Pebs Pennar Successfully Completes MRF Tyres Production Unit at Perambaluru

Pebs Pennar MRF Tyres Production Unit

Project: Manufacturing Unit for MRF Tyres Limited
Location: Perambaluru, Tamil Nadu
End Usage: Production
Area: 51,700 sqm
Completion time: 10 monts

PEBS Pennar has been successfully running towards the eighth financial year with immense growth over the past seven years and competing assertively in the PEB market. PEBS Pennar has executed many distinguished projects in several segments like factory, warehouse, multistorey, power, etc. One of its landmark projects recently completed is the factory building for MRF Tyres which covers an area of 51,700 sqm. It was a challenge to execute such a huge and prestigious project within 10 months. Major design issues were resolved with the support of an experienced team. Structures were designed with built up "I" section for primary & galvanized steel "Z' section for secondary. Successful installation of the structure was done by deploying multiple teams & 3.7 lakh safe man hours.

The biggest challenge was the huge volume in terms of area of work. During conceptualization and design stage, the challenges were cost optimization and minimum construction time. The sheer size of the structure proved a challenge even when it came to deploying multiple teams and resources. The limited timeline of 10 months was yet another area that contributed to the difficulties faced by the team. The manpower used in the project was in proportion to the size and mobilizing sufficient manpower while working overtime was a major contributor to the list of difficulties which were overcome by the team of qualified professionals at hand.

Steel Specifics:

Pebs Pennar MRF Tyres Factory Building
Considering the application of steel in the realm of Pre-Engineered Building and ease of usability, steel was selected as the material of choice.

The built up "I" sections were fabricated from plates of ASTM standard with minimum yield strength of 345 mpa. These built-up "I" sections were fabricated with flange to web fillet welding which was carried out in a continuous submerged arc welding machine. The end plates/gusset plates etc., were joined by continuous fillet welding manually. The secondary members were from ASTM A 653 m with minimum yield strength of 345 mpa. Other hot rolled sections used such as angles/rods etc., were of I.S 2062 with minimum yield strength of 240 mpa.

Execution

Workmanship
Supply of 5,200 MT fabricated structural steel supply completed in 100 days time

Complete installation completed in 10 working months

Total project management effort: 22 man-months.

Safety
For a project of this size, it is absolutely essential to have the safety regulations down to a pat. The project saw safety screening of deployed manpower, imparting onsite safety training, job safety analysis of individual work methods, safety gears like full body harness for workers on height, using safe access methods like boomlifts, man-basket, etc., in order to successfully and safely complete the erection of the design.

Benefits achieved by using steel

Steel is always the natural choice and even the industry standards insist on steel as the major building material for this type and size of building. Steel is the most economical option for construction of such a building. No other construction material can equal the advantages of steel.

This is due to the inherent property of the steel. Steel as a construction material has one of the highest strengths to weight ratio.

Other advantages of using steel
  • Steel is readily available
  • Steel is better suited for earthquake resistance, because of its ductility
  • Steel buildings allow for faster completion time of the project, which has direct impact on the project's profitability
  • Steel is environment-friendly, and can be re-cycled, so the carbon foot-print is minimized.
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