Factory Complex for Hindustan Lever Ltd., Pondicherry.
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Project in Brief : Spread over 30 acres of land, the factory complex comprised of two plant buildings, one for manufacture of toilet soap and the other for detergent bar (NSD Bar). Among the utility buildings were boiler house, compressor house, substation building, DG room, workshop building, pump house, raw water and fire water tanks, effluent treatment plant, pipe racks & bridges. The other facilities included canteen, security office, weigh-bridge cabin etc. Total ground coverage is 14,472 sqm. and the total built-up area is 23,712 sqm. Area under roads is 23,842 sqm. All roads are in RCC. |
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Powder go-down is twin span, (27.5m each) twin bay single storied structure with north light roof having overall plan dimensions of 55m X 12m and a height of 6.8m at tie level. It houses two numbers EOT cranes of two tonne capacity each. The structure is in RCC up to tie level with roof trusses and purlins in structural steel and roof covering of MS pre-coated sheets. Medium Bay is a three storied structure; overall dimensions being 55m X 12m X 15m height. The structural frame is in steel and floors consist of RCC slabs. Roof is of north light construction with MS pre-coated roofing sheets on top. The building houses large soap tanks, heat exchangers, blowers, conveyors etc. A part of the first floor is also used for storage of noodles. |
The High Bay is tall structure having five floors. All the floors are heavily loaded. Four sets of equipment, one set per cascade, like three roll mills, noodlers, sigma mixers, spray dryers, crutchers, weigh hoppers, conveyors etc. have been installed on various floors of the High Bay. Powder and soap noodles storage silos of varying capacities ranging from 15 t to 45t have been erected on floor at 20m level. Bag filters and ID fans are mounted above the silos. The plan dimensions of High Bay are 55m X 12m. The overall height of the building is 25m. A freight lift of 1T capacity has been provided for vertical transportation of men and material.
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High Bay and Medium Bay is in structural steel. The floor slabs are in RCC. The live loads on floors, other than the equipment loads, are of the order of 1000 Kg/sqm. The structural frames of High bay and Medium Bay, in east-west direction, are designed as moment resisting frames. Thus connections between columns and floor beams are of moment resisting type. The frame spacing is 5.5m. The frames in north-south direction are designed as braced frames. The loads on columns in High Bay and Medium Bay are being very large ( the heaviest column carrying a load of the order of 370T) and the soil underneath being very poor ( clayee soil having SPT values as low as 15) pile foundations have been provided. Driven, cast-in-situ piles of 600mm dia. and depths extending upto 20m are provided in-groups of 2,3 and 6, depending on the load on the column. |
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Low bay is a twin span, muli-bay, single storied structure like Powder go-down. The spread of the Low bay is 55m X 54m. The tie level is 6.4m. The roof is of north light construction. The span of roof trusses is 27.5m and the spacing is 6m c/c. MS pre-coated sheets are used as roof covering. The columns are in RCC with spread footing. The Low Bay has soap tablet making and packing machines in it. Part of Low Bay is being used as ware house for storage of packed boxes.
NSD Bar building is more or less identical to Toilet Soap Plant; except for the fact that the width of NSD Bar building is 36m as against 55m of TSP and that NSD Bar does not have the Medium bay at all. Powder go-down is similar to Low bay. The span of roof trusses in Low bay and powder go-down is 36m with no central column. Spacing of trusses is 6m c/c.
High bay is again identical to that of TSP except that the floor loadings are little lesser. The structure and the foundation is similar to that of TSP.
Utility Buildings :Boiler House is 25m long X 20m wide with a tie level at 8m. The building is in RCC up to tie level. MS pre-coated sheets are used as roof covering over steel lattice girder and purlins. Span of roof trusses is 20m and the spacing is 5m c/c. Provision is made in the columns for 1 T capacity EOT crane. Two nos. 18T capacity, medium pressure boilers will be installed in the house.
Compressor House is 25m long x 15m wide X 7m in height. The entire building is in RCC. 1.2m. deep RCC beams span across full width. Intermediate columns have been avoided in order to provide column free interior. Four nos. horizontal reciprocating compressors, 500 CFM @ 7 bar pressure, have been installed.
Substation Building , entirely in RCC, is 25m X 10m X 4.m in height. It houses HT and LT panels. The transformers and the switchyard are on the rear side of the building.
DG room is 20m X 10m X 7m in height. It is in RCC construction and houses 2 nos., 1000 KVA, Powerica make, diesel-generating sets.
Pump House is 15m X 6.5m X 5.5m in height and has RCC roof slab. Two nos., 110 KW fire hydrant pumps and one no. 5.5 KW jockey pump has been installed. Pumps for process water, 2 nos. 30 KW are installed outside the pump house. Water storage tanks, 2 nos., 300 cum for firewater and 1 no. 300 cum for process water, are all in MS construction.
Workshop building is 20m X 15m and has ground plus one upper floor, It is entirely in RCC. The first floor has been designed for a live load of 1000 Kg/sqm.
Pipe Rack structure , 150m long, carries compressed air pipelines, steam pipes, water lines, etc. The multi tier pipe racks are of varying width, 1.5m to 3m. At one point it crosses a road hence 18m span pipe bridge is provided. The total tonnage of steelwork is around 70MT..
Canteen and Welfare Building : A 30m long X 15m wide, ground plus one upper floor building houses canteen on first floor and worker welfare facilities like dispensary, rest room, library, training centre on the ground floor. A provision of dumb waiter has been made to lift food grains on the first floor.
Effluent Treatment Plant is spread over 1630 sqm. of area and consists of oil and grease trap chamber, equalisation tanks, aeration tanks, clarifiers, sludge drying beds, chemical house etc.
Machine Foundations included foundations for 1000 KVA DG sets, 500-CFM compressors, plodders, soap tanks and many others.
| Client | : | Kirloskar Consultants Ltd. |
| Project Cost | : | Rs. 15 Crores |
| Structural Steelwork | : | 1500MT (Approx.) |
| Services Rendered | : | Structural Engineering |
| Year | : | 1996-98 |
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