As part of a series of interviews with prominent civil engineers,
Shubhangi Bidwe meets
SB Malekar, Vice President - Technical, Sterling Engineering Consultancy Services Pvt Ltd."The present day life of a structural design engineer has become relatively easy with the advent of computers and advanced software. Challenges in designing complicated and irregular structures can be boldly considered," says SB Malekar, the 71-year-old Vice President - Technical of Sterling Engineering Consultancy Services Pvt Ltd.
In his hey days, design calculations were performed by sleight of hand. Naturally, he perceives a vast difference in the approach today. However, he is happy with the tremendous progress India has made in design engineering. "Indian engineers today are on par with their global counterparts," he says proudly. "They can design a project of any scale and magnitude."
Born in 1940 in Revdanda village near Alibaug in the Raigad district, Malekar's financial conditions were far from stable. His father and uncle owned a small business of procuring and distributing rice paddy. Known as the 'clever boy' of the family, Malekar was always top of his class. Considering the prevailing financial conditions, he was then advised by his brothers to opt for Arts in college as this would enable him to earn a living on the side. However, destiny had other plans. Almost on the verge of giving in to his brother's wishes, both Malekar and his brother veered away from the original plan and took up civil engineering, on the behest of their school principal. Thus, began one of the most rewarding professional journeys.
A graduate from Mumbai University, Malekar started as Junior Engineer with Development Consultants and worked there for almost 21 years. During this time, he rose from the rank of a Junior Engineer to that of a Chief Engineer. In 1981, he joined Sterling Engineering Consultancy and has been with the company since 1981-85/1999 till today. Prior to this, he also worked for about seven years in the design office of HCC first as Deputy Chief and then as Chief Engineer.
In conversation with
CW, Malekar talks about his experiences, the projects he's been involved in and the design industry in India.
Genesis of the design industryIn 1963, when I passed BE, the tools for analysis of a structure were very restricted. Therefore, people would not go in for complicated designs. Gradually, the code of practices evolved. Earlier, we used foot-pound units; this later changed to the metric system. Earlier, we would carry out manual calculations by slide rule before the calculators came in 1970. Then came the personal computers. So, the entire calculation part of design engineering has become very user-friendly. In fact, the present day life of a design engineer has become very easy as far as design calculations are involved.
Designing basically consists of two parts. First is the analysis and then comes sizing up. Designing is based on the type of material used and changes according to the strength of materials. Based on extensive research, there are codes of practice that have various guidelines and rules and are modified to suit further iterations. This, in turn, results in a change of methodology. For example, earlier, we used the permissible stress method. It was improvised to an ultimate load method, and further, to a limit state method. Similarly, for earthquake and wind-resistant structures, there has been tremendous development. Nowadays, we can develop earthquake-resistant structures of any shape, size or height.
International experienceI was posted in Venezuela from 1975-78 on behalf of Development Consultants. The Venezuelan Government was building a large steel plant called SIDOR steel plant. But, the project did not have the manpower to handle a project of this magnitude. It acquired machinery, equipment and technology on a turnkey basis from Germany and Japan and other countries. The company would mainly receive designs, specifications and drawings from all the main contractors and execute them. But, a review was necessary to determine whether the company was implementing these drawings properly. SIDOR, therefore, was hiring engineers from the US, Britain, Mexico, Argentina and Venezuela to work for it. It then decided to also hire Indian engineers. We were a team of five engineers hired to test the Indian engineers' knowhow. I was the only civil engineer in the team, and my job mainly comprised reviewing and approving the structural designs and drawings of those contractors. I got an opportunity to see how a design is executed on an international platform. It was a huge steel plant like the Bokaro steel plant and had different plants for arc furnaces, blast furnaces, rolling mills etc. In addition, there were ancillary plants, water treatment plants, sub stations, pumping stations, etc. After our successful performance, there were about hundred Indian engineers working for SIDOR.
If I have to draw a line between the two countries, in India, the design and construction phases of a project proceed almost simultaneously, whereas, in Venezuela, engineers first complete the entire design of all disciplines and only then do they hand over the drawings to the respective contractors for execution. The procedure adopted in India often calls for changes in basic schemes, choice of machinery, equipment, etc, while the project work is on. This results in change of design and drawings and affects construction planning for smooth execution. The same is also seen in architectural projects in India.
Designing earthquake- and wind-resistant structuresEngineers worldwide, with the help of their research statistical data, have given certain guidelines for designing a structure. These specifications indicate various factors like how much load is to be considered for the seismic effect along with other design-related parameters. Normally, the structures have to withstand gravity loads. But, in earthquake/wind conditions, lateral forces are exerted. The design of earthquake-resistant buildings is carried out as per IS 1893 and other related codes. Similarly, lateral forces are exerted on a structure by wind. The guidelines for computation of wind forces exerted are given in IS 875 Part III.
Designing for an earthquake- and wind-resistant building calls for a different set of requirements. These dynamic forces try to overturn the structure and so, additional internal forces are developed in all structural elements. We have to size all these structural elements to absorb these forces in addition to those due to gravity in proper combinations, and create safe, stable and serviceable structures. The structural drawings show general arrangements, sizes of all the structural elements, their connections, internal reinforcing steel, etc. Once such drawings are prepared, the contractor then executes the information in actual structures. Well-coordinated drawings with accuracy, adequacy, clarity and neatness are very important for smooth and rapid execution of structures.
Training young graduatesFresh graduates in India have knowledge, which is rather bookish, along with some computer training, but they lack in practical training. They do not have in-depth knowledge of various applicable codes of practice and do not relate to complicated analysis and design. We try to absorb some of these graduates and groom them to create wonders in the actual design process. Understanding the behaviour of a structure and the load flow path is extremely important in creating appropriate errorless structural design.
Looking backAt 71 years of age, Malekar has no future plans as such but is happy to have enjoyed his work so far. "I don't look further now. I look back and feel happy," he beams. He desires to impart his knowledge and experience gained to budding engineers. He expresses his gratitude to all his teachers, his brother, professional colleagues and the members of his family for all he has achieved in his career. Appreciation received by him from seniors, colleagues, associates, clients and contractors for his vast contribution to structural engineering is his pot of gold at the end of the rainbow.
S B Malekar- Bachelor of Engineering from the University of Mumbai (1963)
- Member of the Institute of Engineers, India
- Member of Maharashtra India Chapter of ACI.
Major projects involved inMadras/Narora Atomic Power Project, Mahindra Ugine Steel Plant (Kopoli), SIDOR steel plant, Chandrapur-Padga HVDC project, Reliance Gas Power Station (Goa), Mulund Sports Complex, Kalidas Auditorium, Andheri Sports Complex, substations in Dubai, Ircon Railway Workshops (Damman), Dr Mandke-Kokilaben Ambani Hospital (Mumbai), Peninusula Corporate Park, Sebi Office Building in BKC, Reliance Knowledge City, Kohinoor Square hi-rise, Salalah Pharmaceutical Plant (Oman), Bangalore Sewage Treatment Plant, Panvel Water Treatment Plant, Hotel Lalit International, Ashok Gardens, CIDCO Seawoods Estate, IMAX Theatre, Residence Antilia and many more...
Challenging ProjectsProject: ASHOKA GARDENS, PAREL, MUMBAI.
Period: 2005-2010
Background: Spread over 12 acre, this residential complex by Piramal Holdings has two towers, each 23-storey high, with three wings each. The wings have been structurally isolated by separation joints. There are eight ramps to reach the podium level. The residential levels have spectacular views of the harbour.
Details: The challenge was not only to design the multi-storeyed towers but also the surrounding ancillary buildings with modern amenities, club house, landscaped areas, water features and car parking for their residents. In addition, the complex has a sewage treatment plant and an elegant swimming pool. The structural drawings prepared for this project had to be carefully co-ordinated not only with the MEP services but also with BSES, as two large substations were required.
Project: IMAX THEATRE, WADALA, MUMBAI Period: 1999-2000
Background: India's first IMAX Dome was inaugurated in Mumbai on March 25, 2000. This has the world's largest screen, measuring 13,700 sq ft with a capacity of 520 viewers. It provides hi-fidelity, audiovisual experience, in which the film envelopes each viewer with 12,000 W of digital wrap-around sound. The giant screen dome is about 99 ft (30 m) in diameter.
Details: The 37 m diameter structural dome is made up of fabricated structural steel open web girders, which divide it into 16 segments. These girders facilitate easy installation of several services. They are supported on an RCC ring beam, which in turn is supported by 16 peripheral columns. The girders converge at the pole of the globe where they are connected to a 4 m diameter compression ring. In addition, there are four circumferential steel girders dividing the entire curved length from the ring beam to the compression ring into five almost-equal parts. Diagonal bracing members along the entire structure provide additional strength and stiffness. The structural dome is also designed to support the catwalks, equipments, speakers, etc. The waterproofing for the entire dome has been carried out using special polyurethane foam insulation followed by an elastomeric membrane. This allows for the expansion and contraction of the surface without ing. The two inclined elevational RCC fins on either side were also analysed and designed to resist wind loads. The speciality of this imposing elevational feature is that each fin is supported at only one point beyond foundation. Due to the 30 degrees tilt in the dome, the forces in each of the girders as well as the RCC members were not evenly distributed. Radial members are subjected to axial compression as well as bending. Therefore, the challenge was to make the dome safe and stable without any distortion. To suit the subsoil conditions, all the columns were supported on pre-cast, pre-bored piles.
Project: RESIDENCE ANTILIAPeriod: 1999-2011
Background: Located at Altamount Road, in South Mumbai, Residence Antilia is an extraordinary high-rise building and the private residence of Mukesh Ambani, Chairman, Reliance Industries. The original structure was conceived as a structural, steel-framed building, but it was later changed to concrete. As a structural scheme, the elevator and stair cores from the main spine of the building. The remaining areas are supported on suitable column grids. Apart from gravity loading, special attention was given to seismic parameters. Wind tunnel tests were considered to assess both the design wind loads and acceleration arising from wind induced motions.
Details: Above the main garden, at 44 m, each mega column was split into four tapering circular columns forming an inverted pyramid. The free-standing height of these tilted columns is 22 m. The construction of these 1,600 mm diameter columns posed a challenge. Two-piece, semi-circular steel forms were specially fabricated for each and every column. These forms were rigidly supported on well-designed staging, and the entire staging was kept in position till the upper floor. Tying all these inclined columns was cast and cured.
The second mechanical plant floor at 101 m level as well as the first residential floor at 108 m level is cantilevered by about 9 m beyond the front row of columns. Therefore, a special, well-braced staging of about 56 m height was erected to support the formwork exclusively for these cantilevered floors. This formwork was kept in position for over two months while the superstructure construction advanced.
There are two extraordinary helical stairs within the residence for internal communication. Since the designs for these stairs were not finalised at the time of construction of the residence floors, suitable cut-outs were provided in the floor slabs. Subsequently, elaborate fabricated structural steel stairs were erected and anchored into the RCC floors.
Give us your feedback on this article at
[email protected]
As part of a series of interviews with prominent civil engineers, Shubhangi Bidwe meets SB Malekar, Vice President - Technical, Sterling Engineering Consultancy Services Pvt Ltd.The present day life of a structural design engineer has become relatively easy with the advent of computers and advanced software. Challenges in designing complicated and irregular structures can be boldly considered, says SB Malekar, the 71-year-old Vice President - Technical of Sterling Engineering Consultancy Services Pvt Ltd.In his hey days, design calculations were performed by sleight of hand. Naturally, he perceives a vast difference in the approach today. However, he is happy with the tremendous progress India has made in design engineering. Indian engineers today are on par with their global counterparts, he says proudly. They can design a project of any scale and magnitude.Born in 1940 in Revdanda village near Alibaug in the Raigad district, Malekar's financial conditions were far from stable. His father and uncle owned a small business of procuring and distributing rice paddy. Known as the 'clever boy' of the family, Malekar was always top of his class. Considering the prevailing financial conditions, he was then advised by his brothers to opt for Arts in college as this would enable him to earn a living on the side. However, destiny had other plans. Almost on the verge of giving in to his brother's wishes, both Malekar and his brother veered away from the original plan and took up civil engineering, on the behest of their school principal. Thus, began one of the most rewarding professional journeys.A graduate from Mumbai University, Malekar started as Junior Engineer with Development Consultants and worked there for almost 21 years. During this time, he rose from the rank of a Junior Engineer to that of a Chief Engineer. In 1981, he joined Sterling Engineering Consultancy and has been with the company since 1981-85/1999 till today. Prior to this, he also worked for about seven years in the design office of HCC first as Deputy Chief and then as Chief Engineer.In conversation with CW, Malekar talks about his experiences, the projects he's been involved in and the design industry in India.Genesis of the design industryIn 1963, when I passed BE, the tools for analysis of a structure were very restricted. Therefore, people would not go in for complicated designs. Gradually, the code of practices evolved. Earlier, we used foot-pound units; this later changed to the metric system. Earlier, we would carry out manual calculations by slide rule before the calculators came in 1970. Then came the personal computers. So, the entire calculation part of design engineering has become very user-friendly. In fact, the present day life of a design engineer has become very easy as far as design calculations are involved.Designing basically consists of two parts. First is the analysis and then comes sizing up. Designing is based on the type of material used and changes according to the strength of materials. Based on extensive research, there are codes of practice that have various guidelines and rules and are modified to suit further iterations. This, in turn, results in a change of methodology. For example, earlier, we used the permissible stress method. It was improvised to an ultimate load method, and further, to a limit state method. Similarly, for earthquake and wind-resistant structures, there has been tremendous development. Nowadays, we can develop earthquake-resistant structures of any shape, size or height.International experienceI was posted in Venezuela from 1975-78 on behalf of Development Consultants. The Venezuelan Government was building a large steel plant called SIDOR steel plant. But, the project did not have the manpower to handle a project of this magnitude. It acquired machinery, equipment and technology on a turnkey basis from Germany and Japan and other countries. The company would mainly receive designs, specifications and drawings from all the main contractors and execute them. But, a review was necessary to determine whether the company was implementing these drawings properly. SIDOR, therefore, was hiring engineers from the US, Britain, Mexico, Argentina and Venezuela to work for it. It then decided to also hire Indian engineers. We were a team of five engineers hired to test the Indian engineers' knowhow. I was the only civil engineer in the team, and my job mainly comprised reviewing and approving the structural designs and drawings of those contractors. I got an opportunity to see how a design is executed on an international platform. It was a huge steel plant like the Bokaro steel plant and had different plants for arc furnaces, blast furnaces, rolling mills etc. In addition, there were ancillary plants, water treatment plants, sub stations, pumping stations, etc. After our successful performance, there were about hundred Indian engineers working for SIDOR.If I have to draw a line between the two countries, in India, the design and construction phases of a project proceed almost simultaneously, whereas, in Venezuela, engineers first complete the entire design of all disciplines and only then do they hand over the drawings to the respective contractors for execution. The procedure adopted in India often calls for changes in basic schemes, choice of machinery, equipment, etc, while the project work is on. This results in change of design and drawings and affects construction planning for smooth execution. The same is also seen in architectural projects in India.Designing earthquake- and wind-resistant structuresEngineers worldwide, with the help of their research statistical data, have given certain guidelines for designing a structure. These specifications indicate various factors like how much load is to be considered for the seismic effect along with other design-related parameters. Normally, the structures have to withstand gravity loads. But, in earthquake/wind conditions, lateral forces are exerted. The design of earthquake-resistant buildings is carried out as per IS 1893 and other related codes. Similarly, lateral forces are exerted on a structure by wind. The guidelines for computation of wind forces exerted are given in IS 875 Part III.Designing for an earthquake- and wind-resistant building calls for a different set of requirements. These dynamic forces try to overturn the structure and so, additional internal forces are developed in all structural elements. We have to size all these structural elements to absorb these forces in addition to those due to gravity in proper combinations, and create safe, stable and serviceable structures. The structural drawings show general arrangements, sizes of all the structural elements, their connections, internal reinforcing steel, etc. Once such drawings are prepared, the contractor then executes the information in actual structures. Well-coordinated drawings with accuracy, adequacy, clarity and neatness are very important for smooth and rapid execution of structures.Training young graduatesFresh graduates in India have knowledge, which is rather bookish, along with some computer training, but they lack in practical training. They do not have in-depth knowledge of various applicable codes of practice and do not relate to complicated analysis and design. We try to absorb some of these graduates and groom them to create wonders in the actual design process. Understanding the behaviour of a structure and the load flow path is extremely important in creating appropriate errorless structural design.Looking backAt 71 years of age, Malekar has no future plans as such but is happy to have enjoyed his work so far. I don't look further now. I look back and feel happy, he beams. He desires to impart his knowledge and experience gained to budding engineers. He expresses his gratitude to all his teachers, his brother, professional colleagues and the members of his family for all he has achieved in his career. Appreciation received by him from seniors, colleagues, associates, clients and contractors for his vast contribution to structural engineering is his pot of gold at the end of the rainbow.S B MalekarBachelor of Engineering from the University of Mumbai (1963)Member of the Institute of Engineers, IndiaMember of Maharashtra India Chapter of ACI.Major projects involved inMadras/Narora Atomic Power Project, Mahindra Ugine Steel Plant (Kopoli), SIDOR steel plant, Chandrapur-Padga HVDC project, Reliance Gas Power Station (Goa), Mulund Sports Complex, Kalidas Auditorium, Andheri Sports Complex, substations in Dubai, Ircon Railway Workshops (Damman), Dr Mandke-Kokilaben Ambani Hospital (Mumbai), Peninusula Corporate Park, Sebi Office Building in BKC, Reliance Knowledge City, Kohinoor Square hi-rise, Salalah Pharmaceutical Plant (Oman), Bangalore Sewage Treatment Plant, Panvel Water Treatment Plant, Hotel Lalit International, Ashok Gardens, CIDCO Seawoods Estate, IMAX Theatre, Residence Antilia and many more...Challenging ProjectsProject: ASHOKA GARDENS, PAREL, MUMBAI. Period: 2005-2010 Background: Spread over 12 acre, this residential complex by Piramal Holdings has two towers, each 23-storey high, with three wings each. The wings have been structurally isolated by separation joints. There are eight ramps to reach the podium level. The residential levels have spectacular views of the harbour. Details: The challenge was not only to design the multi-storeyed towers but also the surrounding ancillary buildings with modern amenities, club house, landscaped areas, water features and car parking for their residents. In addition, the complex has a sewage treatment plant and an elegant swimming pool. The structural drawings prepared for this project had to be carefully co-ordinated not only with the MEP services but also with BSES, as two large substations were required.Project: IMAX THEATRE, WADALA, MUMBAI Period: 1999-2000 Background: India's first IMAX Dome was inaugurated in Mumbai on March 25, 2000. This has the world's largest screen, measuring 13,700 sq ft with a capacity of 520 viewers. It provides hi-fidelity, audiovisual experience, in which the film envelopes each viewer with 12,000 W of digital wrap-around sound. The giant screen dome is about 99 ft (30 m) in diameter. Details: The 37 m diameter structural dome is made up of fabricated structural steel open web girders, which divide it into 16 segments. These girders facilitate easy installation of several services. They are supported on an RCC ring beam, which in turn is supported by 16 peripheral columns. The girders converge at the pole of the globe where they are connected to a 4 m diameter compression ring. In addition, there are four circumferential steel girders dividing the entire curved length from the ring beam to the compression ring into five almost-equal parts. Diagonal bracing members along the entire structure provide additional strength and stiffness. The structural dome is also designed to support the catwalks, equipments, speakers, etc. The waterproofing for the entire dome has been carried out using special polyurethane foam insulation followed by an elastomeric membrane. This allows for the expansion and contraction of the surface without ing. The two inclined elevational RCC fins on either side were also analysed and designed to resist wind loads. The speciality of this imposing elevational feature is that each fin is supported at only one point beyond foundation. Due to the 30 degrees tilt in the dome, the forces in each of the girders as well as the RCC members were not evenly distributed. Radial members are subjected to axial compression as well as bending. Therefore, the challenge was to make the dome safe and stable without any distortion. To suit the subsoil conditions, all the columns were supported on pre-cast, pre-bored piles.Project: RESIDENCE ANTILIAPeriod: 1999-2011Background: Located at Altamount Road, in South Mumbai, Residence Antilia is an extraordinary high-rise building and the private residence of Mukesh Ambani, Chairman, Reliance Industries. The original structure was conceived as a structural, steel-framed building, but it was later changed to concrete. As a structural scheme, the elevator and stair cores from the main spine of the building. The remaining areas are supported on suitable column grids. Apart from gravity loading, special attention was given to seismic parameters. Wind tunnel tests were considered to assess both the design wind loads and acceleration arising from wind induced motions. Details: Above the main garden, at 44 m, each mega column was split into four tapering circular columns forming an inverted pyramid. The free-standing height of these tilted columns is 22 m. The construction of these 1,600 mm diameter columns posed a challenge. Two-piece, semi-circular steel forms were specially fabricated for each and every column. These forms were rigidly supported on well-designed staging, and the entire staging was kept in position till the upper floor. Tying all these inclined columns was cast and cured. The second mechanical plant floor at 101 m level as well as the first residential floor at 108 m level is cantilevered by about 9 m beyond the front row of columns. Therefore, a special, well-braced staging of about 56 m height was erected to support the formwork exclusively for these cantilevered floors. This formwork was kept in position for over two months while the superstructure construction advanced. There are two extraordinary helical stairs within the residence for internal communication. Since the designs for these stairs were not finalised at the time of construction of the residence floors, suitable cut-outs were provided in the floor slabs. Subsequently, elaborate fabricated structural steel stairs were erected and anchored into the RCC floors.Give us your feedback on this article at [email protected]
