Home > Case Studies > Hindalco
Hindalco
Large-Scale, Built-to-Spec Facility
— Delivered to Hindalco in Eight Months
Hindalco, a flagship company of the Aditya Birla Group, was setting up a new facility for a key business vertical with a fixed go-live deadline of eight months. This marked a significant milestone—it was Hindalco’s first-ever leased industrial facility, with all previous plants being company-owned.
CHALLENGES
The project required a built-to-suit facility from the foundation up, designed in strict compliance with Hindalco’s global corporate specifications. The scope demanded:
- Wider spans of 15m × 27m in two bays to meet operational needs.
- Merging and redesigning two office blocks into one large corporate space.
- Extensive internal and external utility infrastructure.
- Category conversion of the industrial park from Orange to Red in line with regulatory requirements.
- 5,000 kVA (5 MW) power supply through an express feeder.
With major machinery orders already in process, adherence to timelines was critical. Compliance with fire, safety, and environmental standards had to be fast-tracked without compromising execution quality.
SOLUTION
KSH INFRA delivered a 200,000 sq. ft. turnkey facility with extensive customisation in structure, utilities, and support infrastructure. Before the PEB order was finalised, Hindalco requested non-standard spans of 15m × 27m in two bays. The structure was re-engineered at the foundation stage to meet this requirement, ensuring both structural integrity and on-time delivery.
Close coordination between KSH’s in-house design, civil, electrical, and MEP teams ensured smooth execution across all phases.
Key Deliverables:
Structural & Civil Customizations
- Redesign of the PEB structure to incorporate wider internal column spans, to accommodate non-standard column spans of 15m × 27m and merging of two office blocks into one.
- Adaptation of the design prior to PEB ordering without impacting timelines.
- Widened loading ramps and addition of curved ramps in the external utilities area.
- Installation of 5m × 5m motorised shutters for heavy-duty logistics access.
- Epoxy flooring across the shop floor for durability and hygiene.
Internal Infrastructure
- Lighting upgraded from 150 lux to 300 lux to enhance safety and visibility.
- Installation of 10 HVLS fans for improved temperature control.
- Development of functional spaces including:
- Additional male and female toilet blocks and locker rooms.
- Panel room, tool room, maintenance rooms, and workshop.
- Inward/outward goods handling rooms.
- R&D protolab and inspection room.
- Safety and quarantine rooms.
- Two temperature-controlled rooms.
- UPS room.
External Utility Infrastructure
- ETP tank and platform.
- Gas bank platform.
- Oil storage rooms.
- Scrap yards.
- Creche facility for employee welfare.
Power & Compliance
- Electrical infrastructure of 2,500 kVA + 2,500 kVA via express feeder for 24x7 operations.
- All statutory approvals (Fire NOC, EC, BCC) secured.
- Conversion of the park to Red Category to suit manufacturing requirements.
Office Fit-Out
- Merged and redesigned office blocks into a 15,000 sq. ft. plug-and-play workspace.
- Facilities included:
- Workstations, conference and meeting rooms.
- Training room.
- Canteen and washrooms.
- Recreational area.
- Double-height reception for a strong corporate presence.
OUTCOME
Satisfied with the delivery and professionalism, Hindalco awarded KSH INFRA a second facility of 235,000 sq. ft., further strengthening the partnership.