Tata BlueScope Steel: Enabling Design Optimization with On-time Project Delivery

In an interaction with Industry Outlook, Puneet Mathur - Business Head, Building Solutions at Tata BlueScope Steel, shares his views on the challenges in achieving optimization in pre-engineered building manufacturing, and how they can be addressed.

 India is one of the fastest growing markets in the PEB construction segment. How do you see the current evolution of PEB market in India? What are the major factors driving its growth?

Significant infrastructure growth and rising demand for segments like automotive, power, logistics, pharma, FMCG, and capital goods are driving growth for PEB sector in India. Advantages in construction technology have led to demand for cost-effective, quick and fully engineered structures.  Pre-engineered steel construction and metal roofing and cladding systems are finding great potential in the warehousing sector. Favorable policies such as introduction of GST – one nation, one tax, have further boosted this sector.

The pandemic era has witnessed a boom in the E-commerce business. Online shopping has become the new norm. Many logistic players are setting up their own facilities than renting them out. On the other hand government is focusing on setting up cold storage chains across India for grains, vegetables, FMCG products etc. reassuring investment by corporates in developing modern automated logistic parks. All this has contributed to the overall demand for pre-engineered steel building solutions.

How is Tata BlueScope Steel positioned in this market? How is it facilitating the adoption of PEB in construction?

Customers today demand a one-stop window, hassle-free execution and early occupation of the premise. Tata BlueScope Steel’s Building Solutions business offers a cohesive and comprehensive experience for anyone who wishes to set up a structure with quick, easy and modular options without compromising on quality and construction.  From fully engineered solutions such as BUTLER® and ECOBUILD® that promise a leak-proof performance, with best-in-class construction practices and safety standards; Tata BlueScope Steel enables design optimization with an assured on-time project delivery; which is our greatest differentiator.

What sets us apart is our quest for constant improvement. One of our innovative products is the MR24 Roof System, offered as part of BUTLER® Building Solutions that promises an excellent weather tight performance. Our experienced structural engineers use latest design standards and software tools that ensure precision and complete strength and stability of structure.  We have a strong quality assurance program from procurement of raw material to shop fabrication and mechanized erection. Thus, the product delivered is well tested and quality assured. With advanced construction processes and safety practices executed by trained manpower, further instills confidence for adopting PEB as a building solution.

What are the major potential pitfalls that can happen during the design and manufacturing of Pre-engineered Buildings leading to structural imperfections? How can they be prevented?

Broadly speaking, design is a process of creating the description of a new facility, usually represented by detailed plans and specifications; construction planning is a process of identifying activities and resources required to make the design a physical reality. 

In both design and construction, numerous operational tasks must be performed with a variety of precedence for operational excellence. Such as, wrong input specification by specifiers can have grave repercussions on overall longevity of the PEB. Especially for critical loading conditions like wind cyclonic effects, selection of wind exposure category, building openings to name a few.  One also needs to define what the crane load should be and its application (tandem operation, crane class, skew forces).

Here the designer should be an experienced one to anticipate such impacts. Thus, selecting the right vendor is very important to avoid structural design issues. Our experienced design team provides special attention to details by implementing a two-level check at every critical design stage, thus preventing any adverse effect on the overall design created.

We use advanced software for design and detailing that ensures precision with accuracy in visualization. Additionally it helps in correcting and planning any conflict well before the material is fabricated or erected at site. The quality of details and drawings are world class. A strict and vigilant raw material check is done, which is sourced from reputed grade A companies.

Use of high-quality consumables like welding electrodes ensures adequate design strength. A rigorous quality plan for fabricated steel guarantees flawless fabrication as per shop drawings. One of our distinguishing features is the factory-punched purlins for standing seam roofing profiles such as MR24 that ensures accurate alignment and a weather-tight performance. This is a fool-proof system that nullifies any errors.

Computer-aided designs are today providing enhanced options for planning the appearance of the structures. To what extent do you see the customer’s involvement in this process in India?

3D Cad designs have revolutionized the way architects look at their creations; worldwide. However in India we are at a nascent stage and a lot needs to be done in this area. Even today as Indians we think structures are mere source of utility where we put all our energies on its functionality than aesthetics. Architects globally are creating stunning structures with their own signature styled designs with PEBs.

Computer aided software has made customization a reality. We at Tata BlueScope Steel not only offer best-n-class design assistance, but also a wide range of products in cladding range with multiple color choice and accessories that perfectly complements the overall structure.

Extreme exposure to sun or rain can cause steel to wear out. What steps can be taken to prevent corrosion? How does Tata BlueScope address this issue?

Tata BlueScope Steel offers PEB solutions made from Zincalume steel and Colorbond steel whose coating provides a protective envelope for the entire building, preventing it from oxidation. Zincalume steel combines both galvanic protection of zinc and barrier protection of aluminum. This barrier protection reduces the rate of dissolution of zinc enabling corrosion resistance. To prevent oxidation, primary members are coated with primer and finish coat based on severity and condition of the site location (marine exposure, chemical exposure, etc.) just above the base metal coat, to protect it from external factors such as oxidation.

On average, Zincalume steel lasts up to four times longer than galvanized steel under similar environmental conditions. Adequate metallurgical compatibility of various building components and their accessories further augments structural performance. With proper awareness and guidance on material selection, we ensure our patrons are fully informed thus to avoid shortfall in structural performance; resulting in leakages, unpleasant aesthetics and ultimately huge replacement cost.

Where do you see this market in the near future? What is the future road map for Tata BlueScope Steel?

The current situation is a dynamic one. With complexities in supply chain, on-site manpower etc. induced due to localized restrictions, the efficiencies in manufacturing and construction at industry level are affected. For Tata BlueScope, our pan India presence with our decentralized manufacturing plants and network of trained erectors has helped us cope up with the situation and we continue to offer better service levels to our customers.

Going forward, digitalization of all tools and latest software in design, product development, automation at plant level will help the industry to optimize resources. The pandemic has also opened-up some window of opportunities in segments like healthcare, mid- and high-rise buildings to be converted into buildings in steel. The need for pre-engineered and pre-fabricated, ready to install members to reduce onsite complexities is felt even more today if not in the past and this is an opportunity for PEB industry to serve our esteemed customers.