With new demands encouraging manufacturers to launch high-quality, innovative and technically advanced roofing systems, MONISHA RAO offers a glimpse of some new and state-of-the-art roofing solutions available in the country today.
"I am not not a simple cover anymore; there is more to me. Technology coupled with changing requirements has drastically changed my face and the way I am perceived. Available in various forms and figures, innovation has certainly infused a new shine to my frame." - Testimony of a roof.
The roofing sector is currently upbeat with the forward movement in infrastructure projects such as airports, special economic zones, townships, etc. Roofing's critical role in the construction industry suffices the fact that it accounts for 25 per cent of the total construction cost. Changing requirements and materials have triggered considerable demand, with customers seeking perfect amalgamation of protection, comfort and aesthetics. In this backdrop manufacturers and designers are ideating on new concepts to produce and incorporate innovative techniques to meet the emerging opportunities.
With a wide range of new product offerings coupled with growing demand for innovation, the future of the roofing and cladding industry in India seems robust. The much-awaited boom in industrial and infrastructure development in 2014 will further boost the roofing and cladding market in the country.
INTERARCH BUILDING PRODUCTS
The product: 7200 mild steel structure
User/Customer: Delhi International Airport Ltd
Project location: Delhi
Key challenges of this project: The project had to be completed under strict safety and quality guidelines. Approximatey 50 dedicated safety and almost 50 other dedicated quality engineers were positioned on the site to ensure the highest standards of HSE regulations and quality controlled execution.
Solution offered: Interarch engineered the components of terminal's 'pre-engineered 7-layer roofing system' keeping in mind the customer's and architect's requirements. Moreover, the structure is designed for wind velocity of 50 m per second and seismic zone. Box sections were used for the facade framing of T3 terminal to meet its architectural needs.
Techno-commercial benefits: The structure has been engineered to be manufactured and ready to assemble in order to avoid site modification. This reduces the transportation cost to a bare minimum.
INVOGUE BUILDING SYSTEMS
The product: Pre-engineered building
User/customer: Amar Ujala
Project location: Rohtak
Key challenges of this project: Roofing had to be completed within six days for approximate area of 2,200 sq m with 24 turbo-vents and 12 poly-carbonate sheets.
Solution offered: Puf panels were used for better insulation.
Techno-commercial benefits: The roofing system ensures a long life, faster installation, good aesthetics and requires low maintenance at the same time.
The product: Self supported steel roofing
User/customer: Bangalore Water Supply and Sewarage Board
Project location: Bengaluru
Key challenges of this project: The roof had to be erected from the interior as there was a water storage tank on one side of the building, and a cable trench on the other. An American technology which facilitates on-site panel forming and installation, was used to install about 2,000 sq m in 12 hours. Flexibility and enhanced efficiency with superior workmanship ensured faster project turnaround.
Solution offered: The installed roofing panels are mechanically seamed (inter-locked) and are free from holes, nuts, bolts, overlaps or sealants, which ensure zero maintenance and also offer resistance to extreme weather conditions. This unique mechanical seaming of panels ensures 100 per cent leak-proof roofs.
Techno-commercial benefits: It is a self-supported structure without trusses, purlins or ancillary support and offers unobstructed clear spans of 9-35 m. It provides larger enclosed volumes, free movement and effective handling of goods and higher flexibility of space utilisation. Distinguishing arch shape and alternatives of colours result in strong aesthetic appeal.
AAKRUTI TENSO STRUCTURES AND FACADE
The product: Tensile membrane
User/customer: Windsor Realty
Project location: Mumbai
Key challenges of this project: The challenge was to transfer all the loads to existing columns and beams without disturbing the interiors. Most of the wall or flooring was cladded with stone, wood, fibreglass, glass, etc. At places the gap between the civil structure and wall was more than 750 mm.
Solution offered: Tensile membrane structure was the only option feasible. The structural design form was free of any bending movements, where reaction forces itself directly to the major columns. At locations where the columns were not in the vicinity, supports were taken from two adjacent beams with slanted members meeting at the desired anchor points again having pin joints in the base. This eliminated on site work time to just a week.
Techno-commercial benefits: Lighting is not required during the day time as fabric allows sunlight to pass through and thereby, power consumption is reduced.
VIJAYNATH INTERIORS AND EXTERIORS
The product: 65/400 Kalzip double skin Kalzip roofing system
User/customer: Kempegowda International Airport Ltd and Larsen & Toubro
Project location: Bengaluru
Key challenges of this project: Kempegowda International Airport's complete roof design is based on the theme of a smiling face. The airport's roof was to be completed in a short span of 3 and half months.
Solution offered: Three-dimensional slopes were introduced to showcase the smile effect.
Techno-commercial benefits: Due to faster installation the project was completed on time which ensured faster returns.
The product: Charminar fibre cement sheets
User/customer: Sterling Tools
Project location: Haryana
Key challenges of this project: Due to the nature of manufacturing - forging/streaming process - rusting of the roofs has resulted in weakening of the roof, leakages, etc.
Solution offered: Charminar team made a site assessment, understood the process and recommended Charminar fibre cement sheets for the project.
Techno-commercial benefits: More than 45 per cent savings was achieved compared to other metal roofing sheets and the roof is guaranteed to perform over 40 years. Customer feedback: AD Parasher, Purchase Manager, Sterling Tools says, "With Charminar fibre cement sheets, we have been able to address critical issue of rusting, leakage and improve our productivity. The kind of hassle we had to undergo was immense with metal roofing. We are now looking at our other units for replacing the roof. The entire project cost was lowered and significant saving was achieved."
The product: Firehalt range of roofing shingles
User/customer: Oxford Golf Course
Project location: Pune
Key challenges of this project: Single uniform roofing product had to be applied on the RCC roof, plywood and fibre cement board. Efficient water proofing has to be ensured as the area is prone to continuous rainfall.
Solution offered: Offers low maintenance, new look and long term warranty. Techno-commercial benefits: Low maintenance and sustainable and replacement for life leading to low labour costs.
Customer feedback: Spokesperson from Oxford Golf course says, "We have been generating continuous repeat orders for the highly efficient roofing shingles."
PIONNIER ROOFING SOLUTION INDIA
The product: Endurer roofing tiles and fittings
User/customer: Individual home (NRI customer)
Project location: Kerala
Key challenges of this project: The roof was open with steel fabricated truss work. The challenge was to attain an accuracy level of ¦ 0.1 per cent. Water tightness was also to be achieved.
Solution offered: Coloured concrete roof tiles over clay tiles.
Green features: The raw materials used for manufacturing are cement, sand, fly ash and natural oxides, which are procured without upsetting the environment. The production process is environment friendly as the production process does not produce any emissions. The solid wastes generated are either recycled and slurry dried for making cement blocks or used as fillers for construction of roads and yards.
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