Life-cycle cost studies confirm that the steel roofs are among the most cost-effective roofing systems available for a warehouse, elucidates Mahendra Pingle, Dy. General Manager – Market Development, Tata BlueScope Steel Ltd

How is the warehousing industry driving demand for roofing products?
Growing manufacturing activities, rise in domestic consumption, emerging organised retail sector heavily governed by e-commerce, and increasing private and foreign investments in infrastructure for logistics have enabled warehousing as one of the crucial components within the economic value chain. By 2020, the Indian logistics market is expected to grow at a CAGR of 10.5 per cent, primarily driven by the growth in manufacturing, retail, FMCG and e-commerce sectors. To gain competitive advantage, many global corporates are seeking efficiencies from warehousing and logistics capabilities. A structure which is safe, durable, well insulated, fire proof, incurring minimum maintenance and is easily erected for early revenue generation, is critical for the warehousing sector to overcome challenges, as well as maintain, improve and sustain competitiveness. The applicability of steel roofing in warehouses has increased due its multiple advantages. Low cost, light weight and low maintenance were and still are demand triggers for warehouses. Modern technology has added precision, safety, insulation, durability and aesthetics. Life-cycle cost studies confirm that the steel roofs are among the most cost-effective roofing systems available for a warehouse.

Tell us about the advantages of colour coated roofs in warehouses. How does your solution address the specific requirements of this industry?
Roofing is a critical building component that provides longevity to the entire structure along with protection of goods during extreme weathers. With a plethora of roofing materials available within the construction sector, steel is the most preferred metal due to high strength and longevity.

Durability
A warehouse which is exposed to terse environmental conditions such as heavy rains, cyclonic lashes, intense heat, saline coastal surroundings etc. to name a few, reduces overall structural durability. Moreover, they are often susceptible to fire hazards as they are exposed to materials and goods that could be highly combustible. In case of fire protection, roof and wall cladding sheeting are used as envelope which are designed to prevent the spread of fire, flame. The pre-painted ZINCALUME steel (i.e. COLORBOND steel) is resistant to spread of fire and designed in a way that does not allow fire from spreading across the structure. The high strength of the base steel and a superior paint system combined with outstanding corrosion resistance from the metallic coating makes COLORBOND steel suitable for applications in harsh environments. The strength of metal roof is high with lower weight – a benefit more often realised in seismic belts and also in retrofitting projects. This further reduces the load on the overall structure making it lean.

Superior aesthetics
COLORBOND steel offers architects, designers, builders a lightweight, strong and aesthetically pleasing solution for almost any type of building and environment. Be it curved or pitch roof or single slopped building shape, COLORBOND steel enables unconventional shapes and sizes, giving life to an architect’s imagination. Signature styled warehouses typically opt for COLORBOND steel that offers design freedom with a multiple colour range.

ZINCALUME steel a substrate for COLORBOND steel has a superior ability to resist corrosion up to four times longer than galvanised steel of equivalent coating thickness, curtailing issues like rusting, fading, peeling and chalking possible on other metal roofs. COLORBOND steel is not simply painted, it’s a total System of having seven unique layers that delivers longer life and superior aesthetics. The unique composition of this paint system consists of stable resins and inorganic pigments that do not break down easily even under UV radiation, thus preventing fading and chalking for longer

Thermally efficient and environment friendly
Goods stored in warehouses though under conducive temperature control, may consume higher energy if the roof is not thermally efficient. Roofs that are highly reflective and emissive, such as pre-painted metal sheets, offer a roof system that significantly reduces heat gain into the building. COLORBOND steel with THERMATECH technology offer higher solar reflectivity, reduces the inside temperature by upto 6-degree C; thus ensuring thermal comfort. Being an energy efficient roof, it also reduces the overall energy cost.

Could you give us few examples of your roofing products being used in a warehouse project?
Global e-commerce major Amazon wanted to ramp up their FC’s (Fulfilment Centres) in India with aggressive expansion plans. Tata BlueScope Steel supplied cladding material for this project. ZINCALUME steel was chosen for roofing material due to its excellent heat reflectivity and anti-darkening properties (unique surface coating than other Al-Zn alloy coated steel brands). The lustre of this sheeting material remains intact for longer time apart from long-lasting durability. COLORBOND steel, SURFMIST colour is used for wall cladding (horizontal laying of sheet) has enhanced overall aesthetics of building

Another example is that of Trent Retail’s Westside warehouse in Vapi. The structure demanded an unconventional signature design arrangement followed by Trent Limited. COLORBOND steel offered design flexibility and customisation. COLORBOND steel has been extensively used for many warehousing and land parcel projects in India such as Indospace Industrial and Logistcs Park, Prakhhyat Infra Projects, Arshiya International Ltd. etc. to name a few.

COLORBOND steel has been used in trussless roofing (self-supporting roofing system) typically used in warehousing shades such as central and state warehousing, NCML, logistics companies, factory sheds, etc. The advantage of trussless roofing is that you will have early occupancy of building and it also helps to provide cleaner and hygienic building environments as it does not have truss support for building nest to birds.

Authored by:
Mahendra Pingle,
Dy. General Manager – Market Development,
Tata BlueScope Steel Ltd