Featured Project

Innovative portal frame concept using Tata Structura

Background

Polycab Wires Pvt. Ltd. is the biggest wire and cable manufacturing company in India with an annual turnover of around Rs.4,500 crore. The Company, for its UH3 plant located in Halol, Gujarat, awarded the Design and Build - Turnkey Contract to Devam Enterprises & Shree Prefab Steel Pvt. Ltd., a business development partner for Tata Structura in Gujarat. Tata Structura hollow sections were used innovatively in the portal frames structure of the UH3 plant building.

Objectives

• Fast project completion
• Cost effective solution
• Factory controlled quality
• Solution that requires less maintenance
• Flexibility for expansion
• Energy efficient wall and roof systems
• Eco Friendly building
• Increase in structural stability
• No sag rods for purlins
• Increased torsional capacity

Planning and Execution

The total area of Polycab's UH3 plant building in Halol is 40,000 sq. metre, and the project was executed using several cranes of 15 MT capacity. The overall span is 120 m with five intermediate columns, wherein the eaves height at the end is 8.5 m and at the center is 14 m. The architectural and structural design consultants of the project developed a unique and innovative portal frame concept in which HR plates were used for the web and Tata Structura steel hollow sections were used for the flanges. Tubes were used at locations of flanges and had better stiffness against warping. Lateral bending capacity of the section was better, which indirectly enhanced the vertical bending permissible compressive stresses.

Outcome

This innovative design concept was fabricated to perfection. The project was completed within the stipulated time. Tata Structura steel hollow sections not only enhanced structural strength but also enriched the aesthetic value of the structure.

Revolutionizing heavy framework into light and aesthetic constructs

Background

Few years ago, Eastern Railways in India felt the need to transform their conventional platforms into more functional, contemporary steel structures. The railway authorities decided to bring in new technology that would enable building such aesthetically superior yet cost-effective structures. It is here that Tata Structura's steel hollow sections found way to meet the requisites. Krishnanagar Railway Platform in West Bengal, India was one of the first stations to be refurbished. Around 80 MT of Tata Structura steel hollow sections were used in this Krishnanagar project.

Objectives

• Cost-effective solution
• Corrosion resistant structure
• Concentric strength
• Convenience of fabrication
• Flexible to achieve architectural creativity

Planning and Execution

After elaborate planning, a lighter structural integrity was developed and efficiency in the load-bearing capacity was retained with hollow steel sections. Flexibility was enhanced and the parabolic roofs were supported on fringed columns leading to the main column at both ends of each roof. A smoother execution of the project was achieved with the help of Tata Structura Studio - Kedia Pipes making quality fabrication drawings. The procurement and supply of material was also easily executed as the designs were created in-house by Structura Studio.

Challenges

One of the major challenges faced during the construction of the new structure was to device a design that would eliminate the problems of rainwater drainage, common in the earlier design. Conventional butterfly type design required regular maintenance since rainwater would often get collected around the blocked gutters. This water would then trickle down the structures onto waiting passengers and their luggage and get collected at the base of the pillars, thereby weakening the structure over time.

Outcome

The designs of the platform sheds in Krishnanagar were progressive and revolutionized the conventional heavy frameworks into light and aesthetically pleasing constructs. With the new design, water now was drained directly on the tracks, eliminating the need for a gutter system. The steel consumption also reduced drastically, making the project more economically viable. The steel consumption was 47 kg per square meter with conventional design, while, with the new design steel consumption was just 36.1 kg per square meter – an approximate 30 per cent reduction.