Prefabricated technologies are becoming increasingly popular in the construction industry
Prefabricated technologies are becoming increasingly popular in the construction industry, particularly for large-scale construction. As prefabricated structures continue to evolve and improve, they are being used to construct warehouses, factories, multi-story buildings, industrial areas, etc. In the current scenario, we anticipate adding 43% order booking from Industrial and Warehousing sectors in the next 12 months, avers Nikhil Bothra, Director, EPACK PREFAB.

Project at a glance

  • Area: 13.8 lakh sq.ft
  • Location: Belgaum, Karnataka
  • Framing System: Multispan
  • Roofing: Standing Seam
  • Category: Factory Buildings, Industrial
  • Client: Gold Plus (float glass producer)

Demand for specialized industrial warehouses favouring prefab construction

We are seeing an increase in demand for warehouses at the state and district levels as a result of India’s rapid growth in e-commerce. Furthermore, highway connectivity is rapidly expanding, increasing the demand for warehouses in areas near highways. Industrial areas are being developed across states as a result of push from the government. According to Knight Frank India, India Warehousing Market Report-2023 stated that warehousing across 8 primary markets and 17 other secondary markets have seen a rise. In the financial year 2022-23 (April 2022 – March 2023), the top 8 markets experienced a historic high in demand, reaching 51.3 million square feet (msf). Notably, Mumbai, Chennai, Vishakhapatnam, Bengaluru, and Kolkata witnessed a historically high volume of transactions in FY23.

The ‘Make in India’ campaign, along with the Production Linked Incentive (PLI) programs, has bolstered manufacturing within the nation. As a result, there’s an increased need for storage solutions. The retail and e-commerce sectors, particularly in tier 2 and tier 3 cities, have displayed steady growth. Along with the retail sector, the notable interest also coming from 3PL companies, FMCG, and FMCD sectors. Consequently, companies are aiming to rapidly enhance and enlarge their warehouse capacities. This heightened growth has engendered a demand for specialized industrial warehouses, compelling companies to swiftly embrace prefabricated structures.

EPACK has achieved an impressive 100% growth in its order book, between FY 2021-22 and FY 2022-23. Looking ahead, the company anticipates closing its order book at an even more substantial 1400cr for FY 23-24. The company anticipates adding 43% order booking from Industrial & warehousing sector in the next 12 months.

Southern India’s Retail and E-commerce expansion fuels EPACK Prefab warehousing growth

The warehousing demand in the southern India is on the rise with newer locations emerging in this space. EPACK has observed a major demand from Karnataka, Tamil Nadu, and Maharashtra, led by cities such as Bengaluru, Chennai, and Mumbai. To meet the demand, companies are adopting Pre-engineered structures as this is a better and streamlined construction process which saves up to 50% of the time required, compared to traditional construction methods. With lesser construction time and reduced costs, businesses can swiftly capitalize on market opportunities and optimize their operations.

EPACK is also expanding its production facility in the Mumbatu area of Andhra Pradesh to cater to the accelerating demand. Currently, the company has a manufacturing facility in Rajasthan and in Uttar Pradesh, with a total annual production capacity of 100,000 metric tonnes of prefabricated material. The addition of the new plant will double this capacity to an impressive 187,000 metric tonnes.

With the region’s retail and e-commerce sectors experiencing unprecedented success, EPACK PREFAB is well-positioned to meet the escalating demand for state-of-the-art warehousing facilities. Till date, the company has successfully completed construction of more than 10 million sqft of industrial buildings and warehouses using pre-engineered structures worth Rs 700 crores. Epack has delivered projects awarded from companies such as Coca-Cola, JK Tyre, GAIL, Dalmia Cement, Century Panel, Value Spaces Logistics, Five-star hotels, etc.

The company wanted to build a cutting-edge production facility in the shortest timeCase Study: EPACK creates one of India’s largest float glass manufacturing plants

The company has once again demonstrated its exceptional ability in developing PEB structures by building India’s largest float glass manufacturing plant in Belagavi, Karnataka. The client, a float glass producer, wanted to expand its production capabilities to meet the rising demand for its products. The absence of contemporary amenities and the restricted industrial space had made it difficult for the producer to increase their output.

The company wanted to build a cutting-edge production facility in the shortest time possible to prevent any loss of revenue in case of any delays in construction. EPACK’s impressive track record persuaded the float glass producer to choose the company for developing the facility.

The project was developed and delivered in the allotted 5 months’ time, thanks to the expertise of EPACK’s seasoned professionals, and their persistent efforts to meet the timelines. Today, the enormous structure serves as an example of how swiftly a manufacturing facility can be set up.

It was not as simple, though. After becoming a key project partner, EPACK developed a plan based on a thorough analysis of the location and the company’s requirements. The project involved the procurement and delivery of supplies such as structural steel, roofing and cladding materials, and other necessary accessories required for the building site of a Pre-Engineered Building. It began implementing plans while taking the project’s schedule restrictions into consideration.

Challenges encountered

The project timeline posed significant challenges. There was a specific requirement to complete all the works within a tight timeframe of 5 months. This meant that time was of the essence, and EPACK had to ensure that it maintained a high level of productivity each day to meet the deadline. The total tonnage of the project was approximately 6600 MT; achieving a minimum of 90 MT of erection per day was the target with the assumption that the erection would be completed in 63 days.

Additionally, EPACK had the sheeting works with a daily target of 3000 sqm. per day, aiming to finish the task within 60 days. These targets presented a significant challenge, especially considering that it was the peak of the monsoon season and crop harvesting, which led to labour scarcity. However, EPACK was determined to overcome these challenges and complete the project within the given timeline.

Strategy adopted

EPACK implemented several strategies to ensure smooth progress. Firstly, the procurement team played a crucial role by identifying reliable and approved suppliers who could consistently provide the required materials. This helped in maintaining a steady supply throughout the construction period. The delivery of materials followed the planned erection sequence, and the project team worked closely with the production team to ensure timely delivery by enabling a phased dispatch of full kits.

To expedite logistics, EPACK employed a double driver system, which contributed to faster material delivery. Efficient inventory management was another key aspect. The operations team monitored inventory levels to ensure that an adequate stock of materials was maintained throughout the project’s duration. When replenishment was required, the procurement team was promptly notified. Through close coordination between the project and production teams, any issues or delays were promptly addressed to avoid disruptions. Finally, a dedicated quality control team was deployed to ensure that the project meet the required standards at all stages.

The use of prefabricated materials for the plant’s construction helped to expedite the construction process and commence business operations sooner. Prefabricated materials brought cost and time efficiency, and enabled flexibility in design to easily accommodate changes in production requirements. EPACK’s outstanding work in the field of Pre-Engineered Buildings is of particular significance in the light of India’s search for modern structures.

Sanjay Singhania, Managing Director, EPACK Group

Salient features of the building

The building boasts several salient features that contribute to its functionality and design. Firstly, a 350-meter crane beam runs through all 8 modules, providing efficient support for heavy lifting operations. The roof has a heavily designed monitor with a 5-meter throat width and 3-meter height, allowing for better air changes per hour (ACPH) and improved ventilation. For efficient water drainage, a 1.5-meter-wide and 0.85-meter-deep valley gutter has been incorporated into the building’s design.

The building’s stability is enhanced through the implementation of multi-legged pipe V-type bracings, which have undergone design optimization. To prevent sagging, a dual sag rod system is employed in both the roof and walls. The building also features a continuous strut pipe in two levels, further enhancing its stability. In terms of foundation design, shear keys are incorporated in the column base plate, and anchor bolts are specifically designed to withstand tension forces. These salient features collectively contribute to the functionality, stability, and efficient operation of the building.

The company wanted to build a cutting-edge production facility in the shortest time

Scripting a success story

The newly designed building brings forth a multitude of benefits: firstly, the upgraded infrastructure is tailored to enhance production capabilities, enabling the company to meet increasing demand more efficiently. As a result, employees will experience a smoother workflow, due to the optimized layout and advanced equipment, making their jobs easier and more productive. Moreover, the improved facilities and streamlined processes will contribute to a higher quality of products, enhancing customer satisfaction and loyalty. This, in turn, opens doors for the company to expand its consumer base and tap into new markets, leading to increased revenue and further growth. The facility holds immense potential for the company’s success and prosperity.
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