The Indian pre-engineered building (PEB) industry originally operates on a very stereotypical and common function, wherein the pre-engineered building supplier comes in at a stage when a major portion of a project has been conceptualised and architectural details and elements have been fixed. The PEB supplier then custom designs the building, based on the given requirements of the project, supplies the material and nominates a third party erector with a team of 30-40 people to complete the execution of the structure. A typical pre-engineered project in India caters to any simple shed for industrial or warehousing use.
What makes Interarch’s way of working in India different from the rest of its competition is one of the main reasons that explain the highlights of why the Interarch work at the Terminal 3 (T3) of the Indira Gandhi International Airport (IGI) stands apart.
Interarch is one of the leading ‘turnkey’ pre-engineered steel construction solution providers in the country. The company has the in-house capability and knowhow to provide integrated conceptualising, design, manufacturing, supply & logistics, on-site project management and execution capabilities across its pan-India operations.
Very few of Interarch’s competitors come close to being able to offer the turnkey functions and overall project handling that it can offer. This competency helped Interarch to execute projects of greater and more complex magnitude on a turnkey basis, even before the IGI-T3 project.
Interarch was chosen among many international and Indian-JV bidders from an international bidding process, to come aboard under lead contractors Larsen & Toubro (L&T) and GMR-DIAL, to execute the structural steel works for the Domestic and International Piers of the Delhi IGI–T3 project as well as the entire roofing system for the entire terminal building.
Through its course Interarch would design, manufacture and construct over 7,500 million tonne (mt) of steel within 8 months and would design, procure and lay over 1.2 million square meters (sq. mt.) of roofing material to cover one of the largest buildings in Asia.
Interarch’s ability to provide complete turnkey solutions in pre-engineered steel construction and inhouse handling of the entire EPC function of this project led it to become a critical player responsible for the entire Terminal 3 project.
When Interarch was invited to bid for the tender, it was only asked to consider responsibilities towards the 175,000 sq metre of 7-layer state-of-the-art roofing system that was required for the terminal building. While studying the project drawings during the bid for the tender, Interarch design and technical team realised that apart from the roofing for the PIER’s and the Passenger Terminal Building, the entire superstructure under the roofing system of the International and Domestic Piers at IGI-T3 were being visualised by the customer in steel and were ideal for a pre-engineered steel structural system, rather than the originally planned conventional site fabricated steel system.
Due to its years of experience in structural steel design, Interarch proposed to its customer the advantages of considering a pre-engineered structural steel system for the almost 3 km of terminal Pier’s.
On advanced design and study under the expert guidance of Interarch design engineers, Interarch was able to offer a state-of-the-art design solution for the terminal building piers which would save the project and the customer over 30% in steel tonnage as well as cut the construction time by almost half.
On presentation and acceptance of its abilities to customise and value add to the project in terms of engineering and a complete EPC solution, Interarch successfully managed to convert the project to a pre-engineered steel system to aid to the execution speed and the overall longevity of the project design.
Interarch, having an already nationwide presence with manufacturing units all over the country, went a step ahead in this project and offered one of its manufacturing units in Greater Noida to be dedicated to cater to the manufacture of the high-end steel for the fast paced requirements of the IGI–T3 project. Being located in a 50 km radius to the project, Interarch’s Greater Noida facility took on the challenge to produce some of the largest and most complex, and utterly mind-boggling pre-engineered structural steel systems for the Terminal 3 project.
Interarch’s project management and contracts division took over a 5 acre allotted yard space at the project site and built on location its offices, on-site handling, logistics and satellite manufacturing and finishing facility at the airport site itself.
To save time, Interarch manufactured all its sections in-house in Greater Noida and shipped them to site over night in lots. Close to over 300,000 parts and sections were shipped to site along with hardware for assembly during the course of the project and execution work.
Once the material reached the site, each part and piece of the giant airport terminal was carefully sorted and put in line for final painting and fire-proof coating which was undertaken by specialised painting teams and Interarch sub-contractors at the its site establishment at DIAL T3. Once painting was completed the parts were sorted with respect to part number and location as per grid and location tally spanning almost 3 kms of building construction and were transported up to 2 kms within the site, to the respective work fronts for assembly by simple bolt-on construction requiring no site welding and cutting and then lifted piece by piece to the top of the building to form the roof structure system.
By having everything under its belt from design, manufacture, supply, logistics and project handling – Interarch took over the responsibilities of the structural steel work and roofing works from lead contractor L&T, and under its overall PMC controlled the entire execution and feed to the project site from its supply chain.
The Terminal 3 project was no meagre feat and it required multiple handling of pre-engineered construction activities spread over an area of almost 5 square km and over almost 20 active work fronts on different parts of the building each with their own dedicated resources for power, construction equipment and manpower teams, all deployed by Interarch PMC. The Interarch project management team deployed more than 200 engineers at the site, including heavy construction equipment, and over 2,000 skilled workmen to execute the project work successfully with safety and quality.
All site coordination was handled from its central control at the DIAL T-3 site office and wireless communication over local radio’s assisted construction and coordination of the entire project from material handling & feed to front, to lifting, assembly and final crane lifts to the building location and rooftop.
Interarch shifted an entire team of senior in-house design, manufacture, project management and construction experts to the DIAL site for a period of over 10 months to handle the structural steel execution as well as the roofing of the gigantic terminal building. By coordinating its outputs for an ever-changing airport site, which required constant pre-planning, planning and then further re-planning to cater to the dynamic site conditions, along with constant design and redesign requirements from the customer for interface details and adaptability and compatibility to various construction aspects, Interarch was able to give lightening fast response times and streamline its system dynamically to cater to the project from its design support set up’s directly at site.
The IGI-Terminal 3 building is the second largest integrated terminal building of its kind in Asia and its roof covers an area of more than 45 acres.
Once Interarch completed the structural steel design, in-house manufacturing and execution for the steel package of the project, it commenced operations on roofing.
Interarch operations were deployed after completion of its pre-engineered steel structural systems to roof the gigantic building in a world-class insulated 7 layer roofing system completed in Aluminium.
The entire roof system comprised of seven independent insulating layers, laid layer by layer, by hand, over a coverage area of over 45 acres. That led to almost 7 x 45 = 315 acres of roofing laid in less than 12 months. In engineered terms, almost 1.3 million square meters of roofing came together using some of the most tough to handle roofing material in the world.
Interarch project management deployed over 30 roofing teams totalling over 1,500 people at their peak, to roof the entire building.
With respect to the roofing aspect of the project, unlike the rest of the pre-engineered building business in the country, Interarch reached a new level of command on its position in the industry.
The entire components of the Terminal 3 ‘pre-engineered 7-Layer roofing system’ was although designed completely in-house by Interarch under the requirements of the customer and their architects, none of the bulk material in the roofing system were produced by Interarch.
Interarch here achieved a further new dominant role by becoming one of the largest pre-engineered companies to become buyers of such large volumes of roofing material under a single contract ever in India. Interarch became the first pre-engineered steel construction solution company of its kind to source the best material from all over the world and be in a strong enough financial position to procure close to Rs 180 crore of material before the project even commenced.
Interarch designed and built for IGI T3, a roofing system to cater to a STC – 51 criteria for sound transmission, a never before achieved feat in any Indian airport, as well as insulating properties of U<0.26 W/m2
Each of the seven layers of the 1.2 million square meters of roofing was purchased by Interarch from the leading material vendors in the world and the completely imported aluminium skin was imported from Kalzip.
The ability of Interarch to complete the project under strict safety and quality guidelines, ensured Interarch would deploy almost 50 dedicated safety and almost 50 other dedicated quality engineers on the site to ensure the highest standards of HSE regulations and quality controlled execution.
Interarch faced great unexpected challenges in the project that may have had consequences to the timelines and safety of the project and worked in all aspects and under all weather conditions to deliver a completely dry and world class roofing system.
After the completion of the DIAL IGI Terminal 3 project, Interarch can safely position itself to be the largest turnkey pre-engineered steel construction solution provider to have successfully moved from being just a pre-engineered building company to one of the only EPC pre-engineered steel construction solution providing giants in India.
Today, Interarch stands strong and is capable of handling any critical infrastructure project.
The study was prepared by Interarch, the leading pre-engineered metal building systems and steel construction solution provider in India