TTC Building Roofing – FFCL, Mirpur

Project Overview

Millennium Roofing Systems (MRS) partnered with Fauji Fertilizer Company Limited (FFCL) to renovate the Technical Training Center (TTC) building roof at their Mirpur facility — a critical site that serves as the nucleus for FFCL’s technical operations and training programs.

The objective was to replace the existing asbestos roofing, which had begun to deteriorate and posed health and environmental risks, with a modern, sustainable roofing solution.
MRS proposed the use of Onduvilla premium-quality tiles imported from Turkey — engineered for tropical climates, offering superior thermal insulation, waterproofing, and visual appeal.

The project covered 12,000 sq. ft and was completed in 45 days, delivering a safer, eco-friendly, and aesthetically enhanced building roof that aligned with FFCL’s sustainability goals.

Client Challenges

The TTC building was a highly active operational center, meaning:

• On-site activity could not be disrupted during the roofing work.
• Structural modification options were limited due to the building’s role as an essential facility.

To address this, MRS engineered a new supporting structure over the existing roof. Using precision J-bolts and extended tubular metal framing, the team connected the new assembly to the existing structure without removing or disturbing the underlying asbestos sheets. This minimized downtime, ensured operational continuity, and maintained full structural integrity.

Proposed Solution

MRS deployed a technically sophisticated and environmentally responsible solution designed to improve durability and performance while eliminating asbestos hazards.

System Chosen: Onduvilla Premium Roofing Tiles
Material Specification: 3.5mm imported organic fiber sheets (Turkey)
Design Considerations: Wind load resistance, heat reflection, ventilation, and long-term sustainability
Fabrication Details: On-site fabrication of the tubular structure and precision installation of tile panels
Installation Method: Bolt connections and modular on-site assembly

Sustainability Measures: Energy-efficient design, recyclable materials, minimal installation waste, and a fully asbestos-free roofing system

Execution Process

MRS followed a well-coordinated 4-phase approach:

1. Design Phase: Structural design of the new framing aligned with existing roof geometry and load-bearing limits.
2. Fabrication: Custom fabrication of tubular steel structure and mounting frames conducted on-site for exact fitting.
3. Delivery & Installation: Onduvilla tiles installed with J-bolt connections to ensure stability and longevity.
4. Quality & Safety Control: Rigorous safety protocols were maintained, with elevated work procedures, scaffolding systems, and full PPE compliance.

Challenges & Mitigation:
Despite occasional weather delays and roof elevation complexities, all work was completed without operational interruption, owing to meticulous planning and phased on-site execution.