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| Rohit Ranjan, GM- Marketing, Tata BlueScope Building Solutions |
Steel in Construction
Use of steel in construction is no longer limited to reinforcement for concrete. The steel industry is constantly adopting new technologies to develop products and applications that challenge what was previously thought impossible.Steel construction is evolving from box like steel structures to aesthetically pleasing designs. Acceptance of pre-engineered metal buildings is moving beyond industrial and infrastructure projects, and expanding to residential and commercial applications as well.
A common myth associated with steel is that it is not suitable for construction because it becomes very hot when exposed to sunlight. However, steel has 'higher reflectivity'; hence it does not allow as much heat into the building. Steel also has 'lower thermal mass, hence it does not hold heat for long. This actually makes metal buildings better to work in, and even reduces spend on environment control.
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| Project: Arshiya International Limited, Panvel, Maharashtra Brand: BUTLER® BUILDING SYSTEMS |
Experience with Pre-engineered Metal Buildings
Like any new approach, the shift to metal buildings has been gradual. However, as more people are experiencing the advantages of metal buildings, and skill sets across the value chain are improving, this shift is increasingly gaining momentum.The most significant advantages of metal buildings are time and cost. A metal building can be completed considerably faster, and at a lower investment. This means building owners can start generating revenues, and consequently profits in a shorter time frame.
Additional advantages of metal buildings are: superior aesthetics, greater architectural versatility, better space utilisation, greater flexibility for future expansion, and lower maintenance. Steel construction can better withstand inclement weather, as well as natural disasters.
The performance advantages of steel are continuously expanding the realm of possibilities, and making steel the preferred option for various building and construction applications.
Tata BlueScope Building Solutions Business
Tata BlueScope Steel, an equal joint venture between Tata Steel and BlueScope Steel was established to offer value added steel products and solutions to its customers across South Asia. The Building Solutions Business division brings the desired focus to delivering best in class metal building solutions.Tata BlueScope Building Solutions currently offers design, manufacture, supply and erection of complete metal building solutions, under its premium BUTLER® Building Systems and contemporary ECOBUILD™ Building Systems brands.
The 'FM Approved' MR-24® Standing Seam Roof System, offered exclusively with BUTLER® buildings, has a 360o Pittsburg Double Lock Seam. This seaming process is similar to what is adopted for beverage cans. We offer a 10-year leak proof warranty on MR-24®.
Tata BlueScope Building Solutions also offers the factory punched BR-II™ Roof System with BUTLER® buildings. With ECOBUILD™ buildings, roof options include pierce fixed TRIMDEK® and CUSTOM ORB® profiles. Liner panels, Decking options, and several optional accessories are also offered.
Primary structural frames are manufactured by Tata BlueScope Building Solutions with careful consideration to material and workmanship. Secondary and cladding elements are roll-formed with strict compliance to process and quality. All accessories and components are sourced from the best, for optimum performance across the life of the building.
Tata BlueScope Building Solutions has already completed in excess of 1,000 projects for industrial, warehousing, commercial and infrastructure applications, across various locations in India. Our list of clients includes several prominent Indian and overseas organizations.
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| Project: Cryolor Asia Pacific Pvt. Ltd. Brand: ECOBUILD™ BUILDING SYSTEMS |
Key Customer Benefits
For an industry where the potential to supply exceeds market demand, capacity is a bit of a misnomer. It is a capability that has a far more significant role to play. Our capability to meet customers expectations of On-time, Leak-proof and Safe erection of their metal buildings is what sets us apart from the competition.On-Time Delivery
The most important need of a project perhaps is; to be completed on-time. Delays in completion are a major reason for cost overruns, even compromises with quality.All suppliers promise 'On-Time Delivery'. However, whether delivery actually happens on time is a matter of chance. Often it is dependent on 'special attention' / 'close monitoring' by individuals, when process failures happen.
Over the last few years, Tata BlueScope Building Solutions has adopted 'Critical Chain Project Management' approaches to facilitate on-time completion of projects. We follow full kit rules, avoid frequent shifting of priorities, maintain waiting buckets, and constantly monitor project progress across all stages of project execution.
Our delivery performance has improved significantly, and we are able to provide accurate updates on project status.
Leak-Proof Performance
The next priority for metal buildings is leak-proof performance. Leakages result in loss of revenue and/or profits, loss in productivity and sometimes even damage to goods and machinery.Typical sources for leakages in metal buildings are laps, ends, piercings and roof openings. Early leakages can be attributed to a combination of poor workmanship, tools and even materials. However, there is potential for leakages to develop over a period of time. This happens due to thermal expansion and contraction, caused by repeated changes in ambient temperature.
A dedicated group within Tata BlueScope Building Solutions has extensively analysed reasons for leakages, and has developed check lists, acquired special tools and tackles and conducted extensive training of builder personnel at our in-house training center.
We regularly monitor leakage instances in our buildings, and have seen significant reductions since.
Safe Erection
Tata BlueScope Building Solutions is continuously investing in building internal capabilities, as well as developing logistics and builder partners. This is critical for meeting another key customer requirement, safe and incident free project completion.We are an ISO18001: OHSAS certified company with clearly articulated processes to ensure safety at all work centers inside our plant. Similarly, safety is primary at all our project sites and clear Work Methods have been established for each activity, starting from unloading of material at site.
Our erection practices today leverage the most modern equipment and practices. For example, we have made use of boom-lifts, instead of scaffolding, mandatory for all our projects. These practices prevent accidents, and also help in faster erection.
SkyWeb® is a passive fall protection system that only Tata BlueScope Building Solutions offers. It has advantages during erection, as well as after. Visual safety awareness, training programs, and reward and recognition tools are deployed a tall our sites.
Safety is a Core Value at Tata BlueScope Building Solutions. Our core values take priority over any other business criteria.
Excellence in Design and Delivery
Each metal building is unique, like a signature or a thumb impression! Our teams involve early with project architects, consultants and owners, to understand the specific requirements of each building. The objective is to create aesthetically pleasing buildings that match the functional, as well as aspirational requirements, of our customers.Tata BlueScope Steel Limited uses contemporary design tools that are compatible with the latest building codes for all our buildings. We have access to latest developments in technology through our principals, Butler manufacturing USA.
We are constantly exploring new technologies, tools, methods and business models to deliver innovative and cost-effective solutions to our clients, commensurate with our brand promise. We are amongst the first PEB companies in India to have integrated systems for Engineering, Planning and Manufacturing.
Several listening posts have been established to gain an understanding of emerging customer needs. We have even created one for specifically addressing customer complaints in a formal and structured manner.
Green Building Considerations
The lower thermal mass and higher reflectivity of steel greatly reduces energy consumption for environment control particularly when used in combination with insulation. Use of skylights maximises natural light, and turbo vents allow for natural ventilation.Rain water harvesting is encouraged through use of suitable drainage systems and cladding materials that use lead free paints. Steel allows greater flexibility for design innovation, and optimum usage of steel.
A unique assembly of photo-voltaic panels is available with our MR-24® Roof system.
MR-24® Roof System
MR-24® is probably the only 'truly' floating roof system currently available in the market! MR-24® roof sheets are seamed continuously, along the entire length of the sheet, using a Roof Runner®. The 180deg field formed seam of MR-24® is least susceptible to malfunction.Purlins for MR-24® installation are supplied pre-punched. MR-24® sheets are fixed to the purlins below using a specially designed clip assembly. High strength SCRUBOLT™ fasteners are used to secure the clips to the purlins. The clips are then seamed along with the MR-24® roof sheets.
The clips are installed such that they allow smooth movement along both directions. This is necessary to compensate for roof movement due to thermal expansion and contraction. It greatly reduces potential for leakage as well.
All accessories for the MR-24&reRoof System are fixed to the roof sheets, and not the purlins below. The roof sheets are fixed at the eaves only. The gable trims and ridge are designed to allow for free movement. As a result, when thermal expansion and contraction takes place, the entire roof moves, alongwith the roof vents and skylights.
End laps are also factory punched to ensure accuracy, by eliminating the need to measure, mark and drill holes at site. The specially developed sealants of MR-24® have a high butyl content, for better leak proof performance and longevity.
MR-24® end laps are always staggered, and the splices are always placed just above a purlin. This prevents potential leakages due to foot traffic on the roof and wind uplift phenomenon.
Another advantage of MR-24® roof sheets is that they are easily stacked. This makes bundles of sheets suitable for handling and transportation; something not possible with standing seam profiles offered by most competitors.
Field roll-formed standing seam profiles may be considered suitable for roof surfaces with no roof openings. However, long lengths of profiled sheets are susceptible to handling damages, and this could actually lead to leakages in the long run.
Since MR-24® roof panels are roll formed in the factory, our clients are assured of the best quality of materials and workmanship.
In conclusion
Our operating philosophy is strongly anchored to serving markets which are looking for highest standards of engineering excellence, superior quality of products and workmanship, and timely completion of buildings.Our endeavour is to continuously create aesthetically appealing and functionally superior metal buildings, for markets which value these characteristics.
