The Evolution of Industrial Structure Design
Industrial construction in India has undergone a remarkable transformation over the past decade. Where once builders relied on conventional RCC (Reinforced Cement Concrete) framing for every structure, today's industrial building designs leverage a combination of advanced materials, precision engineering, and smart layout planning to create facilities that truly serve production needs.
At Somappaa Infraa, with over four decades of EPC experience, we have been at the forefront of this evolution - adopting the latest design methodologies to deliver structures that are not merely buildings, but production-optimised environments.
Pre-Engineered Building (PEB) Structures
PEB structures have revolutionised industrial construction in India, and for good reason. A Pre-Engineered Building is designed and fabricated in a controlled factory environment before being transported and assembled on site. This approach offers significant advantages over conventional construction:
- Faster construction: PEB structures can be erected in 40-60% less time than conventional buildings, because fabrication and site preparation happen simultaneously
- Cost efficiency: Factory-controlled production reduces material waste, and lighter steel frames require smaller foundations
- Larger clear spans: PEB technology enables column-free spans of 60 metres or more, providing uninterrupted floor space ideal for production lines
- Consistent quality: Factory manufacturing under controlled conditions ensures every beam, column, and purlin meets exact specifications
- Easy expansion: PEB structures are inherently modular, allowing future extensions without disrupting ongoing operations
Automatic Beam Forming Techniques
A key technology driving PEB quality is automatic beam forming. This factory-based manufacturing process uses computer-controlled machinery to shape steel beams and structural members with millimetre precision. Compared to manual fabrication, automatic beam forming delivers:
- Exact dimensional accuracy across hundreds of structural elements
- Uniform quality regardless of production volume
- Significantly faster fabrication speeds
- Reduced material waste through optimised cutting patterns
Somappaa Infraa's PEB structures are manufactured using these automatic beam forming techniques, ensuring that every structural component arrives on site ready for precise assembly.
Key advantage: PEB structures with automatic beam forming can reduce total project timelines by up to 50% compared to conventional construction - getting your production line operational faster.
Designing for Production Line Efficiency
An industrial building is only as effective as its ability to support the production processes within it. At Somappaa Infraa, the design process begins with a deep understanding of the client's production workflow:
Layout Optimisation
The structural design is driven by the production line layout, not the other way around. Our engineering team works closely with clients to understand material flow, equipment dimensions, clearance requirements, and workflow sequences. The structure is then designed to accommodate these needs with optimal column placement, bay widths, and clear heights.
Auxiliary System Integration
Modern production facilities require extensive auxiliary systems, and their placement directly impacts operational efficiency. Somappaa Infraa designs structures with integrated provisions for:
- HVAC systems: Ductwork routing, equipment pad locations, and ventilation openings are planned during the structural design phase
- Electrical distribution: Cable tray routing, transformer positions, and panel board locations are coordinated with the production layout
- Compressed air and utilities: Header pipe routing and connection points are built into the structural grid
- Fire protection: Sprinkler header routing and pump room positions are integrated from day one
- ELVS systems: CCTV, access control, and networking infrastructure pathways are embedded in the design
Civil Construction Methods for Modern Industrial Structures
While PEB technology handles the superstructure, the civil works - foundations, floor slabs, retaining walls, and ancillary buildings - require equally advanced methods. Somappaa Infraa employs:
Self-Loading Mixers and On-Site RMC Plants
For large industrial projects, relying on external ready-mix concrete suppliers creates scheduling dependencies and quality variability. Somappaa Infraa addresses this by deploying self-loading mixers and setting up on-site RMC (Ready Mix Concrete) plants. This approach ensures:
- Continuous concrete supply matching the construction schedule
- Precise mix designs tailored to each structural element
- Zero waiting time for transit mixer arrivals
- Reduced transportation costs for remote project sites
On-Site Testing Laboratories
Quality control is not an afterthought - it is built into every pour. Somappaa Infraa establishes on-site testing laboratories at project sites to perform real-time testing of concrete cubes, soil samples, and construction materials. This ensures immediate feedback and corrective action when needed.
Latest Material Handling Systems
Efficient material movement on a construction site directly impacts productivity and safety. Somappaa Infraa uses the latest material handling systems - including tower cranes, mobile cranes, and conveyor systems - to move heavy structural components, concrete, and building materials safely and efficiently across the project site.
Industrial Flooring for Production Environments
The factory floor is where production happens, and its quality directly affects equipment performance, worker safety, and product quality. Somappaa Infraa delivers industrial-grade flooring using:
- Laser levelling systems: Achieving floor flatness tolerances of FF50/FL30 or better, essential for automated guided vehicles (AGVs), high-rack storage systems, and precision machinery
- Ride-on trowels: Power trowelling with ride-on machines produces smooth, dense surface finishes across large floor areas efficiently
- Floor densification methods: Chemical hardeners and densifiers are applied to increase surface durability, dust-resistance, and abrasion resistance - critical for heavy industrial use
Production impact: A properly engineered industrial floor with laser levelling reduces equipment vibration, enables smooth material transport, and can extend forklift tyre life by up to 30%.
Electrical, MEP, HVAC & ELVS Systems
A truly production-optimised industrial structure goes beyond civil and structural work. Somappaa Infraa provides complete Electrical, MEP (Mechanical, Electrical, Plumbing), HVAC, and ELVS (Extra Low Voltage Systems) installations as per client requirements. These systems include:
- Electrical: HT/LT panels, transformers, bus ducts, lighting, earthing, and lightning protection
- Mechanical: Compressed air systems, water treatment, and process piping
- HVAC: Central air conditioning, ventilation, exhaust systems, and clean room environments
- Fire protection: Sprinkler systems, hydrant networks, and fire alarm panels
- ELVS: CCTV surveillance, access control, PA systems, structured cabling, and building management systems
All these systems are designed as part of the overall structure layout, not retrofitted later - ensuring optimal placement, energy efficiency, and ease of maintenance.
The Somappaa Infraa Advantage in Industrial Design
What sets Somappaa Infraa apart is the integration of all these elements under a single turnkey umbrella. Rather than engaging separate designers for structure, MEP, HVAC, and electrical, our clients benefit from a coordinated design approach where every system works in harmony with the production layout.
Whether you are planning a new factory, expanding an existing production facility, or building a greenfield warehouse, the latest industrial structure designs can dramatically improve your operational efficiency and return on investment.
