Project Details

Project Name : High Pressure Die Casting Plant for Ashok Leyland (India) and Alteams group (Finland)
Location : Cheyyar, Kancheepuram
Year Of Completion : 2010
Area : 1,79,200 Sq.ft.


The joint venture plant between Ashok Leyland, India and Alteams group of Finland was constructed at Cheyyar, Tamilnadu, about 100 kms from Chennai. The brief was to design phase-1 of the High pressure Die casting plant to produce components for the automotive and telecommunication sector. The manufacturing facility was planned to cater both to the domestic and International Markets. The buildings proposed were a Melting furnace block, Die casting area, Machine shop/Assembly /Loading and Unloading area, Office block, Canteen & Workers locker facilities and other essential service buildings.

The 20 acre campus was zoned to ensure proper circulation route and sufficient space for future expansion. The key aim was to create a green campus that would involve climate responsive architecture, heat reflective materials, maximum use of natural light and ventilation, rain water harvesting and waste water recycling. The above measures were an initiative in the direction to reduce the carbon footprint created by the furnaces which are an essential part of the production process. To address the issue of high heat generated inside the plant, courtyards with linking corridors were introduced into the plant layout. These courtyards acted as ‘lung spaces’ bringing in the prevalent South east winds across the shop floor thereby cooling it naturally. These in combination with the daylight panels in the roof assured zero usage of artificial light during the day.

The Office block was attached to part of the Plant and care was taken to create as coherent a façade appearance as possible with the rest of the fascia. Planned to house 40 Staff, the Office block was intended to be simple yet contemporary. Use of aerocon building blocks to increase heat dissipation, high reflectivity and E-coated structural glazing, heat reflective finishes on the exposed areas such as roofs and walls and under deck insulation were the measures taken to increase the energy efficiency of this air conditioned space. Insulation panels were fixed to the shared wall between Plant floor and Office block to prevent heat gain.

The Canteen building designed to seat 200 people at a time has ample day lighting by way of vertical slit windows. Locker facilities for workers are housed in the first floor of the same block as also the training facilities. An Eco pond with a capacity of 26 lakh litres was created to collect part of the run-off rainwater collected from the roof tops and roads through the network of storm water drains.
Press Links : http://www.thehindu.com/business/ashley-atleams-plant-inaugurated-at-cheyyar/article83290.ece