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IFB Refrigeration Ltd. Manufacturing Facility, Ranjangaon


IFB Refrigeration Ltd. planned to set up a new facility for manufacturing refrigerators in Maharashtra. After due diligence and discussions with the consultant, the client chose Everest to execute the project based on the trust built over a previous project. This project was significant as the facility was critical for increasing the production capacity.

Everest had dual responsibility to not only execute a quality job in the current project but also to retain the reputation of being a reliable partner which was an important aspect. Regular interactions were carried out at the consultant and client’s offices, and on-site to understand the project’s intricacies. Detailed planning was carried out at all phases of the project. The aim was to execute the project within the time frame required by the customer without overlooking economics.

All materials for the building were carefully chosen to meet the client’s requirements for the project. After considering surrounding weather conditions throughout the year at the site, mineral wool of specific R-Value was chosen for roof insulation to maintain the desired temperature inside the building.

The layout of the building was planned to get maximum unobstructed space for material and people movement. The depth of the mezzanine beams was limited to provide maximum clear height under the Deck Slab. Additionally, standing seam was used as a roofing solution for durability and water tightness to prevent leakages, which simultaneously increased the project lifecycle phenomenally.

An important feature of the project was the horizontal cladding color bands in the wall along with louvers. The right amount of ventilation, as desired by the end user, for the building was achieved by using roof monitors and louvers. These features provided the required air changes per hour for a fatigue-free working environment for the workers, thus ensuring more productivity.

Polycarbonate sheets were chosen to provide diffused ambient light inside the building. Additionally, Everest wall cladding of the desired color was used to make the façade attractive. Flush, cantilever fascia, and canopies with reverse slopes ensured an excellent aesthetic look.

The building had a critical height requirement with respect to the lean-to and EOT crane and spans more than 350 meters in length, which makes the building susceptible to temperature effects and stresses during temperature variance. Provisions were made for relieving such temperature stresses. The building also has a mezzanine area designed as a composite deck slab. Portal cross-bracing was used in conjunction for lateral stability and openings.

There are different kinds of loading in the structure like collateral loads on the roof, solar panel loads, etc. Jack beams were introduced for better space utilization and to make way for more accurate machinery and equipment installation without forgoing the important aspect of optimizing structural steel. This made the project unique in its own way.

Horizontal wall cladding installation was a challenging task from an aesthetic point of view and the strict timeline made the task more critical. The team was always alert for any unforeseen roadblocks. This helped in the quick resolution of challenges and avoid any impact on the project timeline. Meticulous execution by the site management team and effective coordination with the project management team and the consultant, led to the successful achievement of milestones and kept the project on track to timely completion.

The deeply forged relationship between the client, consultant and Everest Industries Limited, facilitated excellent and effective communication among all stakeholders. This led to optimum project design, which in turn resulted in huge cost savings for the client. Many challenges and last-moment changes were resolved immediately without impacting the project timeline.



A milk processing plant is a facility where raw milk is received, processed, packaged and stored for distribution. Such plants require a well-designed and well-constructed facility to ensure the safety and quality of milk products. The milk processing plant designed for Country Delight in Haryana is an innovative and functional facility aimed at sourcing raw products from nearby areas and producing good quality and unadulterated and contamination-free milk products.

The site of the plant is planned in such a way that it has a separate entry for trucks and pedestrians. Most of the services are in the front since the electrical line is located there. Entry into the meter room is from outside of the site so that government officials can go in without entering the site. The admin block, boiler and glass plants are placed at some distance and at the end of the site, all the factory operations are placed.

The plant is capable of processing raw milk into various products such as curd, butter, etc. The design of the plant is optimized to ensure maximum efficiency and output while maintaining quality and safety standards. All the milk-processing-related spaces have been assigned to one main shed making the processing and production efficient. Other spaces such as the refrigerator room, boiler room, admin area, RMRD, store room, and tanker CIP shed around it have been given a separate area.

Tankers come into the RMRD and tanker CIP shed where milk gets tested and then sent for processing. A bridge kind of steel arrangement has been placed to aid this process which serves as the lifeline of the project. The steel bridge has cables running and everything carries through it and a hygiene room has been placed at the start for the workers before entering. This cable bridge has been installed at a height of 6 meters in order to let trucks pass beneath it with ease. All the lines are connected to this bridge, including those for the refrigerant area, main shed and other spaces. This steel bridge has numerous services running such as milk inlet, condensed water and hot water along with a firefighting line, steam line, RO water line, etc.

The truck level is 1200 mm higher than the surrounding road level and the shed floor level has been placed at the same level for ease of movement of goods. Inside the main shed the silo is placed on a further elevated level so that milk flow can take place automatically with gravity, without additional machines. There is also a mezzanine planned in steel according to 2metric ton/sq. m. for storing milk products and an ETP is placed strategically at the back planned so as to reduce the smell around it.

Steel is a contemporary and clean material, which is essential in food-grade units. In this milk processing unit, we used a full structure in steel because normal plaster and brick can flake off and runs the risk of contaminating the food. Steel is an ideal construction material in the food industry since it is easy to clean, maintain and sanitize.

Steel is also resistant to corrosion, bacteria and pests, making it ideal for facilities that require high standards of cleanliness and hygiene. The fire-resistant quality of steel also makes steel structures safe and secure for the workers as well as for the products.

Large 100-ton silos for milk storage have been installed made of steel, making them durable and hygienic. The versatility of steel as a material has made it easier to work with and to be used in different parts of the facility, making it a cost-effective and efficient material to use in construction.

Steel is an ideal material for pre-fab construction since it is faster to construct and the components are easy to transport and assemble. The facility was built as a pre-fab construction considering the numerous benefits and scarcity of man force during the pandemic. Pre-fab construction is ideal for such facilities since it is completely covered and constructed in a controlled environment, ensuring high-quality construction.
The PEB structure of this plant has a span of 24 meters. It is a perfect example of how steel can be used effectively to construct a state-of-the-art facility that meets the highest food safety standards.

The project was executed amidst the COVID-19 pandemic, which added several challenges to the project. However, with the collective effort of the teams involved, the project was successfully completed in a reasonable time span, including underground services. The design process was collaborative, involving input and feedback from all stakeholders, including the client, engineers, architects, and contractors, to ensure that the final design meets all requirements and expectations.

Additionally, the project’s construction included underground services that enable the flow through gravity, reducing operational expenses, however, the underground services significantly increase the complexity of a construction project. While adhering to all the by-laws and safety provisions required, our team was able to circle the complexities that arose.

Ensuring food-grade safety was a top priority at every stage of the project, from the design to material selection as well as to avoid cross-contamination. The project managers and engineers worked closely with the architects and the client to ensure that the facility met the highest food safety standards.

The Country Delight milk processing unit plant is a testament to the benefits of using steel in construction in food grade and milk processing industries. This is a functional and efficient facility that ensures the production of good quality and unadulterated milk and milk products. The project is an example of how important is it to select the right materials for food-grade and milk-processing facilities and how steel can be a game-changer in creating such facilities that meet the highest standards of cleanliness, hygiene, and safety. The success of the Country Delight milk processing unit plant shows how teamwork, adaptability and flexibility can overcome any challenges, including those posed by the COVID-19 pandemic.



When one thinks of a villa, one might imagine a grand and luxurious home, complete with spacious rooms, elegant decor and stunning views of the surrounding landscape. This is exactly what was designed for the Mishrikotkar House, a perfect blend of exquisite design, comfort, style and functionality.

The small taluka of Deulgaonraja, located in the Buldhana district of Maharashtra, is known for its hot and dry climate, with temperatures soaring to over 44 degrees Celsius during the summer months. This presented a unique set of design challenges for the villa-style home, as it needed to be designed to withstand harsh weather conditions and provide a comfortable living environment for the Mishrikotkar family.

One of the most striking features of this house is the sloping roof make with terracotta that covers the porch, providing a warm and welcoming entrance to the property. Once inside, one is greeted by a spacious courtyard that divides the common spaces, including the living room, dining room, TV room and kitchen from the private bedrooms. The courtyard is a large and airy space, with plenty of natural light and ventilation to create a comfortable and inviting atmosphere.

One of the highlights of the courtyard is the puja space (worship area), a serene and peaceful zone that is perfect for meditation and prayers. The courtyard also features a deck that offers a stunning view of the horizon, perfect to revel in the setting sun.

The floor above comprises bedrooms and an entertainment zone, complete with a home theatre that is perfect for relaxing with family and friends. The bedrooms are designed to provide the ultimate in comfort and privacy, with spacious layouts, plush furnishings and plenty of natural light and ventilation to create a restful and rejuvenating environment.

One of the key advantages of steel buildings is their durability and strength. Steel is known for its ability to withstand extreme weather conditions, including high winds, heavy rain, and even earthquakes. This makes it an ideal choice for homes that need to be strong and resilient, particularly in areas that are prone to natural disasters. In addition, steel is a highly sustainable building material. It can be easily recycled and reused, reducing waste and minimizing the environmental impact of the construction process. This is particularly important in today’s world, where concerns about climate change and the need to reduce our carbon footprint are becoming increasingly urgent.

An important advantage of composite steel building technology is its speed and efficiency. Since the structural members are fabricated in a factory, the construction process is significantly faster than traditional construction methods. This can help reduce labor costs, as well as minimize the amount of time that workers need to spend on-site, thus, reducing the risk of accidents or injuries.

The structure was erected within just two weeks, saving up to 65 percent of natural resources, cement and water as compared to traditional construction methods. The work done within the said timeline included the erection of the steel structure, along with the concreting of all floor slabs. A total team of ten people was involved in the erection process, conserving labor and natural resources without compromising on strength and quality of workmanship. 48 tons of steel has been used in building the Mishrikotkar House.

To address the climatic challenges of the site, the design team focused on a number of key factors, including the use of AAC block, cavity wall construction, terracotta roof, cement tiles, wooden ceiling and natural plaster with lime paint.

AAC block, or Autoclaved Aerated Concrete block, is a lightweight and durable building material that is known for its excellent insulation properties, making it an ideal choice for the walls of the house, helping to keep the interior spaces cool and comfortable even during the hottest months of the year. Additionally, AAC blocks are made from natural materials, making them a sustainable and eco-friendly choice.

The external walls were planned with cavity walls, which provide excellent insulation to prevent heat gain inside the spaces and also conceal all structural steel members. To further enhance the energy efficiency of the house, the walls were wrapped with vedic plaster, a traditional building technique that is known for its ability to keep houses cool and comfortable even in the hottest climates. The terracotta roof, cement tiles, and wooden ceiling were also carefully selected to improve insulation and reduce heat gain.

Provision of solar power generation, rainwater harvesting, use of recycled water for landscaping, low-flow plumbing fixtures to conserve water and use of LEDs for artificial lighting add to the sustainability quotient.

Overall, the design of this villa-style home was carefully crafted to address the unique climatic conditions of the Deulgaonraja taluka, while also incorporating sustainable and eco-friendly building materials and techniques. By focusing on these factors, the home offers a comfortable, healthy and sustainable living environment for the Mishrikotkar family who will call it home.

Dhana Dhanye Auditorium, Alipore


Dhana Dhanye Auditorium is a premier state-of-the-art multi-auditorium complex in Alipore, Kolkata. The auditorium was named Dhana Dhanye in honour of the renowned poet, playwriter, and lyricist Dwijendralal Ray.

Initially, the project’s target completion was December 2022, but the construction was disrupted due to the pandemic. The cultural relic was finally inaugurated and opened to the public in April 2023.

West Bengal’s Chief Minister, Mamta Banerjee inaugurated this amazing auditorium. The inauguration of this state-of-the-art facility is a significant development for Kolkata’s cultural scene and is anticipated to become a prominent venue for various events in the region.

Structure in Brief
Foundation: RCC Pile Foundation 5KT of reinforcement procured from SAIL and TATA Steel
Total hollow steel sections used for structure: 8000 MT approximately
Tubes at Main Columns, Trusses & Purlins: 1.2 KT out of 1.7 KT supplied by Tata Structura
HR Plate for floor beams: E250 1.5 KT from SAIL (Section thickness 45,56,60 mm width up to 2.5 m)
The conch shell, covered by a sheet of precious zinc and equipped with special lights from Japan is capable of displaying 33,000 different colours
Roofing: Two layers of roofing: Inner layer with composite structure of aluminium liner sheet, cement board, and Rockwool provided by a specialist supplier ‘Kalzip’ as a complete solution
The outer surface of perforated zinc sheet with thickness up to 1 mm which underwent multiple processing (PVDF coating etc.) at Surat and Bangalore with service provider VMZINC India

Design Concept
The Dhana Dhanye Auditorium is a mega project with more than 2,500 seating capacity at two levels. This unique structure is built in the shape of a Conch i.e., ‘Shankh’ which has a deep-seated root to the Indian culture. The structure has a base area of 8,800 sq. mtr. and is built on a land of 4.5 acres.

The project was conceptualized in 2017. During that period, the Tata Structura team was already serving PWD in other projects in the city, and hence, proved the natural choice for the newly conceived Alipore auditorium project. The project was awarded to M/s Ahluwalia as the contractor in 2018-2019 and the Tata Structura team along with the Channel Partner M/s Kedia Pipes continued engagement with the designer and execution team for the project.

Structural Aspects
The auditorium is designed in the form of a conch shell. It has a main auditorium of 2,000 seats with a mini-auditorium of 540 seats and an open stage with 300 seats.

The building has six floors containing a guest house, restaurant, cafeteria, VIP lounge, media lounge, and convention centre. The revolving stage has two concentric circles. The auditorium 510 feet in length and 210 feet in width is made at a cost of Rs. 440 crore.

The complex also uses LV/AV systems, solar systems, building management systems, etc. It has basement parking with two levels of car parking with proper ventilation which also helps to free traffic congestion in the Alipore area.

Facilities Galore
In addition to the auditoriums, the Dhana Dhanaye Auditorium offers other amenities such as banquet halls providing space for events such as weddings, receptions, and social gatherings, and a spacious parking facility on the ground floor that can accommodate up to 250 cars.

A food park is also included in the facility, offering a variety of dining options for visitors. This modern auditorium is expected to be a major cultural and entertainment hub in Kolkata, catering to a wide range of events and performances.

The Dhana Dhanaye Auditorium is expected to become a major cultural and entertainment hub in Kolkata, hosting a wide range of events and performances, and contributing to the rich cultural heritage of the city.

The state Public Works Department has constructed the auditorium and the responsibility for its maintenance has been given to West Bengal Housing & Infrastructure Development Corporation (HIDCO).

Amol Acharya Tales


Your College Name & Place:
Visvesvaraya National Institute Of Technology, Nagpur
Total Years of Experience: 25+ years
Your Idol / Mentor: There are many good engineers who mentored me, but I would like to mention Viral Patel from Walter P Moore along with Abhijit Shah.
Your mantra for success: If you can’t explain a concept in simple words then you don’t understand the concept at all

Talking About Life’s Engineering Saga. ‘TALES’ is a segment that exclusively focuses on the top Project/Structural Consultants across the globe sharing their engineering journey in their own words.

He is celebrating his silver jubilee as an industry professional but his enthusiasm & zeal is still fresh… he is a master of his field & has left his mark in the form of amazing structures across the globe…

Here’s Amol Acharya, Head of Structural Engineer, Walter P. Moore giving us a peak into his thoughts…

What inspired you to take up engineering as a profession?
Engineering has always been a part of my family legacy, with many of my close family members pursuing careers in the field. It felt natural for me to follow in their footsteps and pursue a career in engineering.

How was your learning curve from a student to a pro today?
My journey as an engineer has been quite fulfilling. Starting my career from site execution and gradually moving up to more complex tasks has helped me understand the technicalities of the field better. The recent project that I worked on, the Narendra Modi Cricket Stadium, was particularly challenging and helped me learn a lot. Despite the challenges, I have enjoyed every step of my journey and am always eager to learn more.

What are the various challenges that you face as a structural consultant in India?
One of the biggest challenges that I face as a structural consultant in India is the issue of fees. It can be difficult to negotiate reasonable fees for projects, which can make it challenging to sustain a profitable business. Additionally, there is a lack of adoption of Building Information Modeling (BIM) technology in the Indian construction industry. While BIM can help improve project efficiency and reduce errors, many Indian construction projects still rely on traditional design methods. In contrast, during my work on a large hospital building project in London, I saw firsthand how BIM was used to model every detail of the project, resulting in improved project outcomes.

If you can change one thing in our construction practices in India, what would that change be?
If I could change one thing in our construction practices in India, it would be to prioritize the adoption of modern technology like BIM, digital workflows/processes and 3D printing. I believe that leveraging these technologies can help us improve project efficiency, reduce errors, and ultimately improve the quality of our work. Additionally, there needs to be more openness to using higher-grade materials and adapting to changing technology. I think that this shift is necessary to meet the demands of the modern construction industry and improve the overall quality of construction in India.

How do you see the adoption of the rolled section in the Indian construction community?
I believe that the adoption of rolled sections in the Indian construction community has been steadily increasing and will continue to do so in the future. In fact, I predict that in the near future, nearly half of all building constructions will resort to structural steel as a material of choice, particularly for commercial buildings. I see a substantial impact and penetration of steel in the construction industry in the years to come.

How has your relationship with steel been?
My relationship with steel started with a design competition for an exhibition in Pune. It was a tensile membrane structure with tubular sections and cables. At that time, I did not fully appreciate the significance of non-linear behavior of the material and the structure. However, over the past 25 years, my relationship with steel has solidified, especially with my recent project, the Narendra Modi Cricket Stadium which also happens to be a Tensile membrane structure. Through this project, I have gained a deep understanding of the material non-linearity, how we can cover large spans with sleek and aesthetical framework and the complex erection process of a tensile steel structure. Overall, my relationship with steel has grown stronger over the years, and I continue to be fascinated by its versatility and strength in construction.

Which is your best work in steel so far and why is it so special?
The largest cricket stadium in the world, the Narendra Modi Cricket Stadium, is my favorite steel project due to its unique characteristics. With a seating capacity of over 100,000 people, it is an exceptional example of a tensile membrane structure. The cantilever roof has a span of 30 meters and consists of an inner tension ring pulled outwards by cables attached to an outer compression truss. The PTFE membrane is also supported by these cables. The entire structure is supported by V-shaped columns that are approximately 35 meters tall. Despite the complexity of the design and construction, the stadium’s sleek and simple appearance makes it a remarkable achievement.

Which international steel project truly inspires you for its structural elegancy and why?
The Empire State Building in New York, constructed around 1930, is one of the international structures that I deeply admire. I recall seeing the iconic image of construction workers leisurely sitting on a steel beam, swinging their feet in the air. Looking back, that image may have been a significant inspiration for me. Another notable structure that has always fascinated me is the Astro Dome in Houston, spanning a diameter of about 600 feet, equivalent to that of a football stadium. It was designed by Walter P. Moore, and I had the opportunity to meet one of the veteran engineers who has also worked on this iconic structure. The Astro Dome holds a special place in my heart and that of the company, with numerous tales surrounding it, such as the origin of AstroTurf technology.

How do you update and upgrade yourself with the changing times?
To stay up-to-date with the changing times, I take inspiration from the new generation of engineers who bring in fresh perspectives, new technologies, and innovative ideas. I believe in embracing and adapting to the changes they bring, not just in terms of materials but also in technology. Attending conferences, events, and summits such as SCS also helps me learn about the latest advancements in the field. Continuous learning, being open to new ideas and approaches is vital in staying competitive in today’s fast-changing engineering landscape.

Museum of the Future, Dubai


The Museum of Future is an exhibition space for innovative and futuristic ideologies, services and products. Located in the Financial District of Dubai, UAE, the Museum of the Future has three main elements, namely, green hill, building, and void. Founded by the Dubai Future Foundation, its goal is to promote technological development and innovation, especially in the fields of robotics and artificial intelligence (AI).

In Feng Shui, a round shape represents both the fertile fields of earth and the limitless imagination of the sky above, thus representing the past, present, and future. While the building would evolve with exhibits of the future of education, health care, smart cities, transportation, government services, and more for the next five or perhaps ten years, the void in the center of the building represents the unknown, according to Killa, the architect of the structure.

Art and poetry are manifest in the design, with Arabic calligraphy inscribed onto the exterior that features quotes from the prime minister about the future. But these “inscriptions” are in fact highly engineered windows, a dynamic blend of art and function.

The length of the structure is 132 meters with a height of 61 meters and a width of 39 meters. 2210 diagrid members have been used to build the skeleton of the structure along with 717 diagrid assemblies and equipped with three staircases and two bridges. The weight of the main steel sums up to a whopping 4913 tons.

Connection Design Challenges
Connection design is actually an art of transforming the assumptions made during the main design stage into a practical reality. Normally whenever the structure is not orthogonal and typical, the complexity of performing the connection increases. It is economical to perform connection design with actual forces for every node; despite its tedious and time taking it is worthwhile for these types of structures.

Base Anchor & Embedment Connection
The different types of anchors used are:
• Anchor Bolt
• Elevated concrete pedestal
• Elevated steel pedestal
• Embedment

Detailed design of a structure is a key element to start in the execution of a steel project. The critical among is the coordination with the façade vendor and incorporating the brackets to fix the same. As the façade line cannot be altered, the steel structure needs to be aligned for the same. Hence the complete calligraphy was modeled and moved accordingly. Similarly, MEP services are also coordinated. A greater challenge was met in modeling the feature and spiral stair. Also modeling of the pre-chamber was highly challenging because of the geometry. Fabrication on this curved spatial structure along with achieving AESS requirements, transportation and erection are other challenges were quite a feat to handle.

The final hurdle was the removal of the temporary supports after the erection of the steel structure. A set of temporary elements was used in order to spread the local forces due to up-jacking the diagrid. Given the horizontal stiffness of the bridge side of the structure, ensured by the concrete core, the bridge had to be jacked only in the vertical direction due to the cantilever displacement.

Choice of Material
Steel was the only choice of material to achieve this complex curved diagrid structure. The usage of higgradesrade and appropriate sections made the structure optimal.

In Conclusion
The futuristic thought of the architecture blended with the ideas structured by the consultants and clubbed with an experienced specialist contractor made another wonder on earth.

Need to Push Our Boundaries


Having 30 years of incredible experience under his belt, Raja Shyam Sundar, Partner, PTK Project Consultant LLP is one of the model professionals of the industry and is not shy to point out right from wrong. He believes in challenging one’s creativity and has proved himself time and again with some amazing work.


What are the major advantages of using steel vis-à-vis conventional materials?
Steel is a material that is clean to use, to fabricate and to erect.  Safety standards at the fabrication factory, as well as the erection site, can be enforced because of the premeditated methodology of erection. It might not be sustainable to keep producing new batches of steel in the future due to the slowly dwindling natural resource of iron ore but steel is a reusable material and sustainable which makes it the future of construction.
How structural steel can be innovatively used in construction to provide design aesthetics and at the same time offer an economical solution? 
Steel is very good to play with as a design element. Steel is the obvious choice for large-span structures because of its character and it also adds slenderness and lightness to the structure. As for the economy concerning steel structure, there is an alarming situation that is rising. I deal with steel fabricators on a daily basis and I have come across industry professionals talking about 3kg/ sq. ft.- 4kg/ sq. ft. warehouses without any regard for any basic standard. They talk about building based on the standards set by Metal Builders Manufacturing Association (MBMA). Building based on weight per square meter is not the route to take; a case in point is the failure of RCC which went down that road. This industry is a well-organized one and if this kind of fabrication becomes a standard then it will hit the entire industry as a whole and the result will be devastating.
We have to implore IIT Madras to pass steel structures based on IS codes and not MBMA or American codes. As designers, we respect and follow Indian Standards because that is what is best for construction in India and we expect the same courtesy from others as well and work based on Indian Standard codes and not fall into the trap of weight per square meter if we want to build safe structures. I personally never accept such projects.
What is your take on the variety of sections or grades that are provided by the steel producer to create versatility in design?
The availability of numerous grades and sections is indeed an advantage. It allows me to create versatility in my design and allows me to increase the spacing of rafters or columns. If I want to introduce a crane, for example, a higher grade of steel gives that strength to support large-span cranes.
What trend do you think we are going to witness in the next five to seven years as far as the designing structure with steel is concerned? 
The steel industry has to team up with architects and structural engineers to push the boundary and keep advancing beyond where are at. Maybe create a competition every year that will challenge our own limits. The recognition will serve as an incentive to come up with more and more innovative structures and designs.
What should be the strategy of the industry in promoting structural steel construction in India?
The industry has to work with professionals of various kinds and not just structural consultants. Take for example to deduce velocity of air that passes through a building, we need CFD analysis. And we need to consult HVAC professionals and ask them to provide these details for the required air changes. As of now, we are merely working with Tekla and are concerned about production and deadlines. We have to take it to the next level to better the functionality of the structures that we build.
Which are the iconic steel-specific projects executed by you?
The SRM University in Amaravati, Andhra Pradesh was designed by us. It is a 50 thousand square feet steel structure that floats. If one doesn’t know the works that went behind that structure, one will wonder how can such a huge structure stand on merely 28 columns. I appreciate the effort that Geodesic put in with us while building this structure. The timeline was 5 months, there were time constraints. When we went for site inspection, we were standing on barren land in the scorching heat of Andhra Pradesh. We were standing under a lone tree while discussing and the idea materialized there to build a fifty thousand square feet tree and put the three buildings within. The steel roof connects buildings as a whole unit and not merely as three separate blocks.

Multi-storied,Workshop Facility for Car Service


During the 1960s, standardized engineering designs for buildings were first marketed as Pre-Engineered Buildings (PEBs). In the last few years, PEB steel structures have become quite popular. A PEB is a pre-designed and prefabricated steel structure that can be custom-made according to the requirement and assembled at a construction site.

PEB structures are used for making houses, office spaces, warehouses, hangars, factories, stadium structures, railway auditoriums, cold storage spaces and even shopping malls. They are made using steel beams and columns that can be shaped according to the requirements.

One of the key benefits of PEB buildings is that they can be built in much less time than conventional concrete buildings. The components are engineered beforehand and standardized. This reduces the engineering, production and erection time. The use of software for design and drafting speeds up the design phase. Moreover, the use of highly sophisticated machinery such as beam welding machines, plasma cutting machines and shear cutting machines greatly reduces the time of fabrication of built-up components.

PEB buildings are built of I-frames which are sturdy in nature and are designed to take heavy loads. Since load considerations are already taken into account before construction, this can greatly enhance the quality of the structure. They can also resist the effects of earthquakes.

Even before the manufacturing of a PEB structure starts, the quality of the materials to be used must be taken into consideration. The use of corrosion-resistant steel ensures that the structure can withstand different operating conditions. This reduces the maintenance required on the structure for a longer period of time.

Since most of the engineering of any PEB structure is done in the factory during the prefabrication stage, the efforts required at the actual construction site are greatly reduced. PEB structures can be easily transported to the site and assembled using bolts and nuts. Additionally, since the assembly process is easy, this reduces manual labor.

PEB structures also prove to be greatly cost-effective since the materials are chosen during the design phase and all the calculations are run beforehand, thus, efficient material usage and less wastage of money are ensured. Moreover, a PEB structure can be shifted from one place to another, giving one more return on your investment. Additionally, such structures are preferred for green projects are they are relocatable.





Area / Weight / Value / Specification


Building Area




Mezzanine Area




Total Weight




Design Code



Roof Sheeting

0.5mm Bare Galvalume Screwed Down Single skin



0.5mm Coated Galvalume Single skin


The clients run PAN India vehicle sales and services for almost all major brands of vehicles. They have an existing large facility, part of which was to be relocated for 2-3 years due to some business necessity. The relocation was at the Central Business District in Chennai on a lease-hold land due to the short duration for which the facility would exist at the new location.

There were some specific design requirements for this temporary facility. The buildable area needed to be maximized within a certain height restriction, in a narrow long site with restricted access. The pre-existing superstructure was to be completely dismantled, transported and reassembled at the new site so as to make it an integral part of the major facility that was going to be created. The new facility structure also needed to be capable of carrying heavy service loads and since the facility would be servicing MNCs, a high-class finish was expected. Apart from these, the facility needed to be cost-effective since it was short-term and had to have ease and speed of construction, dismantling and re-erection. All these works needed to be completed within 84 days in a tightly spaced site with access limitations.

The specifications of the project needed the structure to be factory fabricated and pre-assembled components with tight tolerances of quality control and quality assurance compliance. The structure material also had to be capable of standardization, interchangeability and flexibility. Steel was the obvious choice here and it won hands down against all the other competing technology, namely, in-situ construction with steel and concrete, precast concrete, etc.
The entire project consumed a total of 250 tons of steel.

Fixed Portal sitting has been used on the pile foundation. Single span gable type with heavily loaded mezzanine floor covers the entire gable and eaves end and extra provision of holes has been made in the portal. The mezzanine beam has been designed to receive an extensive requirement of the utility framework. In order to ensure full interchangeability of the utility framework, suspenders were standardized into three types with a telescopic arrangement. The structure has been designed for 100 years return period for wind forces with a design coefficient from FM Global.

The entire construction for the primary and secondary frames has been completely bolted to meet the reusability of construction. To avoid damage during transportation through the restricted passageway, the pieces were fabricated in two lengths for the column and three lengths for the rafter. All the structures were fabricated to close tolerances. To facilitate standardization and interchangeability, only uniform segments were adopted. mezzanine beams were fabricated and assembled at the ground level and erected on a grid-to-grid basis for the speed of completion. Shear studs were not used for ease of reuse and sturdier than normal-size decking sheets were used.

Sanjay S. Sahni

In an exclusive interview with Steel Structures & Metal Buildings,
Sanjay S. Sahni, Executive In-Charge (Tubes Division), Tata Steel Limited, helming the steel tubes and pipes business of Tata Steel, shares the challenges faced by the steel suppliers in India, reasons that make Tata Structura the preferred choice of material, the future sections curated for the Indian market, and much more.
Excerpts from the interview…
Inspired by the designs, we have constructed “The Agni” at Jamshedpur and intend to set up a few more sculpture across the country. Notions of India is an opportunity for architects, designers, and engineers to revisit, reimagine and recreate our nation’s heightened ambitions
Being one of the innovators of the steel industry, what is your take on the future of construction in India?
The Indian economy is rapidly growing and is being sustained not only by good infrastructural spending, but also by investments by businesses from both inland and abroad. Several initiatives, mainly in the field of affordable housing, expansion of railway networks, development of the domestic shipbuilding industry, and the opening of the defense sector for private participation along with the anticipated growth in the automobile sector is set to drive the rise in demand in construction space.
To support the growth aspirations of the Indian construction industry, structural steel is a natural choice as a construction material. Construction using structural steel helps deliver projects at much faster rates and enables clients to accrue benefits at a faster pace. In modern buildings, where large column-free spaces are a prerequisite for occupancy, structural steel is best suited to meet the safety and budget requirements of any project.
Owing to these reasons, we have observed over the past few years an increasing trend of steel usage in both residential and commercial sectors. With the growing confidence of architects and the engineering community in structural steel, we can expect a boom in steel-based construction in our country.
How would you describe Tata Structura’s success story?
Tata Structura has spearheaded the use of hollow steel section (HSS) usage in structural steel construction in our country. Tata Structura shaped the steel construction market by adopting HSS usage from conventional angles and channels.  The usage of HSS not only makes projects economical, but also delivers sound aesthetics that serves as an inspiration for many budding architects and engineers. Through deep engagement activities with leading architects and engineers in our country, we have successfully included Tata Structura in many prestigious projects.
Tata Structura has been used in the construction of more than 40 airports (50,000 MT), 7 metro projects, more than 20 stadiums and iconic projects like the Statue of Unity, Ahmedabad; Butterfly, Bangalore; IKEA Showroom, Hyderabad; Infosys Building, Pune; Kolkata Gate; Patna Convention Centre; along with upcoming projects like Milan Mela Redevelopment, International Convention Centre, Kolkata, numerous data center projects, etc. In short, we can proudly say that Tata Structura has played a transformational role by supporting the dream projects conceived by the architecture and engineering community, and we will strive to provide exceptional services in the days to come.
What role have Tata Structura’s innovative products played in changing the industry scenario?
One of the emerging trends in the construction space that is set to dominate is the need for large column-free space. In the urban and semi-urban centers, there is a requirement to access the vertical space for both storage and occupancy. From a design perspective, many clients are preferring minimalistic yet elegant designs with exposed structural systems. Sustainable and environment-friendly construction concepts are fast picking up in our country. To support such emerging needs, as structural steel suppliers, we need to equip ourselves by developing high-strength steel materials and enhance our product range. Foreseeing such requirements from the construction industry, for the first time in the country, we introduced the YST 355 HSS in the Indian market in 2016 which has helped shape prominent landmark projects. For key project requirements, we have gone a step further and developed capabilities and supplied YST 420 grade steel.
We have also increased our product range and are now able to produce sections such as 400×400, 400×200 and 600NB pipes up to 16mm thickness which continues to find its applications in many mega projects. With the adoption of concepts like composite structures and concrete-filled tubes, such sections have a huge potential in regular residential and commercial structures.
Moving forward, we are in the process of enhancing our capabilities to produce 500×500 sections as well. Our products and manufacturing process have been thoroughly assessed and awarded with GreenPro and EPD certifications. With such strong sustainability credentials, green buildings can now be built easily using Tata Structura, and with the ability to serve larger sections and higher-strength steel, Tata Structura would be able to support the growth aspirations of our country in a sustainable way.
What are the key challenges faced by Indian steel suppliers? How do you plan to tackle it?
A One of the key challenges we face in the structural steel industry is the slower adoption rate of new products that in some ways leads to a catch-22 kind of a situation. Any new product, whether in terms of the section size range or higher yield strength steel, when it takes a longer time to adopt, leads to lower order volumes which in turn, discourages production as it does not meet minimum campaign volumes.
Any extra material produced usually tends to move into high-age stock and incurs a heavy loss. Creating awareness and deeper engagement with architectural as well as the engineering community across the country will drive faster adoption of such new products in the design. Often, we closely work with leading research institutions for design assistance that boosts the confidence of the clients while using such new products in their projects.
Tata Steel has launched a design competition Notions of India. How would this novel initiative help the steel construction Industry?
Back in 2007, Tata Structura had commissioned a nationwide design competition “Notions of India” for architects to design iconic sculptures using HSS. The competition received tremendous response across the country and culminated in the construction of “The Charkha” in Mumbai. In 2021, the second edition of Notions of India was organized around the theme “Shaping a billion dreams”. We received a multitude of mesmerizing designs from sculpture from across the country. Inspired by the designs, we have constructed “The Agni” at Jamshedpur and intend to set up a few more sculptors across the country. Notions of India is an opportunity for architects, designers, and engineers to revisit, reimagine and recreate our nation’s heightened ambitions. The intention is to be a vehicle to propel the many different ideas and innovations of the architectural and engineering fraternity into envisaging the symbols that capture the essence of our country and further inspire its citizens to achieve higher things in life.
What steps should be taken by the government to promote steel construction in India?
The Ministry of Steel has been very active in promoting the usage of structural steel in India. Setting up the INSDAG organization has played a crucial role for engineering students and design firms to learn designing using structural steel. Intense research activities are being conducted at institutes like IITs and SERC on structural steel. We believe it would help the steel construction space if all the published research documents could be collated, standardized in the form of guidelines or codes and made easily accessible. The knowledge dissipation will further boost the confidence of structural engineers in adopting structural steel and effectively designing their projects. It would benefit greatly to include advanced fabrication and installation processes in the curriculum for engineers, leading to having a ready subject and industry knowledge when they graduate.
What is Tata Steel’s plan of action for the next five years?
Tata Steel would like to focus on equipping the construction industry to adopt new products and services and continue to enhance our product range to meet the aspirational needs of the country. We will continue to collaborate with clients, architects, and engineers to help with design optimization support of steel structural systems. Increasing knowledge about new technology and tool adoption like automated profile cutting is very important to improve fabrication and enhance our infrastructural development. We also plan to pursue the optimization of designs by using new-age technologies like CFT (concrete filled tubes), composite systems, diagrid and space frame systems, etc. We recognize the need for protecting our environment and support the cause by continuously improving our products to help build a greener future.
What message would you like to give our readers?
The per capita steel consumption is a direct indication of the development of a country. The per capita consumption of steel in India is 75 kg whereas the world’s average is at a level of 230 kg according to 2019 data. Steel construction allows a tremendous reduction in project execution time and instigates improved quality while offering sound safety and sustainability standards. Overall, material quality, durability, life cycle cost and recyclability play an important role in construction and steel has hardly any competition in that area. So, we want to encourage our readers to adopt structural steel in their projects and in some ways contribute to the acceleration of the development of our country.

M&C Saatchi OfficE Richmond


Creative advertising heavyweights, M&C Saatchi pride themselves on bolstering connection and change – creatively, commercially, and culturally. M&C Saatchi has impeccable brand consistency across all their channels, their brand experience is seamless and considered from head to toe. The concept for M&C required that the structure matches the expression of their brand spatially and experientially- modern, leaning tech but ultimately functional and never over-complicated.

M&C Saatchi’s workplace design was informed by considering the company’s own core values. Following the workshopping phase with the client, a design was developed that would be the hero of the brutal simplicity of geometry, led by a grid-driven layout. Through a progressively paired back spatial approach, the design created opportunities for ownable moments of color, texture, and finish.

This manifested in an open-plan approach to the design with minimal built form, encouraging moments of connection and serendipity in the space. The final design is almost free of boundaries, connected through materiality, natural light, and the organic movement in the space, unifying this core element of connectivity. Lustrous materials are balanced with soft and bold-toned upholstery and joinery, di-chromatic window film as the floating boardroom block, and balanced by translucent corrugated sheeting framing the murals.

The grid was left in place and the tiles were removed, allowing them to be re-used on other fit-outs within the building and sprayed out the ceiling a muted green ‘beyond’ the grid. In a world of sprayed white, black, or bold colors, a highly muted green spoke to the level of restraint required by the very best in the creative industry, capturing the essence of never going too far. By using some raw construction materials, the naturalness felt equally well harnessed, acting as a point of contrast to the refined and tech-like feel of the space.

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