety, and storage logic before design even takes shape. The structure must support continuous movement and zero conflict between people, goods, and machines. Steel and PEB systems become the natural allies in this mission, enabling long clear spans, flexible bays, and faster, more predictable construction.
“A warehouse must perform like a machine yet stand proud as architecture.”
— PRASHANT DESHMUKH, PDA
At Studio Linedesign, Ar. Gaurav Varmani echoes the same ethos but frames it with brand consciousness. “Aesthetics in warehouses is not ornamental, it is strategic,” he says. “The form is a direct enabler of operational logic. Docking geometry, circulation, and dispatch zoning dictate the base architecture, but proportion, rhythm, and façade modulation turn it into a brand statement.” His work for clients like Adani Logistics and Panattoni demonstrates how industrial minimalism with disciplined façade breaks and long-span clarity can become a visual language of trust, scale, and order.
Ar. Rahul Jain, Principal Architect at Rahul Jain Design Lab, takes the thought further. “An inefficient warehouse loses its very purpose, no matter how striking its façade,” he says. “Functionality forms the foundation, but modularity allows design expression.” Through thoughtful façade composition, combining ACPs, louvers, ridge vents, and polycarbonate inserts, he transforms industrial frames into architecturally distinguished spaces that perform and inspire.
“In warehouses, design is not about adding beauty, it is about revealing efficiency.”
— RAHUL JAIN, RJDL
BUILDING COMFORT INTO STEEL
In India’s climate, efficiency is environmental before it is structural.
From solar orientation to airflow engineering, architects are now designing warehouses that breathe, balance, and conserve energy without relying solely on mechanical systems.
Deshmukh’s design logic integrates daylight and ventilation through ridge ventilators, clerestory windows, and insulated roof panels, reducing operational costs while improving worker comfort. “Maximising natural light, enabling cross ventilation, and using insulated panels, these are not add-ons,” he notes, “they are the architecture itself.”
Varmani applies similar rigor but with scientific precision. “We size ridge ventilators only after real stack-effect calculations, not catalogue specs,” he explains. His designs maintain a 12–18 per cent skylight-to-floor ratio and orient long façades east-west to minimise solar gain. “Passive performance first, technology second. That’s how you control energy at the source.”
Jain, whose practice spans multiple climatic zones, designs for contextual intelligence. “Sun path, wind direction, and humidity define our building’s skin,” he says. “Steel envelopes can be beautifully adaptive if treated with material empathy from cool roof coatings to ventilated double-skin façades.”
Passive Design in Steel Architecture
- Ridge and turbine ventilators for natural airflow
- Skylight ratio optimisation for daylight without glare
- East–West orientation for solar control
- Insulated roof and wall panels
- Cool roof coatings to cut peak thermal load
- Solar-ready rooftops for energy self-reliance
THE DIALOGUE BETWEEN DESIGN AND ENGINEERING
Every steel warehouse begins as a conversation between architect, structural engineer, and PEB manufacturer.
“In PEB projects, the architect is not just a designer, they are an orchestrator,” says Deshmukh. “Early and continuous coordination is key. We hold joint design reviews to align column grids, bracing logic, mezzanine positioning, and aesthetic articulation.”
Varmani’s tri-party review model between the architect, PEB fabricator, and MEP consultant ensures that “zero improvisation happens on-site because improvisation is the enemy of quality.” He explains how proportion, symmetry, and detail even in a 200-m-long façade emerge from precision in rafter depth, junction detailing, and plinth transitions. “When architecture and structure speak the same language, efficiency looks like elegance.”
Jain adds that pre-engineered systems themselves are a canvas for design collaboration. “Because PEB components are digitally modelled before fabrication, we can visualise and refine every junction from anchor bolts to façade trims,” he says. “This level of predictability lets us achieve harmony between structure and aesthetics.”
BUILDING FOR TOMORROW, NOT JUST TODAY
Automation, AI-driven inventory systems, and high-bay racking are redefining warehouse typologies. Architects now design for height, adaptability, and data, creating scalable frameworks that evolve with technology.
Deshmukh explains, “We now design for clear heights of 12–18 m, column-free spans, and load-ready mezzanines that can take on automation when required.” His layouts anticipate robotic navigation and AGV pathways, ensuring precision in floor flatness and load tolerance.
Varmani, known for his future-ready chassis philosophy, says, “Every warehouse we design today is engineered for its second life. Phase 1 may use only 12 m of height, but the structure is ready for 18.” Modular grids, expansion joints, and automation-ready slabs ensure longevity.
“Adaptability is not an afterthought — it’s the first line on the drawing.”
— GAURAV VARMANI, Studio Linedesign
Jain agrees: “A well-designed warehouse is a living framework not a frozen plan. The best ones anticipate growth, allowing clients to expand without redesigning from scratch.”
Together, their work represents the architectural answer to India’s logistics evolution: structures that scale at the speed of business.
Design for Scalability
- 12–18m clear heights for ASRS compatibility
- Column-free bays for automation pathways
- Modular grid planning for phased expansion
- Mezzanine-ready provisions for hybrid use
- Future loading docks and solar integration points
THE RISE OF THE INTELLIGENT FAÇADE
Beyond efficiency and flexibility lies identity, the moment when a warehouse transcends its function to become a symbol of a brand’s ethos.
“Architectural detailing is where branding meets building,” says Deshmukh. His designs often pair steel façades with corporate office blocks that carry the company’s visual DNA. “Even feature walls, lighting, and landscaped entries contribute to that identity,” he adds. “A warehouse should communicate trust and purpose.”
For Varmani, brand and sustainability are intertwined. “Branding begins with mass balance, silhouette, and arrival sequence, not just a logo,” he says. “The façade rhythm, the proportion of voids and solids, these communicate stability and scale.” He designs envelopes that not only look intelligent but perform intelligently, integrating daylight, ventilation, and envelope insulation into a seamless architectural statement.
Jain, who sees detailing as the defining craft of industrial architecture, adds: “From concealed fixings and weatherproof junctions to rainwater channels and bolt covers, every small detail determines the longevity and visual refinement of steel.” His philosophy is simple yet profound: “Sustainability is not a checklist; it is a mindset that runs through every screw, panel, and shadow.”
THE ARCHITECTURAL PARADIGM AHEAD
As India’s warehousing sector enters a phase of smart automation and ESG-driven design, architects are reimagining the industrial building as a dynamic, adaptive, and brand-forward ecosystem. Tomorrow’s warehouses will be energy-intelligent, automation-ready, and aesthetically engineered, where every structural line doubles as a statement of efficiency.
“A warehouse is no longer a back-end cost centre,” says Varmani. “It is a frontline brand infrastructure, a space where performance and perception meet.”
These architects remind us that the future of warehousing will not be built in haste, but, will be crafted with intelligence. Steel, with its modular freedom and timeless precision, remains the instrument that turns this vision into reality, enabling architecture to finally achieve what industry has always desired: speed with soul.
The Architect’s Lens
- Form follows function but defines brand.
- Passive design is performance design.
- Steel enables both height and harmony.
- Detailing drives identity and sustainability.
- Every warehouse must be automation-ready by design.
CHAPTER III: THE SILENT BACKBONE OF SPEED
India’s logistics growth story is being built not just on land and location, but on the precision of steel. Over the last decade, warehouses have evolved from basic storage sheds into high-performance logistics assets engineered with accuracy, efficiency, and scalability at their core.
What began as utilitarian enclosures for goods has transformed into critical infrastructure that underpins India’s manufacturing and e-commerce ecosystems. As demand rises for faster fulfilment and multi-level racking, structural design has become the silent enabler of operational excellence.
“Every truss and connection now serves a measurable purpose,” says Amit Shah, Director, DCS Consultants. “The higher the design efficiency, the better the results. A more accurate design leads to better optimisation, allowing you to achieve larger spans and greater building heights without significantly increasing costs.”
Arun Kumar, Director, Metis Structures, adds, “Right system selection is key. For 45–60 m spans, tapered-rafter PEBs are unbeatable in economy and speed. But when spans exceed 60–120 m, welded double-layer space frames provide superior stiffness-to-weight efficiency and deflection control, and they integrate beautifully with skylights, vents, and solar systems.”
This structural intelligence where performance, precision, and cost converge is reshaping India’s warehousing DNA.
ENGINEERING SPEED AND PRECISION
The pace of industrial development and logistics expansion today leaves no room for structural lag. Developers demand rapid delivery cycles without compromising design discipline, and PEB systems are delivering on both fronts.
“Structural optimisation is about material, cost, and time, all used wisely,” explains Amit Shah. “Sometimes, using 10 tonnes more steel can save an entire month of project time, which is far more valuable. The goal is optimisation, not minimisation.”
For Kumar, precision starts with process: “We use a kit-of-parts philosophy with pre-approved detail libraries, digital continuity from BIM to fabrication (NC data), and sequencing drawings that prevent errors before they occur. Prototype one bay, freeze the details, then mass-produce and that is how speed and accuracy co-exist.”
Jigar Shah, Director, Divya Consultants, agrees that design and execution are now symbiotic: “PEB shines with fabrication-friendly detailing, BIM-integrated 3D models, and standardized bolted connections that make on-site assembly seamless. Parallel scheduling of foundations and steelwork overlapping further speeds delivery.”
STEEL’S SPEED ADVANTAGE
- Modular spans reduce on-site time by 40–50 per cent
- Factory precision ensures ±2 mm tolerances
- Simultaneous site–shop workflows enhance efficiency
The result? Warehouses now rise in months, not years, setting new benchmarks for India’s construction speed.
DESIGNING FOR LONG SPANS AND HIGH BAYS
In the era of high-bay racking, automated retrieval systems, and flexible multi-tenant operations, the real challenge lies in designing for scale. Large-span, high-clearance structures demand impeccable control over deflection, uplift, and lateral stability.
“Our strategy is straightforward,” notes Amit Shah. “Choose the right structural framework and frame model to maintain deflection limits and lateral stability. Correctly defined support conditions lead to optimal efficiency.”
At Metis Structures, Kumar’s team prioritises serviceability first: “We design to deflection and vibration limits before chasing weight. Cambered rafters, dense purlin lines near high-uplift zones, and lean braced frames at well-chosen bays ensure stability and performance.”
Jigar Shah brings in the PEB perspective: “We use advanced finite element 3D modelling to control deflection and optimise column placement. Pre-cambered rafters and moment-resisting end frames reduce drift and vibration. Jack portals with hollow section columns double as longitudinal bracing, enhancing stiffness without cluttering interiors.”
As these engineering practices mature, India’s warehouse designs are now rivalling international benchmarks in precision, economy, and adaptability.
DURABILITY, FIRE SAFETY & ENVELOPE PERFORMANCE
With structures spanning vast areas and housing valuable inventory, durability and safety are non-negotiable. Corrosion resistance, fire protection, and maintainability have become central to warehouse design.
“Durability starts with the quality of steel,” emphasises Amit Shah. “Use virgin steel from reputed mills, apply high-quality coatings, and ensure proper painting systems including post-erection touch-ups. For cold-rolled sections, we use GI sections with higher coating (275 gsm) for better protection.”
Kumar adds a detailing-driven lens: “Hot-dip galvanizing for purlins and secondaries, zinc-rich epoxy + PU topcoat for primaries, wide gutters and sealed laps, these details prevent under-sheet corrosion and improve roof hygiene. For fire protection, intumescent paint or vermiculite spray ensures compliance without adding weight.”
Jigar Shah reinforces the maintenance side: “Bolted connections allow easy inspection. Engineered gutters, SSR roofing, and properly designed drainage prevent corrosion. Regular recoating schedules extend the structure’s lifespan and fire coatings matched to occupancy levels are crucial.”
Design for Longevity – Consultant Insights
- Weathering steel and zinc coatings for high-humidity zones
- Intumescent paints or vermiculite spray for fire safety
- Roof slope & drainage detailing for monsoon performance
From coatings to connection choices, durability is no longer an afterthought, it is a design philosophy.
SMART, SUSTAINABLE & FUTURE-READY
Tomorrow’s warehouses will not only store goods, but they will also think, adapt, and conserve. Automation, solar integration, and modular adaptability are fast becoming standard design considerations.
“Structural systems must anticipate automation,” shares Amit Shah. “Designs should include floor markings for tracking sensors, allow for crane automation, and maintain simplicity for easy adaptation.”
For Kumar, future-readiness is structural foresight: “We build in upgrade paths, stub columns for mezzanines, MEP corridors for future services, and roofs ready for solar and ASRS rails. Local stiffening at load points prevents future redesigns.”
Jigar Shah adds, “Our grid systems (8–10 m bays) are modular, ready for mezzanine floors or solar panels. Structural supports are pre-designed for conveyors, HVAC, and dense racking. It is about keeping the warehouse flexible for what’s next.”
As India’s warehousing shifts toward automation and sustainability, steel’s adaptability ensures that today’s structures remain relevant for tomorrow’s technologies.
VISION 2030 FOR INDIA’S STEEL-BUILT LOGISTICS ECOSYSTEM
With industrial corridors expanding under PM Gati Shakti and the National Logistics Policy, steel-built warehouses are set to anchor India’s manufacturing and e-commerce growth. The collaboration between consultants, fabricators, and policymakers will define how efficiently these ecosystems evolve, and how smartly they integrate automation, sustainability, and resilience.
As Kumar succinctly puts it: “Future-ready warehouses must be multifunctional and upgradable, from food storage to machine assembly, achieved through economical PEBs for speed and welded space frames for ultra-long spans, both detailed for durability and expansion.”
India’s warehousing revolution is now a story of design foresight. Steel has turned speed into strength, and structure into strategy. India’s warehousing infrastructure is becoming a showcase of engineering precision and structural intelligence, where steel turns time into opportunity, and design into productivity.
“Sometimes, using 10 tonne more steel can save an entire month of project time, the goal is optimisation, not minimisation.”
— AMIT SHAH, DCS Consultants
“Future-ready warehouses must be multifunctional and upgradable, achieved through economical PEBs for speed and welded space frames for ultra-long spans.”
— ARUN KUMAR, Metis Structures
“PEB shines with fabrication-friendly detailing, BIM-integrated 3D models, and standardised bolted connections that make on-site assembly seamless.”
— JIGAR SHAH, Divya Consultants
CHAPTER IV: WHERE STEEL TURNS SPEED INTO STRENGTH
As India’s warehousing and logistics infrastructure scales to meet global standards, the spotlight increasingly falls on precision fabrication and modular engineering, the invisible strengths behind every fast-rising steel frame.
If architects define the intent and engineers refine the skeleton, PEB manufacturers like Kirby Building Systems and Ashtech Prefab turn those lines on a drawing into millimetre-perfect structures that assemble like clockwork.
THE ENGINEERED ADVANTAGE
When you visit a modern industrial site today, the spectacle is no longer of raw steel arriving to be shaped on site, but of ready-to-install, factory-precision components arriving like a kit of parts, designed to fit exactly where they belong. This is where the PEB ecosystem truly shines.
At Kirby Building Systems, precision is not a by-product, it is the process itself.
“All structural components are manufactured in controlled factory environments using automated, CNC-driven lines,” explains P.V. Mohan, CEO, Kirby Building Systems & Structures India Pvt. Ltd. “Every punching, cutting, and welding operation is executed with millimetre-level accuracy, ensuring seamless on-site fitment. This precision directly translates to faster erection, reduced rework, and smooth coordination with civil and MEP services.”
Kirby’s modular approach and pre-planned erection sequencing allow entire warehouse frames to rise weeks ahead of conventional schedules. The company’s projects routinely demonstrate how CNC fabrication and advanced surface finishing deliver both speed and reliability, two sides of the same structural coin.
Amit Agarwal, Director, Ashtech Prefab (India) Pvt Ltd echoes this blend of technology and timing. “PEB systems revolutionise execution through parallel processing of design, fabrication, and site preparation,” he shares. “At Ashtech, our 3D modelling and CNC-based fabrication workflow ensures millimetre-level accuracy across every member.”
Agarwal cites the AIIMS Kichha project in Uttarakhand, a 4.5 lakh sq ft institutional campus, as a model of this precision. “We completed design, fabrication, and erection in just 10–12 weeks, compared to the 6–8 months typical for conventional methods. Even under compressed timelines, alignment and fit-up precision never wavered.”
The result? A new national benchmark for industrialized construction, where accuracy becomes the anchor for speed.
“The warehouses of tomorrow will not just stand—they’ll think, adapt, and conserve.”
— P.V. Mohan, Kirby India
FROM INTENT TO EXECUTION
In steel construction, design intent means little if it isn’t translated faithfully into fabrication. Both Kirby and Ashtech have institutionalised collaborative design ecosystems, ensuring engineering precision begins not at the plant, but at the drawing board.
“At Kirby, achieving engineering precision requires close collaboration across stakeholders like architects, consultants, and clients,” explains Mohan.
“Our teams use 3D modelling and BIM platforms to integrate architectural, structural, and operational requirements early on. This reduces design deviations and ensures the transition from engineering to fabrication is seamless.”
For Ashtech, coordination is both digital and human. “Our process begins at the conceptual stage through 3D design reviews and clash detection simulations,” says Agarwal. “In AIIMS Kichha, we conducted digital twin modelling to validate every structural interface before production. This eliminated on-site conflicts and reduced adjustments during erection.”
The outcome is a shared digital environment where every beam, bolt, and bracing point is pre-verified before leaving the factory floor, bridging intent and execution with engineering certainty.
“When architects, engineers, and fabricators build the same 3D model, precision stops being a promise and becomes a process.”
— AMIT AGARWAL, Ashtech Prefab
THE DIGITAL FOUNDRY OF STEEL
At the heart of the PEB revolution lies an investment in machines that think and materials that endure. Kirby continues to lead this transformation with heavy automation. “We deploy state-of-the-art automated fabrication lines, robotic welding, precision roll forming, and IoT-enabled monitoring systems,” notes Mohan. “These technologies ensure consistent accuracy and traceability across production. We also use high-strength steel grades and eco-friendly coatings to achieve durability with sustainability.”
This technology-first approach not only enhances consistency but also allows real-time quality validation, a concept once foreign to traditional steel fabrication.
Ashtech Prefab has mirrored this philosophy in its own facilities. Equipped with CNC beam lines, plasma cutters, and automatic H-beam welders, the company now tracks production metrics live through IoT-based dashboards.
For their AIIMS Kichha project, they employed E350–E450 grade steel to balance strength and weight, while galvalume roof and wall systems delivered superior corrosion resistance, a crucial feature in India’s diverse climatic zones.
“Technology gives us repeatability,” says Agarwal. “Every beam, every weld is digitally verified, ensuring the same quality standard from the first bolt to the last.” Whereas Mohan claims, “Automation, robotics, and IoT monitoring have transformed steel fabrication from an art of precision to a science of consistency.”
BUILDING INDIA’S SMART STEEL FUTURE
As India races toward 2030 infrastructure milestones, the PEB sector stands at a pivotal juncture, ready to redefine how industrial and logistics spaces are conceived, built, and sustained.
“India’s logistics ecosystem is evolving rapidly,” says Mohan. “PEB technology will play a pivotal role in supporting automation, green building practices, and solar-integrated designs. The future lies in AI-led project execution and sustainability-driven materials.”
Kirby’s roadmap includes integrating renewable-ready roofs, recyclable steel, and digital twins that simulate full life-cycle performance before fabrication even begins. Their goal: zero-waste manufacturing and net-zero-ready warehouses.
Ashtech Prefab sees an equally dynamic future. “Warehouses are becoming smarter and greener,” says Agarwal. “We are already developing solar-ready roofing systems and adopting sustainable coatings that minimize maintenance while extending lifespan.”
For both companies, innovation and sustainability are inseparable, the twin engines that will define the next decade of India’s industrial evolution.
The Fabricator’s Formula for the Future
Kirby Building Systems:
- Factory-automated fabrication and robotic welding
- High-strength steel and eco-friendly coatings
- BIM-integrated engineering and IoT monitoring
- Value-engineered connections and hybrid spans
- Solar-ready, AI-driven, sustainability-focused PEB design
Ashtech Prefab (India):
- 3D BIM modelling and digital twin validation
- CNC beam lines and plasma cutting automation
- E350–E450 high-tensile steel for weight efficiency
- Corrosion-resistant galvalume envelope systems
- Modular design reducing steel by 10–15% and site time by over 40%
The rise of factory-driven precision has redefined India’s industrial construction DNA. The modern PEB plant is no longer a fabrication shed, it is a digital foundry, where algorithms meet alloys and where steel is shaped not just for strength, but for speed, sustainability, and intelligence.
Together, manufacturers like Kirby and Ashtech are shaping the next frontier of logistics infrastructure, structures that are faster to build, smarter to operate, and greener to sustain. This is where India’s steel revolution truly converges: at the intersection of time, technology, and trust.
CHAPTER V: THE ENVELOPE OF EFFICIENCY
As steel structures continue to push the limits of speed and scalability, the performance of the building envelope has emerged as the next frontier in warehouse engineering.
MATERIAL EVOLUTION
“The construction industry is experiencing a transformative leap, driven by advanced materials and technologies,” says Saurabh Jindal, Managing Director, Kingspan Jindal Pvt Ltd. At Kingspan Jindal, we are pioneering high-performance insulation and building envelope solutions designed specifically for PEB structures from Insulated Panels and Architectural Roofing Systems like KingZip, to façades, cold storages, and clean room solutions. These systems offer high structural strength, thermal efficiency, and design flexibility, enabling faster, cleaner, and more efficient builds.”
FABRICATION EFFICIENCY
According to Jindal, the future of warehouse construction lies in simplified, modular, and predictable systems that maintain consistency without compromising quality. “Our single-component insulated panel systems drastically simplify construction,” he explains. “They ensure precision, uniformity, and speed, all while maintaining long-term durability. Complemented by aluminium extrusions, top hats, and flashings, they deliver seamless integration and faster installation even under challenging site conditions.”
SUSTAINABILITY EDGE
Sustainability, he adds, is now integral to every stage of design and execution.
“Guided by our Planet Passionate global vision, Kingspan Jindal develops energy-efficient building envelope systems that significantly reduce carbon emissions and operational energy use,” says Jindal. “Our goal is to create low-impact, high-performance infrastructure that aligns with India’s sustainability ambitions while enhancing user comfort and lifecycle value.”
COLLABORATION WITH DESIGNERS
For Jindal, innovation thrives on collaboration. “Every great building is the result of partnership,” he notes. “We work closely with architects, consultants, and builders right from the conceptual stage to ensure that both functional and aesthetic goals are achieved. This synergy not only accelerates project delivery but also ensures that each structure reflects precision, purpose, and visual harmony.”
“By uniting Indian expertise with global innovation,” concludes Jindal, “Kingspan Jindal continues to lead the country’s insulation and building envelope transformation. Our mission is clear: to build structures that are faster, greener, and more resilient. We are not just creating products; we are helping redefine how industrial and logistics infrastructure is designed, built, and experienced.”
The Kingspan Jindal Edge
- Integrated Envelope Systems – Insulated panels, façades, and roofing tailored for steel and PEB structures.
- Speed with Precision – Single-component systems that streamline installation and ensure millimetre-level accuracy.
- Thermal & Acoustic Excellence – Advanced insulation for energy efficiency and occupant comfort.
- Sustainability First – Planet Passionate initiative driving low-carbon, energy-smart buildings.
- Collaborative Innovation – Early engagement with designers for seamless integration and performance optimisation.
“Tomorrow’s warehouses will be defined not just by their steel frames, but by the intelligence of their envelopes.”
— Saurabh Jindal, Kingspan Jindal
THE NEW BLUEPRINT FOR INDUSTRIAL INDIA
India’s next decade of growth will be built not just on industrial expansion, but on the engineering intelligence of steel. Warehouses are no longer storage boxes; they are strategic, performance-driven assets designed for speed, scalability, and sustainability.
From the structural frame to the building envelope, every contributor across the ecosystem be it consultants, fabricators, and material innovators, are shaping a new blueprint for industrial India, defined by collaboration, technology, and purpose.
Together, these voices echo a shared vision, an India where steel warehouses are not just built faster but built smarter. The convergence of digital design, modular fabrication, and sustainable materials is setting the stage for a new industrial revolution, one where every beam, bolt, and panel works in harmony to deliver efficiency, longevity, and environmental responsibility.
The road ahead is clear: design collaboration is the new construction currency, and steel is the medium that will carry India’s logistics and manufacturing ecosystem into a faster, greener future.
Editor’s Note:
As India steps into a new era of construction, steel stands as the nation’s purest expression of progress that’s resilient yet adaptable, engineered yet poetic. The future will not belong to those who build the fastest, but to those who build with foresight. As the pages unfold, it becomes clear that India’s steel community is not just building structures but scripting the blueprint of tomorrow.
— Mahesh Mudaliar, Sr. Editor, SSMB
