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Barnes

Crane-Ready, High-Capacity Manufacturing Facility
— Delivered to Barnes

Barnes, a global moulding solutions manufacturer, partnered with KSH INFRA to develop a built-to-suit manufacturing facility for their heavy-duty operations. This greenfield project carried a fixed 12-month timeline. While the initial requirement was for 80,000 sq. ft., during the site visit Barnes selected Building B4, factoring in future expansion.

CHALLENGES

The project demanded extensive structural, utility, and infrastructure provisions, including:

  • Redesign of the PEB structure to accommodate 11 EOT cranes.
  • Installation of an express feeder power supply totalling 3,350 kVA (950 kVA + 2,400 kVA) in two phases.
  • Construction of platforms for external utilities such as cooling towers, liquid nitrogen tanks, and compressors.
  • Rockwool insulation across the roof and side cladding to improve thermal performance.
  • Isolated flooring for precision manufacturing machines.
  • HVLS fans for energy-efficient air circulation.
  • Industrial-grade epoxy application across the entire shop floor.

These requirements, defined by Barnes’ global team, were structurally complex and had to be delivered in a phased manner.

SOLUTION

KSH INFRA delivered a 180,000 sq. ft. facility meeting Barnes’ operational and technical standards.

Key Deliverables:

Structural Engineering

  • PEB structure redesigned from the foundation to support crane loads, bay spacing, and the operational movement of 11 EOT cranes.
  • Crane track and rail installation aligned with Barnes’ equipment procurement schedule.
  • Isolated flooring in designated areas to minimise vibrations and maintain the precision of sensitive equipment.

Electrical Infrastructure

  • 3350 kVA power contract demand (950 kVA in Phase 1 and 2,400 kVA in Phase 2), both via express feeder connections for uninterrupted 24x7 operations.

Thermal Insulation

  • Rockwool insulation for the complete roof and side cladding, installed despite challenging monsoon conditions.
  • Installation of nine HVLS fans in the Phase 1 operational area.

External Utilities & Civil Works

  • Cooling tower platform.
  • Liquid nitrogen storage zone.
  • Scrap yard.
  • Compressor room.

OUTCOME

KSH INFRA handed over the facility for operational readiness in August 2025. Barnes received a fully customised, crane-ready manufacturing unit with phased high-capacity power supply, robust utility infrastructure, and advanced thermal controls. With 11 cranes operating under one roof and critical power delivered on schedule, the project stands as a technically precise and well-coordinated industrial build.

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