IFB Refrigeration Ltd. chose Everest to construct a new refrigerator manufacturing facility in Maharashtra, focusing on material choice and aesthetic features.

Project Brief

IFB Refrigeration Ltd. planned to set up a new facility for manufacturing refrigerators in Maharashtra. After due diligence and discussions with the consultant, the client chose Everest to execute the project based on the trust built over a previous project. This project was significant as the facility was critical for increasing production capacity.

Everest had the dual responsibility to execute a quality job on the current project and retain the reputation of being a reliable partner, which was an important aspect. Regular interactions were carried out at the consultant’s and client’s offices and on-site to understand the project’s intricacies. Detailed planning was carried out at all phases of the project. The aim was to execute the project within the customer’s required time without overlooking economics.

Material of Construction

All materials for the building were carefully chosen to meet the client’s requirements for the project. After considering surrounding weather conditions throughout the year at the site, mineral wool of a specific R-value was chosen for roof insulation to maintain the desired temperature inside the building.

The layout of the building was planned to get maximum unobstructed space for material and people movement. The depth of the mezzanine beams was limited to provide maximum clear height under the deck slab. The standing seam was used as a roofing solution for durability and water tightness to prevent leakages, which increased the project lifecycle phenomenally. Horizontal cladding colour bands in the wall and louvres were important features in the project.

The right amount of ventilation, as desired by the end user, for the building was achieved by using roof monitors and louvres. These features provided the required air changes per hour for a fatigue-free working environment for labour, thus ensuring more productivity.

Polycarbonate sheets were chosen to diffuse ambient light inside the building. Additionally, Everest wall cladding of the desired colour was used to make the façade attractive. Flush and cantilever fascia and canopies with reverse slopes were used to ensure an excellent aesthetic look.

Geometry

The building had critical height requirements concerning lean-to and EOT cranes and spans more than 350 metres in length, which makes the building susceptible to temperature effects and stresses during temperature variance. Provisions were made to relieve such temperature stresses. The building also has a mezzanine area designed as a composite deck slab. Portals and cross-bracing were used in conjunction for lateral stability and openings.

Uniqueness

There are different kinds of loading, like collateral loads on the roof, solar panel loads, etc. Jack beams were introduced for better space utilisation and more accurate machinery and equipment installation without forgoing the important aspect of optimising structural steel. This made the project unique in its way.

Challenges

Horizontal wall cladding installation was a challenging task from an aesthetic point of view. The strict timeline made the task more critical. Everest’s team was always alert for any unforeseen challenges. This helped quickly resolve challenges and avoided any impact on the project timeline. Meticulous execution by the Everest site management team and effective coordination with the project management team and the consultant-led to the achievement of milestones. They kept the project on track to timely completion.

Conclusion

The deeply forged relationship between the client, consultant, and Everest Industries Limited facilitated excellent and effective communication among all stakeholders. This led to optimal project design, resulting in substantial cost savings for the client. Many challenges and last-moment changes were resolved immediately without impacting the project timeline.

Fabricator’s Quote

“IFB Refrigeration Limited project executed by Everest Industries Limited was unique because of the technical requirement of the most demanding customer who hunts for quality without foregoing economics. It was a project of strategic importance to Everest as we had to shoulder the responsibility of executing this technically challenging project within the strict economic purview and stringent timelines. More importantly, we had the opportunity to retain our existing customers. This project also has all the labour-related challenges in Ranjangaon that had to be handled without affecting project timelines.

“With this project, Everest has proven to be a reliable partner to our customers and raised the bar higher within the company. We are poised for many more challenging projects to come our way in the future.”

Amit Khaparde, National Sales Head, Everest Steel Building Solutions

Consultant’s Quote:

“This is a very special project for IFB Refrigeration Ltd., where they will manufacture refrigerators. Based on our past experiences with Everest, we chose them to execute this building on a tight schedule. Everest has done a great job and has performed well in quality, time, and services.

Everest extended continuous support and agility in incorporating last-moment important changes in the building during the execution stage, which gave them an edge. Their swift response ensured project execution within the expected time frame.”

Vaibhav Warade, Project Manager, PC Designs Pvt. Ltd.

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