Knorr-Bremse Technology Center, Pune

Knorr-Bremse is one of the world’s leading braking technology companies with more than 110 years of experience in the field. With a strong focus on the Indian market, Knorr-Bremse is devoted to enhance customer loyalty through innovative products and advanced technologies. The organization is governed by the highest global standards of quality and safety, and as architects, DSP Design Associates were responsible to deliver a design that is reflective of the organization’s global character.

Maintaining High Standards
The design brief was to create the facility at Hinjewadi, Pune at par with the organization’s existing international plans, without losing focus on functionality and aesthetics. The design thought was to create a dedicated technology center to cater to the Research & Development requirements of the Knorr-Bremse Group companies, and to support development of best in class mechanical and electronic products for rail and truck vehicle systems. The architecture of the facility had to provide for easy mobilization of resources, foster collaboration and allow all the units of the organization to synergize within the same hi-tech industrial facility.


Functionality and flexibility were at the core of the design for this project. We had to ensure that the design could adapt to future changes and technological upgrades. The core and the services were planned to be functional and easy on maintenance. It is engrained in the DNA of our design practice to arrive at designs that meet the desired utility benchmarks, coupled with aesthetic ambitions, given the setting the project is situated in from an architectural service perspective.
YATIN PATEL, Principal, DSP Design Associates

Thoughtful Planning
The design concept and planning was arrived at after careful understanding of the use and programs which were going to be housed in this facility. The design inclinations were minimalistic, yet functional, with paramount importance being given to the smooth functioning and spatial planning of this industrial facility. It was important to develop a distinct identity and character befitting Knorr-Bremse, also ensuring the criticalities of an industrial design towards an effective supply chain management were also met.

Steel has been a major dominator when it comes to framed structures used within industrial architecture. The shop floor has been constructed using pre-engineered building material with grids of 15m x 28m and overall 96m x 84m having single ridge vents. The structural design has been planned taking into account the requisite seismic and wind loads. Use of steel ensured timely delivery of the project, quality assurance and cost efficiency. It also enabled in making the project energy efficient and earthquake resistant.

Simple & Clean Geometry
The interior design and planning of this industrial structure conforms to green specifications. The design and orientation of the building allows for optimum daylight penetration and cross ventilation thereby allowing for energy conservation. Functionality and flexibility being key in this project, the geometry of the building was kept simple and clean. It was primarily driven by the structural grid, thereby, allowing for modularity and efficiency, while at the same time ensuring an aesthetically designed building. The software used for designing and detailing include AutoCAD, STAAD.

Designing Glory
DSP Design takes immense pride in this industrial project for Knorr-Bremse as the overall experience has been phenomenal. This industrial building was an interesting project to marry the functional detailing of a successful industrial building, the client brief and architectural ambitions. There is extensive due-diligence that needs to be undertaken in aspects like designing of ventilation systems, understanding the working of machinery, their heat dissipation, number of air changes and facility management. The accuracy and success of the project is only driven by well-informed design decisions from the design team that is unique to the context and program, beyond an obviously assumed standard-universal solution.

Project Timeline
Design – 6 months
Execution – 12 months

The Mandovi Shipyard Warehouse, Goa

Established in the year 1993, Mandovi Drydocks has become one of the most widely respected full-service shipyard in Goa. Situated at the bank of the river Mandovi, the shipyard is strategically located to service the repair, modification and new build needs of its customers.

Commitment To Excellence
From the inception of Mandovi Drydocks, the Company’s philosophy has revolved around its commitment to giving its clients an optimum level of service that incorporates a highly competitive rates structure combined to an enviable service ethic. These two key factors combined with its founder ’s unquestionable integrity, has enabled Mandovi Drydocks to consistently expand.

Expansion Plans
Initially started as a repair and dry docking shipyard, later it went in new constructions of all types of marine vessels. The shipyard has taken major dry docking repair for various types of vessels. The shipyard has repaired and dry docked barges, ferry boats, fishing trawlers, patrol boats, catamarans, mini bulk carriers, pontoons, dredgers, tugs, fiberglass boats.

Expanding further, the Company decided to create a space wherein it could be used to store critical components and repairs of its ships. They were in search of a warehouse solution that would not only be qualitative, but, could also be a cost-effective solution. After doing good research and analysis, it was concluded that using Tata Structura’s hollow section would be the best-fit solution to erect their warehouse, keeping in mind all the possible structural and environmental requirements.

Opening of New Doors
Tata Structura, the unique hollow sections from Tata Steel, has opened up new doors for great possibilities in the construction sector in India. Designers architects and structural engineers now enjoy the privilege of having opportunities to experiment with innovative designs and reinvent the art of architectural creations. Tata Structura has made it possible to explore beyond the familiar.

Setting A Tone
One such example is the Mandovi Shipyard Warehouse in Goa. The project demanded design economy, but, at the same time the aesthetic aspect could not be over looked as well. The structure was supposed to have a 25m (80m length-wise) span which meant structural strength of the structure was of primary importance.

In Pursuit of Quality Solution
Tata Structura provided the answer to the quest for a suitable product, and there was no need to look further. As expected, the brand did not disappoint with its dependable strength and quality. Approximately, 200 tonnes of steel were used in the construction work. The steel members used were 122x61x3.6, 91.5×91.5×3.6, 72x72x4, 60x40x3.6 and 38x38x3.2. Tata Structura successfully provided the structure solid support with its high-strength, light-weight hollow sections that came with superior and consistent quality. What’s more, the overall cost of the construction came down significantly due to reduction in steel tonnage.

Setting An Example
Once again Tata Structura shined by providing practical innovative and cost-effective solutions, setting a benchmark in the construction sector. Today, the Mandovi Warehouse stands tall as a perfect example of the relevance of Tata Structura in meeting the challenges in the construction sector of emerging India.

At Tata Steel, we incessantly strive to provide relevant solutions to our customers’ needs that can help them pursue their goals and realize their architectural dreams. Tata Structura is one such product that has successfully changed the complexion of the construction sector in India. I am happy and proud that the brand has proved its worth by being an integral part of the Mandovi Shipyard Warehouse, and played a significant role in making the project a success.

Chief of Marketing & Sales Tubes SBU, Tata Steel


One of the most rapidly growing companies in India, The Earth Group of Companies – run by Bhupesh Babulal Jain and his son Piyush Bhupesh Jain – has projects spanning across Maharashtra, Gujarat, New Delhi, and Myanmar. Honorary members of the Indian Green Building Council – Bhupesh and Piyush have 30 and 8 years of experience respectively. Bhupesh is also associated with PEATA (Practicing Engineers Architects and Town Planners Association) and is a strong promoter of Sustainable Developments and Structural Steel Buildings in India. He is also the Joint Secretary of MSCI Club Mumbai.

Chosen to Design the Classic
Mumbai-based Access Architects were thoughtfully taken on board by the Earth Group to design their classical residential building in Matunga – one of the densely populated, yet, regal places of the Mumbai city. Access Architects, established by Architect Atul Shah in 1981, is one of the leading architectural firms in India with over 400 projects to their credit. Their intrinsic understanding of local culture, aesthetic and planning sensibilities fused with knowledge of the latest technologies and trends, make them one of the forerunners in the industry today. With the second-generation architects – Jay Shah and Anuj Shah fusing their international exposure with the company’s core values – Access’ clientele includes leading real estate developers and Fortune 500 companies.

Right from conceptualization to execution, Access Architects had to ensure that all the bye-laws have been accounted for during the construction. Being a steel building, all the coordination with consultants and planning the sequence of execution was necessary before hand. Thus, they had to generate construction documents with necessarily detailing well in advance. They also made it a point to have regular inspections, check on progress, and ensure the smooth execution of the project.

Located in Central Mumbai, the cost of rehousing the existing tenants in a nearby location was high and caused inconvenience to the client as well as the tenants. Keeping that in mind, we proposed steel construction which was quicker and more efficient. Since fast tracking the construction without compromising on the quality was the major requirement of the client, this proposal was happily accepted. Other benefits like steel construction being quieter, and thus, not affecting the neighbourhood peace too much and being recyclable added to its advantages. Using steel, we were able to detail the project better and take advantage of its non-shrinking and non-creeping-at-ambient-temperature nature. With steel, form-work was not needed, uniform quality could be achieved and transportation and handling was economical. Steel being one of the most sustainable construction materials currently, its strength and durability coupled with its ability to be recycled, again and again, without ever losing quality make it truly compatible with long term sustainable development. I totally recommend it, provided you have the skill and expertise to implement it well.

JAY SHAH, Director, Access Architects


The Classical Features
Earth Classic is a residential tower designed on the lines of a 16th century Roman Classical building, built using modern day building technologies. Adding a touch of royalty to the skyline of Matunga in Mumbai, the project keeps the comfort of the end user in mind, with high-end amenities and services incorporated in it. With 30 residences spread across its 7 floors, it has a basement that can be used for car wash and recreation, and a terrace is designed for community interaction with ample seating and a few patches of green. The steel frame structure used to build the building helped reduce the time spent on erecting the structure and the load on the foundation.

Since this project was a redevelopment of the Kishore Mansion Building located in the congested area of Matunga, and the tenants of the building were provided temporary accommodation at the developer’s cost, it was important to build the new building soon. Using steel, reduced the time of construction and caused minimal disturbance to the neighbourhood. Moreover, it saved cost by using less manpower on site, lesser vehicle movement, and resulted in zero accidents.

Steel helped in optimizing speed of construction, floor area (due to smaller column sizes) and floor height. Steel is also a lightweight construction system which minimizes loads on the foundation, and therefore, saves on sub-structure costs, which can be important for building extensions.

Overcoming the Challenges with Class
This site was a challenging one for construction. Surrounded by existing buildings on three sides, it is connected by a small access road from the main road. A 100 MT compact telescopic mobile crane was placed on site, which added to the challenges, since there wasn’t enough space to place the outriggers. This issue was resolved by placing the crane in a phased manner. It was located partially on ground and partially above the basement using a steel trestle to support the outriggers of the crane. Once that was done, the crane was moved to the road to complete the balance construction.
Besides this, the other challenges included the lack of enough area for material stacking at the site and restriction of the trailer movement during the day, as the site is located in a busy area. To resolve this, logistics for the material had to be planned meticulously with only two loads of material kept on site at a time.

Making of the Frame – A Class Apart

Diagonal braces in personal and car lift were used as the primary lateral load resisting system. The composite beams and columns were used as the gravity load resisting system. The structural steel enabled the 4m cantilevered sections, the principle architectural feature of the redevelopment to be realized. The cantilevered sections consist of a storey-high N type truss with 500mm built-up beams and composite columns of 300 x 600 mm.

The maximum beam depth was restricted to 450mm at other locations using a combination of built-up and hot rolled I sections. JSW SMD’s patented 2-hour fire rated TR80 0.9mm deck was used to achieve spans up to 4m. Beams were placed along the partition walls to avoid the beam visibility/drop inside the rooms. Columns and bracings were encased in concrete to provide fire protection. Vermiculite fireproofing method was used for beams. Modular factory assembled steel staircase were adopted to reduce site assembly time and ease of erection. The entire steel frame work was erected in a record six-week time with the highest safety standards.

Fact File
Function: Residential
Client: Earth Group of Companies
Architect: Access Architects
Steelwork Contractor: JSW Severfield Structures Ltd.
Steel Tonnage: 304 MT
Total Footprint: 38,000 sq. ft.
Status: Ongoing

Sustainable Features
Offsite Manufacturing
The offsite manufacturing of frames led to reduction in the construction programme as compared to a site with more on-site solutions. It also shortened the construction time and necessitated fewer onsite labourers, and reduced the number of deliveries and wastage on site.

Cantilevered Sections
The cantilevered sections allowed excellent use of space, maximising the available footprint whilst maintaining an open feel to the development.

Steel as a building material can be reused and recycled.


Altamount Road is ranked as the 10th most expensive street in the world. Lodha Group acquired the area from the US Consulate for Rs. 375 crore surpassing the bids made by Mahindra Lifespaces and TATA Housing. The previously existing Washington House, home to US Consulate General was a three-storied building, covering an area of 2702 square meters. It falls under the Coastal Regulation Zone 2 and is listed as Grade 3 Property.

Distinctly Noticeable
Lodha Altamount is a luxury collection that the Lodha group has come up with. It aims to be world’s finest luxurious residential projects at the most coveted location in Mumbai. The project is designed to stand distinctly in the skyline of Mumbai. It has been designed keeping the comfort of the end user in mind with most of the high-end amenities and services.

Lodha Altamount is a residential tower of 40 floors including 8 podium levels. The tower consists of modern architecture conceived by German-Iranian architect Hadi Teherani. The development consists of 52 residences fully serviced by hospitality experts, St. Amand. This half an acre development consists of two floors for recreation. Construction technology using steel frame, this is an all glass façade tower with three sides open for panoramic views of Arabian Sea and the Mumbai city.

The Altamount neighbours Mukesh Ambani’s Antillia and Kumarmangalam Birla’s mansion. Lodha Altamount has created history in November 2015 by selling the most expensive apartment in the country. A 10,000 sq. ft. duplex at this signature development has been sold for over Rs. 160 crore at Rs. 1,60,000 per sq. ft.

Design Intent
The intent of the architect was to create a distinct iconic landmark in the Mumbai skyline. The facade of the building has been envisaged such that residents have privacy as well as a complete view of the sea and the cityscape. It has been designed by keeping the high-end luxury and comfort in mind. The club house, guest rooms, cinema, conference, meeting rooms, pool and other amenities have been designed to create a secluded space within the metropolis.

Fact File
Client: Lodha Group
Hadi Tehrani
Access Architects
Structural Consultants:
Magnusson Klemencic Associates
Sterling Engineering Consultancy
Steel Tonnage: 1643 tonnes
Current Status: Topped-off


Structural Elements
All the structural elements are designed to remain essentially elastic during wind and low-level seismic lateral loading, including the core wall coupling beam; the core wall flexure and shear, diaphragms and collectors; basement walls and foundations.

Steel was the best option to overcome the city’s land cost and the time constraints. The floor plans were such that the central core takes the horizontal forces and smaller columns on periphery take the point loads. Flexibility in planning has been achieved by transferring the columns such that they are mostly at the periphery of the building. Steel outriggers have been given at intervals to take the horizontal forces.

Steely Aid
Steel helped in optimizing speed of construction, floor area (due to smaller column sizes) and floor height. Steel is also a lightweight construction system which minimizes loads on the foundations, and therefore, saves on sub-structure costs, which can be important for building extensions.

Working alongside the design Architect, the Structural Consultant had the responsibility of executing the project on site with their inputs, without altering the concept. They had to ensure that all the bye-laws have been accounted for during construction. Their role was to co-ordinate with all the consultants and generate construction documents with necessary detailing. To make regular inspections, check on progress and ensure overall smooth execution of the project.

Lodha Altamount will become a distinct landmark which dominates the Mumbai skyline. It has been designed to provide the residents a grand and luxurious lifestyle. Every minute detail has been executed so as to provide maximum user-comfort. Residents would be able to fully customize the space according to their whim.  The Building has been designed such that all the residential apartments are elevated above the immediate surrounding structures to achieve a prominent panoramic view of the Arabian Sea and the city without compromising their privacy.

Director, Access Architects

Building Geometrics
The structure comprises of 3 basement floors + GR + 8 parking levels in which, 4 podiums are for residential parking purpose and rest for GCP parking. The roof of podium level houses a garden, swimming pool & club/fitness centre. There are 32 residential floors above the top podium level with 2 service and 2 fire check levels.

The total height of the structure is approximately 197m, from ground which also includes a 29.7m tall steel crown structure above the roof. The building has an overall ‘T’ shape in plan with projected widths of 31.0m by 24.5m about the main structural axes for the typical levels.

Considering the height of building and its slenderness, the structure is assumed to have a certain amount of sway. To eliminate this, many options were thought of. Tuned mass dampener (TMD) at the top has been considered to negate the effect. Out triggers have been planned to take additional lateral force.

Structural System
Mat foundation of variable thickness under the entire building footprint.

Floor Framing System
Composite slab and steel beam framing at typical floors.

Steel columns are placed at periphery of the building and in middle of residential units in order to reduce spans allowing reasonable beam depths. The columns in the middle are compromised with the parking layout in lower levels by being transfers at levels above residential car parking floors.

Lateral System
The concrete core walls provide the primary lateral force resisting system. in order to keep on efficient and concentrated lateral system, a closed tube single cell core (large rectangular shape) has been introduced, which is also very efficient for a jump-form climbing form system.

Flooring System
The building structure is built around a RCC core which provides the primary lateral force resisting system. The basement slabs, ground floor and first 5 parking floors are planned as RCC flat slabs with drops supported on RCC columns. The floors above, from 6th to 8th floors (mechanical parking) are structural steel floors with M.S. plate decking. Thereafter, the residential floors are of composite metal deck and structural steel beam framing supported by composite columns of steel and concrete.

As it was unavoidable to extend a few typical floor columns through the parking floors to the raft foundation, steel transfer trusses had introduced to support such columns.

Above 5th floor, the RCC core, in conjunction with two columns interconnected to the core by outriggers is resisting the lateral loads in the Y direction since it is necessary to stiffen the building in that direction to control drift. In the X-direction the RCC core alone resists the lateral loads.

These two columns are composite columns. Below 5th floor the RCC core and RCC columns are acting as a combined unit to resist the lateral loads. The structural composite columns are designed as gravity columns to take up the total gravity load with encasement including the outrigger columns. The column supporting outriggers have designed for axial forces arising due to lateral loads.

Testing of Skills
The significant challenge in this project was designing of embedded connections of the outrigger steel trusses with the RCC core walls. Sequential analysis had used to evaluate the realistic design loads in the members of outrigger trusses and the columns supporting outrigger trusses.

The building is completed in record time, due to advance construction technique of composite structure along with climbing RC core and the construction cycle of 9 levels as follows:

  • Concreting for lower 3 level metal deck
  • Laying metal deck, laying reinforcement mesh and welding studs at middle 3 levels
  • Erection of steel column and beams for upper 3 levels

The RCC slabs and composite metal deck slabs are acting as inplane rigid diaphragms for each of the floors, connecting the columns and the RCC core. The founding strata is hard rock with SBC of 3500kN/m2. The foundation is RCC raft foundation of varying thickness, under the entire building footprint, designed to transfer the loads to the founding strata and resist upward water pressure due to perched water during rainy season. No rock anchors are proposed to stitch the raft to the founding strata.

Steel Sections
Grade Fe350 for structural steel

  • Universal beams – Ranging from UB254x146x31 to
  • UB457x191x98
  • Universal columns – Ranging from UC245x254x73 to
  • UC356x406x35
  • Made-up sections
  • Steel girders
  • Trusses
  • Out triggers

New Integrated Terminal Building Tirupati

Salient Features
Floor area of Terminal Building (approx.):
Level 1 – 12500 sq. mtrs.
Level 2 – 4000 sq. mtrs.
Basement for Services – 6000 sq. mtrs.
Service Block – 1600 sq. mtrs.
Public Facility Block – 500 sq. mtrs.
Maximum Height – 25.5 M
Passenger Handling Capacity – 700 pax at peak hour (500 domestic and 200 international)
Proposed Parking – 320 cars; VIP parking 28 cars, 100 taxis, 10buses
Check-in Counters – 18 nos.
Security Check – 2 (domestic) + 1 (international)
Aero Bridges – 2 nos. (+ 1 no. in future)
Carousel Belts for Baggage Claim – 3 nos. (2 domestic + 1 international)
Inline baggage check-in with 4 levels of checks


The architectural form of the terminal building is a graphic representation of ‘Garuda’ the carrier of Lord Vishnu. This is keeping in view the importance of the city as a religious pilgrimage centre. Tirupati Airport is at a distance of 40kms from the Tirumala temple.

There was an existing airport at Tirupati which handled 1,52,967 domestic passengers in 2006-7. It was the 40th busiest airport of India handling 0.2 per cent of India’s air traffic in the same year. However, since a large number of devotees from all over the world come for pilgrimage to the temple city, owing to the reputation of Lord Venkateshwara fulfilling the devotees’ wishes, a New Integrated Passenger Terminal Building with modern facilities to accommodate both domestic and international traffic was planned by Airport Authority of India. It was a part of the drive for the modernization of the existing airports, addition of non-metro airports, opening up of new international routes, establishment of new airports and restructuring of the existing airports.

The new Terminal Building has three levels and is divided into public concourse, remote departure lounges and contact departure lounges for the international and domestic security holds, remote arrival and contact arrival halls and the baggage claim areas. Three aerobridges and visual Docking guidance to facilitate wide-bodied aircrafts on airside have been planned. The terminal building has been planned in a way that future expansion can be done easily.


Garuda with the head and wings of an eagle and sometimes with the rest of his body like that of a man is carrier of Lord Vishnu and a befitting symbol for the airport at Tirupati due to its association with Lord Venkateshwara and co-relation with the concept of a flight. The wings of the bird in the form of the steel roof sitting lightly on the glass façade are holding up as if in air, nowhere close to the ground. Abstraction of the form has been done to make the structure look very light and contemporary.”

JYOTIMITRA RAGHUVANSH & SUNDEEP KHUSHU, Founding Principals, Aadharshila Consultants


Patron’s Anticipation
The terminal building was to be designed fulfilling the basic norms laid down by Airport Authority of India for a terminal building of this capacity. Since this is an integrated terminal with both domestic and international traffic, it was important to maintain segregation between the two while retaining the openness of the building. The client wanted a building that is contemporary in its outlook with large spans, open plan with large spaces. A lot of daylight streaming into all the areas was also an important requirement.

Design Impression
Since the building is located in the pilgrimage city of Tirupati and a majority of the travellers are expected to be pilgrims visiting the famous Lord Venkateshwara temple, the design team wanted the design of the building to have a contextual relation to this aspect.

Garuda with the head and wings of an eagle and sometimes with the rest of its body like that of a man is carrier of God Vishnu and befitting symbol for the airport at Tirupati due to its association with Lord Venkateshwara and co-relation with the concept of a flight. Abstraction of the form has been done to make the structure look very light and contemporary. In keeping with the inspiration of the design, a canopy is proposed in front of the terminal building on the city side.

Flying Form
The wings of the bird in the form of the steel roof sitting lightly on the glass façade are holding up as if in air, nowhere close to the ground. Full use of the permissible height of the building has been made to highlight this feeling. The roof comprises of five segments, disconnected from each other to allow ingress of light throughout the building and highlight the feeling of lightness in the structure both while viewing the building from outside as well as from inside.

The steel structure has been designed in a way that it hugs the roof closely, enhancing the floating appearance of the roof. The rain water gutters have been planned within the roof structure profile. Interior spaces have been designed in a way that even though the overall volume is very large, individual sections have a human scale to them. Exclusive use of art works like a sculpture, paintings, murals related to the religious character of the place has been done throughout the terminal building providing a unique character to it. Most of these art works have been highly appreciated by the travellers.

Efficient Detailing
Airport terminal buildings are complex structures where functional efficiency, safety and aesthetics are all important parameters for the design. Since terminal buildings are large span structures, special attention has to be paid to the efficiency of the structure. The shape of the roof involved complex geometry and large cantilevered portions, therefore the detailing had to be precise to ensure correct installation at site. Since there is minimal false ceiling at the roof level the structural framework of the roof had to be aesthetically pleasing.

Going Green
The Terminal Building has been designed as an energy efficient and resource conserving building and is due to be rated as a 4 star Green Building under GRIHA. Since the mandate was to design a contemporary looking structure with a lot of day light ingress and openness, this meant use of a lot of glass in the building.

Due to this, a balance had to be struck between use of glass and energy efficiency. This included careful selection of glass, insulation of areas where light transmittance was not needed, use of fenestration and shading. The building enjoys an advantage of orientation as the longer faces aligned with the runway are North/ South facing. The east and west faces have been designed to be less transparent to avoid heat gain into the building

Steel Essence
The core structural frame-work is made of steel and RCC. The structure also includes one basement floor for services making the foundation heavier. The upper part, starting from ground floor upto the topmost point of the building at about 25m from ground, has been designed with a mild-steel structural frame-work to keep the overall look light.

The building is a large span structure with a light-weight double-skin roof on top. These spans are ranging from 23m to 31m to have large column free public spaces. So, to attain these kinds of large spans, without hampering the overall design intent as a lighter building and also ensuring a very stringent and time-effective construction process, structural steel has been used. Autodesk Revit, Auto Cad, STAAD, other MEP design, lighting design & simulation, energy simulation & audit software have been used in this project.

Ishanya Exposition & Design Center

Ishanya is India’s first International Design and Retail Center for the construction industry. A unique concept that encompasses under one roof the gamut of consultants, technology, building services and materials enabling architects, engineers, interior designers achieve a holistic and integrated design/product synergy.

The design brings together the visual arts, architecture, fine arts, music, theatre and cinema that introduces a cultural syntax and brings together the realm of public and commercial space. A series of ‘humane’ spaces, the ‘main street’, ‘courtyards’, ‘kunds’ all woven together into a tapestry that echoes the timelessness philosophy of India and creates an environment that speaks the language of tranquility and serenity that is so essential to creative thought.

The organisation and intertwining of spaces and volumes that exemplify the matrix that is Ishanya needed to be translated through a flexible and lightweight structural system. Steel was, therefore, the natural choice for the primary structural material. It allowed us to specifically model complex intersections and analyse potential problematic areas well in advance. In short, the ability to accurately fabricate the material offsite, as well as its lightness and speed of erection, allowed for significant latitude during the design process. I wanted the environment to speak the language of tranquility and serenity that is so essential to any form of creative thought.”
ARJUN MALIK, Principal, Malik Architecture

Strategic Location
This project is strategically situated in Pune, which in the past decade has emerged as one of the premier business/educational centers in India. Located centrally, very close to the Pune Club Golf Course, just a short drive from the International airport or the city centre, makes Ishanya the perfect, pan-India destination for consumers, the specialty retailers, the architect, space designer, or the builder/developer.

Site Plan
The name Ishanya means North-East – the most auspicious direction according to Vaastu-Shastra, the ancient Indian science of space design. Ishanya is a combination of concrete, glass and steel sinuously and skillfully woven together in lovely symphony, housed in a 10-acre campus with a lush green, yet Zen-like feel! Glass and water bodies are used skillfully to enhance the lightness of the architecture. Carefully designed lighting provides an effect that is both dramatic and aesthetic.

The Mall is divided into six arcades. The arcades are linked together through a circulation spine, ‘The Street’, which runs laterally through the site. This street behaves like a civic space where the visitor is not confined to a closed environment, but is constantly interacting with the outside. Thus, continuously infusing life into the public spaces that otherwise tend to wither due to neglect. Every arcade has its own distinct feature that sets them apart from each other, at the same time echoing a unified architectural language. Ishanya has also implemented intelligent building systems that will result in functional safety as well as energy conservation and efficiency. The roofing is designed with special insulation keeping in mind the energy consumption for air conditioning.

This structure is centrally located on the site and acts as the main entrance space to the mall. Since it is a transitional space between the inside and the outside the visitor enters in a large double height space interspaced with cantilevering and projecting volumes housing showrooms, galleries, cafes etc. Natural light filters into the entrance lobby through large skylights. In plan the structure branches out in different directions thus facilitating access to different parts of the mall. Unlike in the other arcades ‘The Street’ punctures through the lobby on either side making for interesting structural detailing. Due to its grand scale Arcade 0 also doubles as a space for hosting trade events.

Located in the south east corner of the site this L-shaped structure surrounds a beautifully landscaped court, which is dotted with flowering trees. The front entrance showcases a sculptural steel and glass staircase that fluidly snakes upwards, taking the visitor from the outside directly to the first floor. This being one of the longer buildings on site has employed a waffled slab system so as to have flexible, uninterrupted retail spaces within. A basic steel truss roof spans the entire length of the building.

A relatively simple structure with four levels of retail space and a fifth level dedicated to food courts. This building is directly connected to Arcade 0 through pedestrian bridges.

ARCADE 3 & 4
Located in the north east corner of the site this building primarily houses exhibition spaces. This five storey high structure is capped with a dramatic elliptical steel girder roof clad with aluminum composite panels. The roof has well articulated slit like apertures that filter through natural light to different levels in the building. At the entrance the eye is drawn to the upper level, which cantilevers out and makes for an interesting exhibition space.

This is a two storey structure hemmed-in by a large reflective pool to one side and a courtyard with outdoor seating to the other. The structure is divided into two distinct sections cut by ‘The Street’ running through it. The stores fan out along the court with an all glass façade cutting through a high feature wall.

This is the last of the 6 arcades, but in no way is it less striking than the others. ‘The Street’ ends at this building in an internal court, which is flanked with two water bodies. On either sides of the court there are cafes where people can unwind after a long day at the mall. The main structure in this arcade houses art galleries. Many of these galleries cantilever off the structure one even sloping down to the ‘Kund’, which lies beyond. A little further ahead overlooking the ‘Kund’ is an amphitheatre. The amphitheatre stages different cultural events periodically transforming this site into a center for cultural development.

Use of Space
The Kund, the Amphitheatre hosts seminars, conferences, and workshops by day and transforms into the cultural hub with exhibitions, cultural events and fine dining by night. This 450-seat amphitheatre, hosts theatre shows, music, dance and other performing arts. A laser and water show, using animation, lighting effects and fire, transports the spectator into a world of color and light. The show is produced in London, and directed by LSE, Belgium. In addition to the above the Kund, is quaint garden interspersed with large potted trees, skylights and seating areas imitating an Indian market in an abstract and contemporary design format. It offers 9,000 sq. ft. of space for individualized workshops for professionals to manage small-scale events.

The Auditorium and Banquet Hall housed within Arcade 04, hosts conferences, workshops, symposiums, and even music shows and performing arts concerts. A sports bar with a basketball court, pool tables, punching bags, dart boards, giant screens showing the latest sports events and a gaming zone is an exciting place for kids and sports enthusiasts.

At the heart of the project are two art galleries, showcasing sculpture and creative installations. One of the galleries overlooks the wada style court. The Tilting Art Gallery, that gently tilts toward the kund and overlooks the amphitheatre. Indoor and outdoor exhibition spaces designed for flexibility of size and location provides an arena for expo’s, art shows and product launches.

The entrance Arcade exhibit area is constantly changing thus maintaining renewed interest. The exhibition area generates opportunities for vertical display of exhibits in large halls designed in steel, with state of the art lighting systems to enhance the products. A huge library displaying a gamut of information on planning, interiors, furniture, architecture and art history, is amongst the best in the country. Workstations with computer simulation facilities help in developing design solutions and envisioning the finished project.

Appearance and Finish
The project was conceptualized as a series of ‘Humane’ spaces, the ‘Main Street’, the courts reminiscent of the traditional ‘Wada’ typology, the ‘Kund’ all woven together into a tapestry that echoes the timelessness of the thought and philosophy of India.

The Street – is the main circulation spine that ties the secondary and tertiary spaces like the courts and arcades together. This street behaves like a civic space that has been carved out of an otherwise completely commercial scheme.

Wadas – were the traditional form of Maratha architecture predominant to the area in and around Pune. Its style was an amalgamation where features from Mughal, Rajasthan, and Gujarat architecture were combined with local construction techniques. Features like high walls, distinctive fenestrations and buildings of two or more storey arranged around open courts have been incorporated in the design.

Kund – (step-wells) where steps lead down to the water, were not just wells but were also used for religious ceremonies. They developed into an art form. The building scheme features an amphitheatre that overlooks a ‘Kund’ like leisure pool. Throughout the building scheme you can see instances where local architecture has been redefined using contemporary design parameters hence seamlessly relating the project to its surroundings.

Innovative Technology
Use of steel in the buildings coupled with concrete and glass has been a major factor in saving construction time. Prefabricated steel sections were brought in from the workshop just before they need to be installed, this reduced site storage space. Recycled steel was also considered for its value as a sustainable construction material. The interior spaces are designed for flexibility to provide for large exhibition spaces without making any structural changes.

Coffered slabs were used with 8m spans so that large column free areas with ample height could be provided for showrooms and expo’s. These slabs also provide for lighting fixtures within the coffers thus reducing the false ceiling heights. Permanent Aluminum cladding and form finish concrete were used to increase the life of the facade and to reduce maintenance that generally arises with paint finishes. Tensile fabric structures used in the courtyards as shade structures.

Storage and collection of objects that can be recycled facilitates the reduction of disposable waste generated. Storage areas located on site for collection and storage of materials like paper, glass, plastic etc., facilitate recycling. During the construction debris was segregated into concrete, steel, ductwork, wood, paperboard, plastic and packing material etc. and sent to manufacturing recycling plants or used on various other sites that the client was developing.

Recycled steel was used in construction of all steel structures. Recycled aluminum as flashing, framing connectors and window parts was used in the facade in addition to fiber glass insulation used in the aluminum cladding section.

Waste water generated on site is recycled using a sewage treatment plant located in the basement area. This plant filters the water enough to make it suitable for irrigation and flushing purposes. An old wooden house that existed on the site was salvaged and the wood is being used to build a bungalow for the same client in Panchgani, Maharashtra.

New Passenger Terminal Building, Nashik

The new Passenger Terminal Building at Ozar Airfield is an initiative by the Government of Maharashtra and Hindustan Aeronautics Limited (HAL) to provide civil aviation facility to the city of Nashik. This modestly sized terminal will provide complete Departure and Arrival services for commercial airlines while using the existing airstrip originally built for and used by the Indian Air Force.

Capturing the Inspiration
Man has always endeavoured to fly and the birds have been the key inspiration to famous scholars such as Archytas and Leonardo Di Vinci. Drawing upon the visual of a bird’s wings in flight, the modular façade of Nashik Airport Terminal Building seeks to capture the same stance and spirit of momentum.

Design of the terminal building was an amalgamation of two contradictory influences – the historic & religious heritage of Nashik City and the context of HAL’s fighter aircraft facility being used for civil aviation. The underlying philosophy has been to create an ‘iconic gateway to the city’ and the age-old precedent of an arched entrance gate to a community. The ‘arch’, apart from being a historic element, is also one of the most efficient long-spanning structures.

Design of the terminal building was an amalgamation of two contradictory influences – the historic & religious heritage of Nashik City and the context of HAL’s fighter aircraft facility being used for civil aviation. The underlying philosophy has been to resemble the age-old arched gateways marking a city’s entrance, however, with modern iconicity that transcends into the future.

JAYESH HARIYANI, Senior Principal, INI Design Studio (formerly Stantec Consulting Pvt. Ltd.)


Simplified Design to Execute
A bunch of steel arches spring out from one point in 8 directions creating conical columns at 32m spans. A series of these arches create the skeleton for a doubly curved roof with the low points at each of the columns and the high points at the tip of the arches. The modular and repetitive circular geometry simplifies the fabrication process and controls construction cost. This dramatic steel structure thus efficiently provides long un-interrupted spans and has an inherent monumentality. However, in contrast to this monumental grandeur, use of modernistic materials like steel and glass was proposed to introduce an industrial and futuristic character at the same time.

Creating Sense of Transparency
The exterior envelope is expressed as a minimal glass curtain wall which thermally encloses the interior spaces, however, is transparent enough to not interfere with the predominant structure and roof. The internal cabins and offices are expressed as independent structures underneath the roof and most of the passenger areas are accommodated in open concourses divided with glass partitions only.

Passenger facilities planned within the terminal comprise of departure concourse with check-in desks, baggage handling, security check area, departure holding area, VIP and frequent flyer lounges, arrival concourse with baggage reclaim belts along with other amenities such as retail and restrooms. The primarily single storied building has a roof area admeasuring 8267 sqm, out of which 5472 sqm is enclosed on the ground floor with an additional 970 sqm on a mezzanine level, and the rest is available as canopies on all 4 sides. Designed for a peak-hour-passenger count of 300 pax, the space planning complies with IATA congestion standard ‘D’.

Building Highlights:

  • Airport terminal building for peak hour density for 300 passengers (150 arrival & 150 departure)
  • Building size is 64.40 m x 128.40 m
  • Roof is designed with special aesthetics to have international elevation standards
  • Two lane drive way to airport terminal building with suitable landscape
  • Proper parking facility opposite to airport terminal building and plaza

Value-Engineering The Building System
The Nashik Airport project started off with ambitious goals to create a state-of-the-art passenger terminal, although with tight budgets and schedule. Given the constraints, a holistic design is created while aggressively value-engineering the building systems and specifications without compromising on the passenger experience. With national security constraints at the HAL premises, the siting of the building was pre-determined and the Apron was only accessible via transporter buses and no aerobridges could be planned.

The philosophy has been to resemble the age-old arched gateways marking a city’s entrance, however, with modern iconicity that transcends into the future. The building was completed at a cost of INR 84 crore including civil works, building services, basic interiors and site development within a time-period of 18 months. Stantec’s multi-disciplinary office with all design disciplines such as architecture, interior design, landscape architecture and building engineering under one roof, played an important role in achieving the same.

Sustainable design has also been an important goal and some of the most effective solutions such as optimum U-value building envelope, VRF air-conditioning, and building management systems have been incorporated. Clerestory windows bring natural daylight into the centre of the departure concourse minimising the energy demand for lighting.

Wise Use of Steel
The tubular steel used for the roof weighs only about 250 metric tonnes since the use of steel has been limited to purlins and trusses. The primary load carrying members (columns and beams) are in reinforced concrete, thus, saving the cost of fire-proofing structural steel. The landside canopy cantilevers out by 8m with the help of a 112m long triangular truss in the transverse direction supported at every 16m.

The roof has insulation sandwiched between the standing seam aluminium top sheet and trapezoidal bottom sheet (galvalume coated steel) which is perforated for good acoustics inside the large concourse space. The façade consists of high performance DGU glazing, zinc and granite dry-cladding. Use of natural and recyclable materials such as glass, granite, and metal roofing and ceiling systems has also been maximised. The parabolic landside and airside canopy features, till date, one of India’s longest standing seam aluminium roof panels (122m) without any joints.

The existing runway was upgraded to 3500m length and is now able to handle large aircrafts. With additional parking, improved fire-fighting equipment and medical facilities, HAL has already started air cargo operations. The terminal building was completed and inaugurated on 3rd March 2014.

Features within the Building
Airport terminal building is ground floor structure with part mezzanine. The building is having all the sophisticated equipment and facilities like HVAC, electricals, fire protections system, CCTV surveillance, public address system another automotive machineries and equipments including sewage treatment plant. The overall length and breadth of airport terminal building including extended roof structure and pavement is 128.40 m x 64.40 m = 8268.96 sq. m. + overhang area 2860.92 sq. m.

In addition to airport terminal building, separate services building of ground floor structure (34.70 m x 10.60 m) to accommodate various electrical equipments, sewage treatment plant, underground sump, HVAC plant & basement of area 334.92 sq. m is provided. The wall structure is in external glazing of height 11 m, glass partition 3.6 m and 230mm & 110mm thick brick work. The airport building is provided with latest technology baggage handling system to meet international standards.

DMRC Station Building

Delhi Metro Rail Corporation (DMRC) a company set up by Government of India and the Government of National Capital Territory of Delhi, started its operations in 1998 and the first section was made open to the public in the year 2002.

Presently, Delhi Metro is the world’s 13th largest metro system in terms of length serving Delhi, Gurgaon, Faridabad, Noida, and Ghaziabad in the National Capital Region of India.

Environment Management System
DMRC is the first Metro in the world to receive the ISO 14001 Certification for establishing an environment management system at the construction stage of the Metro Railway System.

The entire MRTS project is being executed keeping in mind the environment, health and safety guidelines laid down by DMRC.

DMRT today stands for reliable and safer journeys, time-saving for commuters, reduction in atmospheric pollution, reduction in accident rates, reduced fuel consumption, reduced vehicle operating costs and increase in the average speed of road vehicles, which has helped in improving the quality of life of people in Delhi and making the city a much more attractive city for economic investment and growth.

Key Facts :
Project Name:

Delhi Metro Rail Corporation

Gurgaon – Delhi corridor,
15 Stations

570 MT

Noida-Delhi corridor,
16 Stations

277 MT

Roofing Solutions

Solution Provider:
Tata BlueScope Steel Limited

Products Used:
Colorbond® Steel
Z-type Purlins

India’s First Modern System
Delhi Metro is also India’s first modern public transportation system, which has revolutionized travel by providing a fast, reliable, safe, and comfortable means of transport. A unique feature of Delhi Metro is its integration with other modes of public transport, enabling the commuters to conveniently interchange from one mode to another.

DMRC wanted project to be aesthetically planned and well-maintained. At the same time, they wanted to ensure that the project does not endanger public life nor lead to ecological or environmental degradation. DMRC wanted nothing less than the best for the entire project, which today stands as a benchmark for other cities in India.

Steel The Ultimate Choice
DMRC decided to use steel for roofing of the various stations of MRTS project, not only because of the durability of steel, but, also the lower time required for steel roofing as compared to concrete roofing. Tata BlueScope Steel partnered with top notch international consultants who guided the DMRC on the latest technical know-how all about the Metro Rail business.

India for the first time witnessed colourful steel roofing along with unconventional design aspect (concave/convex) being used for an infrastructure project like Railways System, making it a landmark project that set as proto for all to follow.

Challenges & Solutions
Many challenges at various milestones were faced by the engineering teams. The station buildings proposed were typically curved buildings (both convex and concave).

LYSAGHT® TRIMDEK® 1015 crimp curved sheets and ‘Z’ Type purlins were developed for better production capabilities. DMRC was looking for best material quality with sufficient strength to endure maximum stress and strain in case of any eventuality like earthquake.

COLORBOND® Steel in colours Surfmist, Pale Eucalypt, Sky Blue and Torres Blue was used, attributed by being aesthetically pleasing with high strength and being corrosion resistant, as this was a natural choice. Since it was required to supply material for multiple station building at the same time, Tata BlueScope ensured proper planning with coordination within the cross functional teams including Engineering, SCM and PPC teams.

Tata BlueScope Steel successfully met with the stringent targets, ensuring timely deliverables by providing superior quality of profiled sheets for 16 DMRC stations in Noida – Delhi corridor and 12 TRIMDEK® 1015 crimp curved profiled sheets were supplied along with the supply of ‘Z’ type purlins for 12 DMRC stations.



After having made a positive imprint through its Regional Conferences held in Chennai and Delhi earlier in the year, MX Business Media held the grand finale of its STEEL CONSTRUCTION SUMMIT series in Mumbai last month.

The event was strategically termed as ‘STEEL DAY 2016’ having the revolutionary theme: ‘Faster Execution With Steel’. This mega gathering ambitiously aimed to bring together bright minds to give talks that are idea-focused, and on a wide range of subjects, to foster learning, inspire and wonder, and most importantly – provoke conversations that matter. And that’s precisely the reason why it was termed as STEEL DAY.

STEEL DAY 2016 was held on 28th September 2016 at Hotel Sahara Star in the suburbs of Mumbai, located well within the vicinity of the Mumbai International Airport.
The event was supported by some of the biggest brands involved in steel construction today:

  • Diamond Partner
    L&T Construction
  • Gold Partners
    Bentley Systems Inc.
    Jindal Steel & Power Ltd.
    Tata Structura
  • Silver Partners
    Everest Industries Ltd.
    Kirby Building Systems(I) Ltd.
    Volta Green Structures

Steel Structures & Metal Buildings was the exclusive Media Partner covering this mega event. Through some inspiring presentations and interactions, the event was a highly rewarding one for all the audience who were a part of it.


Panel of Intellectuals
After the welcoming and felicitation session, the business end of the day kicked-off with the most attractive session – the high-profile Panel Discussion of Architects having the theme: Designer’s Dilemma.

The astute panel consisted of some of the renowned Architects from the industry with a proven track record in ideating some of the best projects out of steel. These were:

  • Ratan Batliboi – Principal, Ratan J. Batliboi Consultants Pvt. Ltd.
  • Viren Brahmbhatt – Principal, de.Sign Studio LLC
  • Arjun Malik – Principal, Malik Architecture
  • Anupam De, Principal, Anupam De & Associates
  • Jay Shah, Director, Access Architects
  • Kalhan Mattoo, Principal, Planet 3 Studios Architecture Pvt. Ltd.

The moderator controlling the discussion of this elite group of Architects was Ruchir Panwar, Business Head – Build Solution, Mahindra Susten Pvt. Ltd. who wisely touched upon all the grey areas that every architect would co-relate with, if he has worked in steel.

The session was indeed the highlight of the day wherein all the Architects deliberated upon their rich affair with steel, and had a healthy debate on the real-time dilemma’s faced by the designers today. There were many issues that were surfaced during their knowledgeable talk, which was well noted and appreciated by the industry as well.


Two Tracks Running In Tandem
The conclusion of the panel discussion opened gates for two seperate tracks running parallely to each other for the rest of the day, allowing the audience to listen to the speaker of their choice. The audience were kind of spoilt for choices, as each session witnessed speakers at par with each other, and most importantly, kept the audience deeply involved.

The parallel tracks were segregated evenly as Track- I and Track – II, with 12 speakers in Track – I and 9 speakers in Track – II, whilst the last session of Track – II witnessing another action-packed panel discussion, this time, meant for developers and consultants with another interesting topic. Overall, STEEL DAY 2016 witnessed 22 speakers, 12 panelists, more than 100 CXOs, and around 200 delegates altogether, living up with the expectations of a STEEL DAY affair.


The Track – I started with a bang, with the go-to-man of L&T ECC – K. Veerappan, Vice President & Head of Design Department for Residential & Factory Projects stretching on the effective use of steel in Buildings & Infra Projects, bringing in a different perspective altogether and projecting the real significance of steel. This was followed by Jayesh Hariyani, Senior Principal & CMD of INI Group, wherein he shared with the audience few of the iconic steel projects designed by him, which transformed the design practices of our country.

During his presentation, Akshit Dhawan, Consultant – Structural, Bentley Systems Inc. Presses upon the technology to speed up design engineering construction of steel buildings, which gave the audience something new to take home. He was followed by Kaushik Dutta, Associate Principal, Thornton Tomasetti, a man with an experience of international and national markets, highlighting the innovative way of construction of one-floor at a time.

Post lunch, Anil Hira, Regional Director & Partner – India, Buro Happold Engineering took centre-stage in displaying how steel is efficiently been used in tall buildings in todays modern-day era across thye globe. He was followed by a man with an intent to explore the vast potential of light gauge steel frame industry in our country, Anand Pillay, DGM – Sales & Marketing, Everest Industries Limited whose presentation was all about challenging the convention, which was gladly appreciated by the audience.

Next up was Richard Brotherton, Senior Vice President Sales – Structural Fabrication, AVEVA who is on a mission to modernize the fabrication technology at a global level, and very rightly, threw light on the future of steel construction. He was followed by an IITan with immense knowledge on structures, Siddhartha Ghosh, Professor, Indian Institute of Technology Bombay, wherein he touched upon the Challenges in Connection Design and Detailing, a subject very close to the engineers attending the event.

The penultimate session was signed off by Hariom Gera, Managing Director, Constructure Designs Pvt. Ltd., a man with 5 million sq. mtrs. of composite construction in his kitty, dwelling upon economy in faster construction of high rise buildings, which was perfectly fitting in with the theme of the day.

Post break, the new session was jointly-presented by the dynamic duo of Nitin Killawala, Director, Group Seven Architects & Planners Pvt. Ltd. and Nikhil Shanghvi, CEO, Shanghvi & Associates Consultants Pvt. Ltd. who decoded the innovative use of steel in a residential building. This was followed by an architect with creative imaginations, Vivek Bhole, Founder & Principal Architect, Neo Modern Architects, who presentation was all about the aesthetics of structural steel.

And finally, signing off the track in style was Parish Kapse, Director, Team One Architects whose interesting topic for the day was Finishing of Steel Buildings: Pre Architectured Buildings, which eventually summed up the pattern of the day as far as Track – I is concerned. It was indeed a high-intensity knowledge sharing day for all the delegates as well as the speakers. All that a speaker needs from the audeince is the right signals, and here, the audience were as polished and receptive as one could have wished for.


Whilst Track – I was highly interesting, the second track was not left behind either, and gave the audience all the more reasons to stick to the track. The man with a mission to make construction lighter, faster & affordable, Niladri Sarkar, CEO, Construction Solutions Business of Jindal Steel & Power Ltd. started the Track – II with a bang. He was ably followed by Viren Brahmbhatt, Principal, de.Sign Studio LLC, an architect thriving to challenge the conventional and thinking beyond the predictable, who emphasized on the history and the future present of steel.

Next up was Dr. Vinod Jain, Managing Director, Vintech Consultants whose topic was on design of multi-storey steel structures: Challenges, industrial practice and solutions, wherein he shared the nitty-gritties of multi-storeyed buildings from structural point of view. The next presenter is Prof. Charanjit Shah, Founding Principal, Creative Group who dwelled upon visualising beyond imagination lensing through use of steel – in mega structures.

Post lunch, Vivek Rathore, Principal Architect, Salient Design Studio showered the audience with his unique style with an interesting topic – Man: Steel: Earth – A Relationship Model for Future, which was all about innovations. He was followed by P. V. Mohan, Director – Commercial, Kirby Building Systems who delivered on the trends & challenges in pre-engineered buildings in the current scenario.

A highly techno-driven architect of today’s time, Jay Shah, Director, Access Architects came up with a very interesting topic – Steel v/s Concrete Construction: Can Genghis Khan help us decide? which truly was the highlight of the track. This was followed by Amod Barve, CEO, Volta Green Structures who took the audience through the Emerging Trend of Rapid Steel Construction. And to sign-off the session, Snehashis Sinha, Chief of Sinha & Associates deliberated on the use of steel hollow section in building construction.
Although this concluded the individual presentations for the day, but, the second panel discussion was yet to trigger. And that is precisely what was delivered amidst the intense discussion upon a very healthy topic: Do’s & Dont’s In Steel Construction.


The panel included some of the well-known technocrats from a variety of segments of steel construction were:

  • Dipti Talim – Structural Head, K. Raheja Corporation
  • D. Raju – Managing Director, Kirby Building Systems Pvt. Ltd.
  • K. Veerappan – VP-EDRC, L&T ECC
  • Sundar Rajan Tatachar – Head of Project Developments, Shree Naman Group
  • Hiten Mahimtura – Director, Mahimtura Consultants Pvt. Ltd.
  • Manik Jethi – Director, Technical Projects Consultants Pvt. Ltd.

The moderator for this session was Avneet Singh, Editor-in-Chief, MX Business Media who managed to create a memorable discussion which was worth witnessingh.

To sum it up, it was indeed a monumental day for the steel construction professionals. Where else they could have seen such a huge gathering of like-minded intellectuals all under one roof. It can happen only during STEEL DAY, and make no mistake, it is getting better and better every passiong year. And in all probablities, next year will surely raise the bar, yet again, as has been this year.

Volvo Truck Factory, Bangalore


Volvo India Pvt. Ltd. had planned to expand their facility located at Yalachahally, Tavarekere Post, Hosakote, Bangalore. The total construction area for the proposed industrial expansion was 25000 sq. mtr. with pre-engineered steel building concept. Frame members are designed in accordance with Indian Standard IS 800. Cold formed members are designed in accordance with the Indian Standard IS 801.

The Expansion
The total construction area for the proposed industrial expansion was 25000 sq. mtrs. The critical challenges were to ensure high quality work, while maintaining high standards of safety, and no disturbance to ongoing production activities. This needed teamwork of the highest order between all the stakeholders, viz., Client project team, Design Consultants, FABS as PMC, Contractors and Client Production team. Indeed, one of the key driving forces for success was the strong support from Volvo, both, in the form of motivation as well as direction-setting for all the stakeholders.

Each aspect of the project plan and execution methodology was reviewed through a robust mechanism of team review meetings to ensure all stakeholders were on board before selection of technology/systems/materials was finalized. The PEB and roofing system too underwent this screening process before being ordered and installed.

The PEB Route
The PEB design was taken through a strict process of review with experts, site confirmation and sign-off with all stake-holders including manufacturing teams to ensure that all critical loads, including special overhead crane requirements, were adequately provided for. The size and assembly plan of the PEB components used for steel column, roof truss, purlin and roof sheets/wall cladding were oriented to suit the site constraints and factory inspections ensured compliance with project expectations.

One of the most critical challenges was to connect the new buildings with the existing structures – the PEB transition from old to new structures underwent very detailed reviews by the project team before being finalized, especially since the production activities could not be allowed to halt for project work. The final connections between buildings and services were done as part of a special shut-down process using work holidays, round-the-clock shifts, etc. and this was meticulously planned right down to the smallest detail, including tea/snacks timings for the shift work teams.

The Structural Outline
Frame members are designed in accordance with Indian Standard IS 800. Cold Formed members are designed in accordance with the Indian Standard IS 801. These Pre-fabricated structure at various sizes brought in to site then assembled and erected with bolt & nut system.

Built Up Primary Members: Grade 50 confirming to ASTM A572 materials having min. yield stress of 345 N/mm2. HOT ROLLED Members: IS 2062 Grade A.

The secondary member is the light gauge cold formed sections having min. yield stress of 345 N/mm2. The existing Volvo building was expanded with area of 15,000 sq. mtr. steel building. There are other standalone steel building units with area of 10,000 sq. mtr. steel building considered with 6-meter clear height with overhead crane load.

A FAB(S) Coordination
Material receipt, handling and storage plans were worked out in advance. Close coordination was achieved with the supporting vendors like civil, plumbing, etc. through a system of detailed site reviews and action plans to ready the site for receiving the PEB components. Safety was of utmost priority, and all the site teams were taken into confidence on the expectations and detailed “safe work method statements” were drawn up.


“The size and assembly plan of the PEB components was oriented to suit the site constraints and factory inspections ensured compliance with project expectations. Close coordination was achieved with the supporting vendors like civil, plumbing, etc. through a system of detailed site reviews and action plans to ready the site for receiving the PEB components. Safety was of utmost priority, and all the site teams were taken into confidence on the expectations and detailed “safe work method statements” were drawn up. Before starting erection of the PEB components, the PEB installation vendor team was given a thorough induction into the safety and quality requirements.”

N. SRIDHAR, Operations Head
Facilities And Building Solutions Pvt. Ltd.

Before starting erection of the PEB components, the PEB installation vendor team was given a thorough induction into the safety and quality requirements. On arrival of the PEB components at site, all the above plans were put into action and monitored closely in order to achieve safe assembly and erection of the PEB structure as per design intent. This included a variety of quality tests at key stages to ensure that the work was done “first-time-right”. Success in achieving all this required strong teamwork and positive intent from all stakeholders and we were happy that the project received this in full measure.

Sticking to Safety
Safety and Quality were key focus areas on all the project works and the PEB system presented unique challenges. Volvo adopted a strict zero-tolerance approach to these two subjects and FABS was an enthusiastic partner in this. Safety system tools like Job Safety Analysis, Safe Work Method Statements, Work Permits, Induction and Training, Motivation & Rewards, etc. were implemented to ensure a safe work environment.

Similarly, for achieving the required quality of work, the work teams were given detailed inductions and expectations were clearly set out and then monitored closely to minimize rework or errors. The project won a Global Safety Award within the Volvo factory system, measured across all their factories across the globe. FABS is very proud to have contributed to this project achieving such a prestigious Award.

Some of the complexities faced during the making of the project was the merger of old and new buildings without affecting the existing operations, and to match the profile of existing building with new buildings.

Salient Features

  • Natural Ventilation with Louvers at Monitor & Wall
  • Sky Light provided 5% of total area
  • Screw less Double Lock Standing Seam roof
  • 50mm thick (48 Kg/Cum) Insulation with liner sheet.

Structural Uniqueness

  • The existing Volvo building was expanded with area of 15,000 sq. mtr. steel building
  • Steel building considered with 7.5 mtr clear height with all overhead crane load
  • 2 MT crane to be supported on rafter @ every 6m span
  • 24 mtr span considered without intermittent column

Steel Sections

  • Built-up members: Grade 50 confirming to ASTM A572 materials having min. yield stress of 345 N/mm2
  • Hot Rolled members: IS 2062 Grade A