● Efficient Design and Layout
Each feature of the Vestas facility demonstrates a high level of engineering precision and adaptability, enabling seamless integration of mechanical and electrical production lines within one advanced campus.

• Total built-up area of ~350,000 sq ft accommodates dedicated blocks for nacelle and hub assembly (190,000 sq ft), converter production (100,000 sq ft), and generator assembly (60,000 sq ft).
• A 520,000 sq ft open yard and 250,000 sq ft finished goods (FG) area support heavy-component staging, pre-assembly, and dispatch operations across the 27-acre campus, with reinforced surfaces and ample turning radii for trailers and SPMTs.
• The main assembly building is equipped with dual-level EOT crane systems (80 t, 35 t, 20 t, 15 t, 5 t) across bays, allowing parallel lifting operations and uninterrupted production flow.
• Large clear spans and column-free bays create unimpeded movement zones for nacelles and hubs weighing up to 60 tons.
• A staggered roof configuration – higher above assembly, lower above warehousing – optimises daylighting, ventilation, and steel tonnage.
• FM-grade floors are zoned at 5 t/sqm, 7.5 t/sqm and 10 t/sqm to handle variable process loads while maintaining surface flatness for MHE precision.
• Six inbound docks are provided at 1.20 m plinth height for container unloading; outbound bays 0.30 m high facilitate roll-on/roll-off dispatch of completed nacelles.
• HT electrical infrastructure of 3,000 kW is distributed through decentralised power rooms, giving operational flexibility and redundancy.
• The converter hall maintains 20 °C through precision HVAC systems to safeguard electronics during assembly and testing.
• A G+1 RCC office block (~20,000 sq ft) provides direct line-of-sight supervision of shopfloor operations.
• Separate inbound/outbound gates, motorised access control and a 360° boundary wall reinforce site security.
• Landscaped perimeters and parking zones for four- and two-wheelers ensure organised traffic and workforce comfort.

● Strategic and Well-Connected Location
The Oragadam industrial corridor places Vestas at the heart of South India’s manufacturing ecosystem – deep supplier pools (auto/wind), skilled workforce, and multi-modal connectivity for inbound steel/castings and outbound heavy modules. Proximity to national highways, the GST/GWT corridors and Chennai’s ports underpins both domestic dispatch and exports. Strategically located on the NH-48 industrial corridor, Oragadam offers seamless road connectivity to Chennai, Bengaluru, and Sriperumbudur. With proximity to Chennai Port (~59 km) and Chennai International Airport (~39 km), and upcoming rail connectivity via the Avadi–Guduvanchery line, it serves as a key multimodal logistics hub driving South India’s industrial growth.

● Solution-First Methodology: Built-to-Suit, Process-Led Onboarding
The engagement prioritised Vestas’ process maps over generic shed geometry. Joint Greenbase–Vestas engineering exercises (including benchmarking at a reference Vestas plant) informed value engineering: dual-level roofs for crane envelopes, topography-led dual plinths to cut earthworks and carbon, zoned floor loads matched to stations, and decentralised electricals to minimise plant-wide downtime.

● Partnership and Compliance Excellence
A program-managed delivery aligned civil/MEP, HSE and statutory clearances to Vestas’ industrialisation goals in India. The park’s governance and documentation, coupled with Vestas’ global QA and EHS standards, ensured a compliant, scalable platform. The partnership between Vestas and Greenbase-Horizon was defined by transparency, compliance, and shared commitment to global standards, reinforcing long-term partnership continuity and operational trust. Hear from Vestas on their experience partnering with Greenbase-Horizon.

● Rapid Turnaround Time
Following design finalisation in February 2020, Greenbase-Horizon and Vestas targeted facility delivery by October 2020 for trial runs and production commencement by December. When construction began, the first wave of COVID-19 brought nationwide restrictions, disrupting material movement and workforce mobilisation. To uphold the committed timelines, Greenbase-Horizon arranged on-site accommodation for its construction teams and secured special permissions to resume work within the park. All labour welfare, provisions, and medical facilities were ensured during the lockdown period. Despite the unprecedented challenges, the 27-acre facility was completed and handed over by early October 2020 – within just six to seven months – enabling Vestas to proceed with trial production as planned.

● Value-Added Services
Beyond project delivery, Greenbase-Horizon extended comprehensive facilitation support to ensure Vestas’ operations commenced smoothly and on schedule. The team coordinated statutory licensing processes on behalf of Vestas, enabling timely approvals for production start-up. Greenbase-Horizon also assisted in securing applicable incentives from the Tamil Nadu Government, reinforcing the project’s commercial viability and strengthening Vestas’s long-term presence in the state.

● ESG-Compliant & People-Centric Unit
The Vestas Oragadam facility embeds sustainability and workforce wellbeing into its core design, meeting global ESG benchmarks from construction to daily operation.

• Natural daylighting and ventilation reduce mechanical cooling loads; energy-efficient LED fixtures and 3- to 4-star-rated electrical fittings optimise consumption, leading to a low-carbon footprint.
• Structural provisions allow easy future integration of rooftop solar panels to power operations sustainably.
• Separate lines for domestic and flushing water ensure effective resource reuse and minimal wastage and better water reuse.
• Extensive open yards and paved aprons accommodate safe staging of heavy components while minimising dust and runoff.
• More than 1,500 trees planted, with a total of ~2,500 green cover enhancing microclimate and biodiversity, in a landscaped Miyawaki forest.
• Amenities such as canteen, shaded rest areas, and proximity parking improve comfort and retention in multi-shift operations.
• Construction used low-emission concrete and locally sourced materials to reduce embodied carbon.
• Louvred openings and HVLS fans maintain steady airflow, improving indoor conditions year-round.
• Rainwater harvesting pits and stormwater channels integrated across the 27-acre site promote reuse and recharge.