Built to perfection

01 Nov 2015 CW Staff

The new Nivea plant in Gujarat, with its accurate design specifications, has been built to perfection.

Beiersdorf AG, parent company of Nivea and one of the world´s leading international skin care companies, has over 130 years of experience in skin care. The company, with one of the world´s most modern skin research centres, offers innovative and high-quality cosmetic products. It wanted to set up its first manufacturing plant in India for a range of creams and lotions at Gujarat Industrial Development Corporation at Sanand. Nivea awarded the contract for design, manufacture, supply and erection of the 10,397 sq m industrial building to Tata BlueScope Building Solutions with performance-based bonus. The project, scheduled in the monsoon season, was to be completed in mutually agreed time frame.

Key project requirements
The major requirements of the projects included

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
The project faced several challenges such as:

Ensuring a long term leak-proof roof performance with 80 number of openings in the roof for fixing of turbo vents and with skylights in 4 per cent of the total area.
Completion of the project in mutually agreed schedule during the monsoon season.

Leak-proof Roof System
Considering all the project requirements, the project team proposed a BUTLER® Building System with MR-24® Roof system - the best leakproof solution available for critical industrial applications.

Side Laps

Involves 3600 double lock seaming of side lap. 180 degree 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 of 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.

(Communication by the management of the company)

The new Nivea plant in Gujarat, with its accurate design specifications, has been built to perfection. Beiersdorf AG, parent company of Nivea and one of the world´s leading international skin care companies, has over 130 years of experience in skin care. The company, with one of the world´s most modern skin research centres, offers innovative and high-quality cosmetic products. It wanted to set up its first manufacturing plant in India for a range of creams and lotions at Gujarat Industrial Development Corporation at Sanand. Nivea awarded the contract for design, manufacture, supply and erection of the 10,397 sq m industrial building to Tata BlueScope Building Solutions with performance-based bonus. The project, scheduled in the monsoon season, was to be completed in mutually agreed time frame. Key project requirements The major requirements of the projects included 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 The project faced several challenges such as: Ensuring a long term leak-proof roof performance with 80 number of openings in the roof for fixing of turbo vents and with skylights in 4 per cent of the total area. Completion of the project in mutually agreed schedule during the monsoon season. Leak-proof Roof System Considering all the project requirements, the project team proposed a BUTLER® Building System with MR-24® Roof system - the best leakproof solution available for critical industrial applications. Side Laps Involves 3600 double lock seaming of side lap. 180 degree 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 of 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. (Communication by the management of the company)