This book is presented as a token of gratitude from Suroj Buildcon to Bajaj Auto Ltd., to commemorate the journey of building most advanced, hi-tech manufacturing unit at Chakan phase II, for build and assembly of high-performance bikes like KTM, Triumph, Duke, Husqvarna, KTM RC, Pulsar and so on. At Suroj Buildcon, we are committed whole-heartedly towards building a better India. We undertook this collaboration with Bajaj as yet another opportunity to contribute towards India’s growth and progress.
“Alone we can do so little. Together we can do so much.” - Helen Keller
Bajaj Auto A constant in India’s progress
From HUMARA BAJAJ to becoming The WORLD’S FAVOURITE INDIAN A legacy that started in 1945, and has, today, become the pride of an entire nation! With the roots of Indian values and traditions imbibed deep in its core, Bajaj Auto Ltd. has been one of the most inspiring companies to showcase Indian potential to the world. Today, Bajaj Auto Ltd. takes pride in an impactful international presence, journeying through more than 70 countries with an impressive range of two and three-wheelers.
The new Chakan motorcycle manufacturing plant is Suroj’s first association with Bajaj Auto Ltd. as main contractor. The project, indeed, has become one of our milestone projects and will always remain special for us.
II: Our Vision of Chakan Transcending boundaries
Each bike manufactured within the facility would not only be carrying the identity of being built by Bajaj, but also be a testament of Indian capabilities across the world. This was a major driving factor for us to leave no stone unturned. Suroj was given a canvas of 188 acres to develop a manufacturing facility with an unconventional look and sustainable set-up. This herculean feat was achieved through the team-efforts of everyone working towards a common goal; to deliver a fully-automated, worldclass industrial campus, designed to deliver bikes that match global standards.
Project Masterplan
Vehicle Assembly Shop 2
Engine & Machine Shop
Area For Test Track Vendor Park
Quarry 1
Plant Office
Entrance Foyer
Phase 1 Vehicle Assembly Shop 1
OS Canteen
Football Field Quarry 2
Non-Manufacturing Block
Bus Out
Phase 2
Modern-day automation with a human-centric approach India’s prowess, along with automation, makes it a force to be reckoned with. The Bajaj credo being in sync with this new-age approach, guidelines for new plant was set in our minds – it had to break norms of a traditional manufacturing unit and bring to life an optimized mix of automation and sustainability. Right from its ideation phase, the Chakan plant was envisioned to become a model manufacturing unit that would set precedence of an ideal automobile plant. This aptly resonated with a shared vision between Bajaj Auto, Architects, Consultants, and Suroj. Through our work, we wanted to ensure that India’s future was showcased to its best.
The Chakan plant takes pride in having first-of-its-kind, fully-automated assembly line and production line. In terms of critical technology like painting and engine, as well as labour-intensive work of handling, the unit achieved seamless automation. The balance of implementing such high-level precision, while creating a human-centric, efficient, truly sustainable facility, that was deep-rooted in Indian physiology and, at the same time, echoed a glocal vocabulary, was a challenge that we loved to solve. The project demonstrated a philosophical position of design, with a healthy balance of modernism and tradition, which would go on to become a piece of Bajaj Auto legacy.
nts: Green Footpri Embracing Sustainable Practices Amidst rapid growth and expansion, sustainability has become synonymous with India’s future. With Bajaj ethos and Suroj values in sync, the team worked with NGK studios to implement ideas and create a world-class infrastructure that truly made this project a role-model in sustainable practices.
Water • Rejuvenation of 2 existing quarries to convert them into lakes • Harvesting surface runoff water to increase soil water retention • Building surplus capacity to prepare for possible dry year
Material • Local materials were preferred, without compromise on quality • Materials with less embodied energies, like Kota and wire-cut bricks were used
Landscape • Excavated murum rock was reused for plinth soling, backfilling and retention • Understanding basic attributes like wind direction, topography, sun paths, etc., site layout was oriented in east-west direction • Use of local plants in landscape that thrive in less water
Building Designs • Exposed Brick and Rat Trap bond and Brick jalis provide thermal insulation of 5 to 8 degrees • Use of light tubes to bring in diffused natural lighting • Use of solar photovoltaic panels on roofs and other places to harness solar energy • 30m high roofs and natural stack effect eliminated use of artificial air conditioning almost completely
Excellence fuelled by best-in-class material The Chakan II project was embedded with commonly shared values of Bajaj and Suroj. With every bike having the brand mark of ‘Made in India’, materials used were chosen to respond to the highest calibre of respective performances, ease of maintenance, contextual appropriateness and good aesthetic meaning.
System Formwork - Retaining Wall + Formwork
Exposed concrete ‘Y’ columns
Retaining wall height, ranging from 2.5m to 9m – wherein special shuttering formwork Outinord, from France, was mobilized to meet project requirements.
‘Y’ columns were used throughout different structures, to bring spatial and visual beautification, along with durability.
RMC Plant Fully automated and computerized RMC plants were installed on-site to help provide concrete of international standards, using the best quality raw-material.
Fabrication Yard
Brick Manufacturing machine
PQC Machine Roadwork
Fabrication Yard Layout Dimensions were 165m x140m and defined (Marking+ Cutting+ Drilling) Area, Fit Up area, Welding Area and Painting area workstations, each carrying a team of 70 to 90 people.
Through installation of on-site brick yard at the plant, it was ensured that only best quality of bricks were used for the construction.
High-grade PQC developed roads were constructed at the plant through the most advanced PQC machines which not only helped in reducing wastage, but also ensured highest durability.
In addition, laser screed, dual-tone Galvalume façade cladding, Sigma purlins, guniting & rock grouting helped add visual aesthetics and dependable stability. Use of CNC machines helped with various advantages, like accuracy, efficiency, customization, reliability and sustainability in Fabrication.
Mapping the Road to Success It’s only when we look back at our journey, do we realize how far we’ve come. The project remains a collection of little accomplishments that Suroj adds to its invaluable learning experience.
• Mobilization • Groundbreaking Ceremony
Dec 2021
• Column Erection
Jan 2022 Feb 2022
• Truss Erection
Mar 2022
• Erection Completed
• Roof Sheeting
• Cladding Work
Apr 2022
May 2022 May 2022
• Flooring Work
Jun 2022
• PQC Road Work
• Cladding Work
• Completion of Roofing Work
Jul 2022
Aug 2022 Sep 2022
• Conveyor Bridge
Oct 2022
• Flooring Work Densification
• Completion of Infrastructure
Nov 2022
• Completion of Roofing Work (Paint-shop)
Dec 2022 Jan 2023
• Mr Rishabh Bajaj Site visit (Special event)
Mar 2023
• Mr. Rajiv Bajaj’s 1st visit at Bajaj Auto along with KTM MD.
Embracing Challenges and Overcoming Odds Due to sheer magnitude of the project, additional scope of work that was not envisaged, became part of ad hoc project requirements. Suroj faced these challenges head-on, alongwith intensive discussions with the Bajaj team, and adapted necessary measures to carry out uninterrupted work within stipulated timelines.
Environmental factors Site terrain consisting of hard rock and heavy rainfall during monsoon were unforeseen hindrances. The hard rock strata needed to be blasted and installation plans had to be altered to adhere to timelines. Paint shop work involved many tunnels & equipment foundations below ground-level and were required to be executed during rains.
Paint shop
Paint shop works was critical in terms of constructability as the work involved many tunnels & equipment foundations below ground. Ensuring its execution in the heavy rains made it even more challenging.
Specialized modular requirements Retaining wall height, ranging from 2.5m to 9m – where in special system formwork was mobilized to complete the project requirements.
Lasting Impressions
Mr Kailash Zanzari
Mr Rajiv Joglekar
Head (Manufacturing)
Advisor (Projects)
Bajaj Auto Ltd
Bajaj Auto Ltd
If I were to describe Suroj in one word, I’d call them reliable. Their resourcefulness and mobilization of team; on that particular aspect, they have never let us down.
Suroj was selected out of very tough competition and over international names.
I remember one incident in particular, where I was worried about paint-shop installation. There was a lot of rainfall last year and water accumulation and many such problems were delaying project work. I was worried about whether we would be able to adhere to required timelines. But then, we had two, three deliberations with Suroj. They understood our concern and immediately adapted their strategy to overcome this hurdle. They divided said work into smaller teams, and carried out entire paint shop activity, to catch up with target-date very efficiently, and made up for losses, in terms of time and schedule. That was one really amazing experience that I had with Suroj.
Work-wise, they had right resources and knowledge. Most importantly, they had zest to get things done professionally and with passion. A memorable incident was regarding one of their employees, tea-boy, Raju. The simple act of him remembering everyone’s liking, and his hospitality to bring refreshments without being told when meetings were extended. It showed commitment of Suroj. Having same experience, from Mr. Sachin Biyani to the very last link of Suroj team, talks about embedded values in the DNA of the organization. The Management and Support team demonstrated excellence, providing ample support to everyone. Suroj complimented Mr. Bajaj’s foresight, instilling confidence in our ability to tackle any challenge. Overall, Suroj will definitely be one of our top preferences for future projects.
Mr Pradeep Bijlani
Mr Naveen Nijhawan
Vice President (Real Estate)
VP (Operations)
Bajaj Auto Ltd
Bajaj Auto Ltd
Despite the size and structure of Suroj, they were pretty nimble on their feet to react to whatever work was told. Whether it was changing priorities we had, based on our business plans, or whether it was changes in specifications based on site conditions, we could easily sit with them, communicate as a team and get it done on immediate basis. Unlike a few other companies who have a certain process of working, which can become time-consuming. In case of Suroj, it was pretty quick.
Suroj was comparatively a green horn amongst our choices. Their merit to be chosen was based on their previous projects that we personally visited and examined, feedback of their clients and market reputation. From day one, we could see we had made the right choice.
I’ll definitely say there’s a lot of focus within their organization. Their top management is really accessible, which is something we highly appreciated. Yes, there are lots of things that we got to learn from them and I’m quite sure there are things that they learnt from us. It’s an exchange of knowledge, but overall, our experience with them was Great.
The way Suroj set up their facilities and took care of their manpower, I’d say it was pretty pleasing. If I compare this project from safety point of view, it was well-cared for. Even near-miss incidents were negligible for this scale of a project. Overall, legal compliances were also pretty good. These were a few factors, above cost and timelines, that stood out about Suroj. Secondly, they have respect for their alliances. It’s not about relationships with just customers, but all stakeholders. I personally think that was pretty good about Suroj. That will definitely be one key factor for their success.
Lasting Impressions
Mr Amit Kate
Mr Rahul Kadam
Division Head (Real estate)
Founder, Principal Architecture
Bajaj Auto Ltd
NGK Studio
Working with the Suroj team was a wonderful experience, especially because of our shared values and outlook.
You cannot introduce passion within a person by simply putting a logo on a t-shirt. The logo needs to connect with their heart. This passion was exactly what I found in Suroj.
The Suroj team is very client-centric. Not only did they adhere to our requirements as they arose, but also made insightful recommendations to guide the project towards delivery timescales. I found senior site-team dedicated, proactive, and extremely competent in all aspects. This gave me confidence to take on site decisions undoubtedly. Our passion for achieving targets was well complimented by these qualities of Suroj team. Suroj Senior Management employs a handson approach and vast project experience, which helped us in our decision making during challenging times. Suroj is definitely going to be our preferred partner for future projects.
Right from their higher-management, to department heads, and all engineers and subengineers from team; common point I saw was that they were really involved and committed in their work. I never found them having just a ‘9-to5’ job mindset. We were in-charge of strategic planning and execution. Our amalgamation with Suroj was of dire importance, because we had a lot of great ideas, and we needed an equally competent contracting partner to bring these ideas to life. In a large project like this, there are 5-6 people who are the point of contact for different aspects. With Suroj, each member handled these situational difficulties and worked together as one team.
Ms Kalyani Savardekar
Mr Shridhar Satvekar
Proprietor
Founder
SS Muzumdar Consulting Engineers
Satellite Professional Services
Being second-generation consultants for Bajaj Auto Limited, we’ve collaborated on several projects in past 6 decades.
There goes a lot in achieving such a huge feat as the Chakan plant project, and it’s always dependent on teamwork and coordination between all consultants, clients & vendors. This was my fourth major project with Bajaj and first one working with Suroj. My overall experience was excellent, with Suroj having shown their capabilities on multiple levels and at every stage. Mobilization-wise and technology-wise, Suroj was highly adaptable to project needs and made it possible for us to explore better avenues.
Our experience with Suroj in Chakan 2 project stood out. Considering the sheer size and scale of project, there was lot of effort and dedication necessary from construction team. We found Suroj to be responsive and proactive. We interacted with structural steel works team and RCC team regularly. Every member of Suroj showed immense professionalism and easily adapted to last-minute changes. As structural designers, it is good to have a strong construction partner to bring ideas to fruition. In this matter, Suroj fit our expectations perfectly. Their commitment to timely complete project and deploying resources to achieve it was commendable. There was willingness to collaborate and discuss alternative solutions whenever need arose. Overall, we found them highly professional and result-oriented.
Best thing about Suroj was that their higher management was actively involved during entire project. Their acceptability and positivity to attain success in whatever challenges they faced was really commendable. I would definitely recommend them for future projects and definitely look forward to working with the Suroj team.
A proud contribution to INDIA, and to the WORLD’S FAVOURITE INDIAN The Chakan motorcycle manufacturing plant is all set to create a global mark of the highest standards and we are proud to be contributors in it. The plant nurtures the future hopes and dreams of Bajaj Auto Ltd., as well as India, of becoming a truly empowered, technologically-advanced nation. For Suroj Buildcon, this project will always remain close to our hearts, for being first project with highlyesteemed Bajaj Auto Ltd. This project is a story of encouragement for us, especially because of our shared values with Bajaj, of Integrity, Dedication and Pride of being Indian.
SUROJ is recognized as India’s leading construction company, providing services to reputed MNCs and Indian conglomerates in various sectors. SUROJ is a product of passion, hard work, perseverance and integrity. Our journey began in a meagre office space, but grew to encompass a strong workforce spread all across the nation. For Suroj, excellence is a habit, and the team always strives to do their best. Suroj is an organization with a strong ethical compass and a spectacular track record of excellence in industry. Since past two decades, their proven expertise has culminated into a mammoth number of projects worth millions of square meters. With engineering and construction in our DNA, we understand what it takes to turn projects and imagination into reality. We believe in relentless pursuit of value creation, skill-building and strengthening infrastructural fabric of nation with passion and commitment.
SUROJ BUILDCON PVT. LTD. Bungalow No. 3, Liberty Society Phase-I, North Main Road, Koregaon Park, Pune 411 001, Maharashtra, India. 020 41355999 |
info@suroj.in |
www.suroj.in
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