Industrial Structures

Project :  Infrastructure Development for Dahej Petrochemical Complex on Lumpsum Turnkey (LSTK) basis at Dahej, Gujarat.
Client :  ONGC Petro Additions Limited (OPAL).

FEATURES:
Salient scope for infrastructure shall be as follows :
  • Project management, Surveys, Design, Engineering, Procurement, earthwork, Construction, Commissioning of utilities, Installation of all furnishings / equipment.
  • Area of the plant site is 508 Hectares
  • Development of Green belt area work: 4,40,000 Sqm
  • Construction of various infrastructure Buildings like, Guest house, Company/PMC office, Canteen, Medical center, Earth station and Switchyard which include lightning, earthing, lightning protection, LAN, telephone system, office furniture etc.
  • Top soil of the plant site (black cotton soil an average depth of 0.7 m ) to be removed and replaced with borrow earth
  • Borrow earth to be brought to the plant site and filled up to the plant finished (6.6 m/7.1 m/7.6 M) level. An averages fill of around 1.5 mts of the plant site.
  • Boundary wall and Fencing,
  • Various kind of internal roads about 50 kms up to sub base 4m/6m/10 m wide (internal, external, primary & secondary plant roads including lighting.
  • Permanent helipad with lighting system.
  • External and internal Storm water drains
  • Watch towers
  • Water and Sewerage facilities
  • Tennis court, Musical fountain works,
  • HVAC system, Firefighting pump, Fire hydrant & Sprinkler system, Fire alarm system – Heat detectors, Smoke detectors.
  • Water treatment plant, Sewage treatment plant

Highlights of the project
  • Project completion period is 21 months including two rainy seasons
  • Site is located on bank of the Narmada River, which is subject to tidal influence. Their chance of river inundation for some portion of the plant. Erosion protection to be done towards the river side.
  • A huge quantity of earth required to raise the plant site. The earth is borrowed from the out site the plant. The specification of the earth to meet the BS and IS standards. Meeting the fill material (borrowed earth) specification is the most important criteria for this project.
  • External and internal Drainage system has to be optimal design & simulated using micro drainage software.
  • Guest House Building Architecture to be done shall be as using a world renewed architect like Hafeez contractor as per client requirements
  • Safety is most important for this project, lot of vehicular traffic movement takes place during the earth fill operation


Project :  Civil & Structural works, Offsite & utilities for Guru Gobind Singh Refinery Project of M/s. HPCL - Mittal Energy Limited at Bathinda (Punjab).
Client :  HPCL – Mittal Energy Limited.

FEATURES:
  • Construction of Pre-cast RCC Sliding sleepers and Cast-in-situ RCC Anchor sleepers for laying of above ground Fire water, cooling water and process lines.
  • Construction of R.C.C. Pavements in Pump Stations, valve operating areas and Rail & Road loading Gantries.
  • Construction of Electrical and Instrumentation road crossings (ERC / IRC).
  • Construction of Pre-cast RCC Pipe way Bridges under roads.
  • Supply and Laying of U/G RCC pipes for OWS, CRWS and Sanitary sewer lines.
  • Laying of U/G Carbon Steel pipes for OWS and CRWS.
  • Construction of RCC manholes for OWS/CRWS and brick manholes for Sanitary Sewer.
  • Civil works pertaining to Fire water reservoir and pump house.
  • Above ground GI piping for overhead drinking water tank.
  • Construction of Storm water pond.
  • Approach roads to buildings and units along with drains and culverts.

Project :  EPC Contract for TATA Cummins Limited (TCL) Plant at Phaltan, District Satara (Maharashtra).
Client :  Cummins India Limited & TATA Cummins Limited.

FEATURES:
25 Acres Land under Development.
  • Manufacturing Plant Area:
  • Utility Block:
  • AC Chiller Plant:
  • Office Building (Admin Block):
  • Total Area: 3.28 Lac Sq.ft.

Main Plant Building
  • 150m x 135m covers Area with Concreting over Roof Sheeting with Water Proofing,
  • Plastering & Tiling over insulation.
  • Entire Structure for the Assembly Line & all required Machine Foundations.
  • 15 m Long Roof Primary & Secondary Trusses.
  • Heavy R.C.C. Design for Columns and Footings & Attractive FCR Masonry.
  • Double Skin Insulated Roofing / Cladding / ACP System.
  • Aluminum Metal Cladding Work.
  • Structural Glazing System in the form of Fixed Panels.
  • Motorized Rolling Fabric Shutter System.
  • Granite Flooring & Cladding Work.
  • Admin Building along with ACP & Structural Glazing Work.
  • Chiller Plant with U.C.R. & Fine Dressed CR Masonry.
  • Utility Building (G + 1with U.C.R. & CR Masonry.
  • Material & Main Gate along with the ACP Cladding work.
  • Coolant Shed & Oil Shed along with Roof Sheeting & Side Cladding.
  • LPG Shed along with Roof Sheeting
  • Storm Water Drains & Rain Water Harvesting Pits
  • Paint Shop along with Roof Sheeting & Side Cladding.
  • Scrap Yard along with Roof Sheeting.
  • Internal Roads (Tremix) & Gabion Wall

OTHER WORKS:
  • Area Grading and Site Development
  • Allied Works
  • Boundary wall
  • Internal Roads
  • Tube wells

Project :  Design, Preparation of Construction drawings, Fabrication Drawings of Civil & Structural work for External Coal Handling system at Mundra, Gujarat, India.
Client :  Coastal Gujarat Power Limited (A TATA Power Company).


Civil Work Package: Design and Construction of all Main Civil Works for External Coal Handling System
Structural Work Package : Design and engineering, manufacture, inspection at working, packing and forwarding, supply and delivery FOR site (up to Mundra jobsite) associated with structural steel and other items for External Coal Handling System

FEATURES:
  • All foundations are supported on Piles.
  • Structural Concrete, Stacker cum Reclaimer Foundation, Stock Pile area, Supply, Fabrication, sand Blast, Painting & Erection of Structural Steel, Supply and installation of Sheeting and Cladding
  • On ground and above ground Conveyor Galleries (Two/Four Legged Trestle), Junction Towers
  • Construction of SWGR & Control Room, Dust Pump houses, Dozer shed

Project :  Civil & Structural works including Supply, Foundation, Fabrication, and Painting & Erection of Technology Structural Steel works related to Coke Drum Area of Delayed Coker Unit (030) of Paradip Refinery Project in Orissa.
Client :  Indian Oil Corporation Limited.

FEATURES:
  • Civil structure up to 35 m above GL.
  • Steel Structure upto 130 m above GL, erected in 45 days.
  • Entire structure executed in about 14 to 15 months.
  • Entire steel structure erected in 14 modules.
  • Fabrication got done outside about 100 km away.
  • 1600 MT crane along with three more cranes of 600 ton, 450 ton and 250 ton cranes used for lifting the modules for 45 days costing about 15 lakhs a day

The mammoth concrete foundation for coke drums has been successfully completed on 22nd August 2012 in a record time of 9 months in DCU, PDRP, Paradip. This is the largest & the tallest concrete foundation for coke drums in any of the refinery in World. A brief comparison amongst the existing coke drum foundations in different refineries has been tabulated as follows as per data collected

S. No.
Description
Baroda Refinery
Panipat Refinery
MRPL
Guwahati Refinery
PDRP Paradip
1
Deck Slab Height
28 Mtr
27 Mtr
29 Mtr
25 Mtr
35 Mtr
2
RCC Super structure
6445 Cu.M
5700 Cu.M
6000 Cu.M
5500 Cu.M
10300 Cu.M
3
Time taken for deck slab
8.5 month
10 month
11 month
9 month
9 month


The world's biggest Coke drums (4 no; each weight 630 MT, height 45 mtr and Dia 10.7 mtr.) shall be mounted on aforesaid concrete foundation. Besides aforesaid, supporting steel structure for Coke Drums & Derrick shall be installed on this concrete foundation which will ultimately turn into a tallest structure (128 M) in entire Paradip refinery.

Teams were tirelessly involved to accomplish a strenuous task of mega concrete foundation. With this accomplishment, a major critical mile stone has been achieved in construction of Delayed Coker Unit.

Project :  Construction of Civil Works for the Factory Premises in Kharagpur for TELCON.
Client :  TELCON Construction Equipment Company Limited .

FEATURES:
  • Civil Work for PEB & Non PEB Buildings, Road, Drainage, Water Dist. Etc of entire plant.
  • Telco Construction Equipment Company (Telcon) Factory at Kharagpur, West Bengal, a green field project, was completed within a record time of 23 months by us.
  • Phase-I comprised of 45,000cum RCC including 55,000Sqm vacuum Dewatering Flooring (VDF) in different Pre¬ Engineering Buildings.
    • Training Centre & Hostel
    • Guest House
    • Test Track
    • Roads etc.

Project :  Civil work, Structural Fabrication, Erection and Alignment for the WIRE & BAR MILL Project at JSPL, Patratu (Jharkhand).
Client :  Jindal Steel & Power Limited.

FEATURES:
  • The first green field steel plant executed by company
  • Structural Fabrication and Erection
  • Structural Concrete
  • Walking Beam Furnace & Charging Grade
  • Construction of Cable Tunnel
  • Construction of 50 meter Hight over headwater tank by using slip form
  • Cooling Towers
  • Pre-coated GI Sheeting

Project :  Civil, Structural & Associated UG Piping works of MS Quality Upgradation project at Guwahati Refinery, Guwahati.
Client :  Indian Oil Corporation Limited.

FEATURES:
  • Supply, Fabrication and erection of Structural Steel up to a height of 55m;
  • Electro forged Galvanized Grating along with associated RCC foundation including tanks and underground Piping works
  • Construction of Pipe Rack, Dryer, Compressor Shed, Reactor Structure, Pipe Rack, Splitter, U G Piping, Roads, Culverts, Drains and Dyke Wall etc.,
  • 1) RCC
    2) Reinforcement
    3) Hand Railing

Project :  Expansion of Factory Building (PEB), Civil, Plumbing, Electrical, HVAC, Fire Fighting, Telecommunication and Landscape for Parker Hannifin India Pvt. Ltd. at Mahape, Navi Mumbai.
Client :  Parker Hannifin India Pvt. Limited.

FEATURES:
  • Factory Shed
  • Administration Building
  • Pre- Engineered Building
Electrical Works, Fire fighting, Landscaping, Internal Roads, PEB Shed, Structural Steel, Other items such as plumbing area grading etc

Project :  Main Plant, CW, Offsite civil works and Chimney & Chimney Elevator package for Solapur Super Thermal Power Project ( 2x660 MW) in Maharashtra.
Client :  NTPC Limited.




Scope of Work: Boiler Area, Power house, ESP Area, Chimney, Ash handling system, Admin. Building
  • Foundations for Boiler, ESP, FANS, MILLS, TG, BFP, DG sets, transformer, yard including CW ducts in transformer yard area, auxiliary boiler, BA hopper, FAE tower & other equipments
  • All foundations, over ground civil, structural & architectural works for main plant building, compressor house, air washer buildings, ESP control building , service building
  • All foundations & only RCC floors of superstructure for mill & Bunker buildings, transfer points, Conveyor Galleries & trestles of CHP in main plant area excluding structural steel & sheeting work
  • Building & structures in offsite area (non plant buildings)
  • All Civil, Structural & Architectural works for CW system like CW pump house including maintenance bay, forebay, stoplog and trashrack, SACW pump houses, trash rack, RCC/PCC encased mild steel CW ducts, fabrication, & erection, of all pipes of sizes etc
  • All foundation, superstructure & Architectural works for all buildings and facilities for CPU regeneration area,
  • All foundation, superstructure & architectural Works for all buildings & facilities for ash handling and ash water recirculation system
  • Foundations for fly ash silos, HCSD Silos, settling tank/surge tank , bottom ash overflow tanks ,etc, ash slurry trench , culverts for ash pipe corridor inside plant boundary and road & ash pipe corridor
  • Ash pipe pedestals and thrust blocks inside plant boundary, outside plant boundary upto ash dyke & garlanding pedestals on ash dyke including discharge points
  • Roads/drain inside plant, roads & drain outside plant boundary and up to final disposal point.

Project :  Main Plant, CW, Offsite, AHP civil works, Chimney & Chimney Elevator package for Mouda Super Thermal Power Project, Stage - II (2x660 MW), Mouda, District Nagpur of Maharashtra.
Client :  NTPC Limited.

Scope of Work:
  • Piling work for various structures
  • Excavation for various structures & foundation
  • Concreting for various structures involved
  • Str. steel works includes various Str. like TG area,
  • Pipe-rack & other BOP buildings etc.
  • Painting of structural steel with PU paint
  • Sheeting for the structure.
  • Masonry with autoclave aerated block.
  • Plastering of the structure.
  • Flooring with vitrified, ceramic, granite, marble tiles
  • Door window, glass & glazing work.
  • False ceiling work.
  • Plumbing work.
  • Stop log gate Trash rack, lifting beam etc.
  • Chimney including steel flue, elevator & electrical.

Project :  SG Area & Offsite Civil works package for Kudgi Thermal Power Project Stage-I (3x800 MW) for NTPC.
Client :  NTPC Limited.


Scope of Work:

  • Foundations for Boiler, ESP, FANS, MILLS, TG, BFP, DG sets, transformer, yard including CW ducts in transformer yard area, auxillary boiler, BA hopper, FAE tower & other equipments
  • All foundations, over ground civil, structural & architectural works for main plant building, compressor house, air washer buildings, ESP control building, service building
  • All foundations & only RCC floors of superstructure for mill & Bunker buildings, transfer points, Conveyor Galleries & trestles of CHP in main plant area excluding structural steel & sheeting work
  • Building & structures in offsite area (non plant buildings)
  • All civil, structural & architectural works for CW system like CW pump house including maintenance bay, forebay, stoplog and trashrack, SACW pump house trash rack, RCC/PCC encased mild steel CW ducts, fabrication, & erection, of all pipes of sizes etc
  • All foundation, superstructure & Architectural works for all buildings and facilities for CPU regeneration area,
  • All foundation, superstructure & architectural Works for all buildings & facilities for ash handling and ash water recirculation system
  • Foundations for fly ash silos, HCSD Silos, settling tank/surge tank, bottom ash overflow tanks etc., ash slurry trench, culverts for ash pipe corridor inside plant boundary and road & ash pipe corridor
  • Ash pipe pedestals and thrust blocks inside plant boundary, outside plant boundary upto ash dyke & garlanding pedestals on ash dyke including discharge points
  • Roads/drain inside plant , roads & drain outside plant boundary and up to final disposal point