Planning methods of new industrial parks and retrofitting of existing industrial estates in

Gujarat

Duration: 19 - 22 April, 2017 Venue: Auroville, Tamil Nadu

Training Outputs

Standards. Concepts. Work Plan.

Contents

1. Introduction ..................................................................................................... 4

2. Programme Overview ..................................................................................... 4

3. Training Outcomes ......................................................................................... 5

4. Summary of Major Decisions Taken ............................................................. 16

Annexures

1. Introduction

An important decision was taken during the a day-long workshop organised by the Gujarat Industrial Development Corporation (GIDC) and GIZ on 18th January 2017 at Gandhinagar to initiate retrofitting of 5 nos. of industrial estates, namely, Vapi GIDC, Vatva GIDC, Naroda GIDC, Ankleshwar GIDC and Aji (Rajkot) GIDC; and also revise the site master plan prepared for the industrial park for women entrepreneurs at Sanand with the technical support from GIZ. A first significant step was undertaken by GIZ in the form of an intensive 3-day training on “Planning methods of new industrial parks and retrofitting of existing industrial estates in Gujarat” for the officers of the Gujarat Industrial Development Corporation (GIDC).

2. Programme Overview The programme schedule of the training is given at Annexure 1. The key objectives of the training programme were: Prepare an initial list of Quality Parameters (economic, environmental, social, legal

compliances, infrastructure & services, management & processes) to be integrated into the site master plans, including infrastructure and special provisions needed to cater to women entrepreneurs.

Come up with modalities for plan preparation – e.g., teams from GIDC or consultants, support from GIZ etc.

Next steps and Work Plan for preparing site master plan for retrofitting of GIDC Vapi industrial estate which can be replicated to other industrial estates

The following documents were used for reference:

1. Handbook on planning of sustainable industrial parks - Developed by GIZ in 2017

2. Assessment of the Existing Industrial Areas and Elaboration of a Sustainability Master

Plan - Developed by GIZ in 2017

3. Technical EIA guidance manual for common effluent treatment plants

- Developed by IL&FS for MoEFCC in 2009

4. Technical EIA guidance manual for common effluent treatment plants - Developed by IL&FS for MoEFCC in 2009

5. Guidelines for developing greenbelts

- Developed by CPCB in 2000

6. Rain water harvesting and conservation manual - Developed by CPWD in 2002

All the documents and presentations used during the programme have been formally shared with each one of the participants. The technical sessions during the training programme were inter-weaved with practical work (hands-on exercises) and field visits to understand various low-cost innovative technologies. (Refer pics below).

Pic. 1: Proceedings during training programme

3. Training Outcomes

Product 1:

Understanding quality benchmarks and identifying gaps in site master plans of GIDC estate at Vapi and women industrial park at Sanand

A comprehensive benchmarking system for industrial parks was elaborated to the participants. This system is based on the inputs from DGNB (German Sustainable Building Council) and experiences of GIZ. Also, it includes some of the ongoing thought process of developing international standards jointly by GIZ, UNIDO and the World Bank. This system consists of the 6 quality parameters as depicted in Fig. 1. During the training, participants were divided into 2 working groups to discuss the benchmarks and identify the gaps in their industrial parks. The participants delved into a variety of quality benchmarks which are grouped under 6 categories.

Fig. 1: Quality benchmarks for industrial parks The two working groups listed the benchmarks which are relevant for preparation of site master plans for retrofitting of 5 nos. industrial estates, namely, Vapi GIDC, Vatva GIDC, Naroda GIDC, Ankleshwar GIDC and Rajkot GIDC and also revision of the site master plan of the women industrial park at Sanand. Group 1:

Economic quality » Total investments » Saleable cost » Spatial efficiency » Rental or ownership of plots by

businesses » Incentives for “green” measures

Legal compliance quality

» Compliances at industrial park level as national regulations (Part of environmental clearances)

» Compliances as per national regulations (comes under GPCB/CPCB) Compliance with International agreements/commitments

Socio-cultural quality » Online grievance cell » Gender needs » Security » Primary infrastructure for workers » Participatory processes » Housing » Sports facilities » Creche » Handicap access » Library » Safe food stalls » Public toilet provisions » AED cardiac arrest » Community facilities » Neighbourhood celebrations

Environmental quality

» Company level

Production process

Waste/ wastewater recycling

Lean manufacturing

Sustainable procurement

» Industrial park/estate level

Infrastructure and services quality

» Relevance to urban/ local/ regional master plan (under AUDA etc.)

» Planning concepts » Logistics concept » Art and design » Design quality

Storm water drainage system

Bioswales

Rain water harvesting measures

Free areas as wetlands

Constructed wetlands

Resource efficiency

Effects on local environment

Climate change mitigation and adaptation

Biodiversity preservation

Disaster risk preparedness

By-products

Effects on global environment

» Unique skyline » Scenic views » Passive design » Green buildings » Traffic connectivity » Quality and management of the

bicycle network » Efficient vehicles » Employee transport » Parking » Energy efficiency (GCPC , GPCB

role) » Clean energy strategy » Smart grid » Combined heat and power plant » Waste to power » Thermal storage usage » Irrigation systems » Natural green care » Fresh air corridor » Urban gardening » Functional landscape » Systems connectivity » Cyber security » Smart material selection » Re-use of building stock » Construction work and materials » Resource efficient infrastructure » Business incubator » Equipment rental » Biomass provision » Drip irrigation systems

Group 2:

Economic quality

» Revenues » Employment » Cost cutting for businesses » Saleable cost » Spatial efficiency » Investment safety » Maintenance costs » Rental or ownership of plots by

businesses » Incentives for “green” measures » Competiveness » Special status industrial park » Minimum overheads and

vacancy costs » Reputation of the park developer

Socio-cultural quality

» Employment » Entrepreneurship » Security » Public toilet provisions » AED cardiac arrest » Industrial park day service » Encouragement of NGOs » Elimination of child labour

Management and process quality

» Industrial park management unit » Integration with natural

community » Environmental management

system » Energy management system

» Quality assurance and monitoring

» Facility management

Environmental quality

» Company level

Production process

Waste/ wastewater recycling

Industrial symbiosis

Circular economy » Industrial park/estate level

Water circularity

Water preservation

Non potable water

Storm water Management

Wastewater management

Wastewater pollution control

Minimise non-recyclable goods/materials

Waste preservation

Emissions and air pollution control

Demand for drinking water and waste water production

Resource saving infrastructure

Use of locally and responsible produced materials

Effects on local environment

Environmental monitoring

Climate change mitigation and adaptation

Flood protection

Biodiversity preservation

Legal compliance quality

» Compliance with National Environmental Laws

» Compliance with National Social Laws

» Compliances at industrial park level as per national regulations

» level as per national regulations

Infrastructure and services quality

» Site master plan » Guidance systems » Way finding » Traffic signals » Traffic risk reduction » Promotion of safe transport and

storage » Traffic congestion reduction » Appropriately sized roads » Utility corridors » Parking » Power and energy systems » Plantation and landscaping » IT infrastructure » Resource efficiency » Common infrastructure

Product 2: Conceptual provisions in site master plans of GIDC estate at Vapi and women industrial park at Sanand

Under this product, the two working groups identified the quality parameters which can be positioned in the site master plans of GIDC estate at Vapi and women industrial park at Sanand to reduce their problems or make them more economically, socially and environmentally sustainable. Group 1: Sanand The group 1 worked on the layout of women industrial park at Sanand and listed the parameters which can be included there.

Pic. 2: Quality parameters for inclusion in the site master plan of women industrial park at Sanand

One important reflection from the participants of this group was that the women industrial parks at Sanand is part of a large industrial estate. Many of the provisions have been made in the larger setting. In addition, following can be considered in the central facility zone as marked on map-

1. Provisions for storm water management- bioswales, rain water harvesting systems, micro-climate control

2. Provision for waste water and waste management systems 3. Air pollution control 4. Provision of gender based needs e.g. crèche 5. Social amenities 6. Art and design for branding and identity 7. Green buildings 8. Visitors centre for developing business 9. Laying of pipes for re-use of treated water 10. Bi-cycling system 11. Material selection 12. Space provision for kiosks 13. Sprinkler based watering system 14. Provision for battery operated vehicles 15. Visually aesthetic and functional streetscapes 16. Botanical garden 17. Soil protection

Group 2: Vapi The group 2 worked on the layout of GIDC estate at Vapi and listed the parameters which can be included there.

Pic. 3: Quality parameters for inclusion in the site master plan of GIDC estate at Vapi

During the development of this product, the participants observed the high level of complexity for retrofitting GIDC estate at Vapi owing to saturation of space, thoroughfare of traffic, surrounding industrial areas etc. Hence, it was rather difficult for them to make provision of these parameters on the layout map. However, the group selected following parameters as priority interventions required in the site master plan-

» Redesign of utility systems like electric cables, water supply main, drainage etc. » Street cross section to include gas line, optical fibres, steam transport » Provision for better way-finding systems, e.g. signage with street names and other

facilities » Use of paver blocks » Road side plantation » Augmentation of water supply scheme

The participants were oriented to a systematic, scientific and participatory set of various processes which together can accomplish the site master planning task. On comparison, it was found that the current site master planning process followed at GIDC needs certain plug-ins. Most importantly, currently the planning process results in a DDP (Detailed development plan) which needs to be backed by a report containing process of site selection, site suitability assessment, basis of area calculations for land use and infrastructure (facilities and utilities), summary of provisions made, thematic layers etc. The site master plan document should consist of:

» Report with texts » Thematic maps and plans » Design concepts of the proposed development » 3D visualisations of the proposed development » Broad cost estimates and business models for implementation

» Management structures for developing and operation & management of the industrial park

This shall ensure that physical planning, economic planning and management aspects are interweaved. Implementation would be ensure that adequate provisions are made for different infrastructure, spatial efficiency etc.

Fig. 2: Process map for site master planning of sustainable industrial parks As a conclusion of this exercise, the participants were in sync with the scientific method of site master planning. They considered that the site master plans should be systematically developed and that the following aspects were important to be considered:

» Prepare all maps in an appropriate scale as required for statutory approval from the local authorities.

» Create GIS based database. » Ensure urban integration - Industrial park within an urban area should be designed with

the urban context in mind. For example, the overall site should be designed with good connectivity to public transport and other social and commercial infrastructure. The site should also be respectful of surrounding urban facilities with regards to public realm design, waste management, etc.

» Ensure that all the six Quality Parameters are included in the Site Master Plan, viz. Regulatory Compliance Quality, Management Quality, Economic Quality, Environmental Quality, Social Quality, Infrastructure & Service Quality.

» Integrate planning concepts - soil protection concept, biotope networking concept, integrated water concept, concept of functional mix of uses, integrated traffic concept, integrated energy concept etc.

» Logistics concept - logistic support provisions for factories and employees, including business centre, one-stop-services, administrative building, information centre, warehouses/raw material depots, training centre, design centre, product/material testing facility, commercial zone etc.

Sustainable industrial

parks

» Ensure space utilisation efficiency. » Business clustering/zoning - when similar businesses or production facilities cluster,

supporting services often follow, such as legal, accounting, raw materials and technical services. The groupings of these like-minded businesses and their supporters can lead to opportunities for increased efficiency and the more rapid development of new ideas.

» Green buildings, building standards, building orientation » Mobility management, appropriately sized roads, hierarchies traffic connectivity,

bicycle tracks, pedestrianisation, signage, maps, traffic alert displays, access to mass transportation, freight and cargo management, employee transport, parking etc.

» Energy efficiency, renewable energy systems. The master plan preparation will include stakeholder consultations at various stages. To bring in a dialogue between the stakeholders and the experts, service providers etc., the group decided that an international conference should be organised in Vapi in November/ December. GIZ would provide in-kind support for the planning and organising of the conference.

International conference to be organised by GIDC at Vapi

November/ December, 2017

Product 3: Work plan for development of the site master plan for retrofitting of GIDC industrial estate at Vapi

Tasks involved in site master plan preparation: Following set of tasks will be required to prepare a viable site master plan for retrofitting of GIDC industrial estate at Vapi.

Task 1 Baseline assessment » Updation of all baseline data/information onto scale drawings

in GIS for 6 quality parameters as mentioned in section 3.

3-5 months

Task 2 Preparation of thematic maps » Development of thematic maps (e.g. land use, transportation

and mobility, environmental infrastructure including green spaces, storm water, waste water, social infrastructure, energy infrastructure, solid waste infrastructure) with complete information on GIS based database.]

» Undertake assessments of gaps and additional needs.

» Identify suitability sites/areas in the industrial park for provisioning new requirements in the site master plan.

2-3 months

Task 3 Integration of thematic maps into draft site master plan » Prepare a draft Site Master Plan for the industrial park in an

appropriate scale as may be prescribed by GIDC. The site master plan shall have all the provisions as required by the sustainability standards/benchmarks. The plan shall adhere to all statutory/legal requirements.

2-3 months

» Detail out design concepts that can be used during implementation of the site master plan. e.g. energy and renewable energy systems, landscape, waste water treatment systems, storm water management systems.

» Detail out financial viability aspects and infrastructure and

services delivery mechanisms for various provisions made in the site master plan. Example: Sources of funding, PPP, public funding, private funding etc.

Task 4 Finalisation of site master plan for retrofitting of GIDC industrial estate at Vapi » Prepare the final site master plan with report, thematic maps,

visuals, details of area, and estimates for provisions.

» Incorporate the inputs received from stakeholders and submit finalise the site master plan

1-2 months

Engagement of consultants for site master planning: During the interactive session with GIDC officials, it was realised that GIDC might not have in-house capacity to take up the required tasks. Hence, GIDC may tender it out and select competent consultants. GIZ will support GIDC in developing standard ToRs for issuing out tender.

The time required considering the complexity of the tasks involved and the lacking systematic database readily is 10-12 months. Considering the manpower requirements and the operational costs towards surveys, GIS work etc., the rough estimates for the consultants services for site master planning for one site (e.g. GIDC Vapi) is upto Rs. 1.5 crore.

The consultants’ team may be structured as below:

Note: » The sector experts would include: environmental expert, water expert, energy expert,

landscape expert, buildings expert etc. » The junior experts would consists of: graphic designer, content writer, GIS expert » The operational costs would include field surveys, geographical surveys, GIS, remote

sensing data etc. For engagement of consultants by GIDC, GIZ will develop a proposal including ToR, concept note, time plan, cost estimates etc.

Team leader

(Town planner)

1 no.s @ 6 months

Sector experts

6 no.s @ 4 months

Junior experts

3 no.s @ 12 month

GIZ will provide expert inputs during the preparation of site master plan by the consutlants engaged by GIDC.

Proposal to be prepared by GIZ for GIDC to engage consultants for site master planning

May 31, 2017

Tendering by GIDC and selection of consultants June- July, 2017

Site master planning for GIDC Vapi August 2017 to April 2018

Steering structure:

GIDC should initiate stakeholder processes for compiling baseline data and priorities with key stakeholders- VIA, VGEL, NAA and Industries Commissionerate, Industries & Mines Department of Government of Gujarat. GIDC should also form steering committee headed by the Ex. Engineer, GIDC with representation of site level engineers and industries association (VIA). This committee shall conduct consultations with multi-disciplinary team to ascertain: » Details required in the baseline study » Presentation and agreement on solutions/concepts » Quality check and approval For each task, steering committee should play a key role in generating stakeholder consensus and feedback. GIZ will be part of this steering committee and provide technical support and advisory for baseline study through its in-house team.

Formation of steering committee by GIDC [members from head office, regional office, VIA, VGEL, GIZ, GPCB, NAA, representatives of Sanand GIDC, Vatva GIDC, Naroda GIDC, Ankleshwar GIDC and Aji (Rajkot) GIDC, others ]

May 31, 2017

Implementation of pilot measures in the 5 industrial estates

Pending the development of detailed site master plans for the identified industrial areas, following measures were listed by the participants, based on successful models from Auroville, which could be taken on pilot basis in the industrial estates in Gujarat as an interim solution:

» Use of compressed earth building blocks in the new constructions (e.g., governmental

buildings) » Conversion of existing factory buildings into green buildings » Installation of decentralised waste water treatment systems are recycle/reuse of treated

wastewater » Waste management systems (e.g. composting, wastepaper recycling into handmade

paper & products)+ » Installation of solar PV and renewable energy systems » Provision of public toilets » Plantation and landscaping, including nurseries, organic farming etc. » Development of recreation centres

4. Summary of Major Decisions Taken

1. Retrofit site master planning to be initiated for GIDC Vapi and similar process taken up for other 4 industrial estates [Vatva GIDC, Naroda GIDC, Ankleshwar GIDC and Aji (Rajkot) GIDC] eventually.

2. For retrofit site master planning of GIDC Vapi, a proposal to be developed by GIZ for engagement of consultants. Accordingly, GIDC to engage consultants. GIZ will provide technical support and review the outputs of the consultants for quality checks.

3. Implementation of certain identified measures based on successful case examples from Auroville would be taken up by GIDC for the above 5 industrial parks.

4. For GIDC Sanad, GIDC’s own team will take up revision of the Site Master Plan, or alternately will engage a consultant (similar to GIDC Vapi).

5. A national/international conference will be organised in Vapi by GIDC in

November/December 2017 to prepare for implementation/retrofitting of GIDC Vapi.

6. The GIDC teams of Vatva GIDC, Naroda GIDC, Ankleshwar GIDC and Aji (Rajkot) GIDC will be associated at various stages of preparation of retrofit master plan for GIDC Vapi.

7. GIDC to notify teams for overseeing the activities from GIDC HQ and from the selected

6 industrial estates.

8. Next review meeting of GIDC and GIZ teams will be held after 6 months to discuss on progress achieved in the 6 industrial estates.

^^^

Annexure 1: Programme Schedule

Starting 19-Apr (Wed)

20-Apr (Thu) 21-Apr (Fri) 22-Apr (Sat)

8:00

Arrival in

Auroville

Check in

Breakfast &

Transfer Breakfast & Transfer Breakfast & Check

out

8:30

9:00

9:30 Program Orientation

10:00 Understanding Vapi

& Sanand

Site Master Planning

[Moderator: Anshika

Gupta]

Energy Efficiency

[Expert: Deepak] 10:30

11:00 Assessing

Industrial Parks

[Moderator: Mr.

Raghu Babu]

& Master Planning

[Expert: Suhasini

Iyer]

Field Visit :

Decentralized Waste

Water Treatment

[Expert: Tency]

Renewable Energy

[Expert: Sumedha] 11:30

12:00 Rainwater Harvesting

[Expert: Shama] Carbon Free

Mobility Planning

[Expert: Pawan] 12:30 Site Master Planning

(Contn)

13:00 Lunch

(Well Cafe)

Lunch

(Solar Kitchen)

Lunch

(Solitude Farm) 13:30

14:00

14:30

OPTIONAL:

Orientation

to Auroville,

Matrimandir

and

Boutiques

Field Visit: Earth

Institute;

[Expert: Radhika]

Field visit: SPV

Thermal

[Expert: Deborath]

Plenary: Work Plan

[Moderators:

Anshika, Toine,

Martin]

15:00

15:30 Field visits to

places around

Auroville

Field visit : Sustainable

Waste Management,

[Experts: Kali] 16:00 Tea Break

16:30 Tea Break Plenary: Work Plan

Presentations by

groups

[Moderators:

Anshika, Toine,

Martin]

17:00 Water Planning

[Expert : Tom]

(Location : Purple

Resorts)

Sustainable Urban

Energy [Expert: Toine]

(Location : Purple

Resorts)

17:30

18:00

Free Time Free Time Free Time

Feedback;

Distribution of

certificates 18:30

19:00

Registration,

Welcome,

Orientation

and Dinner

Hands-on Exercise

[Moderator: Raghu

Babu] (Location

Purple Resorts)

Hands-on Excercise

[Moderator: Anshika]

(Location : Purple

Resorts) Departure from

Auroville

19:30

20:00

Dinner Dinner 20:30

21:00

Prepared by: Deutsche Gesellschaft für Internationale Zusammenarbeit (GIZ) GmbH Registered offices at Bonn and Eschborn, Germany B-5/1 Safdarjung Enclave New Delhi 110029 T: +91 11 49495353 F: +91 11 49495391 W: www.giz.de/india Responsible: Raghu Babu Nukala Director Sustainable and Environment-friendly Industrial Production (SEIP) Author: Anshika Gupta, Technical Advisor, SEIP Photo credits: GIZ SUID Photo bank Auroville Consulting New Delhi, May 2017

Deutsche Gesellschaft für Internationale Zusammenarbeit (GIZ) GmbH Sustainable and Environment Freiendly Industrial Production Project Sustainable Urban and Industrial Development B-5/1, Safdarjung Enclave New Delhi 110029 INDIA T: +91 11 49495353 I: www.giz.de; http://seip.urban-industrial.in/