Danfoss Industries Private Limited, a 100% owned subsidiary of Denmark based Danfoss Group, is a manufacturer of mechanical and electronic components and solutions for the refrigeration and air-conditioning industry. Danfoss has setup an integrated campus for its manufacturing and research and development (R&D) activities which is also its largest facility in India.

The project consists of five main buildings – RC Protection and RC&CC Lab Building, Warehouse Building, PE Production Building, RC Lab Building, EOU Building and other small buildings.

Key Highlights

• Primary structural framing includes the transverse rigid frames, mezzanine beams, joists and columns, interior columns, bearing frame rafters, corner columns, end wall wind columns and crane gantry girders and column brackets. All the columns are H/I type only.
• Secondary structural framing includes the purlins, girts, eave struts, wind bracing, flange bracing, base angles, clips and other miscellaneous structural parts. Suitable wind bracings and sag rods are considered at the time of designing the structure to provide stability. All purlins and girts are pre-galvanized.
• Portal bracings are considered for the intermediate & side wall columns.
• All the buildings are covered with FM Approved KSS-600 Standing Seam roofing profile of plain galvalume and sinusoidal wall cladding of color coating with inner wall liner panel.
• Jack beams, longitudinal connecting beams and necessary pipe rack supporting arrangements are provided as required in the buildings.
• Gutters and downspouts are adequa-tely designed for all the buildings to provide proper roof drainage system. All the rain water header pipes are having FRP coating and are made of MS PIPE.
• The foundation bolts are of Class 8.8 as per IS standards.
• 50 mm thick fiber resin bonded fiber glass roll metal building insulation of 24 Kg/Cum density one side with a reinforced WMSK vapor barrier and the other side with galvanized welded wire mesh.
• RC Protection and RC&CC Lab Building, Warehouse Building and PE Production Building are having mezzanine area with Dead Load of 6.25 KN/m2, Live Load of 4 KN/m2 and supported by 54 mm deep deck panel.
• Polycarbonate sheets for skylights shall be provided on the 5% of the roof and wall area. Roof monitor is provided on the roof for all the buildings.
• Two coats of oil paint Zinc chromate (anti corrosive) primer and two coats of synthetic enamel oil paint on all built up sections.
• Canopy with projection of 300 mm on either side to avoid rainwater comings in doors.
• Stub post of 450mm height from roof level is considered on roof to hold the fall protection.
• Platform for exhaust fan / AHU is provided

Project completion:
This project was successfully completed in a span of 15 months.

Aesthetic, dimensional, occupant comfort and fire safety:

The building is provided with sinusoidal wall cladding which makes its appearance aesthetically appealing enough from all the sides. Further addition of glazing at the top on all the sides of the buildings enhances its architectural view.

Steel has the ability to withstand some of the most damaging weather conditions as well as being fire resistant and can be fire resistant by variety of methods. All the buildings are applied with two coats of oil paint zinc chromate (anti corrosive) primer and two coats of synthetic enamel oil paint which helps in controlling the fire.

Design parameters for the project:

Designed as per IS 800:2007 codes without Chapter 12 taken into conside-ration. All the live, dead and wind loads are taken as per IS 875 and seismic load as per IS 1893 standards.

The complete design was vetted by Indian Institute of Technology (IIT).

Sustainable construction

This manufacturing campus at Oragadam, Tamil Nadu has been given LEED Platinum Rated Green Building facility by Indian Green Building Council (IGBC) certifying it as a green and sustainable set up thereby providing clean, safe and healthy work environment.

Impact of the project on environment:-

• Soil pollution – Nil
• Noise Pollution – well within the prescribed limit
• Air Pollution – Nil
• Water Pollution – Nil
• Solid Waste – Solid waste like packing sheets, papers and wood generated during execution of the project was disposed as per the national / local laws.

Rain water harvesting
Solar heating

All the buildings supplied by Kirby are green in nature as they are environmental friendly. Steel is one of the preferred green construction materials that is growing rapidly in the construction sector because of its recyclable quality. These buildings are cost-effective, energy efficient and provide better quality environment due to the favorable roofing material and natural ventilation. These buildings also help in energy saving due to more amount of natural sunlight through skylights and wall lights installed in the building thereby reducing the overall power consumption. Effective usage of insulation materials, louvers, turbo vents and other materials also help in making Kirby buildings as green buildings. All the materials used in making these buildings are recyclable and are not harmful to the environment. This building also reduces the emission of greenhouse gases to the environment. All the environmental protection rules and other guidelines were strictly adhered as per the local authorities.

Health & safety
Kirby’s state-of-the-art facilities produce pre-engineered components in a factory-controlled quality atmosphere for rapid assembly at site. In addition to this inherently safe process, Kirby offers supervision and safety audits at site.

However, additional training sessions are also conducted at the site to educate the builder staff on correct installation procedures and EHS practices to be followed.

Firstly, as the erection process is highly technical and needs skilled and trained manpower to effectively execute the works and handle heavy construction equipments, the builders are selected after a very rigorous evaluation process.

Also, erection method statement for this project was developed & rigorously followed. The principal safety objectives were:

• Safe access and working positions
• Safe lifting and placing of steel components
• Stability and structural adequacy of the part-erected structure
• Securing the components in a safe place & in erectable sequence
• Wear Personal Protective Equipment (PPE) at all times on the site
• Allow access to site to only the required personnel

Daily tool box meetings were carried out to ensure adherence to erection method statement. Also mock sessions were conducted for all the workmen to impart training and make them understand the importance of safety. Postures and banners were displayed across the site to instil them with safety habits to be followed at the site on regular basis.

Kirby construction team successfully completed 1 million safe man hours during the erection stage which was well appreciated by the client.

Project summary
Customer Name : Danfoss Industries Pvt Ltd
Steel Solution Provider : Kirby Building Systems & Structures India Pvt Ltd
Tonnage : 3,200 MT
Area : Approx.73,000 square meters
Jobsite : Oragadam, Tamil Nadu
Consultant : C R Narayana Rao

Kirby Building Systems & Structures India Pvt Ltd
Web : www.kirbyinternational.com