IFB Refrigeration Ltd. Manufacturing Facility, Ranjangaon

PROJECT BRIEF
IFB Refrigeration Ltd. planned to set up a new facility for manufacturing refrigerators in Maharashtra. After due diligence and discussions with the consultant, the client chose Everest to execute 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.

CHOICE OF MATERIAL
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 the mezzanine beams was limited to provide maximum clear height under the Deck Slab. Additionally, standing seam was used as a roofing solution for durability and water tightness to prevent leakages, which simultaneously increased the project lifecycle phenomenally.

An important feature of the project was the horizontal cladding color bands in the wall along with louvers. 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 a fatigue-free working environment for the workers, thus ensuring more productivity.

Polycarbonate sheets were chosen to provide diffused ambient light inside the building. Additionally, Everest wall cladding of the desired color was used to make the façade attractive. Flush, cantilever fascia, and canopies with reverse slopes ensured an excellent aesthetic look.

GEOMETRY
The building had a critical height requirement with respect to the 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 a mezzanine area designed as a composite deck slab. Portal cross-bracing was used in conjunction for lateral stability and openings.

UNIQUENESS
There are different kinds of loading in the structure like collateral loads on the roof, solar panel loads, etc. Jack beams were introduced for better space utilization and to make 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 and the strict timeline made the task more critical. The team was always alert for any unforeseen roadblocks. This helped in the quick resolution of challenges and avoid any impact on the project timeline. Meticulous execution by the 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.

IN CONCLUSION
The deeply forged relationship between the client, consultant and Everest Industries Limited, 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.