IFB Refrigeration partnered with Everest Industries for high-quality execution and timely completion of the cutting edge manufacturing facility in Maharashtra. Meticulous planning, material selection, and innovative design by the leading PEB manufacturer resulted in overall success of the project.

Project Brief IFB Refrigeration Ltd. planned to set up a new facility for manufacturing refrigerators in Maharashtra. After conducting due diligence and consulting with experts, the client selected Everest to execute the project based on the trust built from a previous collaboration. This project is significant as the facility is crucial for increasing production capacity.

Everest had the dual responsibility of delivering a high-quality project and maintaining their reputation as a reliable partner an important aspect. Regular interactions were carried out at consultant’s and client’s offices and on-site to fully understand the intricacies of the project. Detailed planning was conducted at every phase to complete the project within the customer’s specified timeframe while considering economic factors.

Material of Construction

All materials for the building are carefully chosen to meet the client’s project requirements. Taking into account the weather conditions throughout the year at the site, a suitable insulation was selected for roof to maintain the desired temperature inside the building.

The building layout was designed to maximise unobstructed space for material and personnel movement. The depth of the mezzanine beams is limited to provide ample clear height under the Deck Slab. Standing Seam was chosen as the roofing solution for its durability and water tightness, effectively preventing leakages and significantly increasing the project’s lifecycle. Horizontal cladding colour bands on the wall and louvres added aesthetics of the building.

To achieve the desired ventilation for the building, roof monitors and louvres were used. This ensured necessary air changes per hour for a fatigue-free working environment for the labour force, thereby enhancing productivity. Polycarbonate sheets were selected to diffuse ambient light inside the building. Additionally, Everest wall cladding in the desired colour was used to enhance the attractiveness of the façade. Flush, cantilever fascia, and canopies with reverse slopes are incorporated to achieve an excellent aesthetic look.

Geometry

The building had critical height requirements for Lean-To and EOT cranes and spanned over 350 meters, making it susceptible to thermal effects and stresses caused by temperature variations. Provisions were made to alleviate such temperature-induced stresses. The building also included a mezzanine area designed as a composite deck slab, with portals and cross-bracing for lateral stability and openings.

The project executed by Everest Industries Limited for IFB Refrigeration Limited was unique due to the technical requirements set by our demanding customer, who prioritises quality without compromising on economics. This project held strategic importance for Everest as we took on the responsibility of executing this technically challenging project within strict economic constraints and tight timelines while also aiming to retain our existing customers. Additionally, we had to address the labour-related challenges specific to Ranjangaon without causing delays to the project timeline. With this project, Everest has once again demonstrated its reliability as a partner to it’s customers and has set higher standards within the company. We are ready to take up many more challenging projects that come our way in the future.”

Uniqueness

Different types of loading, such as collateral loads on the roof and solar panel loads, were considered. Jack beams were introduced to optimise structural steel usage and allow for the precise installation of machinery and equipment without compromising space utilisation. This aspect made the project unique in its way.

Challenges

The installation of horizontal wall cladding posed a challenge from an aesthetic perspective, and the strict timeline further added to the hurdles. Everest’s team remained vigilant for unforeseen challenges, enabling quick resolution without impacting the project timeline. Meticulous execution by the Everest site management team and effective coordination with the project management team and consultant ensured the achievement of milestones. They kept the project on track for timely completion.

The strong and collaborative relationship among the client, consultant, and Everest Industries Limited facilitated excellent and efficient communication among all stakeholders. This led to an optimal project design, resulting in significant cost savings for the client. Many challenges and last-minute changes were promptly resolved without causing delays to the project timeline.

“This project is particularly significant for IFB Refrigeration Ltd. as they venture into refrigerator manufacturing. Based on our previous experiences with Everest, we selected them to execute this building project within a tight schedule. Everest has done an exceptional job, delivering high quality, meeting deadlines, and providing excellent services. Everest exhibited continuous support and flexibility in accommodating important last-minute changes during the execution phase, giving them a competitive advantage. Their prompt response ensured the project was completed within the expected timeframe.”

(Client: IFB Refrigeration Ltd. Consultant: PC Designs Pvt. Ltd. EPC: SCON Projects Fabricator (PEB): Everest Industries Ltd.)