COVER STORY

PED, Heavy Engineering Plant, Gujarat

Godrej Process Equipment Division (PED) is a leader in manufacturing static Process Equipment for process industries. Godrej Process Equipment manufactures the entire range of process equipment for end-users in core industry segments like Oil & Gas, Refineries, Petrochemicals, Fertilizers, Power, Water, Chemicals and Pharmaceuticals around the world. Godrej PED, is the first company in Asia to be accredited with ASME U3 Stamp certification and are one of the very few manufacturers to have supplied Pressure Vessel (hydrotested at 1500 Bar).

Dahej SEZ plot, this location with water front towards Narmada estuary was selected for further expansion. The main plant building (phase-1) comprises of 5.51 acres of ground coverage, and is built on a plot of 55.79 acres.

Building Functionality
The Overall plant footprint is a massive Steel Structure: 363m X 160m with 29.45 m height, Phase-1 being 308.33 Mts. x 78.55 Mts. and height of 29.45mts. The factory building (Main Plant) is oriented in the North – South direction. A complex network of services and utilities are provided to support the manufacturing plant. The facility has various machines & electric operated cranes required for the manufacturing process. The plant comprises of areas like plate cutting & processing, radiography room, heavy & light machine shop, nozzle & shell preparation area, assembly & fabrication areas & hydro testing areas. The master plan prepared has various ancillary buildings supporting the manufacturing plant with the required infrastructure. The plant now comprises of Phase -1 of the project, which is of Main Plant Building – (THE STEEL STRUCTURE) + Utilities serving the main plant.

Structure Specifics
The Main Plant is a Steel Structure above plinth & RCC structure below plinth level. The total consumption of structural steel is about 5500 metric ton in the first Phase. The Building comprises of multi span, single storied PEB building. It comprises of double girder with various crane capacities ranging from 50 -150 tons & 300 tons in future spans. The size of the Plant building in Phase-1is 308.33 Mts. x 78.55 Mts. and height of 29.45mts. The Building is divided width wise into 3 bays (A to D) & Length Wise into 39 Grids. Additional 3 bays (D to G) 81 Mts are planned in future.

 

Design Concept
The proposed structures are analyzed and designed as per IS800 and IS456 to sustain the anticipated load for mean probable safe life of 50 years. The sub-structure is mainly on friction and/or end-bearing piles, as adequate soil bearing capacity was not available at shallow excavation levels. The plant is optimized as steel portal with RCC pedestals resting on pile caps and pile foundation to suit specific ground conditions.

Dahej is in seismic zone 3 as per IS 1893. For the seismic detailing the capacity design concept similar to that developed and prescribed in chapter 12 of IS 800-2007 have been adopted. The structure can withstand Seismic loads as per Zone III with a zone factor of 0.16, an importance factor of 1.75 and in compliance with Special Moment Resistant Frame norms. Building is designed including the provisions of Chapter 12 : IS 800 : 2007 & is done considering Plastic Sections. Most of the Steel Buildings are done using Semi- Compacted Sections and exclude the provisions of Chapter 12.

Due to the proximity to the sea and exposure to salt-laden moisture in air, and possibility of presence of chlorides in the moisture a minimum thickness of 6mm has been considered for primary members with design corrosion allowance of 1.5mm. Wherever Cold form section is used; the minimum thickness was 2.0 mm. The surface treatment of structural steel needed additional focus considering the harsh environment. Painting is done with Epoxy Paint which is High Alumina Volume Solid Paint having good anti- corrosive proprieties giving longer maintenance-free life. Butler system of TBSL was used for the roofing component, with pre-coated 0.75 TCT galvalume Tata Bluescope sheeting.

Construction & Logistic considerations
The main construction challenge for structural steel was the fabrication, transportation and installation of the 10 -18 mts. high columns, and the 25m to 30m portal rafters above the columns. Additionally, the crane girders had to be installed on column brackets ensuring proper alignment and levels.

 

The Heavy Engineering Plant at Dahej, has been a success with involvement and collaborative working of all stakeholders involved in the project. The change from a conventional truss, to a PEB structure, after close interactions and detailed reviews with all the stakeholders at conceptual stage. This change brought in advantages in the execution of the project, with better quality, safety and timelines, including reducing the height of the structure, which brought in savings. We ensured execution of the project was effective and efficient to meet the stakeholder’s expectations without compromising on the values of Godrej like safety, integrity, and environment. M30 Triple Blend Concrete (Cement+ GGBFS+ Fly ash) was used, for long term structure durability, which also helped in reduced carbon footprint. The Project execution was completed with 4 million safe working hours.
Cyrus Shroff, Project Head,
Godrej & Boyce Mfg. Co. Ltd (Godrej Construction)

Challenges Faced & Resolved
While going through the discussions with contractors, fabricators during pre-execution phase it was identified that fabricating and erecting conventional Truss (2.5m X 0.6m) would be difficult. Considering the safety and quality aspect being a major factor into the thought process, after numerous brainstorming sessions, involving all relevant stakeholders the entire structure was redesigned as Prefabricated Plate Girders with bolted connections. These Design revisions in structural sections permitted us to reduce the height of the Structure. Plate girder sections of 1.0m depth against existing section of open web truss of 2.5 m depth, enabled us to restrict the height to <30 m.

Safety Aesthetics
R S Mandrekar & Associates were appointed as the Proof Checking Consultants to verify the Consultants Design. The dedicated Godrej Project Team & PMC Cushman & Wakefield ensured that all works were done with 100 % Safety & Quality and the project was completed with more than 4 Million Safe Working hours. The Project has a Zero Accident record. The Result is a Project where almost every International Client who has visited the facility for evaluation has appreciated the facility and given positive response.

Fall protection system installed on the roof, is one of the best in class (Lathway Fall protection system). The Nylon sky web which is patented product of TBSL is installed for complete length and breadth of the roof for additional safety. Structural Steel doglegged staircase are installed for accessing roof height of 29.45, and internally for gantry and crane access, considering all the ergonomics and safety of people. Service platforms with railing on both side of gantry girders for safety in maintenance and servicing of cranes is also installed.

Fact File
Client/Owner: Godrej & Boyce Manufacturing Co. Ltd  (Process Equipment Division)
Architect & Structural Designer: IPS-Mehtalia Pvt Ltd
Peer Reviewer: R. S. Mandrekar & Assoc.
PMC: Cushman & Wakefield India Pvt Ltd
Soil & Material Testing (NABL): Geostruct Engineering Services
Steel Fabricator & Erection: JSSL (JSW Severfield Structures Ltd)
Roofing: TBSL Butler System
Steel Tonnage: 5500 MT
Civil Contractor: DCPL (Desai Construction Pvt. Ltd.)
Piling Contractor: KELLER Ground Engineering
Status : Phase-1 Completed

Embassy Industrial Park, Chakan

Ten years ago, no one was able to recognise the potential of warehousing in India. Today, logistics cost contributes 13-17 per cent of Gross Domestic Product (GDP) in India and Warehousing contribute approximately 25 per cent of logistics cost. The explosive growth of retail markets and the E-commerce industry, the emergence of international players, a renewed focus on manufacturing led by the government’s “Make in India” campaign and the impending implementation of GST in the country – are driving a paradigm shift in the industrial, light manufacturing and warehousing sector.

Embassy is committed to bringing quality Grade A industrial, light manufacturing and warehousing spaces in close proximity to leading consumer and industrial clusters across India.

Getting the best on board
Today clients no longer need simple warehouses to store their goods. They are looking for turnkey solutions that maximize supply chain efficiency while minimize operating costs. Embassy Industrial Parks provides build to suit spaces, with all necessary approvals, to meet the need for modern industrial and warehousing spaces. These spaces are master planned to meet the most exacting requirements for power, water and connectivity to distribution centres along major logistical corridors and ports. To meet the client’s expectations, Embassy had taken on board Architect’s and consultants of repute as their design partner to realize company’s vision.

 

It is in the ethos of Embassy Industrial Parks to be on point when it comes to timely delivery, specs, cost, and construction. We are highly invested in our esteemed list of customers. We identify the pain-points of our clients and make it our priority to take charge of them ourselves. Service to us is as important as the product and we continue to set new benchmarks for Grade-A quality warehousing solutions. Embassy Industrial Parks – Chakan has been delivered to clients already. Having the first mover’s advantage makes our future look bright.
Anshul Singhal, CEO, Embassy Industrial Parks

Having realized the potential of the selected consultants and architects for this business they have given them a free hand at:

  • Bringing to the table their innovation and creativity at the core while envisaging and designing the
    industrial park.
  • Envisioning the Turnaround time (TAT) for the project deliverables to enable a faster Return On Investment (ROI).
  • Explore possibilities of Value engineering within the designs to bring about cost efficacy within the project and also take an innovative approach through technology.
  • Ensuring that all architects and consultants approached this project in the most confidential manner thereby safeguarding Embassy’s interests.

Facing Encounters
The first & foremost relevant agenda on board was to secure land positions which allowed expandability & flexibility for our customers. Embassy Industrial Parks is a highly customer centric service company, so this was very essential to us. Today we can buy land & construct anywhere in the country at a pace 30 % percent faster than the market. Making tenants aware about the benefit of ‘’A’’ grade warehouses was taken as one of the key initiative. Also, among other challenges, was to understand the government policies for various processes of statutory approvals to funnel down to single window clearance, it was envisaged and successfully done for our project locations. As the expectations in the market are increasing day by day, the challenge also remains to keep the project at cost and rent as per market dominated by local/unorganised player. It needed strong persuasion and marketing strategy.

Take on steel
Steel Buildings is future of construction in India. Steel is also recognised as the sustainable ‘green’ product that can be recycled. Steel being the sturdy metal, also helps preventing buildings against the natural disasters. Steel Buildings is the fastest way to build a safe and quality assured structure that generates minimum pollution and makes minimum use of natural resources such as water and electricity. Steel structures are easy to transport as they are lightweight. Also, there are no health hazards of using steel structures in construction. This technology should be made mandatory for private and corporate buildings also in cities. It requires minimum space for construction and erection can be done in few days without any hindrance to traffic flow and there is no dust and noise pollution, like one sees in the conventional method of construction.

Striking Features
Buildings has a large span of 120.0 mt with module of 24.0 mt. Also, intermediate column spacing is taken at 17.0 mt. So, all internal column grid spacing considered 17.0 mt x 24.0 mt for racking arrangement and free movement of equipment. Roof sheet has taken standing seam with sheet thickness 0.6mm colour coated with SRI value 78 as per green building norms. Louvers has taken all around the periphery of building and Roof monitor at Ridge of building for efficient air circulation as per NBC. For daylight Polycarbonate skylight has been used as per industrial norms to save the electricity in day hours.

Pre-Engineered Steel Building was supplied by Zamil Steel Buildings India Pvt Ltd. They have used ASTM A 572M with Yield strength 345 MPA steel for primary members. All the section used in buildings has design and detailed by manufacture as per available thickness size of steel plates in market. However, all the steel members have been fabricated as per design requirement in Manufacturer factory.

 

Fact File

Architect: Venkataramanan Associates
Structural Consultant: Tata Consulting Engineers Ltd.
Logistics Consultant: Miebach Consulting
Client: Embassy Industrial Parks
Steel Supplier: Zamil Steel Buildings India Pvt Ltd
Steel Tonnage: 45,700 MT

Alphathum Tower, NCR

Alphathum is one of the tallest buildings in India which has been designed with the composite construction concept and have been executed at the site. The project consists of three buildings which are connected at the top with the bridge and the swimming pool extending to all the three buildings.

Preliminary Design
Vintech Consultants provided the structural design consultancy for this project which includes to complete project design along with furnishing complete design and fabrication drawings. The project is to be completed in shortest possible time duration with optimized cost. The design team plans to create simple straight-line structure with elegance and should be construction friendly

As the structure is located in highly seismic zone and owing to its sleek geometry and height, the structure is more vulnerable to wind and earthquake forces. Therefore, to cater to the lateral load, an optimum combination of shear walls and bracings were worked out to achieve economy and construction speed. The framing of the building has been designed to provide large office spaces without compromising on the clear floor-to-floor height and foundation is a raft system.

        

“The project is a good experience to be completed in shortest possible time duration with optimized cost. We have to plan simple straight-line structure
with elegance and should be construction friendly”

Manoj Singhal, Managing Director
& Sanjay Vithalkar, CEO Space Combine

Challenges faced
The major challenge was to reduce the structural steel consumption so that the project cost is comparable to the RCC option. At the same time, maintain the constructability for fast execution. After various iterations and discussions, composite structure was chosen. After the choice of material, it is the research on Eurocodes and AISC one has to do as Indian codes do not have composite design provisions. However, the design parameters, load factors, material safety factors had to be modified in order to encompass the Indian construction scenario and honoring the Indian codes of design.

The shear wall construction was a bit slower than the steel frame. However, generally, the shear wall should go above the steel frame with the help of advanced shuttering methods. This problem was rectified by special steel composite connections such that the advancing steel frame does not have to wait for the shear wall construction.

Steel used
The frame is a dual system of Special concentrically braced frame and shear wall systems. The columns are composite column with steel fabricated I sections of 550 grade encased in concrete which eliminates the ‘Achilles heel’ of steel which is buckling and low fire resistance.

The beams are steel beams of 450 grade fabricated and rolled parallel flange I sections designed compositely with the slab. The composite action with the slab facilitates lower depth of the beams, lower material consumption and lower deflections. The shear transfer between beams and slabs is facilitated by channels of 75 mm depth ensuring slab behaves compositely with beams

The slab system is designed by JSPl Speedfloor® system which is as fast and cost effective as the metal deck system and at the same time give higher composite action for the beam design. The bracings are box bracings of high grade steel. Box sections provide great finish and are efficient structurally in providing strength and stiffness in both axes. The connections worked out for the project are bolted connections to expedite construction and get superior quality of construction.

After completing numerous high-rise buildings in RCC, Alphathum project have been a great opportunity for Vintech Consultants to foray in the multi-storey steel buildings. The collaboration with the architects led to efficient design, open spaces and faster construction. Moreover, the association with the Bhutani group, who are the client have been great for Vintech consultants as projected is marketed well and one of the most prestigious ongoing commercial project in NCR

Dr. Vinod Jain
Managing Director, Vintech Consultants

Striking Features
The salient part of the project is the bridge connecting the terrace of the three buildings. It has one of the longest swimming pool in the world spanning more than 200 m in length which will further require expansion joints. It is proposed to have the dampers installed in the bridge to cater to the expected sliding forces and structural integrity.

With respect to the architecture, Alphathum will use solar + wind + fuel cell + geothermal energy systems to reduce dependence on fossil fuels. Double glass glazing, naturally day-lighted interiors and light-colored building rooftops with sky gardens will help reduce heat absorption and ensure energy efficiency. The whole building will be created from an energetic and vibrant pure center.

      

Structural Uniqueness
The structure is unique because of its minimalistic design and a beautiful blend of the structure with architecture. The periphery bracings bring out the structural steel aspect of the building. Due to these factors, the building has been completed in a staggering figure of 4.5 kg/ square feet of structural steel which is an achievement in a 33 storey building in a high seismic zone.

 

Fact File
Client & Developer: Bhutani Infra
Architect: Space Combine
Steel Fabricator: Jindal Steel & Power Limited
Steel Supplier : Jindal Steel & Power Limited
Steel Erection: Waho Infra LLP

JSPL Staff Accommodation, Angul

JSPL has setup an integrated steel and power plant at Angul, Odisha on approximately 4,000 acres of land, and to cater for the housing demand of their staff, guests, trainees, students, and workers around 300 acres of land is earmarked. The layout of residential area includes low and high-rise towers, villas with amenities including parks, play areas, schools, hospitals, shopping centres, clubs, and sports facilities. This project includes type F residential towers for staff and is to be built on 10.05 acres of land. It comprises of 9 blocks of G+11 floor having 8 nos 2BHK units per floor. The total built-up area per block is 1, 05,260 sqft and of the entire project is 8, 52,080 sqft.

Design Intent
The residential towers are envisaged to be built using structural steel sections for gravity and lateral force resisting superstructure system. The sub structure up to plinth shall be built in reinforced concrete. The superstructure consists of Steel column-beam frame and has been analyzed as rigid jointed multi story non-sway frames in accordance with stringent Indian standard (IS Codes) provisions and detailed intricately to take residential occupancy into account.

Cross bracings have been provided at locations not to hinder with the aesthetics and functionality of the building and to resist the lateral loads due to wind and earthquake. Skeleton were the structural engineering consultant; to provide engineering design and technical assistance.

 

The architectural intent was to create a very vibrant, young, flexible space for the employees of JSPL. The use of steel and the speed floor concept really created a sleek looking building and interior space.

Nejeeb Khan, Managing Director, KGD Architecture

Structural Geometrics
Angul being a remote area, there was scarcity of skilled labour and traditional methods of construction were thus not feasible.

Various, alternative technologies were studied, and pre-engineered steel concept was adopted owning to the advantage of being an offsite and customizable method. The primary frame of the building comprises of ordinary moment resisting steel Beam-Columns frame with cross bracings in vertical plane.

The floor system consists of 90mm concrete screed over the light weight Speed floor joists and will act as rigid diaphragms in horizontal direction. The Speed floor system is a unique suspended concrete flooring system using open webbed, roll formed, galvanized steel joists. Another unique aspect of the projects is use of Schnell wall panel which consists of a sheet of polystyrene sandwiched between two mats of welded wire mesh.

The total design lateral forces are resisted by the columns-beam frames and bracings in proportion to their lateral stiffness at all the floor levels. Hollow tubular sections are preferred for cross bracing due to slenderness benefits resulting from higher radius of gyration. Moment resisting connections are considered for column-beam junction for rigid and stable behavior and being lighter. Steel columns are analyzed as pinned at top of RC pedestal and support reaction at that location were considered for substructure design in order to make the substructure lighter.

 

Increasing demand of residential dwelling units in country and huge gap created due to speed of conventional construction technique has encouraged usage of RAPID MASS HOUSING through STEEL frame construction integrated with SPEEDFLOOR system and LGFS/other dry wall systems. Added advantage is assured quality of output building for enhanced durability and performance. SKELETON has developed expertise and competency in producing such buildings and structures contributing to growth of country.
Abhay Gupta, Director, Skeleton Consultants Pvt Ltd

Structural Uniqueness
The project has many unique features, some of which were used first time for a multi-story tower construction. The superstructure is designed in structural steel which offers flexibility and strength, in addition to light weight material. Under the action of earthquake forces, the structure is required to be flexible and low weight, as heavier structures attract larger forces when an earthquake occurs. Using structural steel, forces in the structure are reduced and its foundations are therefore lighter. This reduction of design forces significantly reduces the cost of both, the superstructure and foundations of a building.

Speedfloor System
Speedfloor is a suspended concrete flooring system using a roll formed steel joist as an integral part of the final concrete and steel composite floor. The system has been developed combining modern techniques and roll forming technology for a fast, lightweight, concrete/steel composite floor at a cost-effective price.

The joist is manufactured from pre-galvanized high tensile steel in a one pass roll former, where it is roll formed, punched, pressed and slotted to a high degree of accuracy at a fast production rate. The ends are simply bolted to the joist which are then ready for shipping to site. The Speedfloor System essentially is a hybrid concrete/steel tee-beam in one direction and an integrated continuous one-way slab in the other direction.

The floor system comprises of Speedfloor joists. Speed floor joist is a unique concept where roll formed joist of 350MPa yield strength are used. The joist is manufactured from G 350 Z275 pre-galvanized steel. The roll formed shape with its pressed web produces a rigid and accurate steel section that has a high load carrying capacity and therefore good spanning characteristics with no propping requirements. The joist needs no shoring and is light enough to be manhandled into place, the services can be passed through the holes pre-punched in the joist. The joist utilizes the composite action with the concrete topping and thereby offers a fast, lightweight and cost-effective solution.The lockbars support the temporary plywood formwork between the joists during construction. They are spaced approximately 300mm apart and engage in the slotted holes punched in the top section of the joist. They also maintain the exact spacing of the joists.

High-density paper overlaid 12mm plywood is used as formwork to produce a first-class finish to the underside of the slab. The rigid plywood sheets are used in conjunction with the lockbars and when locked in place, provide lateral stability to the entire Speedfloor system during the construction phase. The wall system consists of a sheet of polystyrene sandwiched between two mats of welded wire mesh. The panels have excellent insulation properties, besides being light in weight, easy to handle, and convenient to transport to the remote areas. The wall panels have 35mm shotcreting on both side, which increases the strength of the wall.

Steel used
The growing number of multi-storey residential buildings being specified with steel frames clearly demonstrates the ability of structural steelwork to comfortably meet all of these demanding requirements. With steel, the benefits of off-site manufacture can be seen, and felt, during construction and in use. The speed of steel construction can lead to earlier returns on investment and more predictable completion dates. On tight urban construction sites, where access and space for storage and materials handling are at a premium, steel deliveries can be timed to reduce traffic congestion and minimize storage requirements.

For Primary framing members, UC and UB sections manufactured by JSPL having yield strength of 345 MPa confirming to IS 2062 are used. Hollow tubular sections are considered for cross bracings having yield strength of 310 MPa.

Industrial plants were situated in distant locations and were not easily accessible. The success of every plant lies on its infrastructure development, facilities and build environment. JSPL coming up with a mega steel & power plant at Angul, Odisha, which will produce 12.5 MTP steel and generate 2600 MW of power in phases. With the construction being in full swing, the need to complete the plant in scheduled time, tremendous manpower is required. To cater to their habitation, a massive housing demand is generated for their workers and staff. This was not feasible to achieve by traditional method of construction in such remote areas, where the scarcity of skilled labour persists. To achieve the housing demand, I was forced to explore new construction techniques to meet the housing requirements and this became an ambitious project for me. Various construction technologies were studied. The pre-engineered steel structure concept was adopted along with various other technologies for other elements.

New Integrated Terminal Building, Aurangabad

Aurangabad is located in the Marathwada region of Maharashtra and is a very important tourist destination for both, domestic and international tourists. The city is also an industrial base, rapidly growing as an important commercial center in the region. All these factors put together provide immense potential for air travel to the city of Aurangabad.

The existing facilities at the airport provides only for handling of domestic air traffic. The runway is suitable for handling AB-320 class of aircrafts; the apron can accommodate 1 no. AB-320 and 1 no. ATR class Aircraft. The terminal building is suitable for 100 departing and 100 arriving passengers and with the growing air traffic becomes inadequate. A large number of foreign tourists come to Aurangabad, but, they reach via Mumbai or Delhi taking domestic flights, as facilities for handling of international flights is not available at Aurangabad.

Keeping in view the above situation, the Airports Authority of India planned the Development of Aurangabad Airport.

The Aurangabad Airport is a perfect example of the brand’s power to shine with excellence. The Airport was planned to be an important hub augmenting the nation’s connectivity. It was all the more vital as the city of Aurangabad was the gateway to the world-famous tourist destinations – Ajanta and Ellora Caves and other places of interest in the vicinity.

In addition, Aurangabad and its neighbourhood is also rapidly evolving commercial centre that has experienced a spurt in to be a prime catalyst for the economic development of the region, as it could facilitate better air connectivity that translated into faster mode of transportation of people associated with the businesses and the cargo required to be delivered.

 

 

I really feel privileged to get myself associated with the part of the great team involved in the work of Development of Aurangabad Airport. I had very good cooperation from the people not only associated with work also from general public with whom we have interacted for this work. Especially People of nearby villages adjoining Airport are very nice, cooperative and helpful in giving the land and understanding the specific requirement of Airport for the development. With all their help, Guidance of our senior officers from Mumbai & Delhi and with the active participation of our team of officers and staff of Aurangabad Airport we could successfully complete the work of New Terminal Building and Extension of Runway, so that Aurangabad can be placed as one of the best Airport in the map of International Airports.”
G. Prabaharan, General Manager (Engg-P), Airports Authority of India


Landmark Architecture
Vinay Hedaoo was selected as the structural designer for the modern structure and M/s KITCO was assigned the job of fabricators. This new Integrated Terminal Building at Aurangabad Airport was to be a glass and steel structure offering all kinds of passenger friendly facilities. Tata Structura hollow sections were chosen, as the brand was capable of meeting the requisites of the specific design and engineering. Tata Structura was used extensively to lend the structure an innovative, modern and classy finish that would turn it into a showpiece of creativity and a signature of exclusivity. Today, this landmark airport stands as a symbol of pride, not only for Tata Structura, but for the nation as well. Aurangabad Airport is not only a spectacular structure that represents sustainability, but also epitomizes world-class architectural splendour with its aesthetics.

Committed to Excel
Tata Structura has always stayed committed to its customers with its single-minded focus on delivering ‘the shags to come’. In course of fulfilling the commitment, the brand has adhered to its vision of excellence and innovation to emerge as a market leader steering the construction industry towards a future resplendent with possibilities. From airports, metros and railway stations to IT complexes, industrial clusters, commercial centres, malls, infrastructure and more – Tata Structure has successfully inspired the industry experts to redefine the skyline of tomorrow’s India. Tata Structura has empowered architects, engineers and designers to shape their dreams and fly unfettered on the wings of creativity.

TECHNICAL SPECIFICATIONS
Steel Work
Supplying, providing, fabricating, assembling and erecting at site tubular structure consisting of MS Pipe Rakers, purlins, and metal casing conforming to IS 1161 Grade 310 in the profile shaped as per the drawing with special plate connectors, pinion joints using SAW/MMAW/MIG welding process with cleaning the surface and applying a coat of epoxy primer, and including transportation, cutting, threading, machining, leads and lifts upto all heights, tools and plants and necessary scaffolding, etc. required for all operations involved to make structure of main terminal building. The tubular structure system with plate connectors, pinion joints, etc. is to be provided. The complete structure to be painted with one coat epoxy primer, including preparation of shop drawings had to be approved by the Engineer-in-Charge before start of work.

The above item includes supplying, providing, fabricating, assembling, and erecting at site tubular structure in the bended profile shaped as per the drawing with special plate connectors, pinion joints, using SAW / MMAW / MIG welding process with cleaning the surface and applying a coat of epoxy primer.

Materials
MS Pipes were used as per IS 1161 YST 310 Gr. / ASTM A106 Gr. B or equivalent standards. Bolts are high tensile bolts of minimum 10.9 grade having black phosphate coating as per IS 1363/1364 provided with a washer of sufficient thickness to avoid any threaded portion falling within the thickness of the parts bolted together if required.

The bended purlins in the profile as per drawing connected to the profiles MS Rakers with suitable arrangement, metal casing provided at the end of Rakers as per the drawings. The bending of the members wherever specified were in exact profile as per requirement.

Connector were used of high strength, manufactured out of similar grade of pipe material of required dimensions and holes for the bolts in the required position and direction. The item includes cleaning the surface and painting one coat of epoxy primer. The structure was properly bended, connected welded and aligned to get the required profile.

At Tata Structara, we believe in integrity at every step of the process which enables us to stand the test of public scrutiny which is of vital importance to us. We also believe that before we understand our product, first we must understand the people we work with, and our valued customers. Excellence has always been a significant part of our core values, which is why we are where we are today – at the core of your hearts and your structures. We work cohesively as a team to bring the essence of this excellence to you in the form of the hollow sections that revolutionize what you build and make a difference to your creative aspirations.
VINEET SARAF, Chief of Marketing & Sales, Tubes-SBU, Tata Steel

EXECUTION
Tubular framework (in truss pattern as per design and drawings) got executed by specialized agencies having requisite experience in execution of similar works of similar magnitude as approved by Engineer-in-Charge. The structure was properly bended, connected, welded and aligned to the required profile, i.e. work was executed as per designs given and workshop drawing prepared by the agency and got approved by the Engineer-in-Charge.

Tubular structure system with plate connectors, pinion joints, etc. was provided in all respects to make the structure of the main Terminal Building. All components of tubular frame were cleared off the dusts/scales etc. completely before applying primer.

TEST & CODES APPLICABLE
Welding was done in accordance with the following Indian Standards applicable:

  • IS 816 Code of Practice for use of metal arc welding for general construction in mild steel.
  • IS 820 Code of Practice for the use of welding in tubular construction.
  • Shearing, chipping or gas cutting prepared profile of fusion faces. In all cases, the faces dressed by chipping, filling or grinding and made regular.
  • The surface to be welded and adjoining metal for distance of at least 20mm must be clean free of rust, scale, paint etc.
  • Each bead of metal had the slag removed by light hammering and wire brushing before the next bead was deposited. The weld must show a good clean contour and on a cut specimen good fusion with parent metal. Before applying paint, the weld had to be carefully chipped and wire brushed.

The works included preparation of shop drawings giving complete information, necessary for the fabrication of the component parts of the structure including the location, type, size, length and detail of ail welds, and nuts, bolts, rivets etc. as per provided by the design drawings. The shop drawings were sufficient to ensure convenient assembly and erection at site. These drawings also included full details of all joints, connections, splices etc.

 

FABRICATION PROCEDURE
Assembly
All connections were either bolted or welded as shown on the drawings. The contractor shall not redesign or alter any connection without prior approval of the Engineer-in-Charge. The components parts were assembled in such a manner that they were neither twisted nor otherwise damaged and prepared such that the specified cambers, if any, are provided. Drifting done during assembly did not distort the metal or enlarge the holes.

Bolting
All steel work which is bolted together shall be in close contract over the whole surface. Where two bolted surfaces are to be in permanent contact after assembly, each shall be thoroughly scraped free of loose scales, dirt and burs and a heavy coat of red oxide, zinc chrome or other approved paint applied after cleaning and drying.

All bolts were provided with washers under the nuts and the washers shall be tapered on the inside of the flanges or RS joists and channels. Bolts and studs project not less than one full head through the nut after tightening. Unless otherwise specified, the ends of the bolts were burred after erection of prevent the removal of nuts.

High strength bolts were used in bearing of friction as shown on the drawings. High strength bolted joints were made without the use of erection bolts. Bolts shall be of a length that will extend not less than 10mm beyond the nuts. Bolts shall be entered into the holes without damaging the thread-members. They shall be brought tightly together with sufficient high-strength fitting up bolts which shall be re-tightened as all the bolts are finally tightened. Bolt heads shall be protected from damage during placing. Bolts that have been completely tightened hall be marked for identification. Bolted parts shall fit solidly together and shall not be separated by interposed compressible materials. The contract surface in high strength bolted connections shall be free of oil, paint, lacquer, loose scale or other coatings. The facing surfaces shall be machined flat. Final tightening of high strength bolts shall be by turn-of-nut method.

Anchor bolts were set by use of templates secured firmly in place to permit true positioning of the bearing plates and assembles. When in drawings anchor bolts are shown to be installed in sleeves, the sleeves shall be completely filled with grout.

Welding
Proper Bead Shape
Minimized penetration to prevent dilution of the weld metal with the alloy elements. Preheating, controlled interpass temperature and controlled heat input.

Welding was performed only by qualified and tested welders specifically trained and experienced for the type of job required to execute the welding work to the complete satisfaction of the Engineer-in-Charge. It was a criterion that the welder should have minimum five years of experience in the job of similar nature.

Use of standard weld symbols as adopted by IS:813 is mandatory. Prequalified jointed which are detailed, prepared and welded in accordance with the requirement of IS:816 shall invariable be used. Structural welding shall not commence until joints elements are bolted or tacked in intimate contract and adjusted to dimensions shown with allowance for any weld shrinkage that is expected. Welding sequence was planned and controlled to minimize undue stress increase or undue distortions on restrained members. Heavy sections and those having a high degree or restraint was welded with low hydrogen type electrodes.

Field Welding shall not be permitted unless shown on the drawings. Subsequent to fabrication, the overlapping or contracting surfaces or other closed sections (such as tubular, box section) which are inaccessible to painting shall be seal welded when the end of the tube is not automatically sealed by virtue of its connection by welding to another member the end shall be properly and completely sealed. Before sealing, the inside of the tube shall be made dry and free from loose scale.

Order of assembly of the tubular section shall consist of welding the tensile member to the main member first. Compression member shall be cut back to overlap the tensile member and then welded to both the tensile members.

Erection
As far as possible, the contractor delivered the fabricated steel work to the site in the same sequence as that which he wishes to follow for the erection. Dispatch was scheduled to avoid cluttering up of the site. The bolts required for erection was bagged according to size prior to dispatch.

All structural work was erected in accordance with IS:800, IS:806 and IS:1915 and as per the approved erection drawings. The contractor shall be responsible for setting out the works. The suitability and capacity of all plant and equipment used for erection shall be to the satisfaction of the Engineer-in-Charge. These shall be regularly serviced and maintained. Occupation safety practices shall be strictly adhered to and shall be to the satisfaction of the Engineer-in-Charge.

Individual places shall be plumbed, leveled and aligned. Drift-ins be used only to bring together the several arts. They shall not be used in such manner as to distort or damage the metal. Temporary bracing, but-line and staging shall be provided to ensure proper alignment and to adequately protect all persons, property and to withstand all loading to which the structure may be subjected during erection.

Attachment of such temporary steel work to the permanent steel work shall only be done with the approval of the Engineer-in-Charge. Temporary steel work shall remain in position until the structure is stable and self supporting and permanently bolted or welded to the satisfaction of the Engineer-in-Charge after removal of temporary steel work, the permanent structure shall be made good to the complete satisfaction of the Engineer-in-Charge.

No permanent bolting or welding shall be done until proper alignment has been obtained. Erection of the parts with any moderate amount of reaming, chipping or cutting shall be immediately reported to the Engineer-in-Charge. The steel work shall be rejected unless corrective action is approved by the Engineer-in-Charge.

Placement of joists shall not start until the supporting work is secured. Temporary bridging, connections and anchors shall be proved to assure lateral stability during erection. Bridging to steel joists shall be installed immediately after joint erection, before any construction loads are applied. Horizontal or vertical bridging shall be provided in accordance with the type of span of the joists. Ends of the bridging lines shall be anchored at top and bottom chords where terminating to walls or beams.

Festival City Noida

Festival City is luxurious commercial project, it will be India’s largest open air high steel project in 25 lacs sq. ft. with over 1500 retail shops, offering huge prospectus to tap huge market. The project offers at very competitive and affordable price. This project is adjacent to several excellent academic institutions alongside and also provides a modern-day parking facility with multiple automation entry point for simple entry and exit for convenience.

Layout
It is strategically located at main exit on Noida expressway. It has three different courts: Entrance Court (Green & Beautified); Festival Court (International concept – Giant Carousel and Iconic Clock Tower) and Fountain Court (India’s large musical concept just like Bellagio in Las Vegas and Burj Khalifa).

The project Festival City Noida is adjacent to several excellent academic institutions alongside 1200 acres JP Wish Town city with over twenty-five thousand people residing in near projects. Also provides, a modern-day parking facility with multiple automotive entry points for simple entry and exit for convenience, about to keep over 7000 cars.

Earlier the Tower was conceived as a non-glazed building with individual balconies. But now the facade system has been changed to fully glazed building without balconies. There is a double height landscaped forest floor as a segregation between the retail floors and IT Office. At 18th floor, the offices have been recessed to achieve an architectural depression and along with this a vertical recessed facade is planned to gain the balanced composition. Iconic Sky club has been planned on the roof top of the Tower.

As an Architect Urban Designer, my ongoing journey through this project has been a wonderful experience. Many factors have contributed towards the exclusivity of this under – construction IT Complex, spanning across 25 Acre site, on Noida Expressway. First and the foremost being the first of it’s kind high rise ‘ Pre-Engineered Building’. The idea behind the adoption of Steel Building Structure, was primarily to make the 150m high rise structure, lighter in weight so as to avoid excessive expenditure on the piling; and over that gaining the advantage of escalation in the pace of erection, as compared to the conventional RCC Structure. The high yield structural steel, which has been produced for the very first time for this Tower, has given us the flexibility to explore spans within the range of 10.5m, which would not have been possible with RCC structure. The Credit for such a futuristic decision on the adoption of PEB structural system goes entirely to Mr. Satinder Singh Bhasin (Bhasin Group), whose vision will be an inspiration for the times to come.
Kulpreet Singh Khokhar, Director, Studio AMK Architects

Accreditation
This full steel building has got many first to its credit:

  • It is first steel high rise Skyscraper in Noida area and National Capital Region of the Country.
  • It is the first 30 floors storey high rise in steel structure, actual number of storey being 32.
  • It created a sensation in real estate market of national capital region, by targeting for the first time and announcing a completion time of less than one year essentially because of adopting composite construction philosophy for the basic skeleton framing and slabs.
  • For the first time in India speed floor construction for composite slab has been adopted. Its unique feature of fast removal temporary joists was a big contributor to the owner’s efforts to achieve very tight construction scheme.
  • Special structural bracing system to provide resistance to seismic action. Delhi begin seismically active zone. Special care had to be taken in designing the bracing configuration and member types and sizes.

Experts Involved
The building provides a very effective blending of the technical skill and innovation and track records of similar composite structure of the design team of the project structural consultant, in this case being Constructure Designs Pvt. Ltd.

The consultant with the willingness of the owner and the architect to take bold decisions with the capability and strength of Jindal Steel, they were invited to work on this project to look after construction aspects specially from the angle of economy and cutting short construction time. Jindal Steel supported the project by bringing in speed floor concept with proper demonstration and presentation and acceptance for the same for all parties concerned.

 

The main focus of the structural system concept of the building was speedy construction, while keeping the cost quite competitive, Compared to R.C.C, the composite construction of column and beams with high grade steel and concrete was favored. The adoption of steel construction was proved right the main frames with floor slabs being completed in a very short time. Bracing system was provided in vertical plane on outer frames of the building to limit lateral
deflection in earthquake and wind.
HARIOM GERA, Director, Constructure Designs Pvt. Ltd.

Facing Challenges
Steel structure building with composite construction is a new concept in this country and constructing 30 plus storeys for the first time in national capital region by itself, posed a big challenge both for designer and the contractor. The combined efforts and proper co-ordination of the structural consultant, the contractor and the architect backed with technical support of the project team of owner created a positive environment which helped to handle confidentially the challenge.

Structural Steel Sections
Mostly grid size of 10.5m x 7.5m and 7.5m x 7.5m were used, some variation being provided locally near stair, lift well etc were used. Although, as in normal practice, main beams were envisaged to be fabricated plate girders, the steel section manufactures could propose nearest ready made rolled sections. This also resulted in a substantial saving of fabrication time.

Bracings used were primarily hot finished structural hollow sections. High grade steel Y350 were used in all cases. Total quantity of structural steel utilized for the project was 4500T, which include rolled I-section joists, box sections and rolled channel sections.

Composite Construction Details
A very slender slab section of 90mm thickness was placed integrally above the floor beams. Such a low thickness was possible with the introduction of speed floor system whose inherent feature required a system of closely spaced temporary beams average spacing of beams being approximately 1000mm welded wire mesh were provided as reinforcement in the concrete. Concrete grade used for the slab was M-30.

Speed Floor System
Speed floor system used was design snipped by Jindal Steel and Power Ltd in collaboration with Speed Floor Holidays Ltd, New-Zealand. Speed Floor system essentially a hybrid Stal fee beam known as speed floor joist in one direction and an integrated continuous one-way slab in other direction. The joists of different depth are manufactured in roll former where it is roll formed, punched and slotted in a fully computerized machine.

Unique feature of the computer system are the lock bars which support the temporary plywood for work between the joists during construction. They are spaced approximately 300mm apart the top sections of joists are imbedded in concrete and has following four features:

  • It serves as compression element of non-composite joist during construction.
  • It provides chair for the weld mesh of reinforcement.
  • It locked in and support the slab shuttering system (lock bars and plywood forms).
  • It will give a continuous shear connector for the composite system after the concrete has matured.
  • The bottom section of the joist acts as a tension member both during the construction phase and when the joist is acting compositely with slab.

After concrete has set the lock bar will be released and plywood framework will be removed.
The whole system has worked very effectively for the festival city project which led to substantial saving in construction time and saving in weight of concrete which further helps in reducing dead load on the structural system.

Composite Columns
Composite columns with steel sections encased in concrete were used throughout the building covering all the floors. Concrete grade M-80 was utilized for all the columns. At upper floors concrete grade was reduced to M-40. Apart from strength the concrete provides the required fire proofing which is an added advantage of casting concrete. The concrete casing basically provides increase in stiffness of column which assist in controlling lateral displacement which is critical criteria for structures in seismically active region like Delhi.

Fireproofing
Steel columns are fully encased and therefore additional fireproofing was not envisaged but considered necessary for steel beams, no fireproofing is required whatever false acting is provided. However, for exposed steel beams.

Seawood Darave-Uran Railway Line, Navi Mumbai

The Commencement
Navi Mumbai is a planned satellite city of Mumbai. Gadgil Planning committee of State Government of Maharashtra recommended considering a twin city, to ease the ever-increasing population load on the island city of greater Mumbai. The Navi Mumbai project began in 1971, with the formation of City and Industrial Development Corporation (CIDCO) a company registered under company act. CIDCO was entrusted with developing necessary social and physical infrastructure. Forty-one years later, CIDCO carved out an eminent nest of planned, sustainable and self-sufficient inhabitation, out of a common, undeveloped expanse of 344 sq. km., once a marshy sanctuary to salt pans and paddy fields. As per the latest census which was carried out in 2011, the urban / metropolitan population of Navi Mumbai NT was 18,394,912 and is rapidly growing with the growing real estate in this planned city.

Railway Network of Navi Mumbai forms lifeline of the NMNT (Navi Mumbai New Town) connecting the residential population to their work places in the Island city and its suburbs. The extended harbor & trans harbor sub-urban rail commuters’ systems are a major part, of the Railway Network in Navi Mumbai. A 29-km Mankhurd-Belapur-Panvel corridor has been operational, along with inception of this city. A 23-km Thane-Turbhe-Nerul/Vashi Trans harbor suburban corridor connecting Navi Mumbai with Thane city, is also operational. The hallmark of suburban railway stations is its unique architecture, commuter amenities, double discharging platforms and subways/over-bridges for easy exit and entry; integrated facility layout of modal split of commuters as forecourt area. Use of air space of forecourt as commercial complex above and adjacent to railway station is very innovative & successful idea introduced in this new town.

Concepting Commuters Lifeline
Hiten Sethi & Associates were appointed by CIDCO to design the phase, i.e. 4 out of 10 stations on the Seawood Darave–Uran railway line. Sagarsangam Railway station and Tharghar Railway Station are being constructed, with RCC as the principal structural material, whereas Bamandongri Railway Station and Kharkopar Railway Station are designed with superstructure in structural steel.

The brief given by the client was that – the concept plan and other requirements, should cover all the operational activities of the stations including the forecourt area for the various amenities, transportation facilities, parking for modal split and commercial activities. The various connectivity for the movement of commuters was also to be examined and the provisions for Escalators, Skywalk/Foot over Bridge, foot under bridge/subway, dedicated footpaths and pedestrian walkway etc. had to be considered where necessitated.

 

Working on Bamandongri and Kharkopar stations has been a privilege for me. It always is a matter of pride and joy to be a part of the process of creating a new identity for a locality and these railway stations will be iconic structures coming up in the said areas. This is thus not just an opportunity for us as Architects but also a responsibility to design a space that shall serve the people of Bamandongri and Kharkopar and be the face of the locality. It is a unique experience where we act as an interface with most efficient institutions of our country like the Railways and CIDCO along with the execution agencies.

Hiten Sethi, CEO, Hiten Sethi & Associates

 

Designing Within The Guidelines
The proposed stations were to be designed considering railway requirements and norms and as per applicable bye-laws and Urban Design Guidelines of Navi Mumbai – as directed by CIDCO. The task also included the preparation of the manual for standards and specifications for railway stations set out by Indian railway board under Ministry of Indian Railways as well as other special requirements, if any, in the specification, the type of planning, construction methods, materials and innovative structures.
The proposed station building also had to be planned, based on the National Building Code (except in case of fire system for station building where NFPA has overriding priority over NBC), Bureau of Indian Standards, American Standards, such as NFPA, ASTM, AASHTO (American Association of State Highway and Transportation Officials), British Standards, International Standards, and conforming to all norms as applicable for development of Railway Stations in Mumbai Metropolitan Region and Navi Mumbai area.

It was supposed to be aimed to utilize the full Floor Area Ratio (FAR), accommodating work space for departments with appropriate basic amenities. Block design in the form of elevations, 3D forms, and full parking requirements were to be done for the full FAR, as per the requirement of respective department as detailed out in the scope of work. The basic planning considerations to be considered were designing with environment-friendly elements which were not just good at construction stage, but, were appropriate for operation and maintenance of a public area like this. Universal Design was also one of the basic criteria of design.

Seawood Darave -Uran line is an under-construction railway line in Navi Mumbai. This railway line will cater to the passenger traffic demands generated by Jawaharlal Nehru Port, port-based industries, ONGC, Defense establishment at Uran, other residential, industrial, and warehousing complexes in Uran taluka and the commuters for the proposed Navi Mumbai International Airport. CIDCO intends to develop the station complexes with state-of-the-art architectural and structural designs, functional and efficient planning with low maintenance finishes which shall become icons of the city.

Connectivity Plan: Kharkopar Station
The architectural design consists of a 270 m long x 30 m wide parabolic curve roof, with combination of polycarbonate and aluminum roof sheet over platform area, supported by 35m long parabolic truss spaced 15 m C/C on cylindrical hollow steel columns. The steel framed roof has enabled the architects to design a column free, larger spanned island platform, thereby, giving an experience of grandness and huge space on the platforms. A 92 x30 m wide and 13.00 m high roof has been provided above the concourse area there by creating a grand entrance to the station.

The project is one of the finest examples of the User Centric Design, where each space has been designed keeping in mind the various users and their movement patterns. The drop off and pick up areas are designed keeping in mind the users and their priorities at the station and to enable the users a quick commute through the station in to the trains. The multiple access points to the platform area are designed such that the route of the regular pass holding commuters and the ones travelling after buying the ticket is totally segregated. This enables the regular commuters to fast track their passage through the station to and from the platforms converting negative filled mass in to passive by subways and through vision. This also helps the ticket buying commuter to avoid the rush hour crowd while entering the station.

Essence of Seawood Darave -Uran Railway Line

  • Length: 27 km. approx. Approved Cost By Railway Board Rs.1412.17 crore
  • Number of stations: 10
    Names of the stations: Seawood, Sagarsangam, Targhar, Bamandongari, Kharkopar, Gavan, Ranjanpada, Nhavasheva, Dronagiri & Uran
  • Road over bridges: 5 Nos
  • Road under bridges: 15 nos.
  • Track under bridge: 1 no.
  • Major bridges: Important Bridge of 751 m span across Panvel creek completed, 4 major bridges, one viaduct
  • Number of rakes: 11 nos.
  • Platforms: 270m platforms for four B.G. tracks to cater 12 car EMU rakes with double discharge facility.

Design Features
There is a direct access from residential to the railway station by foot, it has convenient interchange facility from one corridor to another. It possesses double discharge platforms at every station, easy to follow routes are comfortable. These projects are being monitored by PMO under the ‘Pragati Portal’. This made it a time bound project. The design-detailing execution and commissioning of the project has been meticulously worked out.

This also became a springing point for deciding the structural system and architectural envelop. The design had to be modular to accommodate the future expansion for proposed second railway line. Another most important criteria while finalizing the design of the project was designing of the public infrastructure with minimum operation and maintenance cost post occupancy.

Steel Stands Out
Pre-engineered steel structures were found to be the best option for the fast execution of the project, this was one of the most important criteria for the success of the project. Fabrication of the said pre-engineered structure was carried out under Controlled Environment (Factory Fabrication) in order to ensure standardization of quality and efficient site management during construction.

Steel structures provides modularity in design pattern and flexibility for future expansion of the station complex. Steel is also a structural strong and comparatively lighter material for such long span designs. Steel is one of the materials with high recycled content and is a highly recyclable building material having minimum wastage ratio.

Design Geometrics
The architectural design is based on the principle of ‘Less is More’ using clean lines and simple geometry. The building profile is lining with symmetrical massing on both sides of the railway track. The internal spaces are designed to maximize and give commuters a sense of grandeur. The volume of the structure is designed to create specific user experiences based on the intended function of the said space.

Learnings & Studies
This is one of the most interesting projects that Hiten Sethi & Associates are working on. This project is a unique combination of the highly technical aspects to be combined with peak hour crowd management while designing an iconic structure that shall become identity of the said locality. The only way to achieve these was through efficient team work between all the stake holders. As architects, HSA had an opportunity to do an in-depth study of the behavioral aspects of the users and crowd management and translate it in to physical spaces that work through architectural design. Software like AutoCAD, Sketch Up, 3D max and Revit were used for Architectural design and visualization. Software like Etabs and Tekla were used by the structural engineers for structural designing and detailing.

The execution of the project was begun in February 2017 and the construction is scheduled to be completed by April 2018.

Diesel Engine Major’s New Facility Centre

Background
The customer wanted a strong, durable, leak proof and aesthetically pleasing roof for its third manufacturing plant in Phaltan. The scope of work included design, manufacture, supply, project management and installation of new roof for this upcoming project.

Leak-Poof Solution
Due to high end manufacturing operations, the customer was looking for 100 per cent leak proof solution. LYSAGHT FLEX-LOK® profile comes with on-site roll forming option and provides single length of the sheet from ridge to eve, wherein no fasteners are exposed to atmosphere and eliminates chances of roof leakage. This system provides excellent weather tightness and wind uplift resistance. Due to a large roof area, the overall quantity of sheets would be more if used in standard length and transportation would have be cumbersome. LYSAGHT FLEX-LOK™ sheets of 52-meter length were roll formed through on-site roll forming method for this project.

Timely Completion
Availability of finished goods at site due to onsite roll forming option eliminated transportation time and accelerated the installation work and enabled timely completion of work; the same was achieved through onsite roll forming method which could roll out upto 5000 sq. mtr. area of LYSAGHT® FLEX-LOK™ sheets on daily basis.

Quality Workmanship
With the use of machine seamed and on-site roll formed LYSAGHT® FLEX-LOK™ roofing sheets, Tata BlueScope Limited delivered a 100 per cent leak proof roofing, thereby exhibiting superior quality of workmanship.

 

The new age construction technology from LYSAGHT® team was put into place to enable the workforce to execute the job seamlessly. Due to safety trainings and regular supervision, the project was completed without any unsafe incidence. With the use of LYSAGHT® FLEX-LOK® on site roll formed sheets; the client was able to complete the project in time, resulting to substantial savings in overall project cost and time.

Ajay Rattan, GM – Sales (Construction & Engineering),
Tata BlueScope Steel

 

Against The Odds
Tata BlueScope Steel has the clean slate in this project of safely working at the height of 15 metre (50 feet) and maximum sheet length of 58 metres. It was an uphill task of facing strong winds, since the work was being carried out at a height was challenging enough for the TBSL team. This was met by adopting high safety standards and accurate supervision of the entire activity.

The new age construction technology from LYSAGHT® team was put into place to enable the workforce to execute the job seamlessly. Due to safety trainings and regular supervision, the project was completed without any unsafe incidence. With the use of LYSAGHT® FLEX-LOK® on site roll formed sheets; the client was able to complete the project in time, resulting to substantial savings in overall project cost and time.
Value engineering by LYSAGHT® team helped to optimize the steel usage by providing on site roll forming. Single length sheet of 58 meter from ridge to eve avoided any joints and eliminated any kind of leakage. This also helped savings in lap lengths thus reducing the input material and installation time.

As the customer was looking for leak-proof roof, Tata BlueScope Steel gave installation support of the best quality workmanship to achieve the goal of leak-proof roof, and the average sheet length of 50 meter was used in project. Project site was located at dry industrial area. Thermal stress developed in the roofing system due to high variation in temperature, however, LYSAGHT FLEX-LOK® specially engineered aluminium clips and thermal pads slide neatly onto base of clip which can reduce the thermal bridging effects. Frequent inspections were taken place to achieve the high quality of installation.

LYSAGHT® Flex-Lok™ 500 profile is made out of high end raw material such as COLORBOND® and ZINCALUME®. COLORBOND® material is environment friendly due to the use of lead free paint system and is a 100 per cent recyclable material (steel).

 

For our global client in India, we have delivered a landmark project, benchmarked against the company’s world-wide operations. Tata BlueScope Steel, with its value engineering, new age construction technology, followed by an on-time project completion undertaken with world class safety practices, has truly delivered a structure worthy of an International repute. Right from the beginning of the construction phase, TBSL team has been collaborating with the best quality workmanship for the entire installation process.

Sadik Khan, Venkatramanan Associates, Pune

Fact File
Customer: Diesel Engine Manufacturing Market Leader
Location: Phaltan, Maharashtra
Project Size: 72,000 sq. mts.
Profile Used: LYSAGHT® FLEXLOK™ 500, LYSAGHT® TRIMDEK® 1015
Contractor: B. G Shirke, Pune
Consultant: Venkatramanan Associates, Pune

2×660 MW Thermal Power Project, Central India

 

L&T-S&L have been involved in 2×660 MW Thermal Power Project as an architect engineer to a major EPC contractor in power industry. This project is based on environment-friendly supercritical technology which consumes less coal for unit power generation. It is one of the large projects in central India. As an architect engineer for the entire power project, the scope of structural engineer includes design of various buildings, facilities and equipment foundations namely: turbine building, turbo generator foundation, pipe racks and other plant and non-plant structures. Major portion of the total scope of steel is consumed in turbine building (TG Building) itself (approximately 65-70 per cent) of total 19,000 MT scope.

Picture Perfect
TG building – a 270m long, 42m wide and 33m high building – is the heart of the power plant housing major equipments like steam turbine, generator, condenser, boiler feed pumps, deaerator, cranes, etc. Geometrically, the building mainly comprises of two bays – turbine bay of 30m span and heater bay of 12m span. There are several equipment floors in the building to support equipment and piping. The turbine bay hall is provided with 30m roof girder. Moreover, for plant services, a cantilever steel support is provided outside the building. For operation and maintenance of the equipment, two cranes of 220 MT in simultaneous operation in Turbine Bay and single crane of 45MT in heater Bay is provided.

Steely Push
Due to large length, the building is divided into three portions namely Unit 1, Control Bay and Unit 2 by two expansion joints. The primary frame consists of moment resisting frame along transverse direction and braced frame along longitudinal direction. The secondary frame consists of floor/roof framing. High strength structural steel of grade E350 is used for columns, roof girders and framing beams along transverse direction. Structural steel of grade E250 is used for vertical bracings, tie beams, crane girders, floor/roof framing members, girts / side runners / wall beams, purlins and staircases.

The TG Building is built using approximately 13,500 MT of structural steel totally shop fabricated by an Indian supplier. Usually, client specification recommends use of steel as major part of building material for TG Building because of its high strength to weight ratio, high speed of erection, low maintenance costs and good behavior under cyclic (wind and seismic) / fatigue (crane) loads. Using structural steel as material, it is easy to ensure quality and consistency.

Color coated insulated sandwich panel is being used as façade of TG Building. RCC deck slab over truss/girder is provided as roofing system of the building. Structural slope and adequate waterproofing is provided to prevent ingress of water through roof slab. Internal floors/platforms consist of RCC deck slab/grating/chequered plate on steel floor framing.

 

A challenge of simultaneous engineering and fabrication for a heavy and complex bolted structure was attempted with positive spirit, collaboration with stakeholders and passion to achieve something which has no visible past references. A success was visible at every stage like engineering, procurement, management, fabrication, transportation, erection and quality assurance. Each stakeholder could benefit in terms of completion of scope in time, controlled cost and required quality. It also reassured the spirit of engineering profession “everything is possible… just attempt it with plan and zeal to achieve.
JIGNESH CHOKSHI, Sr. Dy. General Manager, L&T-Sargent & Lundy Ltd.

 

 

Changing Trend
Usually for an architect-engineer like us, the scope such TG building includes the detailed engineering and preparation of design drawings. These design drawings are then used by detailer to make the steel shop drawings to be used by fabrication workshop. Traditionally, especially in India, this building has been constructed with field weld connections. As labor requirement is substantial for field welding of the members and due to scarcity and increased cost of skilled welder, the trend has been changing slowly over past few years where the contractors have started relying on bolted connections.

As this is one of the long lead items and its erection needs to start within 10 months from the project award date, the fabrication needs to start quite early so that material can be shipped to site in time. This is one of the reasons due to which the choice for bolted structures is gaining popularity.

Timely Challenge
A major challenge for the bolted structures is that the member sizes are required to be finalized quite early so that the bolt holes at correct locations are punched. This results in limited flexibility to engineer and the task is to finalize most of the members in first place itself. Due to large size of the building and late procurement of critical equipment and associated piping and electrical services, the engineering of such building is done in progressive manner and usually, the entire building is progressively completed. Conversely, the bolted construction requires early completion of the engineering so that correct members are erected at site.

Innovative Solutions
To resolve this issue of progressive engineering, yet moving ahead for construction to meet project schedule, scope of making fabrication drawing was also included as part of detailed engineering. This has been a unique attempt that was planned to be implemented in a live project, which required unique and innovative approach. Probably, simultaneous engineering of the building with bolted connections and issuance of fabrication drawings has no past references.

A meticulous plan was made to meet such requirement, where there was no prior experience or references, we adopted latest technology of making fabrication drawings, unified design and erection drawings and also progressed on deciding connections for items that will be engineered progressively. To cater the needs of large volume of the work like updating the member sizes based on latest design, generation of design drawings for client submission, application of connections and generation of fabrication drawings, the work was performed on a shared platform. A proper control and monitoring mechanism was implemented to avoid discrepancies between engineered items and fabricated items.

This unique attempt has greatly benefited us, both in terms of time and cost, as entire work was done within same roof and did not required frequent communication with external detailers for design changes. No expediting was required from client side with external detailer or with engineer like us, as they got everything from one stop. This one stop solution resulted in a good progress on fabrication front and less involvement of multiple agencies. It took around 11 months to complete the detailed engineering of major portion of building and issuance of its fabrication drawings. A novel and unique approach adopted for assembly tagging and part tagging resulted in smooth fabrication at shop and uninterrupted erection at site. The initial planning with all the stakeholders of this task greatly benefited in making right sequences for each activity, thus resulting no excess material at shop or site as well as just in time material availability.

Fact File
Function: Power Plant
Architect: L&T-Sargent & Lundy Ltd.
Structural Consultant: L&T-Sargent & Lundy Ltd.
Tonnage: 13,500 MT
Status: Ongoing

Zenith Factory-cum-office Building, Mumbai

Zenith Industrial Rubber Products Pvt. Ltd., based in Dombivali MIDC, Thane, manufacture variety of rubber products which are used in industrial and other areas. Along with main manufacturing set up, the company wanted to have one more sister manufacturing unit on their own separate plot having area of 6900 sq. ft. in MIDC Dombivali. This new plant is designed for ground + two floors with partly basement area.

This multileveled manufacturing building is designed in such a way that in first stage raw material comes to factory and directly moves to third topmost level, and then process starts from top to bottom in various levels through machines placed one below other, and finally, finished product comes out at ground level; then it is taken out for further dispatch.

Design Notion
The industrial manufacturing unit consists of heavy steel columns with a depth of 800mm-900mm HEB sections spanning a height upto 15m upto terrace level and the roof columns have a height of almost 21m with a fabricated tapered roof truss at the top. The structural building consists of a part basement with two floors of manufacturing and storage activities and a terrace floor. The building also has additional 3 mezzanine floors each at different levels to suit the clients need for manufacturing activities.

Delcons were approached as structural engineers, to discuss whether the proposed project can be completed within a very short period of time without having to manufacture any ingredients on site. The client was considering a pre – cast structure but was looking at other alternatives.

Steel structures have lots of advantages in terms of quality of material, consistent strength in both tension and compression, no manufacturing time on site unlike concrete by storing and mixing materials. If the connections and sizes are standardized along with the spans then fabrication time is also reduced. No deshuttering or curing time is required and any shapes and designs cab be generated. This building was completed in less than a year.”
BAL KULKARNI, Chairman, Delcons Consultants India Pvt. Ltd.

Structural Features
The building was to be 4 to 5 floor structures with various levels and plan areas to be used for different purposes with varing loading patterns. The client wanted to have, a made to order building with various levels and various areas designed for particular applications and loading. These loads were not in any particular order but were varying as per the work flow and activities. For example, some areas needed some machines to be mounted and immediately adjacent areas to be designed for the computer input for operating such machines.

The factory-cum-office building was delivered with varying loading conditions and also large column free spaces. To save time and quality control most of the materials were bought out from standard materials available. This saved a lot of time and on-site activities of scaffolding and mixing and curing and deshuttering. The metal deck sheet slab ensured that no time was spent in shuttering and deshuttering and also offered a uniform hard floor for all the activities proposed in the factory.

Also, it facilitated piece meal construction as two bays from one floor level were completed and next another area of another floor was completed. So, the sequence of events was not related to completion of the lower or adjacent levels. The areas on which the machines were to be erected were completed before. So that the commissioning activities could jump start and that helped in reducing the completion time of the project. The primary framing was in MS wide flange beams and columns with a 9.0 m grid in both directions. The secondary grid was modified to suit the requirements of the usage of the particular floor.

Structural Uniqueness
The company has various plants at various locations and needed to upgrade the existing building to suit the new manufacturing standards. The owner was worried that rebuilding his factory would take at least two years for the conventional system and was worried that a good team has to be put in place to ensure quality as most of the areas were heavily loaded. Also, the machine installation could start only after finishing of many activities in the adjacent or lower floors which made the required time span unreasonable.

With the use of steel wide flange sections all doubts about quality and strength were ruled out. Also, parts of the building could be completed and handed over to the machine erectors so that the final completion time was not extended. Large spans were possible in reduced depth which helped in reducing the overall height of the building.

 

As per requirement and demand of project for large spans for manoeuvrability of material, and at the same time, requirement of floor loads of 3-tonne per sq. m. with maximum height restriction of floor-to-floor height of 5.0m as per rules, we opted for designing this building completely in steel members above ground. Because of availability of various heavy steel beams and sections of different manufacturers, it was great advantage in the designing, wherein using these steel sections, we could achieve the load carrying capacities with minimum depths of floor beams, minimum column sizes and other members, and because of this, we could get maximum clear floor heights. Further, steel decking sheeting and concrete floor above the floor beam grid; provided us faster construction without any scaffolding and centering material.
CHAVADEKAR JAGANNATH,
Director, A. J. Architects & Interior Designers Pvt. Ltd.