Introduction

The Exide Project

Exide Energy is building a lithium battery cell plant at Devanahalli Industrial Area near Bengaluru. This greenfield project, spanning 40 acres with a production capacity of 6000 GW, is a major milestone for Exide. Safety in construction was a top priority, and Pramila Projects being one of the major erectors among other companies which in total achieved zero incidents over 3 lakh man-hours, demonstrating our commitment to a safe work environment.

Exide Project: Comprehensive Overview

Client and Project Introduction

Introducing Exide: Core Business Models and Industry Impact

Exide Industries, a leader in battery manufacturing, is expanding into lithium battery production to meet the rising demand for energy storage solutions. This move supports global trends towards renewable energy and electric mobility.

The Main Cell Exide Plant: Advancing Client Goals

The Main Cell Exide Plant will boost Exide’s production capabilities, helping them capture a significant share of the lithium battery market and supporting the transition to sustainable energy.

Detailed Breakdown of Sheeting and Erection Work

Sheeting Process

Pramila Projects handled sheeting the roof area of 71,550 sqm and cladding area of 31,180 sqm. The deck sheet area covered 24,428 sqm. This required careful planning and execution to ensure structural integrity and weather protection.

Erection Tasks

The erection process involved assembling and positioning steel structures weighing a total of 8,400 MT. The project was divided into four zones, each with specific challenges and timelines. The team maintained strict safety protocols to ensure precision and stability.

Timeline of Excellence

Project Timeline and Key Milestones

The project was executed in phases, with key milestones in each zone:

A highlight of Zone 1 was erecting structures on an RCC slab with a load capacity of 20 MT per segment. We safely lifted the mainframe structure using a 500 MT crane from the perimeter of the zone area, completing the primary structure within 28 days by working from the outside.

Safety Challenges: Tackling Big Risks in Major Projects

Identifying Safety Risks

Inherent Safety Risks in Large-Scale Construction

Large projects like the Exide plant come with inherent risks, including accidents during equipment movement, structure erection, and working at heights. Identifying these risks early helps in planning effective safety measures.

Major Risks Highlighted in the Safety Assessment

The safety assessment identified risks such as equipment movement, load handling, structure lifting, and working at the roof edge. Each risk required tailored mitigation strategies to prevent incidents.

Detailed Risk Assessment

Discussion of Safety Risks Identified

The risk assessment evaluated job site conditions, identified hazards, and assessed their potential impact. This helped develop effective strategies to mitigate risks and ensure worker safety.

Our Safety Commitment in Action: 3 Lakh Man-Hours, Zero Incidents

Proactive Safety Measures

Actions Taken to Mitigate Identified Risks

Job Safety Analysis (JSA) and Hazard Identification and Risk Assessment (HIRA) were crucial in identifying and addressing safety risks. Measures included deploying flagmen, checking crane load charts, and using guide ropes for structure lifting.

Effective Risk Management Plans

Implementation of Risk Management Strategies

The risk management plan included forming a safety committee, conducting weekly equipment inspections, maintaining a Permit to Work (PTW) system, and providing skill development training and motivational programs.

Harnessing Technology for Safety

Using Technology to Enhance Safety Measures

Digital induction systems were implemented for better project understanding and safety compliance. Technology played a vital role in saving lives and time, ensuring that workers were well-informed and equipped to handle tasks safely.

Specific Safety Protocols and Innovations

Morning Tool Box Talks (TBT) were mandatory for all staff and workers to discuss safety experiences and learnings. A penalty system for safety violations reinforced compliance.

Learnings from the Project

Key Takeaways

Lessons Learned from Maintaining a Zero-Incident Record

Maintaining a zero-incident record reinforced the importance of commitment to safety. It boosted the confidence of the team, gained client trust, and showed that the organisation values worker safety.

The Importance of a Safety-First Culture in Future Projects

A safety-first culture ensures skilled workers are properly engaged, tools and equipment are safely used, and the work environment remains stress-free. Proper housekeeping and safe disposal of waste and fuel further contribute to safety.

Enhancing Future Projects

Recommendations for Improving Safety Measures

Future projects can benefit from digital induction systems, Best Behavior Safety (BBS) training, and increased awareness of safe working culture. A centralised record system for safe man-hours, near-miss reports, and Lost Time Accidents (LTA) can help track and improve safety performance.

Key insights include the importance of skilled resources, daily site meetings for planning, reliable equipment, and experienced project leadership. Strengthening material management systems can also improve client material accountability.

Celebrating Achievements

Project’s Success in Maintaining Safety and Achieving Zero Incidents

The project’s success in maintaining safety and achieving zero incidents over 3 lakh man-hours is a testament to Pramila Projects’ commitment to excellence. The team’s dedication ensured a hassle-free work environment, improved morale, and significant time and cost savings due to the absence of injuries.

Acknowledgment of the Team’s Dedication and Efforts

Pramila Projects extends heartfelt appreciation to the entire team for their dedication and effort in achieving this remarkable safety milestone.

Commitment to Continuous Improvement

Reaffirming Pramila Projects’ Dedication to Safety

Pramila Projects remains committed to prioritising safety in all future projects. The lessons learned from this project will serve as a foundation for continuously enhancing safety standards.

Vision for Ongoing Enhancement of Safety Standards and Practices

The vision for the future includes ongoing improvements in safety protocols, technology integration, and fostering a safety-first culture. Pramila Projects aims to set new benchmarks in construction safety, ensuring a safe and productive work environment for all.

What are Pre-Engineered Buildings (PEBs)?

Pre-Engineered Buildings (PEBs) are steel structures that are designed and fabricated in a factory and then assembled on site. They are customized to meet the specific requirements of each project, such as size, shape, load, and aesthetics. PEBs are also known as Metal Buildings or Steel Buildings.

Why are PEBs the Future of Construction in India?

PEBs have many advantages over conventional construction methods, such as:

• Speed: PEBs can be erected in a fraction of the time compared to traditional buildings, as they are pre-fabricated and ready to install. This reduces the project duration and saves time and money.
• Cost: PEBs are more economical than conventional buildings, as they require less material, labor, and maintenance. They also have lower transportation and foundation costs, as they are lighter and more compact.
• Quality: PEBs are manufactured in a controlled environment, ensuring high quality and accuracy. They are also resistant to corrosion, fire, earthquakes, and other natural hazards, ensuring durability and safety.
• Flexibility: PEBs can be easily modified, expanded, or relocated, as they are modular and adaptable. They can also accommodate various architectural features, such as skylights, windows, doors, and insulation, enhancing the aesthetic appeal and functionality of the building.
• Sustainability: PEBs are eco-friendly, as they reduce the carbon footprint and environmental impact of the construction process. They are also energy-efficient, as they optimize the use of natural light and ventilation, reducing the need for artificial lighting and cooling.

How are PEBs Driving India’s Infrastructure Development?

India is witnessing a massive infrastructure boom, as the government has launched several ambitious projects, such as:

• Gati Shakti: On October 13, 2021, Indian Prime Minister Narendra Modi launched the Pradhan Mantri Gati Shakti (PMGS) scheme. The primary objective of this initiative is to break inter-ministerial silos and integrate the planning of infrastructure projects.

• A national master plan for multi-modal connectivity, which aims to integrate road, rail, air, and water transport networks, and boost the country’s economic growth and social welfare. [Source]
• Pradhan Mantri Gati Shakti National Master Plan: Targets

• The national highway network will be extended to expand the limit of roadways and touch the 2 lakh-km mark.
• The scheme imagines the making of around 200 new airports, heliports, and water aerodromes to support aviation worth approx. 2.12 trillion INR
•  The limit of railways to move cargo will be expanded to around 1,600 tons by FY25 could easily surpass $100 billion or more, depending on the scope and scale of the project.
• The transmission network for power will be extended to 454,200 circuit km to easy access.
•  The scheme intends to increment renewable capacity to 225 GW by FY25 and complete around 17,000 km of gas pipelines.

• Kochi Projects:Three infrastructure projects totaling ₹4,000 crore in Kochi – a new dry dock and an International Ship Repair Facility (ISRF) of Cochin Shipyard Ltd (CSL) and an LPG import terminal of Indian Oil Corporation Limited (IOCL) at Puthuvypeen near here – are in line with the vision to transform India’s ports, shipping and inland water transport sectors by boosting capacity-building and self-sufficiency, Prime Minister Narendra Modi said here on January 17 (Wednesday) after inaugurating the projects. [Source]

• Uttar Pradesh will hold the fourth edition of Ground Breaking Ceremony (GBC 4.0) at Indira Gandhi Pratishthan here from Monday, launching over 14,000 projects worth Rs 10 lakh crore in the presence of Prime Minister Narendra Modi, defense minister Rajnath Singh, Chief Minister Yogi Adityanath and over 4,500 investors, and guests coming from across India and abroad.
• These projects coming up in 60 districts of the state would generate more than 34 lakh job opportunities, said a government spokesperson. Over 8,000 of these projects were pledged during UP Global Investors Summit (UPGIS), held last year,  when investment proposals of Rs 40 lakh crore were received. The MoUs for remaining 6,000 projects were signed after the GIS, the industries department officials said. As many as 262 of these projects are worth over Rs 500 crore and 889 between Rs 100-500 crore.

 These projects require fast, efficient, and reliable construction solutions, which PEBs can provide. PEBs are ideal for various infrastructure sectors, such as:

• Airports: PEBs can be used to construct airport terminals, hangars, cargo buildings, and maintenance facilities, as they can span large clearances and heights, and accommodate heavy loads and equipment.
• Metros: PEBs can be used to construct metro stations, platforms, bridges, and tunnels, as they can conform to complex geometries and curves, and withstand seismic and wind forces.
• Warehouses: PEBs can be used to construct warehouses, cold storages, and logistics centers, as they can offer large column-free spaces and high eave heights, and facilitate easy loading and unloading of goods.
• Sports Facilities: PEBs can be used to construct stadiums, arenas, gymnasiums, and indoor sports complexes, as they can create aesthetically pleasing and functional structures, with features such as curved roofs, domes, and arches.

What are the Challenges and Opportunities for the PEB Industry in India?

• The PEB industry in India is growing at a remarkable rate of 33%, and is expected to become a major player in the global steel building market in the next 7-8 years. However, the industry also faces some challenges, such as:
• Lack of Awareness: Many people are unaware of the benefits and applications of PEBs, and still prefer conventional construction methods, such as Reinforced Cement Concrete (RCC) structures.
• To overcome these challenges, the PEB industry needs to:

• Increase Awareness: The PEB industry needs to educate the public and the stakeholders about the advantages and applications of PEBs, and showcase the successful PEB projects in India and abroad.
• Improve Quality and Design: The PEB industry needs to improve the quality and design of PEBs, and offer more variety and customization options, to cater to the diverse needs and preferences of the customers.
• Expand Capacity and Reach: The PEB industry needs to expand its production capacity and distribution network, and establish more PEB factories, warehouses, and service centers across the country, to meet the growing demand and reduce the delivery time and cost.

Vendor infrastructure

• The PEB industry also has enormous potential and opportunities, as it can cater to various sectors, such as:

• Power: PEBs can be used to construct power plants, substations, transmission towers, and solar panels, as they can withstand high temperatures, voltages, and loads, and facilitate easy installation and maintenance. 
• Infrastructure: PEBs can be used to construct bridges, flyovers, highways, and railways, as they can span long distances and heights, and cope with dynamic loads and vibrations.

These projects require fast, efficient, and reliable construction solutions, which PEBs can provide. PEBs are ideal for various infrastructure sectors, such as:

• Airports: PEBs can be used to construct airport terminals, hangars, cargo buildings, and maintenance facilities, as they can span large clearances and heights, and accommodate heavy loads and equipment.
• Metros: PEBs can be used to construct metro stations, platforms, bridges, and tunnels, as they can conform to complex geometries and curves, and withstand seismic and wind forces.
• Warehouses: PEBs can be used to construct warehouses, cold storages, and logistics centers, as they can offer large column-free spaces and high eave heights, and facilitate easy loading and unloading of goods.
• Sports Facilities: PEBs can be used to construct stadiums, arenas, gymnasiums, and indoor sports complexes, as they can create aesthetically pleasing and functional structures, with features such as curved roofs, domes, and arches.

• Logistics: PEBs can be used to construct ports, docks, shipyards, and container terminals, as they can handle heavy and bulky cargo, and resist corrosion and saltwater.
• Others: PEBs can be used to construct other sectors, such as industrial, commercial, residential, institutional, and agricultural, as they can suit any type of building, function, and location.

Conclusion:

PEBs are revolutionizing the construction sector in India, as they offer fast, cost-effective, quality, flexible, and sustainable solutions. With the government’s vision and support for infrastructure development, the PEB industry is poised for unprecedented growth. By overcoming the challenges and seizing the opportunities, the PEB industry can not only transform the construction process, but also contribute significantly to the nation’s progress.

As a leading PEB construction company in India, we are proud to be a part of this transformation. We have the expertise, experience, and equipment to deliver PEB solutions for any project, sector, and location. We have successfully completed PEB projects for various clients, such as airports, metros, warehouses, sports facilities, and more. We are committed to providing the best PEB solutions for our customers, and creating a lasting impact on the society and the environment.

If you are looking for a PEB construction partner, look no further than us. Contact us today, and let us help you build your dream project with PEBs.

We are thrilled to welcome you all to our new digital home. A new website and a new beginning. After a month-long planning and designing, we are finally ready to unveil our website, and we are super excited about it. We want to tell you all about the new features and design choices, but first, let’s understand why we decided to build this new website while we already had one.

Why This New Website?

As a company, we understood the importance of a website and digital landscape from the early days. However, our decision for this new website goes beyond just a facelift to our online home. It was about redefining how we connect, engage, and serve you.

Our previous website served us well, but with time, it demanded adaptation. As a forward-thinking company, we embrace the changes and thus this new website.

What’s New?

In a quest to provide an improved user experience, improved and updated content, and overall experience, it pushed us to reimagine every aspect of our new website. After months of meticulous planning, designing, and testing, we are finally launching our website. Here are some highlights of our new website:

1. New & Improved Navigation

We understand how important of a role navigation plays in ensuring a smooth user experience. That is why we gave a great deal of time and thought to designing the navigation system. This new and improved navigation allows users to smoothly and effortlessly explore different sections of our website without any learning curve.

2. Clean & Modern Design

There has been a significant shift in web design trends in the last couple of years. We have invested a great deal of time and effort to ensure that every part of our website follows that industry trend.

The result is this beautiful-looking website that not only looks great but also enhances readability and user engagement.

3. Updated Service Pages

We have grown so much as a company in the past few years, and so have our offerings. We are not just a PEB installation company anymore; we now offer design, build, installation, and full EPC (Engineering, Procurement, and Construction) solutions.

Our new and improved service pages reflect our new offerings with updated content and helpful illustrations. You can explore our services by visiting the services page.

4. New & Updated Projects Page

We’ve also updated our projects page, showcasing some of our proudest projects completed for some of the biggest brands in India and beyond.

We are also committed to consistently updating the projects page with new projects as soon as they finish. You can explore our projects by visiting the projects page.

5. Improved Career Page

We are constantly looking for new talents to come and join our growing team. This updated career page is a step in that direction. Our revamped career page gives you a look at the work culture at our company.

This page also now lists all the current openings we have in our company for those looking for a career change, or to be part of a company that prioritizes a balanced work culture.

What’s Next?

We are all deeply committed to growing our digital presence, and this revamped website is just the first step in that direction. In addition to the website redesign, we have exciting plans to publish a series of well-researched and in-depth articles that will cover a wide range of topics.

Moreover, we will be regularly updating our website with the latest news and events happening within our company.

We also have big plans for our social media. We will be publishing some interesting facts, data, and project updates on our LinkedIn, Instagram, and Facebook pages. Be sure to follow our social media to not miss our new posts.

We Want To Hear From You

The primary goal of this website is to give you an improved user experience, and we want to hear from you. We invite you to explore the website and let us know how we can further improve this website to best serve you. Your opinion matters, and we are committed to continuously enhancing our website based on your input.