Structure Enhancement

Industry:
Construction and Heavy Equipment Manufacturing

About the Customer:
A global leader in construction equipment, this company entered the Indian market in 1979 and has since established itself as the segment leader for backhoe loaders. Starting with its first manufacturing plant in Ballabhgarh, the company expanded its footprint with a modern plant in Talegaon, Pune, in 2006-07. Today, it operates three facilities across India, serving both the domestic and global markets with state-of-the-art equipment production.

The Backdrop:
For the construction of a new facility in Jaipur, a prominent engineering firm provided a 450MT steel structure for the plant, which was divided into eight bays. Initially, 200MT of steel was used to erect the first manufacturing bay, with columns installed for the remaining bays but lacking the necessary gantry and truss installations.

During the initial assessment of the site, Sparkline identified potential stability concerns, noting that the absence of end ties might impact structural integrity under load. After installation of a 5MT capacity SGEOT crane and lightweight rail system in the first bay, structural instability became evident as the structure swayed during crane operation, highlighting an urgent need for reinforcement to ensure safe material handling.

The Challenge:
The primary challenge was to achieve structural stability for safe overhead material handling, particularly in the first bay with dimensions of 20m x 70m. Despite attempts by the original supplier to reinforce the load-bearing columns, the structure continued to sway, posing a significant risk and rendering the bay unsafe for operations. This structural instability not only jeopardized crane use but also threatened the timeline for completing the facility.

The client required:

  • Structural Reinforcement: A solution that would secure the structure, allowing safe crane operations without swaying.
  • Time Efficiency: Rapid project completion to avoid delays.
  • Cost Optimization: A solution that minimized resource waste and optimized the use of the existing structure.

The Expectations:
Initially, the customer approached the original supplier to reinforce the structure. Although reinforcement work was undertaken, it failed to resolve the swaying, leaving the bay unstable and unusable. Faced with the prospect of scrapping the structure and starting over, the customer sought a new approach and turned to Sparkline for a safe, stable, and cost-effective solution.

The Solution:
Sparkline undertook a comprehensive analysis to identify the root cause of the swaying and instability. Rather than replacing the entire structure, Sparkline recommended targeted reinforcements to make the existing steel structure robust enough for overhead crane use. The key steps included:

  1. Reinforcement of Load-Bearing Columns: Sparkline reinforced the columns along the width of the first bay, increasing structural rigidity and eliminating the sway during crane operations. By reinforcing specific areas, Sparkline achieved stability without needing to scrap the initial 200MT of steel.
  2. Addition of End Ties: To prevent lateral movement and enhance stability, Sparkline supplied end ties for all eight bays. These end ties addressed the structural weaknesses missed in the original design and provided the necessary support for safe crane operation across the plant.
  3. Efficient Use of Existing Steel: Rather than discarding the remaining 250MT of steel, Sparkline repurposed some of it to construct freestanding structures required elsewhere within the Jaipur plant. This approach minimized waste, reduced material costs, and optimized resource use.
  4. Custom Structural Solutions for Remaining Bays: For the remaining seven bays, Sparkline designed and supplied structurally robust frameworks that could handle overhead loads and ensured all bays met safety requirements. Each bay underwent a detailed load certification process to verify compliance with safety standards.

Through this strategic reinforcement and reuse of materials, Sparkline successfully completed the structure enhancement within the required timeline, allowing the customer to resume safe, efficient operations.

A Statement of Overall Benefit:
Sparkline’s innovative reinforcement approach provided the customer with a safe, stable structure without the need to scrap valuable materials. By optimizing the existing steel framework and addressing the root structural issues, Sparkline delivered a cost-effective solution that saved time, minimized waste, and ensured operational safety.

Benefits:

  • Proven Structural Stability: The reinforced bay has operated safely and without issue for over eight years, proving Sparkline’s solution to be durable and effective.
  • Reduced Project Delays: Sparkline’s solution expedited project completion, minimizing delays associated with structural instability and ensuring the facility met its timeline.
  • Cost Savings through Material Optimization: By avoiding the scrapping of 200MT of steel, Sparkline’s approach significantly reduced costs and conserved resources. Repurposing unused steel for other structures further optimized material usage.
  • Enhanced Safety and Compliance: All bays, including the reinforced structure in the first bay, received load certification, ensuring compliance with safety standards and secure overhead handling.
  • Optimized Resource Use: Sparkline’s design and material handling expertise enabled the safe and efficient reinforcement of the existing structure, saving on material and installation costs while delivering a robust solution.

Sparkline’s cost-effective reinforcement approach allowed the customer to fully utilize their structure with minimal waste, achieving safe operations and reducing costs through optimized use of resources.