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Garden Reach Shipbuilders & Engineers LIMITED, Kolkata

PROJECT SIZE = 1,800 MT

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The Project

Module Hall of size 28m wide, 99m long and Eave height is 26m. All side wall laced columns were standalone of height 19m with fixed base support. There were 3 movable roof blocks of each length 33m long and height of 6m & 7m. Out of 3 roof blocks, First and last block is of same eave height and Middle block shall move over the lower blocks which is necessitated for lifting of Ship block to take it out for assembling and painting. There are #2- 20 MT EOT cranes which are directly resting on standalone laced columns. The uniqueness of the project is such that all movable roof blocks shall move with the help of EOT crane on wheels which were designed to ensure for safe travel during operations.

Very Simple manual lever system was designed to keep all movable roof blocks in position during normal condition and wind uplift as well. These roofs will be generally operated / moved from original position when wind speed at 20 KMPH

The Challenges

  • All main columns are to be considered as twin owing to building requirements.
  • As roof blocks are movable on one over the other so it requires closed detailed attention during design stage with lots of preconceived thoughts in all aspects.
  • Each movable roof block is to be designed as independent unit with considerable anticipated loads during design in view of stability and performance.
  • Both gable end walls are to be extended up to movable roof block top so it is considered to be a cantilevered wall.
  • At both gable ends a wider sliding door supported from top structure and having a guide rail at ground level.
  • All movable roof blocks to move freely one over the other with minimum possible tolerance so that no water ingress inside of the building.
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The Solution

  • All main columns base condition has been considered as fixed support to enable to restrict sway within code provisions.
  • Movable roof blocks were designed and detailed in such a way with closed dimensions and ensured no water ingress inside of the building.
  • Each movable roof block had been considered as a single unit so wall bracing is completely connected to each columns so that no anticipated torsion in each block.
  • Wind girder had been considered on both gable walls to support extended wall up above it with back support in view of standalone cantilevered wall.
  • At Both gable wall a wider door loads had been considered in supporting structure to ensure for free movement of the door during operation.
  • Precisely designed and detailed all movable roof blocks so that each can move one over the other without blockage.

MAZAGON DOC SHIPBUILDERS LIMITED, MUMBAI, INDIA.

PROJECT SIZE = 4,000 MT

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The Project

Sub marines manufacturing Building of size 42m wide, 220m long and Eave height is 39m and total steel utilised was 4,000 MT. Building was constructed on the banks of Arabian Sea where wind gust is quite heavy. There are various types of cranes and capacities which were designed in line with manufacturing needs. There are 2 types of Goliath cranes positioned along each Side Wall Columns of capacity 2x150MT and 60 MT which will be travelling at a height of 24m. Another set of EOT crane of each capacity 30MT at two levels in tandem. First set of EOT Cranes posited at 29m level and 2nd set of EOT Cranes positioned at 33m level.

The Challenges

  • Main columns sizes are restricted owing to constraint in size of available space.
  • Series of Goliath and EOT Cranes and Load combinations in analysis and design.
  • Deliberations on series of operations of EOT and Goliath Cranes.
  • Restriction in size of Crane runway beams.
  • Serviceability Criteria to be complied as per IS CODES.
  • Steel consumption to be optimum.
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The Solution

  • By using thicker plates all main columns are restricted within desired depths.
  • Analysis has been performed in tune with code requirements.
  • All crane run beams were designed within restricted depths by using thicker plates.
  • Maintained overall building serviceability within code limits.

Renuka Sugars, Kandla, Gujarat

PROJECT SIZE = 4,344 MT

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The Project

The size of the building is 80m x 285m x 4m eave height and 40m height at the ridge. Eighty metre clear span is the requirement of the client to facilitate conveyor, which is functioning along the ridge. This facility is created for the storage of white sugar, which is being imported from neighbour countries. This is the first in PEB such a wider clear span with a solid web. There are three identical buildings constructed side by side for sugar storage. There is an RCC wall all along the periphery of the building to retain sugar. The roof slope is 40 degrees, which is kept in a perceptive of pyramid shape forming of sugar whilst disposing of roof conveyor. Wind velocity is 180 kmph.

The Challenges

  • Base moment is quite high owing to fixed base support conditions.
  • Whole buildings to be analysed in 3D modelling to observe the behaviour of the building due to wind loads, seismic loads, and temperature loads.
  • Owing to longer building suitable expansion joints to be considered with double frames.
  • Bracing systems to be provided in view of structural stability.
  • Tie runners to be provided at suitable locations to keep the building standalone during construction.
  • Both gable walls are to be designed in such a way that these could be erected first to keep the portal frames in position for subsequent bays.

The Solution

  • Higher diameter anchor bolts used to keep the structure intact with designed forces.
  • Building is analysed in a way that all the members are designed for design forces with the utmost care during design, connection design and detailing.
  • Double frames are detailed properly to ease the construction.
  • Bracing systems detailed in a way to foresee the issues that may occur during construction.
  • Both gable walls are detailed intact with construction requirements.

Tata Steel, Jamshedpur

PROJECT SIZE = 1,250 MT

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The Project

The building size is 104m wide, 130m long and the ridge height is 25m. Along the sidewall, there are 4m height RCC columns on which the steel frame will get connected. This is an expansion to the existing space frame structure which is age-old. The shape of the building is parabolic in nature having various dimension variations. Inside of the building, standalone Goliath crane for which both gables ends were open up to 12m clear height for crane movement. Due to wider spans truss system is adopted to optimise stell usage and also to limit serviceability within code requirements. The depth of the truss is 3m; all the members connected with bolts. Due to limitation in size of logistic for deeper depth members and for efficient logistic cost. This is first in nature for a much wider span with an open web truss option.

The Challenges

  • Configuration is the challenge as there are no firm drawings at outset.
  • Steel consumption minimal in view of space frame weight as the client has already been experienced.
  • Open web truss with all necessary design parameters to ensure the stability of the structure during design and construction.
  • Consideration of the bracing system intact with structural stability which could ease construction further.
  • Tekla detailing software to be used.

The Solution

  • Arrived configuration in line with levels obtained from the existing space frame.
  • Open web truss was chosen which imparts the desired sectional modulus and minimal serviceability.
  • Bracing systems are adopted in view of erection feasibility.
  • All tie runners are details revisited to suits faster construction.
  • Tekla is helped to finish detailing error-free.

Zindal Polyfilms pvt ltd, Nasik

PROJECT SIZE = 1,100 MT

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The Challenge

The big challenge here in the project was to connect new building to existing metal building which was not constructed by us. And also needed to connect crane brackets for crane beams on existing columns and where another hurdle was existing columns were to be strengthen with extra web and flanges to take future loads of crane.

jindal

The Solution

Before doing detail schedule we made survey of existing building with total station and we found that existing columns were not in straight line and lots of columns were out of plumb. We have decided to keep new building columns in straight line and made crane brackets of variable length so that we get crane beams and rail above beams in straight line . overall task was challenging to weld overheads and overcome fire hazards which was controlled by making fire blankets booth around welding areas. At the end task was completed with accurate alignment and end client appreciated our wok with appreciation letter given below.

Jindal

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