Leak-proof Roof System

Tata BlueScope Building Solutions successfully completed the contract for design, manufacture, supply and erection for Nivea India in the desired time-frame. Nivea India wanted to set up its first manufacturing plant in India for a range of creams and lotions at Gujarat Industrial Development Corporation at Sanand. A case study was conducted on Leak-proof Roof System which enables Nivea to meet their productivity goals. Nivea India awarded the contract for design, manufacture, supply and erection of the 10,397 sq m industrial buildings to Tata BlueScope Building Solutions with performance based bonus. The project was scheduled in the monsoon season and required to be completed in mutually agreed time-frame. Key project requirements 10 years leak-proof warranty. 48.0 clear span to facilitate process requirements. On-time project completion without compromising quality, safety and leak-proof performance. Challenges Roof System: To ensure a long-term leak-proof roof performance with 80 openings in the roof for fixing of turbo vents and with skylights in 4 per cent of the total area. To complete the project in mutually agreed schedule during the monsoon season. Solution Offered Leak-proof Roof System: Considering all the project requirements stated above, TataBluescope proposed a BUTLER® Building System with MR-24® Roof system, which is the best leak- proof solution available for critical industrial applications. Its Building Solutions team made customers aware about the advantages of the exceptional features of MR-24® Roof System. Side Laps: Involves 360¦ double lock seaming of side lap. 180¦ is seamed at site by Roof Runner® to achieve a greater leak-proof assurance; pre-punched purlins for fixing of roof clips helps in better alignment of side laps, faster installation and superior aesthetics. Roof Clip: 32.5 mm clip movement in both directions abolishes roof expansion joint till 250 ft of panel length; centering arrangement in Roof Clip ensures thermal movement in both directions; triangular bar with thin cadmium coating in clip assembly helps in reducing friction and provides greater sensitivity to thermal movement. End Lap Design: Pre-punched panels ensures tighter and neater end laps; splice position exactly above purlin ensures that the joint does not weaken due to foot traffic; only two MR-24® panels are joined at end laps and staggered end lap splices helps in reducing chances of leakages. Roof Curbs: Internal flange design of curb conceals fasteners with curb that helps in eliminating the possibility of leaks; diverter flashings at roof curbs prevents ponding on the high side of the roof curbs; curbs are secured to roof sheet and not to purlins, this ensures uninhibited thermal movement of entire roof system. Valley Gutter and Header Pipe System: Stainless steel valley gutter and fully engineered MS header down take pipe system ensures effective drainage of rain water from the roof. Quality Assurance at Site: Hundred per cent supervision by a dedicated MR-24® roofing team ensured consistency in the quality of workmanship at site. Timelines The Nivea project was classified as a White glove project, a well-established Tata BlueScope Building. Solutions process which involves double checking methodology to eliminate errors at any stage. The White Glove Methodology ensured delivery in full and on-time without any errors at any stage. The entire project was completed without any site claims or urgent material request. At an early stage of the project, the team requested the customer to provide PCC floor and 4,000 sq m of elevated laydown area with compacted soil to facilitate safe equipment movement. This helped the TataBluescope team work continuously even in monsoon. Project Milestones and Performance Roof sheeting was completed in 125 days from start date of the project. No leakages were observed in the MR-24® roof system. Results MR-24® Roof installed at site has no leakages. The elaborate product design and the impeccable installation of the MR-24® Roof System has resulted in a leak-proof building. The safe and on-time completion of engineered steel buildings in the first phase of the project has helped Nivea to start this factory extremely quickly. The project was handed over on-time and with no compromise on the quality and service. The management of Nivea India has announced to pay Tata Bluescope the bonus of Rs 10 lakh for superior performance in completing the project on-time and meeting the commitments given to them. (Communication by the management of the company)