Ludhiana Beverages

Ludhiana Beverages – the authorized bottler of the Coca-Cola company is involved in manufacturing of Coca-Cola products. The client floated the tender for their upcoming greenfield facility where Kirby India bagged the Pre-Engineered Steel Building (PEB) requirement with tough competition from various other PEB players. This is the largest project executed by Kirby India in the northern most part of India consisting of Punjab, Himachal Pradesh, Jammu, and Kashmir.

Kirby is proud to get associated with the prestigious client – Ludhiana Beverages for their upcoming manufacturing facility. As it has already executed many facilities for beverage manufacturing companies across India and this project is one of the flagship projects in company’s history.

kirby was involved in design, drafting, fabrication, supply, and construction of pre-engineered steel building. kirby used its highly customized sap system implemented in 2008 for complete project tracking and monitoring right from enquiry stage to dispatch to final invoice. The entire project was smoothly handled with proactive steps with timely escalation and resolution of any issues, material tracking, deployment of labour at site, etc.

All these enabled to complete the project as per the schedule committed to the customer with highest safety and excellent workmanship thereby leading to zero accidents at site.

Specifications

This project consists total of 10 buildings as given below:

Building A – Production & Finished Goods Area

Building B – Raw Material and Office Area

Building C – Chemical & Lubricant Store

Building D – Water Treatment Plant + Compressor Room + Refrigeration Room + Worker’s Area

Building E – Boiler House

Building F – Powerhouse

Building G – Scrap Yard

Building H – Driver Sitting Area

Building I – Pump House

Building J – Pre-Foam Plant

Structural Details

All Buildings are combination of BC-1 / Mezzanine / RF structure. All the columns are I-sections with plates up to 15 mm used in fabrication of primary members.

Buildings A & B are the most important part of the project totalling to approximately 1,650 MT. They are one building having common corridor at ground & first floor. Building A with a height of 14.3 meters and live load of 1500 Kg/square meters is spread over an area of 16,000 square meters approximately having curved eaves at junction of sheeting. It is used for right from raw material intake to finished goods dispatch.

Building B is a G+2 level structure with total area including mezzanine of 16,500 square meters. Ground floor is used as QA Lab Area + Pulp Cold Storage at temperature of -30 degree Celsius + Utility Area, second floor is used as Office cum Pantry / Canteen + Storage Area with common corridor for monitoring the production and third floor is used as Raw Material Storage. All the floors have live load of 1500 Kg /square meters.

Elevation of Building B is combination of RCC, Wall Cladding, Glass and Aluminium composite panel. Block work up to 3 meters height above which Kirby Wall Cladding up to 10 meters height above which is 1.2 meters brick work above which wall cladding up to 16 meters with curved panel at two locations & glass fixed with aluminium composite panel work.

Remaining sheds put together are totalling to 750 MT. The Pre-Foam Plant is having a width of 155 meters. This was a time bound project which led us to ensure that construction is carried out even during the monsoon period despite heavy rainfall.

Steel as an Essence

The complete structure was built in steel which is more than 80 per cent recyclable. All the raw material such as plates and coils are procured from India’s top steel mills as per the customer’s specifications thereby supporting government’s VOCAL FOR LOCAL initiative and then processed as per the shop floor drawings with different dimensions and modularity with strict control on accuracy.

All the raw material procured from the steel mill undergoes quality testing as per our standard’s and then released for fabrication by the Quality Laboratory. After the fabrication as per the shop floor drawings approved by the customer, finished product once again undergoes inspection and quality check for final dispatch to the jobsite.

HT Plates of ASTM A572 and HR Coils of 345 MPa grade are used for primary & secondary members. Kirby Wall cladding of 0.5 mm thickness is used in combination of Arctic White and Desert Beige in 345 MPa and 550 MPa sections. Kirby Standing Seam Roofing System (KSS-450) having width of 450 mm and thickness of 0.5 mm was used which is 100 per cent leak proof. This roofing system is roll formed and installed at the site using KSS machine thereby avoiding any damage to the roofing system. Most of the coils & plates are procured from JSW Steel and Skylights / Wall Lights are of GE Make.

Efficient Erection & Welding

For Erection three numbers of 50 MT crane were used for all the buildings. The buildings were installed using Kirby’s standard erection procedure as the final look and feel of the building depends to a great extent on the quality of the installation at site. The erection process was highly technical and required skilled and trained manpower to effectively execute the works and handle heavy construction equipment. Erection was carried out under the company’s supervision with world class safety standards. Regular training sessions were conducted at the site to educate the builder staff and workmen on correct installation procedures and Environment Health & Safety (EHS) practices to be followed on day-to-day basis.

Structural Welding was in accordance with the American Welding Society standard AWS 2010 specifications. All the sections were double side welded at factory and transported to the site. There was no site welding involved.

Facing Challenges

Major challenges faced during the erection of the project was installation of roof sheeting during the monsoon period. The site was filled up with water and the project had to be handed over to the client as per the schedule without any delay.

Because of heavy rains, KSS mill was installed on temporary platform built on the existing foundations and the sheet was roll formed and installed by deploying double manpower.

Safety at its Best

Safety is of utmost importance and plays a very important role during the erection of the structure. All the projects executed by Kirby follow global safety standards and guidelines laid down for all the people working at the site with regular training on all safety aspects and closely monitored & evaluated on weekly basis.

Kirby adhered to all the safety standards such as safety gear usage, display of posters, toolbox training, training on working at heights, motivational programs, etc. which is followed regularly across the project locations.

“Ludhiana Beverages is one of the prestigious client for whom we have executed this project in difficult and challenging conditions. The client also appreciated for the efforts put in by Kirby team at all stages and the resources deployed for timely completion of the project. Kirby is proud to get associated with this project which is being used for manufacturing of Coca-Cola products.”

P V Mohan, Director-Commercial, Kirby Building Systems & Structures India Pvt Ltd