Nestled in Hyderabad, Everest Industries embarks on an ambitious journey towards shaping the future of aerospace manufacturing. Tasked with constructing a world-class facility, Everest steps into the forefront of India’s Make in India initiative in collaboration with Tata Advance Systems Limited and Airbus France. As the project unfolds, Everest stands poised to revolutionise the industry, blending technical prowess with economic understanding.

Project brief

The world-class aerospace manufacturing facility in Hyderabad is an aspirational project for Everest Industries Limited for many reasons. Apart from the complexity involved in the design, this project is part of the Make in India revolution by the Honorable Prime Minister of India because of its complexity and scale. The state-of-the-art manufacturing facility in Hyderabad is a Joint Venture between Tata Advance Systems Limited and Airbus France. This facility will manufacture critical components required for manufacturing an aircraft in a fully Flyaway condition. Everest was selected as a successful bidder for this project after stringent scrutiny by the Tata Advance Systems Limited team on both technical capability and execution front without overlooking the economics. The project has been awarded to Everest, considering the stringent timelines involved in its execution. With every eye from inland and offshore nations monitoring the progress of this project, the project is an essential milestone for Everest. The successful execution will undoubtedly open new avenues in the Aerospace industry. 

Material of construction

The facility required the best materials for functionality and aesthetics. However, this facility will be fully airconditioned; hence, end users and consultants have carefully selected Thermal insulation with liner panels to maintain the temperatures within the building for energy conservation. The roof of this building spans more than 100m as a single sheet length. Hence, specially designed floating clips were used for roof sheeting for thermal expansion and contraction.

To make this building airtight in certain areas, special consideration was given to flashing and sheeting trims. The robust design and use of best-quality sealants made the project unique and one-of-a-kind.

Geometry

The factory layout has been meticulously crafted to optimise the production line for aeroplane components. The structure is tailored to accommodate heavy-duty cranes with a single-sloped design and multiple-width modules. Columns feature a fixed base design to meet stringent serviceability standards and minimise deflection. Additionally, mezzanine areas are incorporated into the structure, with composite joists carefully engineered to limit joist depth. Ensuring smooth transverse movements of personnel and equipment within the building was a priority during the planning phase.

Architectural features     

With the roof spanning more than 128m, specially designed thermal clips were required to allow thermal expansion of the Standing Seam roof. The building’s elevation was provided with intermittent Louvers to ensure required Air Changes in non-airconditioned areas. Careful selection of insulation with the required R-Value was essential for maintaining ambient temperature within the building. The width of the building and mono slope called for careful designing of gutters and downtake arrangements for smooth rainwater drainage.

Liner panels have been used inside the building to make it visually appealing and provide thermal characteristics.

Polycarbonate sheets with UV coating and high transmissibility have been provided regularly to provide ambient natural lighting inside the building and conserve energy in non-airconditioned areas.

Uniqueness and challenges  

A single Slope Roof for such a large width gives the building a unique look. Given the type of roof, designing sufficient gutters per the location’s maximum rainfall intensity was a challenge.

Strict adherence to a very tight execution schedule was also an added challenge. Hence, completion of the Design phase, manufacturing, and well-orchestrated logistic support ensured completion of 1st phase execution well before time. There was no room for error as that would delay the project, and such delays would have caused loss of precious time and delays in this marquee project. Everest Industries and its internal teams were quick enough to address early challenges that had put pressure on the project’s complete schedule and got it back on track.

The customer appreciated Everest’s accurate planning and agility towards the change matrix during the execution phase. “Our unmatched design expertise enabled us to provide the most optimum design for the structure, which led to significant cost savings for the customer. We have been working with numerous cranes, boom lifts, and Farhana’s in this project, and with strict adherence to Safety guidelines, we have clocked more than 1,00,000 Man hours in this project, and we are confident that we will conclude the project with all safe practices being followed” says the spokesperson from Everest. This project, in particular, will open doors of numerous aerospace industry requirements to Everest.