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Everest Industries meticulous planning, accurate design and agility save significant cost for a JV aerospace manufacturing project

Everest Industries meticulous planning, accurate design and agility save significant cost for a JV aerospace manufacturing project

Project brief

The world class aerospace manufacturing facility in Hyderabad is an aspirational project in PEB industry for many reasons. Apart from the complexity involved in the designing, this project forms a part of ‘Make in India’ revolution by the Honorable Prime Minister of India because of its complexity and scale. The state-of-the-art manufacturing facility in Hyderabad is a Joint Venture between Tata Advance Systems Limited and Airbus France. This facility is going to manufacture critical components required for manufacturing an aircraft in a fully Flyaway condition. Everest was selected as a successful bidder for this project after stringent scrutiny by the team of Tata Advance Systems Limited on both technical capability and execution front without overlooking the economics. The project has been awarded to Everest considering the gamut of stringent timelines in the execution of this project. With every eye from inlands and offshore nations monitoring the progress of this project, the project is an important milestone for Everest. The successful execution will certainly open new avenues in Aerospace industry.

Material of construction

The facility required best materials for functionality and aesthetics. However, this facility is going to be fully air conditioned, hence end users and consultants have carefully selected Thermal insulation with liner panel to maintain the temperatures within the building for energy conservation. The roof of this building is spanning more than 100m as a single length of the sheet. Hence, specially designed floating clips were used for roof sheeting to take care of thermal expansion and contraction. In order to make this building air tight in certain areas, special consideration was given to flashing and trims of sheeting. Robust designing and usage of best quality sealants made the project unique and one of its kind.


The plan of the factory has been carefully laid out to facilitate the production line of components of aeroplane. The factory is single sloped and it has multiple width modules. The structure is designed for heavy duty cranes inside the building. To minimize deflection and satisfy serviceability requirements, the columns have been designed with fixed base. The structure has mezzanine areas for which composite joists have been designed for restricting joist depth.

Careful lookout was extended to ensure transverse movements of men and equipment inside the building.

Architectural Features         

With the roof spanning more than 128m, it necessitated usage of specially designed thermal clips which will allow thermal expansion of Standing Seam roof. Elevation of the building was provided with intermittent Louvers to ensure required Air Changes in non air-conditioned area. Careful selection of insulation with required R Value essential for maintaining ambient temperature within the building. The width of the building and monoslope called for careful designing of gutters and down take arrangement for smooth rainwater drainage.

Liner Panels have been used on the inside of the building to make it visually appealing and also provide thermal characteristics. Polycarbonate sheets with UV coating and high transmissibility have been provided at regular intervals to provide ambient natural lighting inside the building and conserve energy in non air-conditioned areas.

Uniqueness and challenges

Single Slope Roof for such a large width gives the building a unique look. Given the type of roof, designing of sufficient gutters as per maximum rainfall intensity of the location was a challenge. Strict adherence to very tight execution schedule was also an added challenge. Hence, completion of Design phase, manufacturing and well-orchestrated logistic support ensured completion of 1st phase execution well before time. There was no room for error as that would delay the project and such delays would have caused loss of precious time and delays in this marquee project. Everest Industries and its internal teams were quick enough to address early challenges which had put pressure on the complete schedule of the project and got back the project on track.

In conclusion 

The customer has appreciated Everest for its accurate planning and agility towards the change matrix during the execution phase. Our unmatched design expertise enabled us to provide the most optimum design for the structure which led to significant cost savings for the customer. We have been working with numerous cranes, boom lifts and Farhana’s in this project and with strict adherence to Safety guidelines, we have clocked more than 1,00,000 man hours in this project and we are confident that we will conclude the project with all safe practices being followed. This project in specific is going to open doors of numerous requirements of Aerospace industry to Everest.


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