Special Stories

GOA Integrated Terminal Building, Dabolim


At any point of time, the Airport Terminals have always been known for their modern design, magnificent form, bold architectural interpretation and flawless structure – but ‘The Wave’ redefines all these parameters of evaluating the quality of Airport Terminal Architecture.

Key Seperators
The iconic stature, the bold and sleek form, the transparent façade, the vibrant interiors, the modern structure, the use of latest mechanical and electrical services and the cost effectiveness are few key features of this Goa Airport Terminal Building which separates it from any other contemporary airport terminal building.

The brief by the client was to create the facility as an Integrated International terminal within the Indian navy operational airport which has very limited city side land available, practically abetting on the main national highway. Due to less availability of city side land, the architects had to create the car parking in a multi level fashion.

Design Formation
The intial thought process of the architects while designing the terminal was to be able to glorify the culture and historical background of the city as well as the state for placing it as a tourist attraction. Being a city with multiple beaches and touching the Arabian Sea, the decision to replicate the ‘wave’ in the design was spontaneous. The wave represents aspirations- the aspirations of a nation which is quickly becoming a technological and economic giant in the global platform. The wave represents freedom- the freedom that Goa being a global tourist hub offers to the numerous tourists who come here for holiday and party from all across the world. The wave represents the ecstasy- the ecstasy which no individual visiting Goa can miss.

When asked, Prof. Charanjit S Shah, Principal, Creative Group described the form: “The terminal is formed with the oldest geometric shape – a circle. The terminal forms a semi circle resting on ground with a half arch emerging from the one end of the semi circle. The terminal form has been derived as free flowing, symbolizing a wave representing the proximity of sea and beaches of Goa.

Being a major tourist hub and a holiday destination, every year a large number of tourists visit Goa and with each passing year this number is increasing, hence, a requirement of a new world class airport terminal with all modern facilities has long been felt and was acknowledged by Airports Authority of India when they invited bids for the designing of the new integrated terminal building at Goa Airport. This work was finally awarded to Creative Group in consortium with their global partners Fredric Schwartz Architects and Genslers.

Steel As Building Material
The new terminal building has to satisfy both aesthetical and functional requirements. Consequently, a large infrastructure project like an airport is looked upon as a large span column free structure to provide a panoramic view connecting the inside and outside spaces. Thus, steel is used as the dominant building material due to its versatality with which a designer can achieve the shape and size of large span structures with steel plates and portals.

The wave-like structure of the airport is in steel plate portal with a large cantilever of 14 m with steel louvers on the curb side. It also makes the interior spaces column free and spacious, as it can cover large spans. The building form developed is very simple and bold. It is free flowing and is curvilinear in one direction. The building envelope consists of long curved glass façade which gives the building the transparent and modern look with a solid roof with sleek skylights which is free flowing in form resembling a wave and hence the proximity to the sea.

Apart from having an iconic form, this building also has to function as a terminal which makes the passengers comfortable and their basic function of boarding/ un-boarding the flight fast convenient and comfortable. Hence, the new terminal is distributed into 4 and a half levels- basement, ground floor, first floor, second floor and mezzanine.

MS Steel plate sections of YST 250 grade were used in creating the steel portal which were either TATA/Corus and are mostly readily available in the market. The technique used for erection was very simplistic as each portal has been fabricated and welded in segments of the site which were lifted by cranes. Proper precautions were taken to avoid deflection due to self load, wind and other constructional disturbances. The stability of the crane, its location and its movement are very important which was duly verified and designed as per the loading of the structure.

Architect Gurpreet S Shah, Principal Architect, Creative Group shared some interesting view points about this building. According to him, this building’s roof is designed with large overhang which covers the kerb, however, to achieve lightness, sun breaking louvers have been conceived on the kerb road ahead on the city side, thus, providing shade and comfort to the passengers. The building has long glass facade which gives the building transparent and modern look. A specially made double glass unit with protective film is specified for this terminal which provides much needed thermal and sound insulation. The use of steel in the main structure also enhances the modern image of the building.

With their experience of using steel in all the airports designed by them, Creative Group architects feel that steel is the material of tomorrow and have a very bright future. Formerly, steel was mostly used or bridges, flyovers, stadiums and other such projects, but now, it has great opportunities in terms of being used in skyscrapers and multi storeyed buildings. The global technology has reached this part of the world and as professionals, the architects can visualize the endless uses of steel in creating a new and modern India.

Terminal Planning
The Basement floor caters to the need of service area comprising of In-line Baggage system, storage, Baggage break up and baggage make up areas. Ground floor furnishes integrated arrival hall with 64 check-in counters on one side and separate domestic and international departure hall on the other side which can be integrated when required.

First floor have security check for international and domestic passengers on one side which can also be integrated to be used as domestic or international security check as required and other side caters to the immigration counters for arriving international passengers and concessionaries. This floor also has the Transit Lounge for Transit passengers.

The Second floor has security hold rooms & Airport Lounges for international and domestic passengers & and lastly the Mezzanine above has the building service equipments like AHU units, cooling towers etc. This new integrated terminal building caters to both domestic and international passengers with a peak hour capacity of 2040 domestic and 800 international combined together into 2840 passengers.

This building caters to various challenges and has to provide solution to various existing problems. Goa being a tourist destination has seasonal crowd and at this time it has to cater to large number of chartered flights. Also being a naval base the civil flights are allowed to function at specific time slots only both during day and night time. Hence, the terminal is planned to have high flexibility in terms of integration of both international and domestic passengers as the passengers rush increases considerably during peak hours.

The airport site is surrounded by the sea on one side and the main highway on the other hence the scope of expansion is also limited. As the site has its own limitations and a high floor area was desired, this terminal is designed to accommodate maximum built up area for limited ground coverage by introducing more floor slabs in the same volume. Hence, this building is more efficient in terms of the economics achieved as compared to any other contemporary airport. A Multi Level Car Parking is designed in six levels consisting of two basements to accommodate around 600 cars. This has significantly reduced the pressure on already constrained Site.

The building interior scheme is subtle as well as vibrant. Different types of specially designed glasses are used which gives vibrancy and holiday flavor to the building interiors. Many back lit double height feature walls strategically placed near the escalators and staircase creates the visual interest and guides the passengers to move in the certain path. As in this terminal the flow of passengers is designed vertically, these types of feature walls are essential for providing the visual cues for the passenger movement. The use of textured granite stone on the flooring reminds the passenger of the visual texture of the sea beaches. The use of Compact Laminated panels a recyclable green material is used as wall cladding which provides the visual softness to the interiors.

Project Cross-Roads
Talking about the various challenges the team faced during the project, Prabhpreet Shah, Executive Director, Creative Group asserted that though this has been a very challenging project in respect of the site constraints and conditions, being a Brownfield development and also being managed and operated on the air side by the Indian navy, all these factors had actually led to many construction issues. They had to pass through many sensitive times and had to take various instant design changes so as to convince the Indian navy personels and solve inter departmental issues. The end result is that Goa airport is a cost-effective terminal with very optimized project budget wherein it has been able to complete the facility of more than 1 lakh sq. mtrs. within a cost of INR 335 crores.

The building services are planned in a very sophisticated and intelligent manner. All service equipments for mechanical, electrical, plumbing etc are kept in the basement and their cooling towers (which requires open air) and AHU’s are kept on the mezzanine floor at the top which is open to sky. Hence, lots of floor space are saved on main floors and is utilized to achieve higher usable floor area. The substation building is also located in the basement itself, hence achieving higher cost effectiveness.

This terminal building provides a visual delight to the passengers to create a strong first and last impression in the mind of the passengers flying in or out of the country. This building is sleek, modern, transparent and bold and portrays the image of a nation which is quickly becoming an economic and technological giant. In its vibrant interiors it will set the holiday and party mood right inside the terminal which is most apt for a place like Goa. Hence, next time when you visit Goa, this iconic building will welcome you and will set your mood for the various possibilities offered by this state for your entertainment and self discovery.


The building’s roof is designed with large overhang which covers the kerb, however, to achieve lightness, sun breaking louvers have been conceived on the kerb road ahead on the city side, thus, providing shade and comfort to the passengers. The building has long glass facade which gives the building transparent and modern look. A specially made double glass unit with protective film is specified for this terminal which provides much needed thermal and sound insulation. The use of steel in the main structure also enhances the modern image of the building.
GURPREET S SHAH, Principal Architect, Creative Group

Jaipur Exhibition & Convention Center


The Jaipur Exhibition & Convention Center (JECC) at Jaipur consists of 2 exhibition halls, multipurpose halls, food court, and cafeteria. It has a total covering area of 4 lac sq. ft. The entire project is in structural steel, as the concept of exhibition halls is based on functional flexibility and aesthetics. The clear span of exhibition hall is 65m while the overall length of exhibition hall is 160m with clear height of 18m. The concept of exhibition halls is such that it can be used as a single exhibition hall in case of international large scale exhibitions with single column free space of 2.5 lac sq. ft. At the same time, it’s planning is such that it can handle 6 nos. of small scale exhibitions with a provision of roof hung central partitions.

The Plan
Being a project of PPP nature, JECC is one of the most prestigious project of M A Architects with a humongous volume and a very elaborate design brief – which was to develop 2 large exhibition halls and convention centre, in addition to development of 42 acres of malls, hotels and other commercial activities, entertainment facilities and kid’s zone to silent conference zones, art exhibition halls and auditoriums posed a big challenge of managing circulation and zoning to maintain a proportion of interaction channels and isolation screens with the understanding of flexibility of space and time of use, hence, bridging every aspect with a barrier free design catering to every need of all kind of users from every age group.

The project houses a combined 2.5 lac sq. ft. in exhibition and convention areas with retractable seating column free spans, exceeding over 200 ft. making it an engineering marvel and an architectural treat for the city.

Structural Aspects
The noticeable structural aspects of this exhibition center are as follows:

  • Truss type is open web curved roof truss, curvature of truss at both top and bottom chord.
  • Clear span of the truss is 65m
  • C/C span of the truss is 10m
  • End support is steel columns
  • Ridge height is 20m
  • Eaves height is 15m
  • Overall length of exhibition hall 160m
  • C/C span of purlin 1.5m

Challenges/Complexities Faced
There were quite a complexities involved in the making of project. The covering span of 65m was arched/curved shape from the top and bottom chord. The end supports needed to be single support instead of latticed columns, which required to be designed with large amount of forces laterally. The joints and connections had to be designed architecturally as it would be exposed internally. The eaves end had to be architecturally finished wherein the real time complexities were to hide end drainage gutters, maintenance systems, cat walks etc.

The total facade had to be free standing on 20m brick-work with stone cladding to be integrated/merged with the main structural steel supports. The main columns were to be designed for support on one side with all services including AC, chillers etc. and another side support was to be designed for cantilever canopies to cover large entrance area without any intermediate columns or supports. As this project was extremely time-bound, with most economical design concept with maximum aesthetic architecturally, it was also a challenge as far as structural engineering was considered. All primary members were open web arch/curved roof trusses span 65m at 10mm center to center of supports, whereas the secondary system is interconnected purlins and bottom tie chords.

Salient Features
The exhibition center has a 65m clear span open web curved roof trusses – with end supports structurally as sleek as possible. The end supports were designed with loads of all service platforms internal as well as external with large covering canopies externally. All these had to be achieved in extremely tight budgeted cost and time constraints. The roof trusses were to be designed in such a way so as to divide 160m span into three separate exhibitions halls covering 50m each.

Also it was important in the concept that once three separate halls were divided with curtain walls, it should be such that there should be no sound transfer when all three halls were functional at the same time. Also, when large exhibitions would be held, no intermediate supports should be visible throughout the 160m span. For covering such a large span roofing system, structural steel is the ideal solution, and cannot be executed in concrete. All structural steel sections used were hollow sections/tubes.

For structural engineers, it was to achieve a milestone in the project category which is high in architectural aesthetics, high in safety, extremely tight in budgeted cost, and high in completion time, with unconventional large spans to cover for functional and planning use of the structure, extremely precise systems for erect ion and fabrications. It does require past experiences to control all above mentioned salient points of the complex structural systems. It took one year to execute the two exhibition halls of 65m x 160m long.

Steel Selection
Once the master plan was chalked out, the major hurdle was to construct the exhibition hall within a short time frame. Steel being a factory fabricated material and having flexibility to work on RCC at site simultaneously saves time. Large span of 62m wide achieving in any other material is very difficult or nearly impossible. Steel frames provides immense flexibility to run all services and cat walks through open spaces. Single hall large span buildings which are expansion joint less, best suited for steel structure.

Essential Facilities

  • Two Indoor Exhibition Halls of minimum 10,000 sq. mtrs. each
  • One Outdoor Exhibition Space of minimum 10,000 sq. mtr.
  • Multi-Purpose Convention Hall with modular retractable seating arrangement for a minimum of 1000 delegates
  • Two Meeting Halls of 50 and 30 pax. capacity each
  • Two Board Rooms with 30 pax. capacity each
  • Two VVIP Lounges with 30 pax. capacity each
  • Administrative and Office Space
  • Food and Beverages Facilities
  • Provision of car parking to be made as per RIICO / Local Building Bye-Laws
  • Other common and support facilities such as internal roads, street lights, water harvesting system, solid waste disposal, main sewer line, water supply including storage tank(s), transformer, electrical sub-station, green patches etc.


It is with great pride that we would like to inform you that ‘Jaipur Exhibition cum Convention Center’ (JECC) is the largest purpose built state-of-the-art convention facility not only in India, but, also South Asia for that matter. Also importantly, there are features which are unique to us and which segregate us from the rest. At the outset we have two indoor exhibition halls of 10,000 sq. mtrs. each; both of which are column less and have a clear height of 13m or 40 feet, and more so, both the halls are air-conditioned. We have a total exhibition area rounding to 40,000 sq. mtrs. at one single space and a 250-rooms business hotel all at one venue along with Food & Beverage facilities. We think JECC, in short span of time, will be not only the talk of town of Jaipur city, but, will also create a different and unique space in the Indian Exhibition & Convention Industry and be the face of our country in the times to come
ARIF KHAN, Project Head & Chief Engineer, Dangayach Group

Once the master plan was chalked out, the major hurdle was to construct the exhibition hall within short time frame. Steel being a factory fabricated material and having flexibility to work on RCC at site, simultaneously saves time. Large span of 62m wide achieving in any other material is very difficult or nearly impossible. Steel frames provides immense flexibility to run all services and cat walks through open spaces. Single hall large span buildings which are expansion joint less, are best suited for steel structure
SHARAD MAITHEL, Principal, M A Architects

The overall experience as structural engineer was to achieve a milestone in the project category which is high in architectural aesthetics, high in safety, extremely tight in budgeted cost, and high in completion time, with unconventional large spans to cover for functional and planning use of the structure, extremely precise systems for erect ion and fabrications. As structural engineer, it requires past experiences to control such complex structural systems
VIVEK GARG, Director, Global Engineering Services

Railway Stations, Naya Raipur


The State of Chhattisgarh is undergoing an urban facelift, the focus of which is the proposed Smart City of Naya Raipur. Following the attention that the Prime Minister’s initiative for India’s 100 smart cities is receiving, Creative Group Architects based in New Delhi, believe that the idea of a smart city should be one of livability, sustainability, highest quality of life and economic viability. Prof. Charanjit Shah, Founding Principal of the leading firm, is working relentlessly towards his vision of redefining an Indian Smart and Sustainable City and the design of the railway stations at Naya Raipur is just one small piece of the ‘Smart City’ crossword.
Amongst the many global firms, Creative Group was the sole Indian firm to have participated, and later, won the Global Design Competition for the proposed stations. Owing to the firm’s experience of designing metro stations at Chennai, and various intermodal hubs in Ahmedabad and Gandhinagar, the emphasis in this project was on creating simple, yet, visually appealing and easy to construct stations modulated with steel framing. The project includes the design of 4 stations, the Naya Raipur station being the central hub providing effortless intra-city and intercity connectivity bringing people from Raipur and Naya Raipur closer, whereas the other 3 being the suburban stations. Spread over an area of 40 acres, the Naya Raipur Station has multiple platforms and similar thought process as the rest of the stations in terms of its design and structure.

On-Site Planning
The understanding of the site directed the designers towards providing an arterial road for entering the station to avoid any traffic congestion on the main road that holds the existing BRT system. The drop off and parking facilities have been provided on the west side. Through this, the designers were also able to achieve direct connectivity between the BRT and the railway station through a foot-over bridge which is handicap-friendly.

Further, to elevate the passenger experience, the architects have laid out a public piazza at the centre of the west side development which includes informal shops, sitting spaces, green walkable streets and a water body to captivate the passenger as he moves along the station. The green walkable streets amidst the commercial shops inculcate a sense of serenity and comfort by avoiding the harsh sun and let the passenger interact with nature. The piazza is user friendly with a clear cut movement pattern. The spaces on the left and right side of the public piazza are dedicated to Central Business Districts and other mixed use developments using the elevated track mound.

On the east side, recreational nodes are designed in the form of green pockets which are open to the public to relax and interact, thus making the station complex a bilateral transit hub.

Station Design
The station platform is provided on the first floor whereas the ground floor is utilized for the public piazza. Formal shops and kiosks are well distributed in the piazza braced with sit out spaces. Lifts and staircases are provided to move to the other floors. A salient feature of the station design is the skylights that provide natural light to the piazza through the cut outs that are made on the track level. Apart from their practical duty of bathing the stations with natural light, these skylights make the station more sociable and energy efficient. The reason behind incorporating these skylights is to provide a certain character to the stations that conveys openness and transparency.

Skylights have also been used on the roof of the station to maximize daylight and minimize dependency on artificial sources thus optimizing energy costs. These skylights have been extended on the concourse area to create an outdoor indoor environment. A monumental staircase connects the ground floor to the second floor which is equipped with a food court and cafeterias to engage the users even further. The foot over bridge from the BRT is directly linked to the second floor.

Building Structure
Steel being the predominant material has helped in achieving the iconic form of the station. The building structure has been designed as a dual skin. The outer shell is derived with a steel portal frame with steel intermediate tie beams and purlins that support the stand-up seam metal roofing system thus creating the external envelope. The primary portal has been tilted to achieve the desired shape that exhibits a strong architectural expression without any structural complexity. The metal roofing provides insulation and lowers down heat consumption, thus making the station an eco-friendly transport hub. Horizontal louvers are given on the façade which additionally allow light inside the station complex. The floor plates are made up with cast in SITU RCC framed structure consisting of RCC columns, beams and slabs.

According to Prabhpreet Shah, Executive Director, Creative Group, they envisioned these epochal railway stations as landmarks for commuters with world class facilities that also make them commercially viable. It is important for Tier II cities like Raipur and Naya Raipur to have such intermodal hubs to connect them and bring them at par with the rest of the country.

Still grappling with the nuts and bolts of building a smart city, our country is on the lines of fully understanding what an ‘Indian Smart City’ should be. Undoubtedly, the architects and planners of today need to re-look and penetrate into various challenges which our cities are facing. Thus, adding such landmarks to new city skylines that provides seamless intercity and intra city connectivity, and also links various modes of transport together, provides easy traffic management and user friendly movement. The cynosure of such projects is on building a facility that enhances the user experience and encourages use of public transport, thus, making the city ‘smart’ in the absolute way.

Nivea India Pvt. Ltd., Sanand


Beiersdorf AG, parent company of Nivea is one of the world’s leading international skin care companies. With more than 130 years of experience in skin care and with one of the world’s most modern skin research centers, Beiersdorf stands for innovative and high-quality cosmetic products.

Project Scope
Nivea India wanted to set up its first manufacturing plant in India for a range of creams and lotions at Gujarat Industrial Development Corporation at Sanand.

Nivea India awarded the contract for design, manufacture, supply and erection of the 10,397 sq. mt. industrial buildings to Tata BlueScope Building Solutions with performance based bonus. The project was scheduled in the monsoon season and required to be completed in the mutually agreed time frame.

Key Project Requirements
Out of the many requirements, some of the crucial necessities of the client were as mentioned below:

  • 10 years leak-proof warranty was desired
  • 48.0 meter clear span to facilitate process requirements
  • On-time project completion without compromising on quality, safety and most importantly – leak-proof performance

The Challenges
The most important and crucial challenges revolved around the roof system and the strict timeline. The most vital task was to ensure a long term leak-proof roof performance with 80 nos. of openings in the roof for fixing of turbo vents and with skylights resulting in 4 per cent of the total area. The timeline provided was to complete the project in a mutually agreed schedule during the monsoon season.

Solution Offered
Leak-proof Roof System
Considering all the project requirements stated above, the team of Tata BlueScope Building Solutions proposed a BUTLER® Building System with MR-24® roof system, which is the best leak-proof solution available for critical industrial applications like these. The Building Solutions team made the customer aware about the advantages of the exceptional features of MR-24® roof system which are never equaled, and never surpassed in its history of 45 years.

Side Laps
The roof involves 360 degree double lock seaming of side lap out of which 180 degree is seamed at site by Roof Runner® to achieve a greater leak-proof assurance. Using the pre-punched purlins for fixing of roof clips helps in better alignment of side laps, faster installation and superior aesthetics.

Roof Clip
Use of 32.5 mm clip movement in both the directions abolishes roof expansion joint till 250 feet of panel length. The centering arrangement in roof clip ensures a thermal movement in both the directions. A triangular bar with thin cadmium coating in clip assembly helps in reducing friction and provides greater sensitivity to thermal movement.

End Lap Design
The pre-punched panels ensures tighter and neater end laps. Also the splice position exactly above purlin ensures that the joint does not weaken due to foot traffic. Only two MR-24® panels are joined at end laps and staggered end lap splices helps in reducing chances of leakages.

Roof Curbs
The internal flange design of curb conceals fasteners with curb that helps in eliminating the possibility of leaks. Diverter flashings at roof curbs prevents ponding on the high side of the roof curbs. These curbs are secured to roof sheet and not to purlins, as this ensures uninhibited thermal movement of entire roof system.

Valley Gutter and Header Pipe System: Stainless steel valley gutter and fully engineered M.S. header down take pipe system ensures effective drainage of rain water from the roof.

Quality Assurance at Site: 100 per cent supervision by a dedicated MR-24® roofing team ensured consistency in the quality of workmanship at site.

The Nivea project was classified as a White glove project, a well-established Tata BlueScope Building Solutions process which involves double checking methodology to eliminate errors at any stage. The White Glove Methodology ensured ‘delivery in full and on-time’ without any errors at any stage.

The entire project was completed without any site claims or urgent material request. At an early stage of the project, Tata BlueScope team requested the customer to provide PCC floor and 4,000 sq. mt. of elevated laydown area with compacted soil to facilitate safe equipment movement, which helped the team work continuously even in the monsoon season.

Project Milestones & Performance
Roof sheeting was completed in 125 days from start date of project
No leakages were observed in the MR-24® roof system

MR-24® Roof installed at site has no leakages and is thus enabling Nivea to work continuously without any work stoppages and achieve their set production targets to meet their business goals. The safe and on-time completion of our engineered steel buildings in the first phase of the project has helped Nivea to start this factory extremely quickly, it is the fastest in the history of Beiersdorf. The elaborate product design and the impeccable installation of the MR-24® Roof System has resulted in a leak-proof building.

The leak-proof performance is providing greater assurance to Nivea that their state of art machinery and property is well protected and their operations team is able to work continuously to achieve productivity goals. Nivea India Project Team was impressed with Tata BlueScope’s project planning and execution capabilities. The project was handed over on-time and with no compromise on the quality and service. The management of Nivea India has announced to pay Tata BlueScope the bonus of 10 lakh rupees for its superior performance in completing the project on-time and meeting the commitments given to them.

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