Project Name: Century Panel in Kadapa, Andhra Pradesh
Construction landscape of our nation is seeing some remarkable changes. As there is a rapid development in our infrastructure and construction, the need for sustainable, innovative, and efficient structures is also growing.
One classic example of a project that integrates all these values is the construction of India’s largest integrated wood panel manufacturing plant. EPACK Prefab has successfully delivered it to Century Panel in Kadapa, Andhra Pradesh.
Spearheaded by EPACK Prefab one of the largest pre engineered buildings manufacturer in India, this project not only showcases cutting-edge engineering but also sets a new standard in the pre-engineered building sector.
This case study delves into the intricate details of this monumental project, highlighting the challenges, solutions, and technical prowess demonstrated by us.
About Us
EPACK Prefab, established in 1999, is a leader in offering turnkey solutions for pre engineered buildings (PEBs) in India.
We have world class manufacturing facilities in three major cities – Greater Noida, Ghiloth, and Tirupati. Our sales offices are across all the major cities in the country. We have specialization in manufacturing innovative, energy-efficient, and sustainable solutions for different industries.
Our expertise is in different different solutions, from LGSF to pre engineered buildings. Besides, we also develop different building enevlope panels, such as PUF, EPS, ROCKWOOL, and GLASSWOOL.
Our production capacity exceeds 187,000 MT every year. We are well-equipped to handle large scale projects for different industries across India.
Project Overview
The integrated wood panel manufacturing plant for Century Panel in Kadapa, Andhra Pradesh, represents our monumental effort in making robust pre engineered buildings on an industrial scale.
The project’s scope included the construction of two major buildings:
- The MDF (Medium-Density Fiberboard) building, and
- The HPL (High-Pressure Laminate) building.
The project was undertaken for Century Panel, with EPACK Prefab serving as the contractor, Sijcon Consultants Pvt. Ltd from Gujarat acting as the architect and PMC, and Divya Consultants from Nagpur providing structural consultancy.
This project was inaugurated by Andhra Pradesh Chief Minister Y.S. Jagan Mohan Reddy.
MDF Building Details
The MDF Building is an expansive structure designed to accommodate large-scale manufacturing processes.
- Spanning an area of 44,898.81 square meters, the building measures 158.428 meters in width and 283.402 meters in length, with a clear height of 10 meters and a high bay height of 32 meters.
- The roof slopes are 1:20 (Ridge to GL A) and 1:16 (Ridge to GL U), with provisions for a 24-meter wide future expansion at GL-U to X.
- The building is designed to withstand wind speeds of up to 44 meters per second and is situated in Seismic Zone III.
Load Specifications and Design Codes
The MDF Building’s load specifications includes:
- A roof dead load of 0.15 kN/m²
- A roof live load of 0.57 kN/m²
- A solar load on the roof of 0.3 kN/m²
- Mezzanine dead load of 3.75 kN/m², live load of 3.5 kN/m², collateral load of 0.3 kN/m²
- Cable tray loads of 150 Kg/m, 250 Kg/m, and 500 Kg/m.
The structural design adheres to:
- AISC-2010 (Unified) LRFD, with wind load specifications from MBMA 2012 and AISC 07-10, and seismic load specifications from IS-1893-2016 (Part –1).
Challenges
The MDF Building’s construction posed several challenges, including its unsymmetrical structure with different heights, spans, slopes, and multiple transition frames. Columns with base plates at varying levels added complexity, as did the provisions for a 24-meter wide future expansion.
Complex jack beams were required for mat former openings and connections between lean-to structures and the main building. Additionally, the comprehensive cable tray system, with periphery cable trays of varying tiers and loads, necessitated additional structural supports.
HPL Building Details
The HPL Building, while smaller than the MDF Building, presents its own set of challenges and specifications.
- It spans an area of 24,955.97 square meters, with dimensions of 97.45 meters in width and 256.09 meters in length, and a clear height of 10.5 meters.
- The roof slope is 1:20, and the building is designed for significant future expansion, with provisions for a 32-meter wide expansion at GL-U to Y and a 64-meter wide expansion at GL-A to I.
- Like the MDF Building, it is designed to withstand wind speeds of up to 44 meters per second.
Load Specifications and Design Codes
The HPL Building’s load specifications includes:
- A roof dead load of 0.15 kN/m²
- A roof live load of 0.57 kN/m²
- A solar load on the roof of 0.3 kN/m²
- Mezzanine dead load of 4.375 kN/m², live load of 3.5 kN/m², collateral load of 0.3 kN/m
- Cable tray loads of 125 Kg/m, 150 Kg/m, and 500 Kg/m.
The structural design adheres to:
- AISC-2010 (Unified) LRFD, with wind load specifications from MBMA 2012 and AISC 07-10, and seismic load specifications from IS-1893-2016 (Part –1).
Challenges:
The HPL Building’s construction also posed significant challenges. It was designed for substantial future expansion on both sides and required long jack beams critical for structural integrity at multiple locations.
The extensive cable tray system needed to ensure efficient routing and support for electrical infrastructure, and multiple mezzanines were designed to support heavy live loads. Additionally, the building had to accommodate four 10MT EOT cranes, necessitating robust structural support.
Technical and Structural Insights
The construction of integrated wood panel manufacturing plant involved addressing several technical and structural challenges. We at EPACK Prefab ensured that the facilities meet operational demands while adhering to stringent safety and design standards.
Key structural elements included jack beams essential for providing additional support, especially in areas with heavy machinery or structural transitions.
The cable trays were designed to manage extensive electrical cabling, with provisions for different tiers and load capacities. The end wall façade, supported on tube structures and using HPL panels, was designed for durability and aesthetics. Mezzanine floors were engineered to support significant dead and live loads, crucial for industrial operations.
Conclusion
The integrated wood panel manufacturing plant for Century Panel in Kadapa stands as a testament to EPACK Prefab’s expertise in delivering large-scale, complex industrial projects.
The meticulous planning, adherence to international design codes, and innovative solutions to structural challenges highlight EPACK Prefab’s commitment to excellence and sustainable construction.
This project not only enhances India’s manufacturing capabilities but also sets a new benchmark in the pre-engineered building sector.