Project brief
IFB Refrigeration planned to set up a new facility for manufacturing Refrigerators in Maharashtra. Post due diligence and discussions with the consultant, the client chose Everest for executing the project based on the trust built over a previous project. This project was significant as the facility was critical for increasing the production capacity.
Everest had dual responsibility to not only execute a quality job in the current project but also to retain the reputation of being a reliable partner which was an important aspect. Regular interactions were carried out at the consultant and client’s offices, and on-site to understand the project’s intricacies. Detailed planning was carried out at all phases of the project. The aim was to execute the project within the time frame required by the customer without overlooking economics.
Material of construction
All materials for the building were carefully chosen to meet the client’s requirements for the project. After considering surrounding weather conditions throughout the year at the site, Mineral wool of specific R-Value was chosen for roof insulation to maintain the desired temperature inside the building.
The layout of the building was planned to get maximum unobstructed space for material and people movement. The depth of Mezzanine beams was limited so as to provide maximum clear height under the Deck Slab. Standing Seam was used as a roofing solution for durability and water tightness to prevent leakages which at the same time increased the project lifecycle phenomenally. Horizontal cladding colour bands in the wall along with louvers were important features in the project.
The right amount of ventilation, as desired by the end user, for the building was achieved by using roof monitors and louvers. These features provided the required air changes per hour for fatigue free working environment for labourers, thus ensuring more productivity.
Polycarbonate sheets were chosen to provide diffused ambient light inside the building. Additionally, Everest wall cladding of the desired colour was used to make the façade attractive. Flush and cantilever fascia, and canopies with reverse slopes were used for ensuring an excellent aesthetic look.
Geometry
The building had critical height requirement with respect to Lean-To and EOT Crane, and spans more than 350 meters in length, which makes the building susceptible to temperature effects and stresses during temperature variance. Provisions were made for relieving such temperature stresses. The building also has mezzanine area designed as a composite deck slab. Portal and cross bracing were used in conjunction for lateral stability and openings.
Uniqueness
There are different kinds of loading, like collateral loads on the roof, solar panel loads, etc. Jack beams were introduced for better space utilization and to give way for more accurate machinery and equipment installation without forgoing the important aspect of optimizing structural steel. This made the project unique in its own way.
Challenges
Horizontal wall cladding installation was a challenging task from an aesthetic point of view. The strict timeline made the task more critical. Everest’s team was always alert for any unforeseen challenges. This helped in the quick resolution of challenges and avoided any impact on the project timeline. Meticulous execution by the Everest site management team and effective coordination with the project management team and the consultant, led to the successful achievement of milestones and kept the project on track to timely completion.
Conclusion
The deeply forged relationship between the client, consultant and Everest Industries, facilitated excellent and effective communication among all stakeholders. This led to optimum project design, which in turn resulted in huge cost savings for the client. Many challenges and last-moment changes were resolved immediately without impacting the project timeline.
IFB Refrigeration project executed by Everest Industries was unique because of the technical requirement of the most demanding customer who has a hunger for quality without foregoing economics. It was a project of strategic importance to Everest as we had to shoulder the responsibility of executing this technically challenging project within the strict economical purview and stringent timelines and more importantly, we had an opportunity of retaining our existing customer. This project also has all labour-related challenges in Ranjangaon which had to be taken care of without affecting project timelines.
With this project, Everest has yet again proved to be a reliable partner to our customers and raised the bar higher within the company with this success. We are poised for many more challenging projects to come our way in the future - Amit Khaparde, National Sales Head, Everest Steel Building Solutions
This is a very special project for IFB Refrigeration, where they are going to manufacture refrigerators. Based on our past experiences with Everest, we chose them to execute this building on a tight schedule. Everest has done a great job and has performed well in terms of quality, time and services. Everest extended continuous support and agility in incorporating last-moment important changes in the building during the execution stage which gave an edge to them. Their swift response ensured project execution within the expected time frame - Vaibhav Warade, Project Manager, PC Designs Pvt Ltd
