V. B. SOOD
Director (B&S) SB-II, RDSO, Indian Railways
V. B. SOOD
Director (B&S) SB-II, RDSO, Indian Railways
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 :
Delhi Metro Rail Corporation
Gurgaon – Delhi corridor,
Tata BlueScope Steel Limited
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.
R. K. Lodhi,
Vice President – Sales & Marketing, Indian Steel Corporation Limited
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:
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:
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.
TRACK – I
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.
TRACK – II
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:
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 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 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.
How would you compare modular buildings vis-à-vis traditional buildings?
D. Raju : Modular buildings also called as Pre-Engineered Steel Buildings (PEB) are constructed using off-site based construction method, during which individual building components are designed, engineered and manufactured in a factory, transported to the site and assembled at the jobsite using nut and bolt technology. Traditional buildings are constructed by using on site construction method where all the components are built at site step by step in a phased manner.
Modular buildings have many advantages when compared to traditional buildings such as single source responsibility, faster construction with savings in time of over 50 per cent, flexibility in expansion, factory controlled quality, environmental friendly, lower maintenance, earthquake resistant, faster return on investment, lesser project cost, green building features, etc.
Other advantages in technical terms include quicker design with changes easily accommodated even at execution stage, larger clear spans without intermediate column, simple and light weight foundations, lighter weight structure, easy and faster erection without any major field labour for site work, outstanding architectural design through standard features and interface details and many more.
How best one can economize the usage of steel to achieve optimum weights?
D. Raju : Offering optimized design comes from intelligent use of steel, form and experience. These in addition with use of high strength material, use of built-up/tapered built-up sections for frames, use of high strength cold form sections for purlins and other secondary members enable to come out with most economical design and optimum weights. All the buildings designed by Kirby are with high strength steel having the most optimized weight. The company uses it global expertise of over 40 years in PEB industry spanning across Middle East & Africa, India and South East Asia enables to provide designs for different types of steel structures through its Global Center of Engineering Excellence based in India with highly optimized weights for any type of application. Design optimization varies from project to project such as end use application, experience, type of design software, design codes, project location, wind speed, seismic zone and various other parameters taken into consideration for designing the structure to come out with the most economical design.
What change in the mind-set have you observed over the years as far as using steel in construction is concerned?
D. Raju : In late 90s, when Kirby introduced this PEB technology and pioneered the concept in India, there was lot of resistance in acceptance of steel as a construction material except in some simple buildings and warehouse applications. But, with Kirby’s continuous efforts in pushing this technology across all the industry segments resulted in huge success immediately after its six years of operation where in another 3-4 companies entered this all together completely new segment citing Kirby’s phenomenal growth in such a short span of time. Currently, Kirby has designed, manufactured, supplied and constructed over 16,000 buildings across India spanning different industry verticals for wide range of applications.
This has resulted in change of mindset among the people in acceptance of steel construction as an alternate construction technology. Other major reasons behind change of mindset are faster construction, earthquake resistance, ease of re-location, resale value when sold as scrap, lesser project cost, etc.
Today, this can be widely seen as PEB is being used across all the industry segments for different type of applications such as multi-level industrial buildings, warehouses, workshops, shipyards, aircraft hangars, exhibition centers, showrooms, supermarkets, offices, malls, college buildings, schools, etc. This has also further resulted in creation of more than 30 companies across India which created additional employment and further enabled in changing the mindset towards steel construction.
What new innovative areas of business are being explored by the PEB and structural steel building industry today?
D. Raju : PEB and structural steel building industry have grown by leaps and bounds over last 16+ years in India, but, yet to achieve its full potential. Steel construction is still not completely accepted across all industry segments when compared to its level of acceptance in developed economies such as USA, UK, Middle East and other European countries.
Kirby has always been at the forefront of innovation by investing in new production technologies and enhancing the performance through continuous product development. Integrating the company’s strength and expertise along with innovation has helped the company lead the Indian PEB market. Kirby is the first PEB company to venture into unknown geographies and industry segments where PEB was never heard of and laid the roadmap for steel construction technology. Some of these segments include metro rail, shipyard, power, steel, pharmaceuticals, etc.
Some of the new application areas being explored by the industry include heavy industrial structures, high rise buildings – commercial & residential, multi-level car parking structures, cement, chemical, solar power, rack supported warehouses, etc. Many of the segments such as power, steel, etc. are witnessing increasing preference towards factory controlled fabrication when compared to onsite fabrication, thereby, leading to new design innovation for these complex structures.
To what extent is the recent slowdown affecting the PEB and structural steel business? How do you anticipate the market in coming few years?
D. Raju : Indian economy has grown by over 7 per cent over last 5 quarters and is the fastest growing economy in the world surpassing China. The economy was going through a lean phase in 2013 and 2014 with GDP growth of less than 5 per cent because of many factors. During this phase, PEB and structural steel industry were also affected because of lesser number of project finalizations and witnessed a decline in overall demand. Despite all these, Kirby was able to maintain its overall volume growth because of its complete solution offerings.
Changing economic conditions over the past few quarters because of various reforms announced by the new government such as Make in India initiative, development of 100 Smart Cities, likely introduction of GST in 2017, increase of FDI limit in defense, etc., major changes in ease of doing business, etc. are expected to result in higher GDP growth. In addition, promotion of manufacturing sector through Make in India initiative and increase the overall manufacturing growth and contribution to India’s GDP from 16 per cent in 2015 to 25 per cent by 2022 and create 100 million additional jobs. All these will create huge demand for PEB in coming years and catapult the industry to high growth trajectory path and will exceed the current growth rate, thereby, building a sustainable and environmental friendly future.
What are the prime reasons behind PEB technology being adopted in metro rail projects?
D. Raju : All the metro rail projects are built in a city passing through busy roads and junctions with heavy traffic congestion where traditional mode of construction is not at all possible due to lack of space and other site constraints. PEB technology is the only ideal option for construction as they are pre-fabricated in a factory controlled quality environment and transported to site for erection. There are no site related works, as different activities are simultaneously implemented at the same time such as building fabrication at factory and civil works at site, so that civil activity is completed by the time building components are transported to site for erection thereby leading to faster project completion.
Most of the upcoming metro rails are using this technology to build stations, workshop building, repair bay, inspection bay, stabling yard, etc. The major reason behind PEB technology being adopted in metro rails is because of maintenance free, environmental friendly, earthquake resistant, longer life span, recyclable, no sound pollution, saving of natural resources, etc.
Kirby became the pioneer in metro rail system way back in 2005 by installing most of the stations for Delhi Metro including the workshop and stabling yard buildings. This also laid the foundation for other PEB players to enter this segment where PEB became the preferred mode of construction. Delhi Metro was the first-of-its-type with curved rafters and the first metro rail to use PEB technology which was followed by Bangalore Metro with installation of sheeting using reverse rolling methodology. The entire box shaped support structures for Delhi Metro stations were also made of pre-fabricated steel and supplied by Kirby instead of RCC. Currently, Kirby is executing most of the metro stations for L&T Hyderabad Metro and is in pursuit of various other metro rail projects across India.
Why is PEB construction still limited in its application in the residential sector?
D. Raju : PEBs have hit the construction market in a major way owing to the many benefits they possess. Steel is a more versatile material than concrete and can cater to a wider range of applications. However, it is still not completely explored with the engineering and systems because of different type of architectural requirements for residential purposes though it is widely being used in the industrial spaces.
PEB penetration is very low in the residential sector and is in the nascent stage of development. But the concept is fast catching up in the commercial/office buildings as the scope of growth is guaranteed looking at India’s huge infrastructural requirements. Kirby has already executed some projects for residential sector such as G+13 building in Jammu, G+7 buildings in Mumbai and is currently executing similar other projects for both commercial and residential sectors across India. Change in market dynamics where faster completion, immediate occupancy, more aesthetic features with combination of different architectural features, etc. are fast becoming the norms of the industry. Though this may take some years, but, we are sure that PEB will become the preferred mode of construction for the residential sector as well in coming years.
PEB construction can also be used to fulfill government’s dream of providing housing for all through affordable and low cost housing which can be very well achieved only through this technology.
Cargill Incorporated is a 150-year old US-based privately held conglomerate with major business interest in food processing commodity. The company’s Rs. 600-crore corn milling plant near Bengaluru is going to become operational this year, catering to food processing and pharma industries. Pre-Engineered Steel Buildings concept is used in this project due to higher span requirement considering heavy equipment loadings, and because of advantage of faster construction which is not possible with RCC construction, thereby, generating faster return on investment.
Steel is used for constructing all the buildings and utility supports including conventional roofing system and mezzanines. Kirby India is involved in design, manufacture, supply and construction of pre-engineered steel buildings covering the complete superstructure. Kirby India designed all the 10 buildings as per the client’s requirements.
The design standards used in the project are as per IS 800:1984 Working Stress Method and Serviceability Criteria as per IS 800:2007. All the 10 buildings are process buildings interconnected with each other for corn mill processing. These buildings namely include Refinery Building, Wet Mill Building, Services Building, Maintenance Building, MDX Glucose Storage Building, Co-Product Packing & Storage Building, Malto Packing Building, Malto Spray Dryer Building and Corn Intake Cleaning Tower Building.
Wet Mill and Refinery buildings are connected by Services Building. Both these buildings are having two mezzanines floors each, with each floor in both the buildings loaded with heavy equipments ranging from 20 MT to 100 MT with dynamic operations, and collateral load of 100 kg per square meter.
These two buildings are equipped with monorails and pipe racks running along the length and width of the buildings. The maximum height is for both the buildings is 21 m connected with external staircase upto roof level. Corn Intake Building is a multi-storied building consisting of lift supporting structure and load of 1 MT mono rail crane.
All the buildings are supplied with galvanized secondaries with shot blasting and 1 coat of zinc phosphate and 2 coats of enamel paint applied at our facility. Pre-galvanized purlins/girts are 275 gsm cold formed sections with adequate provisions of sag rods and sag angles and knee bracing. The roofing area for all the buildings is provided with 5 per cent translucent FRP sheets for skylights. The buildings are provided with necessary accessories such as skylights, wall lights, roof curbs, roof jacks, louvers, side gutters, valley gutters, down take pipes, ventilators, etc. All the buildings consist of 345 MPa steel star columns and I-sections with tube bracings between each floor as most of them are multi-storied consisting of more than one floor each.
Boom lifts are used for erection of all the buildings including internal and external staircases, lift supporting structure and other utilities. For heights above 5 m only boom lifts are used and scaffoldings are used only upto 5 m height which is one of the major safety initiative taken for this project.
Erection of multiple process buildings, especially, for the food industry is always one of the major challenge and the same was overcome by Kirby India’s construction management team through proper and strategic planning, scheduling, efficient project management, management of available skilled and unskilled manpower, etc. and the completion time which is of most primary importance for the erection team.
There are multiple other challenges faced during erection of any building be it direct or indirect and the erection team implemented innovative technologies and skilled project handling strategies. Construction as such, is a complex array of interdependent activities which in itself throws up multitude of challenges which is not encountered in any other industry. The work involves functioning in remote sites with accessibility problems as there are difficulties in applying automation and requires adoption of technical innovation besides cost control.
The project involves size, cost, and complexity and also the work is also not performed in controlled conditions as it is highly impacted by weather and other environmental conditions. Kirby India erection team overcame all the challenges through its experience of handling and successfully completing such large and mega projects over the last 16+ years in India.
Kirby India implemented and recorded all the safety measures right from beginning of the project till final completion and handover to the client which is a regular practice and followed across all the projects. Safety was given primary most importance both by Kirby India and the client and was strictly adhered to each and every person visiting the jobsite.
The project is executed with high quality workmanship and highest safety. This was celebrated at the site and was well appreciated by the client who rewarded Kirby erection team with excellence performance certificate for meeting all the safety norms and completing the buildings with all the aesthetics specified by the client. The company also awarded its certified builder’s team with gifts for best performance in their respective areas of operations. Kirby was able to successfully complete 2 million safe man hours during the erection of the project which is in it a remarkable achievement citing the difficulties and challenges faced during execution of this project.
All the safety measures such as PPE for all personnel at the site location, safety net, use of life line, tool box training, height work safety training, firefighting training, training on safe handling of construction equipment and tools & tackles, safety postures and many other measures are implemented and to be strictly adhered to by all the people working at the jobsite.
All the elements of the building are double side welded as per the AWS standards with high end electrodes to have the highest precision, consistency and efficiency during welding. Over 3,700 MT of steel is involved in construction of different buildings spread over an area of 9,250 sqm. Most of the raw material such as coils, plates, etc. used in fabrication for this project was procured from JSW Steel, Tata Steel, etc.
Client: Cargill India Pvt. Ltd.
Architect: L&T Integrated Engineering Services
Structural Consultant: L&T Integrated Engineering Services
Steel Solution Provider: Kirby Building Systems India Ltd.
Tonnage: 3,700 MT approx.
Sections: Built-up sections
Status: Construction completed
Aaditya Heights is one of the recent feathers in Access Architect’s innovative projects cap. Since this was a redevelopment building, the client wanted to create separate towers for sale and the existing rehab clients. Another key aspect of this brief was that they wanted to finish the project quickly. The architects were asked to come up with a design that not only suited the brief, budget and timeframe, but, also aesthetic in looks, especially because this was a building to be erected in South Mumbai amongst many other iconic structures.
Need of the Hour
Since the building is located in Mumbai Central, rehousing the existing tenants for a longer period in a nearby location would definitely turn out to be expensive for the client and the tenants. Hence, constructing this building in steel was proposed. Fast track construction was utmost important to the client, hence, the entire team readily agreed carry out the building in steel. This was not only an environmentally safer bet to construct, but, also provided a shorter timeline for construction. The core of the building has been planned in RCC for now.
Speeding up the Process
The need for speed in construction and the difference in cost were the two major reasons why steel was recommended for this project. To keep protecting the environment, reinforcing steel is now commonly used. There were many reasons why steel was chosen for this particular project. Steel can be adjusted or changed according to the owner’s requirement. For instance, wall frames made from this type of material can be repositioned or altered easily in order to widen the space or create a new interior building layout. This ability to adapt to changes allows for easier expansions, and at the same time, helps extend the lifespan of the structure.
Steel offers a stylish way of creating large, column-free interiors, thereby, giving the building a sense of openness. It’s also malleable, giving structural designers the freedom to explore ideas in terms of creating stylish shapes and textures in order to make the building distinct. It is light-weight which makes it easier to transport, and thus, reduces fuel costs and accelerates project schedules. Aside from this, it is also energy efficient and can be recycled, creating minimal raw material wastes.
Intensifying the Design Aspects
The elevation and façade of this building is modern. Parking in done in a one-way ramp style. This is an extremely difficult aspect of designing a building, but, the architects have been able to achieve this in their design. The Rehab tower has a car lift parking, while ramp parking has been decided for the sale building. It is a linear plot which has been able to achieve the optimal design output within all government rules. Access Architects believe the parking structure of any project is just as important as the building itself. In all their projects, they spend an equal amount of time designing the parking as for a typical floor. Most design firms have a practice where designs are planned for a typical floor and the same columns are then taken down to accommodate parking. But, Access Architects design their parking separately, no matter how big or small the project.
Expressing The Geometrics
The plot is very linear and it is a T-shaped sale building with a square rehab building. The wing has spacious 2 BHK and 3 BHK apartments, and a good floor to floor height of 3.30 mtrs (11 feet). Above 90 mtrs, personal double height apartments, also known as the penthouses have been proposed. The project has a basement that is meant only for services. The building elevation is very modern. There is a double-heighted entrance lobby and a shuttle elevator for parking. There is also a proposed Jain Temple within the project. The project is designed keeping in mind all the modern needs – the club house, party area and an outdoor swimming pool at the 30 mtrs level.
Planned to Perfection
Autodesk Revit has been used for designing this project. Revit is a design software specifically built for Building Information Modelling. Typically, by designing in Revit the architects assure the client of all drawings required till completion – delivered even before the foundation of the building is completed. The Revit file allows for infinite sections, elevations and 3D’s to be pulled out for the building. When there are other consultants also working on the project, it allows to foresee clashes and problems before they reach site. The value of this increases exponentially where the complexity and size of project increases. The designing of this project was very challenging because it has been fully designed using the BIM software Revit, and the structure is designed in steel which is quite a challenging combination. The project timeline is decided to be 15 months for the Rehab which is a 70 mtrs building.
Indian economy is witnessing growth rate of over 7 per cent for past two years, since the new government has been formed at the centre, and is expected to grow by 7.5 per cent for next three years. This GDP calculation is driven by three main areas – agriculture, manufacturing and services, with services accounting for more than 56 per cent of the GDP’s share, followed by agriculture and manufacturing each contributing 28 per cent and 16 per cent respectively. The services sector has grown rapidly over the last 15 years due to easy availability of skilled manpower, thereby, resulting in reduction of percentage share of agriculture and manufacturing to Indian GDP.
Warehousing – A Vital Chunk
Emergence of India as one of the fastest growing economies after China resulted in higher FDI inflows and a number of multi-national companies setting up their facilities to meet the rapidly growing Indian consumer demand and take advantage of cheap labour, thereby, giving a boost to the Indian manufacturing sector, but, was much lesser than the growth of services industry. This has also resulted in development of back-end infrastructure which consists of logistics segment with warehousing forming an integral part of this segment. The logistics industry consists of many other components such as transportation, warehousing and other services out of which transportation is a major stakeholder in the industry in India and then followed by other services and warehousing.
The logistics industry is one of the largest industries in India as the logistics framework development accounts for more than 13 per cent of the GDP as compared to less than 8 per cent spent by the other developing countries. Indian logistics market has witnessed buoyant growth and is expected to grow at a CAGR of 12 per cent by 2020 driven by the growth in the manufacturing, retail, FMCG and e-commerce sectors. The current logistics industry is worth over US$300 billion. This growth is also based on the implementation of GST which will enable logistics companies to setup larger warehouses as per the region’s requirement and then easily transport from these warehouses to the different manufacturing plants, retail outlets, wholesale outlets, etc.
Most of the logistics companies are integrating IT and technology by investing in automation in their day-to-day activities to bring efficiencies in their operations and meet the increasing customer demands. The industry as a whole has moved from being just service provider to the position where they provide end to end supply chain solutions to their customers. The logistics market in India is largely unorganized as several local or domestic transporters with a very small fleet size accounted for more than 65 per cent of the total fleet size for road transport in India. The scenario is undergoing change because of quick delivery and tight service level agreements witnessed over last 3 years because of e-commerce boom.
Kirby – Pioneering the Innovation
Warehousing forms a crucial link in the overall logistics value chain. It accounts for approximately 5 per cent of the Indian logistics market and is growing at an annual rate of 10 per cent with the size pegged at INR 560 billion excluding inventory carrying costs. Warehousing also plays an important role in the logistics segment as storage of any type of material whether it is raw material, semi-finished goods, finished goods after production and goods stored at different locations require proper infrastructure in place. This is fulfilled by setting up of right type of warehouses and Kirby Building Systems India (Kirby India) is a pioneer in providing a complete warehousing infrastructure solution. The company is transforming the nation by partnering with all the leading logistics companies, 3PL, individuals, etc. in setting up their warehouses across India and changing the landscape of country’s warehousing industry.
Corporate – Shrewd Planning for Growth
Improving domestic economy has encouraged many foreign firms to set up their manufacturing base in India, which in turn has given a boost to the industrial and logistics segment. The main demand drivers were third party logistics (3PL), e-commerce, fast moving consumer goods (FMCG), automotive, pharmaceuticals, agro industry, etc. Most of the leading corporates are setting up their own warehouses across different regions of India to cater to growing needs of Indian consumers and cut down on the delivery of the product. They have become a central part of function for many industries as they act as a storage place for all the materials starting from raw materials to finished goods spread over entire life cycle of any product.
This significant growth in warehousing would be due to the major growth in the organized retail industry, commodity markets, and growth in industrial manufacturing and development. Many of the organized players are in the process to set up their base through the FTWZ and logistic parks which have warehousing as their key component. The cold chain industry is rising as a fast-growing logistics segment in India with major advancements and growth in the food processing sector, organized retail and government initiatives driving the industry forward.
The growth in warehousing in India is primarily being driven by the following factors:
Indian warehousing industry is segregated based on their percentage share of occupancy – Industrial / Retail warehousing (55 per cent), Container Freight Stations (CFS) / Inland Container Depot (ICD) (14 per cent), Agri warehousing (15 per cent) and Cold stores (16 per cent)
3PL, e-commerce logistics and cold chain are the 3 biggest segments in the logistics and warehousing industry in India based on future growth. The pressing need for time-sensitive delivery has reshaped the logistics industry as many traditional logistics players are now diversifying their services portfolio to make space for e-commerce logistics.
Based on the rise of QSR market in India, cold chain market is also witnessing remarkable growth. The increased foreign trade has led to the CFS/ICD segment of warehousing industry to record impressive growth rates in the recent years and is expected to continue the same for the forthcoming years. It would not be wrong to say that logistics could be the defining factor for success of e-commerce companies in retaining their customers.
PEB – Leading the Warehousing Construction
In earlier days, warehouses were constructed with traditional brick and mortar construction which was followed by steel building with trusses and other types of sections. But, with the advent of sustainable construction, Pre-Engineered Steel Buildings (PEB) technology came into limelight in the warehousing segment and Kirby India is the torch bearer for introducing this technology in India. Kirby’s warehouses buildings are customized to meet the unique demands of the customers. As a result, today Kirby has become synonymous with PEB warehouse buildings in the Indian market mainly because of its unmatched speed of construction, quicker delivery, highest quality and commitment, excellent customer service, good safety practices, future expansion, etc. Today PEB technology has become one of the most preferred modes of construction for warehouses being setting up across India.
The success of PEB concept in warehousing has now become a widely accepted solution with proven benefits for construction in the Indian environment. Some of the other natural advantages related to the success of PEB in the warehousing segment include factory controlled fabrication on CNC machines, most optimized design due to usage of standard design software, large scale material procurement by Kirby India thereby lessening the costs, reduction in manpower costs and time because of supply of material without any delay, accident free installation with the highest safety and many such factors.
Green Thrust – Eco-friendly Construction of PEB
Also with eco-friendly construction fast catching up the growth curve in the Indian market, PEB is the most viable construction solution as it is a green product with very little impact on the environment. PEB is also perfect fit for developing warehousing sites because of the recyclable nature of steel used in construction of these buildings as it has a re-sale value when the building is dismantled and sold as scrap in comparison to RCC construction which has to be completely demolished and cannot be re-used. Kirby India buildings are designed and installed as per the green building norms so that the customer can reap the benefits with this eco-friendly construction.
PEB come in virtually any size with options for exterior features and are customized to suit specific clients, i.e. an end user, size and geographical location. Kirby India provides warehouse buildings with options to incorporate aesthetically appealing features such as stone facade, aluco bond panels, etc. along with structural integrity and durability. Kirby India has constructed many warehouses and cold storages for all the reputed clients such as ITC Ltd, Indospace Logistics, Hindustan Lever, TCI, All Cargo Logistics, KSH Distriparks, Shree Shubham Logistics, Container Corporation of India and many small and medium enterprises and individuals across India. All these buildings are in different sizes with mezzanines and multi levels and are being used for storage of wide range of products across all industry segments.
Trending In – Modern Warehouse Infrastructure
Demand for modern and sophisticated warehouses has witnessed a tremendous increase in last few years because of influx of multinational companies or manufacturers which has attracted many private equity firms to invest in the warehouse infrastructure. Most of the warehouses are standard box type buildings as the design and other infrastructure for any warehouse depends on the storage requirements. Kirby has always taken care of all these requirements right before starting the design of the building. Also, the trends in technology along with innovations are further giving impetus to the PEB technology in the warehousing segment.
In current market scenario, more than 80 per cent of warehouses are being built with PEB which has taken over the conventional mode of construction mainly because of its various advantages such as cost savings, faster return on investment, quicker delivery, faster installation, single source responsibility, low maintenance, flexibility in expansion, earthquake resistance capability, superior quality, etc. which have become vital for any type of warehouse construction.
Warehousing plays a very vital role in promoting agriculture marketing and ensuring food security in the country as more capacity is required for storing all major crops highlighting the huge demand-supply mismatch. All the warehousing space owned by government agencies lack in optimal size, adequate design, ventilation facility, inventory management and storage system as they have been built following the traditional norms.
This is where demand for modern warehousing infrastructure has witnessed rapid growth and other dynamic market requirements have made it imperative for Indian warehousing players to overcome challenges, as well as maintain, improve and sustain competitiveness. The Government has also eased FDI norms and is promoting PPPs to pump in more investments in warehouses. Cold chain industry is also being given special incentives as it is vital to upgrade the food processing industry. Despite its strategic importance in the Indian economy, the Indian warehousing sector faces several challenges and need to be overcome with collaborative efforts of all stakeholders.
Need for large scale warehousing or dedicated logistics parks is fast catching up in India as it is mostly fragmented and unorganised industry dominated by many small players. This will enable companies to have larger warehouses supplying the distributors in the region, thereby enabling them to invest in better warehousing infrastructure and technology which will lead to increasing demand for PEB.
Kirby – Meeting the Warehousing Demands
Warehouses are increasingly addressing specific requirements for its customers such as offering bare storage, storage with crane facilities, food storage, storage with multi-level stacking and open storage. Kirby India provides a package solution for these types of requirements with its new concept of Rack Supported Warehouses based on the end use of that warehouse. It is the only player to offer such packaged requirement and has already supplied such buildings to leading logistic companies. Kirby is present in both in PEB and Storage Solutions and it becomes strategic for the company to provide end to end solution for increasing demand for such type of requirements in the market.
PEB technology has become the centre of attraction across India especially in the agro and food & beverages industries due to series of measures announced by the government to provide proper warehousing and cold storage facilities for fruits and vegetables, food grains, etc. Lack of temperature controlled warehouses close to farms and transportation of same in temperature controlled vehicles has become a major concern as they preserve the quality, integrity and longevity of the product. This has given huge opportunity to logistic players to set up temperature controlled warehouses or cold storages as the industry is estimated to grow rapidly over the next few years. This will give further boost to the PEB technology as the building part of these cold storages can be done by this technology.
Kirby has already executed such type of warehouses and is in the process of creating a separate packaged solution citing the increasing demand for cold storages. A well maintained warehouse also increases the life of the product and PEB technology acts as a major contributor to this because of its environmental friendly nature apart from the temperature control environment. Most of the modern warehouses coming up nowadays have multi-purpose functionality i.e. they can maintain various temperature levels at the same time for different variety of products as all the temperature controlled warehouses or cold chains built over 4-5 decades back does not have this facility.
To conclude, Kirby is the only PEB manufacturer in India that is capable of supplying a packaged solution for all warehouse requirements maintaining international quality standards. Today, Kirby has become a generic name in the PEB market in India and has maintained its market leadership through its innovation and vast experience. Its buildings have stood the test of time, time and again against all odds – manmade and natural.
Rupa Renaissance is a 1.8 million square feet IT Park in Turbhe, Navi Mumbai. It consists of more than 1.5 million square feet of Commercial/IT space and the rest is service apartments and guest house rooms that cater to this commercial development. It is one of the largest commercial projects in steel composite construction in Navi Mumbai. The project aims to set a benchmark for other developers who are considering steel technology.
The plot has been designed in a way that circulation is streamlined and there are only unidirectional roads along the perimeter of the plot. Pedestrian circulation is designed to be independent at the center of the plot and never intersects with any vehicular circulation. The pedestrian entry opens up into a plaza with shops and restaurants in it. There is also a double height grand lobby for the IT building. All amenities like the restaurants, gym, swimming pool, service apartments and guest rooms are designed and provided within the plot to help optimize utility by the employees. The project also aims at being self-sustainable with the use of solar energy and optimal building orientation for sun incidence.
Much like Arjuna did with his quiver of arrows, one must inherently understand the tools available at one’s disposal. Composite steel construction has been a relatively new building technology available in India for residential, commercial and hospitality buildings. We have always believed in the significance of understanding new techniques of design or construction to add value to the projects we plan and/or design. Having designed almost a dozen buildings using this methodology, it allows us to recognize the advantages of steel construction and use it correctly in a location like Navi Mumbai, where cost of construction must be minimal. To use it cost efficiently, one must plan and design for composite steel construction from inception
JAY SHAH, Director, Access Architects
From their varied and vast experience in designing commercial buildings, the team at Access Architects was very focused that every aspect of the design needs to be efficient and coherent. Structure, services, circulation, materials, urban and interior planning has been coordinated concurrently to create this efficiency. The core was specifically designed so as to reduce the size of the columns. The plan was designed to simplify the parking circulation and outdoor circulation. All parking floors have separate shuttle elevators which makes the entry to the office spaces above streamlined with a single point of entry from the lobby below. The best in HVAC and electrical systems have been proposed to optimize efficiency, also keeping in mind the practicality.
Access Architects has delivered exceptional design ideas and solutions to more than a thousand buildings through their creative blend of human need, environmental stewardship, value creation, science and art. The firm’s emphasis on providing value-added design services to their clients in a range of marketplaces has resulted in the design of projects throughout India. It’s award-winning portfolio of projects spans across the country and addresses a range of scales and typologies including residential, commercial office buildings, hospitality venues, corporate offices, cluster development and education facilities. They have become particularly well known among the Mumbai community for complex high rise, mixed use projects within the dense urban fabric.
The form of the building evolved considering the circulation of people and climate. The plot is designed in a way that the guest house and service apartments create an urban plaza, whereas, the commercial building breaks its immense scale with terraces every few floors. There are two completely independent wings that can be made into one large floor plate, if the need arises from a tenant. The two wings have two different orientations – one wing faces the vast expanse of the highway, and the other wing offers the view of the hills and terrain nearby.
Steel, even though it’s been extensively used all over the world until recently, has not been used as often in India. With the fall in steel prices serving as a big incentive among other factors for this project, steel construction was the most appropriate for this development. The IT building has been designed from scratch considering steel composite construction.
Some of the important factors for choosing this kind of construction are the amount of time it saves, overall cost comparison with RCC, more flexibility in future design changes if any, increase in usable floor area, reduction in constructed area when compared to RCC, similar to international construction methodology for commercial spaces and a reduction in concrete use.
Access Architects is one of the earliest firms to complete full projects on Autodesk Revit. With an experience of 10 years on Revit, the architects are using this software for the whole project design, since it provides the BIM level and sophistication that is needed to execute a project of this size in a timely manner. Access Architects aims to complete the construction of the shell of the full building within 18 months, and this is only possible due to the steel construction technology used. Design development on this project began 6 months ago and the construction has already begun. The aim is to have the full building ready in approximately 30 months’ time.
The steel sections (computing to 7500 MT) that have been designed, will be manufactured according to the plan by the chosen steel contractor. LERA Consulting Structural Engineers have been hired as peer review for the structure of the IT Building. The architect’s design process is an interactive and collaborative one, promoting open communication facilitated by effective leadership. Throughout the design process, clients are engaged and informed in making decisions in order to reach consensus and move projects forward to successful completion.
Access Architects believes in moving ahead of the time, and this is evident in their early use of new technology from conception to execution. In the early 90’s, it was one of the first firms in India to begin using AutoCad when this was still a relatively new product in the Indian market. They were the first firm in India to complete a large project on Revit. Kanakia Samarpan Royale, a luxury residential building, was completed in Revit in 2006. As with any new tool used for design, there has been an evolution in use. In the first few projects, Revit was mainly used from design development to construction documents. As its use in the office increased, it started being used for schematic and concept design. Aside from visualization, it was also used for analysis.
As a result of this, it was used in the concept stage for various other things like wind analysis or sun path diagrams and these helped to envision and design projects more efficiently in the earlier stages itself. Added information was derived earlier in the design process which aided in designing a building more efficiently.
To allow for cost effective and fast construction, the architects were one of the first to use aluminum shuttering as well as pneumatic shuttering systems for high rise buildings in India. More recently, they are using steel and precast concrete technology in a proprietary blend that complements the economics of development and the contemporary Indian ethos. They have completed more than 1000 buildings, including 2 residential projects on the ultra-luxurious Altamount Road, 5 completed buildings in Bandra Kurla Complex including Sofitel, and a 5 star plus Luxury Hotel. They also recently completed The Ruby, the tallest commercial building in India.
To express that ‘outside the box’ thinking, the design team uses Revit as their choice of design tools. The drawings and plans produced with the program play an integral part in all phases of the project. Access Architects has an internal group that works on finding the innovative solutions for the potential issues such as the use of eco-friendly materials, pre-cast concrete, steel and using an innovative approach to avoid direct sunlight in glass building. It has earned success with numerous local and regional awards, and most of their design work has been constructed. But, it’s the quality of drawings and renderings that has been the basis of their growth.