Project: Re-roofing of damaged roof with double skin TRIMDEK and KLIP-LOK 700 roof system. Variable height supporting brackets were also provided to ensure perfect alignment to the existing undulated roof.Client: Salcomp Manufacturing India.Location: Sriperumbudur, Chennai.PurposeSalcomp wanted to set up a manufacturing unit for mobile accessories for a global brand Nokia, within an area of 12,000 sq mt with re-roofing of total 160 tonne.BackgroundFinland-based Salcomp, one of the global leaders in the mobile phone charger market, with an existing capacity of manufacturing 150-200 million chargers annually, wanted to further expand their manufacturing capacity by another 100 million chargers per annum. The existing site had a 10-year-old PEB building. There were severe leakages from several locations, which were amounting to huge production losses. The structure required a comprehensive inspection by a reliable roofing consultant. Salcomp approached Tata BlueScope Steel, who implemented an in-depth study of the existing structure.Customer requirementAfter a comprehensive investigation, Tata BlueScope Steel's team identified the root cause of the problem. It was evident through investigations that the existing structure had many collateral loads, hanging from purlins and rafters. Many rafters were already deflected leading to further deflecting the main purlins, resulting in several undulations in the existing roof, which was Single Skin Screw Down System. Undulations caused rainwater stagnation ensuing huge leakages at many places.Solution offeredTo address customer's primary concern for leak-proofness, Tata BlueScope Steel suggested LYSAGHT KLIP-LOK 700 widest concealed roof system with LYSAGHT TRIMDEK as the liner panel. LYSAGHT KLIP-LOK made from high strength ZINCALUME steel has long been a design favourite for prestigious commercial, industrial and architectural projects across the globe. Not only performance, but with bold rib geometry rising from wide, flat pans, LYSAGHT KLIP-LOK roof provides a strong visual statement and its flat pans also offer excellent water carrying capacity. It is one of the strongest profiles with longer spanning capability. Absence of piercing and its special clip locking ensures zero chances of roof leakage. Tried and tested at NATA Lab (Australia), under rigorous cyclonic and non-cyclonic applications, LYSAGHT KLIP-LOK offers on-site roll forming preventing step joints and end laps. While the solution seemed straightforward, there were a few onsite challenges that had to be addressed going beyond standardisation, ensuring customer-centric solutions.Design challengeThere were too many undulations along the slope length of roof due to deflections in the main frame rafters and purlins. These undulations needed to be rectified to achieve leak-proof roof system.SolutionContour layout was conducted to measure the undulations at every 5 m along the roof length. Accordingly, supporting brackets with heights varying from 40 mm to 140 mm were designed and detailed to get the same level or plane of top sheet.Operational challengeFixing of LYSAGHT KLIP-LOK clip was a challenge, since sub-purlin line was not straight due to longitudinal misalignments of main purlins.SolutionSupporting brackets were designed and detailed to support sub-purlins. Alignment was made to bring the sub-purlins in line, parallel to building length to achieve KLIP-LOK clips in straight line.ConclusionProject completed with zero harm: New age construction technology from LYSAGHT team was put into place to enable the workforce to execute the job seamlessly. Due to safety training and regular supervision, the project was completed without any unsafe incidence.Right solution with on-time delivery: LYSAGHT team proposed the technically correct offer, which was eventually accepted by the customer. Furthermore, on site roll forming and excellent project management ensured on-time delivery.100 per cent leak-proof solution: Single length sheet of 60 m from ridge to eve avoided any joints and eliminated any kind of leakage. This also helped savings in lap lengths, thus reducing the input material and installation time. Since the customer was looking for a leak-proof roof, installation support and best quality workmanship were provided to achieve the desired objective. Inspections were undertaken on a daily basis to achieve the highest quality of installation.With collaborative team work, design optimisation and an efficient supply chain management, the project was successfully delivered to customer’s satisfaction.