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  • Writer's pictureEngineering Division

Retrofitting of an Industrial Pharmaceutical RCC Building: A Case Study in Jejuri, Maharashtra

Updated: May 17


In the realm of industrial infrastructure, the safety and longevity of structures hold utmost importance. Retrofitting, the process of upgrading existing structures to enhance their strength and stability, becomes imperative, particularly in environments where structural integrity directly impacts operational continuity and safety standards. In this blog post, we embark on a comprehensive journey through the retrofitting process of an industrial pharmaceutical RCC building situated in Jejuri, Maharashtra. From initial assessment to execution, each step underscores the criticality of retrofitting in ensuring structural resilience and occupant safety.

Identifying Issues:

The initial step in retrofitting any structure involves a meticulous examination to identify existing issues compromising its integrity. Upon inspection of the pharmaceutical RCC building in Jejuri, several concerning issues surfaced. These included cracks in columns, ponding in the slab, visible cracks in beams all of and bent columns, which raised red flags regarding the structure's stability, necessitating immediate attention.

issue solve- temporary support provided to all slabs

issue solve- bending in beam

issue solve- column buckling

issue solve- slab bending

Inspection and Analysis:

To address the identified issues comprehensively, a thorough inspection and analysis of the structure were imperative. Non-destructive testing (NDT) methods were employed, augmented by laser equipment to detect deflections. Manual checks were also performed to assess the extent of cracking and buckling. The insights gleaned from these inspections served as crucial data points for further analysis and informed subsequent decision-making.

Designing Solutions

Armed with a comprehensive understanding of the structural deficiencies, the focus shifted towards devising robust retrofitting solutions. Utilizing cutting-edge structural analysis software such as STAAD and finite element method (FEM), engineers meticulously dissected the original design and construction methodologies. Unveiling discrepancies in design and execution practices, the groundwork was laid for a comprehensive retrofitting blueprint. This blueprint encompassed a spectrum of strengthening measures including rebar reinforcement, column fortification, introduction of steel beams beneath RCC counterparts, and augmentation of slab thickness. Detailed working drawings crystallized these solutions, laying the groundwork for the imminent execution phase.

staad design

staad design

Execution and Monitoring:

With the retrofitting plan finalized, the execution phase kicks off. Third-party vendors are enlisted to implement the structural modifications outlined in the designs. Regular inspections are conducted throughout the execution process to ensure adherence to the retrofitting plan and maintain comprehensive documentation. This stringent approach to execution is indispensable in upholding the structural integrity and safety of the pharmaceutical RCC building.

execution and monitoring

execution and monitoring

execution and monitoring


The retrofitting of the industrial pharmaceutical RCC building in Jejuri, Maharashtra, underscores the paramount importance of proactive maintenance and structural upgrades in safeguarding existing structures. By meticulously identifying issues, conducting comprehensive inspections and analysis, designing effective solutions, and executing the retrofitting plan diligently, the structural integrity of the building was successfully restored. This not only ensures the safety of occupants and assets within but also enhances the resilience of industrial structures against unforeseen challenges. This case study serves as a compelling testament to the significance of retrofitting in fortifying existing structures for the future.

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