Minimizing Redundant Steel In Orca Offshore’s Analysis


Massive but Movable
When Centrica acquired the F3-FA field in the Dutch sector of the North Sea, it planned to develop the field for four years of production and then relocate to another field. A EUR 200 million reusable platform was crucial to the project’s success. ORCA Offshore joined a team of design, fabrication, and installation contractors to provide the naval architectural analysis for transport and installation of the nearly 9,000-ton, self-installing platform. ORCA Offshore provided motion and stability analysis, multibody dynamic analysis, structural spectral analysis, and scale model testing. Bentley’s MOSES offshore platform design and installation software simulated and analyzed the transportation and installation of the unique production platform.

Tapping Marginal Fields
The F3-FA field was discovered in 1971, about two miles below the surface of the North Sea. Centrica is the third owner and acquired the field along with its acquisition of Venture Production in 2009. With only about four to five years of production life, it would be too costly to develop the F3-FA field by installing a conventional fixed platform. Instead, Centrica planned to deploy a self-installing platform that is constructed in harbor, transported by barge, and installed by putting down legs on the seabed and elevating the platform.

When the field is exhausted, the supports are taken up, and the platform is transported by barge to the next location. The cost savings across three or four marginal fields would be significant. The F3-FA platform footprint measures 63-by-45 meters, and the structure reaches a height of 133 meters above the sea floor. Each of four 440-ton suction piles is 13 meters high and 15 meters in diameter. The design weighed in at about 8,800 tons. During transport, the platform’s piles would be raised and attached to the barge with temporary sea-fastening beams. Because of the size of the piles and the proximity to the wave zone, huge hydrodynamic loads would act on the piles. For the design to be viable, the team had to know the size of these loads at an early stage.

Unconventional Analyses
It quickly became clear that the F3-FA platform design posed a challenge in strength management, in part because the four legs were without braces and subject to the direct force of the waves. The team used finite element analysis to model the entire platform including about 200 load cases. These included the static and dynamic loads, which had to be balanced to optimize steel quantities. Bentley MOSES offshore analysis and design software was used for the static calculation, in combination with an ANSYS model.

ORCA Offshore used MOSES to provide the multi-body dynamic analysis for the extreme conditions during transport. The challenge was to convince the project stakeholders that this unconventional method would give reliable results. The loads during transport and upon lowering the suction piles and legs had to be accurate to size the steel to hold them. MOSES determined those loads using a five-body model, with each body having its own hydrodynamic database to derive the motions and loads acting between bodies. A model test verified the MOSES results to the stakeholders’ satisfaction.

MOSES was also used to confirm the structural strength of the platform during transport and installation. The spectral structural analysis allowed ORCA Offshore to derive the structural loading without being unnecessarily conservative. Conventional methods would have determined the maximum load acting on each pile and combined that with maximum motion loads acting on the whole structure. The MOSES approach considered the natural relationship between loads to reduce the quantity of steel required for the platform itself and for the temporary sea fastenings.

Model Tests Prove Valid
Compared to conventional analysis, ORCA Offshore’s analyses provided a more realistic representation of the loads and stresses during transport. Model tests carried out in a towing tank validated the transport plan for the F3-FA platform. After an initial attempt scuttled by severe weather, the successful transport journey to the F3-FA field in the North Sea took about three days. The platform withstood extreme wave loading, which proved the reliability of results produced by the project team’s unconventional methods of analysis.

Installation work in the 40-meter-deep water was concluded within 52 hours. The leg sea-fastening system required no steel cutting or welding. Suction piles were driven into the seabed using submerged water pumps, the entire topsides attached to the four legs with 16 two-ton super-bolts, and the 4,000-ton deck lift system used strand jacks to maximize workability. The whole design concept proved to be easy to install.

ROI across Fields
With the integrated capabilities of MOSES, ORCA Offshore was able to perform the numerous analyses required to ensure fast, simple, and safe installation of the F3-FA platform. Optioneering support enabled design exploration to eliminate redundant steel work in the topside and legs, resulting in reduced material costs. Validating the self-installing platform concept and design had both environmental and economic benefits. All remnants of the self-installing platform are removed from the seabed upon relocation. The ability to reuse a self-installing platform three or four times over the course of its lifetime not only reduces field production costs but also taps smaller reservoirs in marginal fields that would otherwise be too costly to operate. This ensures that energy resources are fully exploited.

Project Summary
Organization: ORCA Offshore
Solution: Offshore Engineering
Location: Dutch sector of the North Sea
Project Objective:
• Safely deploy the F3-FA self-installing offshore platform on time and on budget.
• Utilize the best available analytical tools to minimize redundant steel.
• Minimize the size of the sea fastening to allow for safe handling.
Products used: MOSES

Fast Facts
• Single-body marine transport analysis included ballast condition, intact and damaged stability, bollard pull analysis, motion analysis, and barge longitudinal loading
• Multi-body marine transport analysis resolved leg and deck support loads
• Structural transport and fatigue analysis looked at deck, joint, and leg-member utilization; and grillage and sea fastening

• Complex analysis and model tests reduced both steel quantities and project risk
• The self-installing platform design was easy to install, which saved project-delivery time

MOSES software can perform real-integrated analysis for any type of marine structure in a dynamic sea environment, which contributes to the realization of innovative offshore structures

HERM BUSSEMAKER, Managing Director, ORCA Offshore



Project Type : Factory (Operational Centre)
Location : Jaipur, Rajasthan
Client : JCB India Ltd.
Architect : CP Kukreja Associates
Structural Engineer : CP Kukreja Associates
Steel Fabricator : Larsen & Toubro Ltd.
Steel Supplier : JSW Steel Ltd. & Essar Steel
Steel Tonnage : 10,000 Tonnes

a ‘box’ designed ‘out of the box’

In today’s construction engineering scenario, any project needs to be delivered on time, with each and every phase of it being put to the most perfecting detail with cost and construction efficiency allowing least waste of resources. In such a condition, a design just not merely end with a drawing on the architects drawing board, but is greatly dependent on material handling, fabrication, assembly and post construction maintenance – this is especially true of large scale industrial projects and it is needless to say that structural steel is one of the most distinguished materials that makes such extreme engineering technology feasible in crunch time.

Aspiring With Culture
J C Bamford Excavators Ltd (universally known as JCB), a British multinational Corporation serving as the world’s third largest construction equipment manufacturer, who already had their operational centres in Ballabgarh and Pune, aspired their ambition to try higher with their new culture which has now become JCB’s single largest footprint in India with 1 million sq. ft. of new factory space on a 115 acre site – such a new facility was envisioned to put the company as a market leader in production of construction equipment, thereby, making a mask in the growing Indian economy.

Responding With Glory
The basic brief for the JCB project at Jaipur justified it as a Greenfield project which has to respond to the existing desert topography in an environment friendly manner. JCB is a company who has committed itself to the development of the grounds around its factories through high quality planting and landscaping, and if possible, with appropriate formulation of lakes.

Following such landscape and site-planning philosophy, a masterplan for the entire project had to be developed, which was carried out in two phases: Phase-1 covering 70 acres had 85,000 sq. mtrs. of manufacturing and fabrication facilities; and Phase-2 witnessed construction of another 46 acres of land. The first phase was also envisioned to contain large office facilities over 12,000 sq. mtrs. that would allow the factory to start operating as soon as the construction is completed.

The two phases were planned in a manner keeping in mind an uninterrupted production flow so that the workability of a factory is not hindered even when the second phase was still being constructed. Besides all these factory functions, an auditorium of 300 capacity was also proposed in coordination with the assembly block. Together, the brief suggested a comprehensive, yet, compact development with judicious site utilization, smart work flow and high environmental restrictions.

Designing With Holism
The project was envisioned as a holistic approach from the site level to the building level – over a master plan level. It was aimed to merge the blocks seamlessly with a local topography, which is characterized by an arid landscape with occasional greenery and water holes; the grounds were emphasized to match into natural contours of the surrounding area with possible formation lakes and plantations.

Attempt was maximized to utilize the natural contours of the site while necessary ‘cut & fill’ techniques were carried out with soil present on site only, which promised minimum cost of site-grading, while creating high ground for the building and a depression for a water body, which becomes an oasis amidst the desert landscape.

At the architectural level, the project was conceived as two separate buildings that allowed controlling the footprint of the built-up area as well as landscape to flow as a continuous natural layer within the site. The project, hence, was as much significant as a master planning exercise, as it was an architectural design.

Gracing With Steel
Such a large scale project could only be imagined as a steel intensive engineering which allowed to install the latest industrial architecture technology into the design. Such designs varied from those of the ‘hung loading’ (that allow material handling from 50 kg/sq. mtr. in fabrication units to 250 kg/sq. mtr. at the assembling units) to the designing of roof-frames aided by jack beams (for enabling the ‘overhung conveyor belts’ to move manufactured goods from one space to another), and even more critically, design of service systems which are really complicated and forms the backbone of any functionally efficient industrial building.

Although an industrial space is mostly dominated by machines, it needs to be critically designed respecting human working conditions. In this context, the most important need is to facilitate proper lighting, cooling and ventilation. Other than artificial lighting, steel on roof, walls and other structural members are painted white by spectrography-tested steel paints which reflects 80-95 per cent of natural light coming through skylights, and allow the workspace to be lit up by reflected diffuse light, which is best for eyes working in enclosed spaces for long hours.

As far as heating and ventilation are concerned, they are managed by controlling the stratification level (the interface between the sedimented cold air pumped by air conditioners and the lighter hot air floating above) which is designed to be 2 to 3 metres above the finished floor level. The temperature within this volume is comfortable for working, unlike the hot air floating above which gets heated due to friction and vibration of machines inside.

However, the hot air is circulated through exhaust fans which are incorporated amidst the complex roof design. Thus, steel in such an architecture, not only fulfill structural stability, but, also allows super-efficient service and maintenance that holds the secret behind the successful functioning of the factory allowing it to manufacture 105-110 equipments a day, instead of an ordinary rate of 50-60 equipments which is otherwise common in such circumstances.

Specifying With Architecture
All JCB projects are subject to strict architectural specifications, which are part of the guidelines for developing each of the factories for the company. Such specific array of guidelines are adopted to bring in high perfection in work delivery as well as defining a distinct identity for the brand JCB. The project in particular had some extra specifications like the roofs that were painted white and differ from the green colour typically used for JCB buildings. This was done considering the extreme heat of the Jaipur climate that could only be countered by reflecting 85 per cent of the solar heat that allowed cutting down massive air condition load.

The other architectural considerations consciously observed included construction of the projects as two separate buildings that allowed:

  • Landscape to flow as a continuous natural entity on site
  • A fabrication unit to start functioning as a separate block independently, even when phase-II was under construction
  • Allow more space for natural lighting within the building
    Bring paint shop facilities convenient to outdoor areas present between the two buildings

Identifying With Geometrics
JCB factories typically identified themselves as ‘box’ structures with buildings rising from a considerably higher ground in comparison to the surrounding landscape. This allows the buildings to break the skyline, yet, being visible from great distances.

JCB also defines its internal architectural dimensions as clear, long spans with uninterrupted visibility. All these called for the use of pre-engineered building (PEB) techniques which has put both, architectural and structural dimensions of the project a class apart.

The project has been processed digitally through typical architectural and structural design software viz. STAAD.Pro, ETab, AutoCAD other than several more engineering software that have assisted in heat-flow analysis, energy analysis, sun path diagrams, work flow diagrams and animation for walk through generation. The main frame of the building consists of large pre-engineered building parts of span 20 mtrs x 40 mtrs resting on jack beams at every 6-metre interval. The different steel sections used were Fe 350, Fe 345, Fe 450 as structural steel and Fe 500 where ever RCC was used. The machines used for the construction were hydro lifts, cranes etc.

The project has been as much a milestone for JCB in India, as much it has been for CP Kukreja Architects. The major designing achievements can be enumerated as:

  • Creating a large industry of the scale and complexity with seamless communication among 20 prime construction experts hailing from engineering disciplines that provided a world-class design to take shape
  • Completing the entire project and inaugurating it in a record time of 15 months Accomplishing With Efficiency.

There were few major challenges faced by the concerned firms while executing the project. It required accomplishing a much needed coordination and joint effort by engineers from multiple disciplines that allowed the project to set high standards in the field of industrial design development. The project of such scale completed within record time of 15 months also ensured 100 per cent safety record. Another accomplishment was fabrication and erection of extremely large spans of pre-engineered building parts, without which the project could not have been completed so efficiently and speedily.

The best part of this project, I believe, is that the functional requirement of a large factory, which is manifested through intensive mechanical engineering, have been contained in a relatively much smaller footprint – that too juxtaposed harmoniously with the soft landscape, the combination almost becoming an interesting interplay of the hard machine and soft nature. Such a conscious blend in the design, accompanied with the soft and subtle choice of color, merges the architecture of these industrial buildings with the desert landscape almost like sand dunes. This is a large industrial facility which is intensively equipped with mechanical engineering and despite its robust architectural character, merges with the soft landscape without becoming a strongly forced imposition. This project proves that even industrial architecture can be designed at par with the principles of sustainability to utmost detail.

DIKSHU KUKREJA, Principal Architect, CP Kukreja Associates



As a designer, C.P. Kukreja Architects has been involved in the recent years in several large landmark industrial projects for major national and international clients in different parts of the country. In that context, the entire spectrum of design parameters for a modern industrial project starting from site selection to functional requirements, material selection, construction techniques and cost-and-time factors make such designs much more than just constructing steel sheds.

S. K. NANDI, Principal Consultant, CP Kukreja Associates

BASF Catalyst India Pvt. Ltd., Chennai


The design, fabrication, supply and construction of PEB package for project Pasumai was awarded to Kirby India by one of its Indian BASF divisions – BASF Catalyst India Pvt Ltd. Kirby Building Systems India Pvt Ltd has been the pioneer of Pre-Engineered Steel Buildings (PEB) in India. The team convinced the client to go ahead with PEB, as all their requirements related to process changes and various other specifications can be easily accommodated during the design stage which was well appreciated by the client who firmly believed in the company’s capabilities and awarded this project. Headquartered in Germany, with world-wide operations, BASF is the largest chemical producer in the world and supplies products to a wide range of industries.

The building at Chennai is itself a contemporary example of a large scale operation and flexibility of designs. The project consists of five buildings – Production Building, Slurry Tower, Finished Goods Storage/Warehouse Building, Central Operations Building and Utility Building.

Project Specifics
This project is named as BASF “Pasumai” project; with “Pasumai” in Tamil referring to green which symbolizes the unique concept of using green and sustainable construction model and techniques used in constructing this plant. This project is built up in Mahindra World City on the outskirts of Chennai, Tamil Nadu. Highly technologically advanced and among the largest and most sophisticated processing plants, this BASF facility will ultimately manufacture catalytic converters used in automobiles. This facility near Chennai will cater to all the automobile facilities located in and around the region, thereby reducing the overall transportation cost and lead time for all automobile manufacturers.

The buildings are designed as per IS 800:1984 codes with serviceability criteria as per IS 800:2007 codes with all the geographical data like wind velocity (IS 875), seismic loads (IS 1893:2002), loadings (IS 800:1984), etc. taken into consideration. The design of the building is complex in nature with new innovation techniques used to meet all the stringent building requirements that could meet all their processes. The plant is dependent on the process right from building specifications to machinery layout. Even with the project being in the construction phase, all the design changes in the building layout were incorporated right from beginning to the end, without hampering the schedule of the project.

The engineering team successfully managed to overcome the restrictions on height of the column and on depth of both beams and columns to fit in all the client’s requirements. Special emphasis was laid on the design parameters in order to ensure that all changes, including the complex pipe racks arrangement running all around the building with varying loads and levels, were accommodated to suit the varying processes for different type of vendors.

Structural Elements
All the buildings feature majority of heavy star columns (double I section columns) and beams where a single piece is spanning 15 m long and weighing upto maximum of 14 MT.

The Slurry Tower is the highlight of this project with its G+4 structure. Built at a height of 27 m, this tower consists of cruciform columns with heavy loads to the tune of 100 KN/sqm or 10 MT/sqm on each mezzanine floor which are loaded with very heavy machinery. Glove fit accuracy defines the design for the heavy pipe racks and utilities that run all across the structure. This design perfection is the byproduct of employing latest engineering/drafting tools with the highest precision of fabrication well within the allowable tolerance limits as per MBMA standards. Mezzanine layout on all four levels ensure that the members were connected with ease at site, ultimately aiding in reduction of overall construction time. Some part of the slurry tower is provided with fascia which consists of MS box sections, mainly for fixing the BASF logo on the fascia with additional steel supports.

This building also consists of 8 mono rails from 4 MT to 6 MT, at different levels to take care of machinery movement without any outside crane requirement. Many openings are given all around the building to ensure free movement of the machinery from one place to another with the help of internal cranes. FM Approved Standing Seam roofing system is used with solar panels loads which makes the building 100% leak proof. Sinusoidal wall cladding has been used with high precision finishes to make it aesthetically appealing and architectural beautiful.

Finely Fabricated
The expertise of Kirby design department helped in giving special aesthetics to the utility building with curved fascia on side walls and architectural wall cladding in front of the building, which is one of the most unique features of this project. The fascia fins dropped from the top of 27 m to a varying height upto 15 m, the curved roof of the utility building, the cantilever staircases, valley gutters made of stainless steel materials, fire rated paint applied to the operations building and many such features with high-end and super rich specifications make this project unique in nature.

Multiple cranes up to 80 MT capacity with 120 boom lifts, suspended platforms, and aluminum scaffoldings were employed during the erection stage. The structure was erected in grid pattern in order to achieve the required speed thereby maintaining the safety and stability of the structure.
All the materials fabricated went through a stringent welding process as per the AWS standards with very negligible tolerances. The welding quality is ensured by tests like Dye Penetration Test/Ultrasound Test for the automatic Submerged Arc Welding (SAW) process used for the flanges to web welding & the Flexible Core Arc Welding (FCAW) used for the various fitments of child parts and the dimensional accuracy is verified for compliance to the acceptable tolerances.

Steel Specification
• Built-up Section Plates – Grade 50
• Hot Rolled Sections – Grade 36
• Cold Formed Sections – Grade 50
• Roof & Wall Sheeting – Grade 80
• Stainless Steel Gutters & Handrails-Grade 26

Overcoming Challenges
Due to availability of very less space for the storage and erection, handling of materials at site was one of the major challenges. The project management team at plant and construction management team at site, handled the project very efficiently with a detailed plan chalked out in order to supply materials in the required erectable sequence without affecting customer’s priorities.

To ensure timely project completion, a detailed micro-level plan backed up with precise supply chain management was followed through Kirby’s SAP system, right from the enquiry stage till the final dispatch. Kirby India’s SAP has been used to interlink design, detailing and fabrication, thus enabling proper coordination and timely sequential delivery of material to site. Communications and checks were initiated at critical points. Further, regular meetings were called internally to monitor critical paths and to endorse corrective actions as and when required.

Safety First
In addition to the inherently safe practices followed by Kirby, it also offers supervision and safety audits at site. The company deployed innovative solutions like highest safety standards which were followed in line with international norms to achieve zero accidents. The Kirby execution team showcased highest level of safety standards, with over 150 skilled workers working on-site at the peak. Daily tool box meetings were held to review the project status and the way forward was planned with regular quality check in collaboration with the client. Moreover, corrective measures were taken to meet the client’s schedule and all their requirements with world-class service.

There were safety sign boards installed at various locations and a session on safety induction was conducted for workers. Apart from this, workers also had to undergo medical tests at regular intervals. Personal protective equipment (PPE) was made mandatory for all workers to ensure safety of each and every person for different type of works handled at the site.

Tested and certified by authorized third party agencies, the project made use of boom lifts to take the labour to the required location, fall arrestors, life lines, safety net, aluminum scaffolding, etc. at the site.

With the erection process being highly technical, additional training sessions were also conducted at the site to educate the builder staff on correct installation procedures EHS practices to be followed. Skilled and trained manpower was employed to effectively execute the works and handle heavy construction equipment.

Employing Steel
With a total of over 3 lakhs man hours consumed for construction of all the buildings, over 4,500 MT of steel was used in this project and a major portion of the raw material such as plates, coils, etc. was procured from leading steel manufacturers based in India and other parts as per the project requirement.

Project Highlights

  • Standing seam roofing sheet of 24 gauge with 360 degrees double lock system outside and 26 gauge color coated liner sheet inside
  • Sinusoidal wall cladding of 26 gauge is installed and is constructed only up to 1m height. There is a gap of 200 mm between the column outer flange and wall. The sheeting is placed on the outside of the wall at a distance of 430 mm from the outer flange of the largest column on any given grid.
  • Fiberglass insulation of 50 mm thickness with GI mesh for entire roof area
  • Pre-galvanized secondaries (120 gsm)
  • Framed openings & canopies with necessary trims & flashings and soffit panel.
  • 4 per cent of roof and wall area consists of skylights and wall lights each for all the buildings
  • CHS (Circular Hollow Section) pipe bracing considered for roof and wall
  • High strength bolts (HS Bolts) have been used for all primary connections
  • 3 coats of paint involving epoxy primer, low VOC MIO intermediate paint and final polyurethane finish paint giving excellent durability and long term recoatability with total DFT (Dry Film Thickness) of 250 microns. Central operations building is fire proof and can withstand upto 2 hours of continuous fire.

Client: BASF Catalyst India Pvt. Ltd.
Architect : Aswathanarayana & Eswara LLP
Steel Solution Provider : Kirby Building Systems India Pvt Ltd
Steel consumed : Over 4,500 MT
Total Area : 15,900 sq. mtrs.
Status : Completed



Based on the winning design from Living Steel’s International Architecture Competition, RESTELLO reinvents luxury living. The idea behind RESTELLO was to design and execute an environmentally responsible steel structure to cater to the need of society in terms of luxury, comfort and cost and to bring customers closer to the future trends in building. Conceived by UK architects Piercy & Conner, it combines traditional eastern architecture with innovative sustainable practices to create the very latest in modern living experiences.

Design Brief
Steel building is the future for providing sustainable development. At the outset, the design team was provided a simple brief to bear in mind – the main structure would be steel. The steel ‘skin’ of the building comprises one perforated steel screen and a second inner skin of floor to ceiling glazing. About 90 per cent of the construction material used was to be manufactured at the factory end, and later assembled at site. The structure was envisioned as having a highly superior finish thanks to the steel walls. Moreover, the steel structure would also allow for long spans, creating uninterrupted living spaces; and the perforated façade filters the light while providing natural ventilation.

Creating the Vision
With a competent team at the helm, the project made use of cutting edge technology to develop a unique building. Living Steel, a worldwide, collaborative program designed to stimulate innovative and responsible housing design and responsible housing design and construction was launched in 2005 by the World Steel Association. The program was developed to help address the unprecedented, communities and the quality of people’s lives stemming from growing urban population. The members of Living Steel manufactures include Arcelor Mittal, Baosteel, BlueScope Steel, CELSA Group, Corus, Erdemir, IMIDRO, Posco, Ruukki, SeverStal and Tata Steel.

The project, however, came with its own share of challenges. The prime reason being that the technical specification was unlike that of any normal contemporary buildings. The grade of concrete required was specific to the project and was not readily available; it was the efforts of a competent research team at Jadavpur University, Kolkata that help surmount the problem. Moreover, vendors for a project as unique as this were not easily found and a few had to be developed. It was the acumen and experience of the team behind the project that these seemingly difficult issues were overcome. The result – RESTELLO is not only a unique building in Kolkata, but, in entire India.

Redefining Concepts
Featuring 12 exclusively designed boutique duplex homes, with enviable area efficiency, RESTELLO offers a harmonious balance between the outside world and your own personal space. The perforated steel sheets on the exterior give a unique façade, provide greater thermal comfort and reduce the need for air-conditioning. Its unique geometry with two layers of filtered light façade acts as resistance to high winds and heavy lights at the same time allowing proper ventilation and day light.

Each apartment boasts a double height terrace, encased in an adjustable perforated steel façade. This allows fresh air to circulate, without ever compromising on privacy or security. The striking façade notwithstanding, this building also impresses in terms of utility, offering resistance to earthquakes and fires, thanks to its efficient designing. RESTELLO uses recycled steel, reducing the material used and energy intensity in the manufacturing process. Galvanized and painted steel protects against corrosion, damp and termites – ensuring a longer life for the homes. RESTELLO espouses the latest in smart, sustainable residential design without compromising livability.

RAVI TODI, Managing Director, Shrachi Group
In our way forward in developing cutting edge technology in the art of smart living, Shrachi Group in association with Piercy Conner Architects, UK, has developed the very first steel residential building RESTELLO in the country. Located in the opulent neighborhood of Rajarhat in New Town, Kolkata, RESTELLO is a class apart and takes luxurious boutique living to the next level. The building portrays a striking medley of traditional eastern architecture and innovative & sustainable design from the west combined to offer the very latest in modern living experiences. Designed to fit the ultra-modern lifestyle, RESTELLO is the building of the future with state of the art thermal insulation and enviable double height terraces. Built out of recycled steel, RESTELLO offers a harmonious balance between the outside world and your own personal space. Based on the winning design from Living Steel’s International Architecture Competition, RESTELLO beckons you to come and experience your very own urban utopia

ARCHITECT STUART PIERCY, Director, Piercy & Company
Conceptually, the project is the symbiotic relationship of a sealed, conditioned contemporary living space enveloped by a permeable and responsive patterned outer skin. Looking to the expressive and perforated architecture of Kolkata, the pattern of the outer skin is a direct response of layering sun paths with external views

Client : Shrachi Group, Kolkata
Architect : Piercy & Company, UK (formerly Piercy Conner Architects)
Structural Engineer : Price & Myers, UK
Steel Sections : Manufactured according to need
Software : AutoCad, STAAD.Pro and StruWalker evolution
Timeline : 24 months
Status : Ongoing



A product warehouse building was conceptualized by ONGC Petro additions Limited (OPaL) and Engineers India Ltd (EIL) for IOT Infra to cater requirement of product handling and storage of OPaL’s Petrochemical Complex. Built at Dahej, Gujarat this is a 1-km long and 135m wide structure covering an area of 1,40,000 sq. mtrs. The complete work of product warehouse including pre engineered building was awarded as LSTK job to joint venture of Katoen Natie and IOT Infrastructure based on International Competitive Bidding (ICB). PEBS Pennar was selected by IOT Infrastructure for design, fabrication and installation of pre engineered building of product warehouse, which was accomplished with peak manpower of 250 workers and approximately 9.2 lac safe man-hours.

Project Brief
With a simple brief given to design the state-of-the-art product warehouse with flexibility to select bagging machines vis-a-vis silos, and to have maximum possible storage space, the building is designed with unsymmetrical frames. The silo frames are the mainstay of the structure with rafters resting on the RCC building. The building is the widest multigable building ever done by Pennar. Designing of the structure was done using continuous jack portal; where 24m jack beam was used as the portal to make column-less space inside the building, as the customer required free end space of 135m by 24m along the length of the building.

The complete design is vetted by EIL, which gave the approval for the design after being satisfied with the codes and the design methodology adopted. Star columns are used at each expansion joint in order to maintain portal stability and economics in longitudinal and transverse direction. In addition to space restriction, the clear height had to be maintained along valley time to facilitate the movement of machineries and vehicles. The entire building is installed with Double Lok roofing system which ensures 10 years of leak proof warranty.

Structural Elements
The basic structural system consisted of main frames with secondary members provided between these frames for sheeting support. The columns and rafters of the building are of varying web depth, with a maximum web depth of 1000mm. The rafters are resting on jack beams at the interior of the building. These jack beams span across 24m and were for full length of the building at five locations wherein the maximum web depth of the jack beam was 1400m. The secondary members are cold formed “Z” or “C” sections varying in thickness and having maximum thickness of 2.5mm.

Structurally Exclusive
The project is a unique and challenge in respect to both, designing as well as installation. There was no such reference which made the entire design to be contesting. Stability was the major concern with collateral load of dust, wind speed and seismic load. The entire team of engineers toiled hard for the approval of the project.

Fabrication and transportation of huge structures was an exceptionally arduous task as it was not possible to carry out welding onsite. Apart from this, the biggest challenge was to gather and maintain a huge task force of skilled workers together and maintain the momentum at project site. Despite several challenges and constraints, the team at Pennar accomplished the project successfully with the best of its quality and time.

Steel Specifics
Considering the application of steel in the realm of pre engineered building and ease of usability, steel was selected as the material of choice. This impressive structure was instituted using multiple deployments of resources and was erected from different expansion joints and by connecting the junctions. The built-up “I” sections and jack beams were fabricated from plates of ASTM with minimum yield strength of 345 mpa. These built-up “I” sections were fabricated with flange to web fillet welding which was carried out in a continuous submerged arc welding machine. The end plates/gusset plates etc. were joined by continuous fillet welding manually. The secondary members were from ASTM A 653m with minimum yield strength of 345mpa. Other hot rolled sections used such as angles/rods etc. were of I.S 2062 with minimum yield strength of 240 mpa.

The biggest challenge for this project was the huge volume in terms of area of work. During conceptualization and design stage, the challenges were cost optimization and minimum construction time. The sheer size of the structure proved a challenge even when it came to deploying multiple teams and resources. The limited timeline of 8 months was yet another area that contributed to the difficulties faced by the team. The manpower used in the project was in proportion to the size and mobilizing sufficient manpower while working overtime was a major contributor to the list of difficulties which were overcome by the team of qualified professionals at hand.

Safety First
For a project of this size, it is absolutely essential to have the safety regulations down to a pat. The project saw safety screening of deployed manpower, imparting onsite safety training, job safety analysis of individual work methods, safety gears like full body harness for workers on height, using safe access methods like boomlifts, man-basket etc. in order to successfully and safely complete erection of the design.



Design Concept
The site is located in the north-east corner of a residential complex in Kharghar, Navi Mumbai. The elongated southern section of the site is reserved for a future low-rise residential development, and the commercial building is restricted to the elongated L-shaped bulb at the northern extremity.

The raised residential development on the west, resulting in a sunken section within the site, along with the shape of the plot, the orientation of the views, and the surrounding hills stretching from west to east along the north, and the fragmented building program have contributed to the development of the building concept.

Two perpendicularly oriented prisms form the bulk of the building area. The lower one contains flexible, free span work spaces for sale/lease, and the upper one is specifically formatted to suit the requirements of the client’s corporate office. The long and slender lower block hovers above a landscaped sunken courtyard that also contains the lobby and public spaces. The building volume serves as a transition point between two conditions within the landscape. On the south, where cars approach the lobby, the building projects out from a steeply banked grass berm that merges the levels from the road access to the raised section on the west. The movement under this hovering monolith creates a volumetric expansion towards the north where a large water sheet creates a space of calm and reflection where the lobby and public areas open out onto.

This movement is a spatial and transitional analog for the barely plausible relationship between the upper and lower building blocks. The impression is one of balancing on the edge as the upper block turns at 90 degrees and perches delicately on the lower one, cantilevering out 16.0m over the sunken courtyard below.

This volumetric separation and reorientation reduces the perceived mass of the building, creating inverted and differentially scaled ‘T’ sections in 2 axes, and especially as the building is approached, the sensation is of an elongated edge hovering above the water and a large prism balancing delicately over it. From a distance, the volume of the corporate office becomes the attractor, a point of reference.

Structurally Fluent
These precise transitions need a highly tuned and nuanced set of structural solutions, as well as a unified skin that would break from the traditional scale of a stratified expression, developing instead a more ambiguous monolithic proportion that would heighten the sense of a series of precarious intersections between massive, porous volumes.

Apart from the shear core in the south, the superstructure consists primarily of steel. A lightweight web of slender members expresses the structural behavior of the building. The final solution is simple and elegant, but disguised within this coherent network is a complex engineering process that has effectively managed to reconcile an ambitious idea with the practical optimization and scalable replication and detailing during the fabrication process that is required to execute the structure.

The structural configuration went through multiple iterations before the design team reached a solution, but overall, it was found that the engineers from Cantor Seinuk (WSP) were able to substantially reduce the material consumption and member sizes by working with a delicate, distributed web. The maximum impact has been achieved at the ground level and volumetric intersection points where a lightness that is commensurate with the design intent has been expressed.

Aesthetics and Exteriors
The double skin solution, with superimposed layers of glass and a punched/perforated aluminum screening system enables excellent views outside of the office spaces while filtering the glare and heat. Controlled daylight floods the internal spaces, reducing energy costs through a scientific analysis of perforation patterns while also eliminating the need for any internal solar control blinds.

This layered assembly of perforated aluminum, glass and the exposed network of structural members creates a sense of density, lightness and porosity that vitiates the mass of the building volumes.


Malik Architecture

Cantor Seinuk (WSP)

STAAD Pro, Acad, Revit, TEKLA


Fe 410 (YST-250 Mpa)/ Fe 490 B (YST-350 Mpa)

1200 MT

Tender Stage