What Is a Green Field Industrial Project?
A green field project starts from scratch - vacant, undeveloped land with no existing structures, utilities, or infrastructure. Everything must be built from the ground up: site access roads, compound walls, drainage, water supply, electrical connections, the building itself, and every system within it.
This is where the true capability of an end-to-end solution provider becomes critical. Unlike brownfield projects where existing infrastructure provides a starting point, green field developments require comprehensive expertise across every discipline of industrial construction.
With over 40 years of EPC experience and 60+ completed projects, Somappaa Infraa has the proven capability to take any green field site and transform it into a fully operational production unit or warehouse.
The Green Field to Production Journey
Every successful green field project follows a structured sequence of phases. Here is how Somappaa Infraa approaches each stage:
Phase 1: Site Survey & Feasibility
Topographical survey, soil investigation, environmental assessment, and feasibility study to validate the site for the intended industrial use.
Phase 2: Statutory Approvals
Building permits, environmental clearances, fire NOCs, factory licences, and all regulatory compliance handled by our statutory services team.
Phase 3: Engineering Design
Complete architectural, structural, MEP, HVAC, electrical, and production layout design - all coordinated under one design authority.
Phase 4: Site Development
Land levelling, compound wall, access roads, storm water drainage, water supply, and temporary construction facilities.
Phase 5: Construction
Foundation works, structural erection (civil or PEB), roofing, cladding, industrial flooring, and ancillary buildings.
Phase 6: Systems Installation
Complete electrical, MEP, HVAC, fire protection, and ELVS installation, tested and commissioned for production readiness.
Civil Construction: Building the Foundation
The civil construction phase establishes the physical foundation of the entire facility. Somappaa Infraa uses advanced construction methods that ensure speed, quality, and cost efficiency:
Self-Loading Mixers and On-Site RMC Plants
For green field projects - which are often located in industrial zones away from urban concrete suppliers - self-loading mixers and on-site RMC plants are essential. These systems provide:
- Continuous concrete supply independent of external transit mixers
- Precise mix designs calibrated for each structural element
- Elimination of transit time degradation of concrete quality
- Significant cost savings on remote or semi-urban sites
On-Site Testing Laboratories
Somappaa Infraa establishes on-site testing laboratories at every major project site. These labs perform:
- Concrete cube testing for compressive strength at 7 and 28 days
- Soil testing for bearing capacity and compaction density
- Aggregate and sand testing for gradation and quality
- Steel reinforcement testing for tensile strength and elongation
Real-time test results enable immediate corrective action, ensuring every element of the structure meets design specifications.
PEB Structures with Automatic Beam Forming
For industrial buildings requiring large clear spans and rapid erection, Somappaa Infraa uses PEB (Pre-Engineered Building) structures manufactured with automatic beam forming techniques. These factory-fabricated structural components arrive on site ready for assembly, dramatically reducing erection time compared to conventional steel structures.
Learn more about how modern PEB designs optimise production line layouts.
Industrial Flooring: The Production Surface
The factory floor is arguably the most critical surface in any production facility. Its flatness, strength, and durability directly impact equipment performance, material handling efficiency, and worker safety. Somappaa Infraa delivers industrial-grade floors using three advanced techniques:
Laser Levelling Systems
Laser-guided screeding systems produce floors with precise flatness and levelness tolerances (typically FF50/FL30 or better). This level of precision is essential for:
- Automated guided vehicles (AGVs) and robotic material handling
- Very narrow aisle (VNA) high-rack storage systems
- Precision machinery that requires vibration-free mounting
- Uniform load distribution across large floor areas
Ride-On Trowels
Ride-on power trowels are used for finishing large floor areas efficiently. These machines produce a dense, smooth surface finish that is:
- Resistant to tyre marking from forklifts and material handling equipment
- Easy to clean and maintain in production environments
- Uniform across areas of 5,000 square metres or more in a single pour
Floor Densification Methods
After trowelling, chemical floor densifiers and hardeners are applied to the concrete surface. This densification process:
- Increases surface hardness by up to 40%
- Eliminates concrete dusting permanently
- Improves abrasion resistance for heavy industrial traffic
- Creates a light-reflective surface that improves facility lighting efficiency
Combined impact: Laser levelling + ride-on trowelling + floor densification produces an industrial floor that is flat, durable, dust-free, and maintenance-friendly - the ideal surface for any production environment.
Electrical, MEP, HVAC & ELVS Systems
A production unit is not complete until all its building systems are installed, tested, and commissioned. Somappaa Infraa provides complete system installations as per client requirements:
Electrical Systems
- HT/LT switchgear and transformer installation
- Bus duct systems for efficient power distribution
- Industrial lighting - LED high-bay and task lighting for production areas
- Earthing and lightning protection systems
- DG set installation and automatic transfer switches for power backup
MEP (Mechanical, Electrical, Plumbing)
- Compressed air systems: Compressors, air dryers, and distribution piping
- Water treatment: ETP, STP, and process water systems
- Plumbing: Water supply, drainage, and sanitary installations
- Process piping: Customised piping for specific industrial processes
HVAC (Heating, Ventilation & Air Conditioning)
- Central air conditioning for office and controlled production areas
- Industrial ventilation - fresh air handling, exhaust systems, and fume extraction
- Clean room environments for pharmaceutical and electronics manufacturing
- Comfort cooling for worker welfare in hot production zones
ELVS (Extra Low Voltage Systems)
- CCTV surveillance - IP cameras with NVR recording and remote monitoring
- Access control - biometric, card-based, and boom barrier systems
- Public address (PA) systems for emergency announcements and communication
- Structured cabling - Cat6/Cat6A networking and fibre optic backbone
- Building management systems (BMS) for centralised monitoring and control
Industries and Warehouses We Build
Somappaa Infraa's end-to-end capabilities serve virtually every industrial sector:
- Automotive & auto components: Assembly plants, machining centres, and component factories
- Textiles & garments: Spinning mills, weaving units, and garment manufacturing facilities
- Food & beverage: Processing plants, cold storage, and packaging units
- Pharmaceuticals: API manufacturing, formulation plants, and clean room facilities
- Logistics & warehousing: Distribution centres, e-commerce fulfilment centres, and bonded warehouses
- Engineering & fabrication: Heavy engineering workshops, steel fabrication yards, and testing facilities
- Plastics & rubber: Injection moulding, extrusion, and compounding plants
- Electronics: PCB assembly, LED manufacturing, and consumer electronics facilities
No matter the industry, Somappaa Infraa delivers complete facilities tailored to your specific production requirements - from green field land to a fully operational unit. As a one-stop turnkey EPC contractor, every aspect of the project is managed under one roof.
Why Choose an End-to-End Solution Provider?
Building a production facility from green field involves dozens of specialised activities. An end-to-end solution provider like Somappaa Infraa offers distinct advantages:
- Single accountability: One contract covers everything from soil testing to system commissioning
- Integrated design: Structure, MEP, HVAC, electrical, and production layout are designed together, eliminating conflicts
- Faster delivery: Parallel execution and pre-fabrication compress project timelines significantly
- Quality consistency: One quality standard applied across all trades and systems
- Cost predictability: A comprehensive scope eliminates surprise costs and change orders
- Proven experience: With 60+ completed projects and 10 lakh+ sq ft delivered, Somappaa Infraa has the track record to deliver your project successfully
