Compendium 2009 to 2014

BEST OF
BEST OF

Compendium 2009 to 2014

Equipped In the year 1979, the late Mr. Vinayak Mehendale, a technocrat
with his long-standing experience in crane manufacturing, laid
the foundation of ElectroMech at Pune.

to Excel The aspiration was to manufacture a variety of high-quality

cranes, hoists and material handling equipment and provide
solutions at most reasonable prices. This, combined with
efficient before and after-sales service, completed the picture.
Aims and goals appear closer when skilled hands are willing to
work hard and minds are full of novel concepts and ideas. The
founder of ElectroMech never lacked both. As a result, the
company soon earned a firm footing and a veritable reputation
as one of the leading crane manufacturers in India. Its growing
customer base spanned across various industry verticals all over
India.
The year 2000 was a gloom-casting year for ElectroMech when
the founder passed away unexpectedly. On this backdrop, his
elder son, Tushar Mehendale took over the reins of ElectroMech.
Since then, he has been ably pursuing the illustrious founder's
ambition to make the ElectroMech equipment base span the
entire world.
The infrastructure
At ElectroMech, we have been involved in the design,
manufacture, erection and commissioning of material handling
systems with a special emphasis on cranes and hoists
since 1979. ElectroMech’s main manufacturing facilities are at
Pirangut, near Pune, India.
The Pirangut factory is considered to be the single largest
dedicated overhead crane manufacturing facility in India. This
facility is spread over 76,000sq.m of land and has more than
20,000sq.m of covered manufacturing area. This factory is
equipped with state-of-the-art machinery like CNC cutting
machines, semi-automated girder manufacturing fixtures, a
shot-blasting unit and a paint booth.

2
Exploring technology
To maintain the highest product quality, newer concepts of
material handling are continuously explored by our R&D.
ElectroMech has always prided itself in being at the forefront
in adopting newer technological advances in cranes and is
considered as a pioneer in various fields by its peers. Constant
development is being undertaken with the sole intention of
maximising the value delivered to the customer in terms of lower
costs, higher reliability, higher safety and faster productivity.
Far-reaching solutions
As a result of our pursuance of world-class technology, our
equipment can be seen operating flawlessly at diverse locations.
ElectroMech supplies a variety of cranes and hoists in capacities
ranging from 80kg to more than 200MT across different industry
verticals like Automobile, Steel, Power, Shipbuilding, Heavy
Engineering, Fabrication and General Engineering.
ElectroMech equipment is also conspicuously present in the
infrastructure segment. We are proud of the fact that a lot of
major infrastructure projects like roads, bridges, dams and
power plants have been made operational by using equipment
supplied by ElectroMech.
Variety, versatility, safety, affordability, convenience and peace of
mind are the standard features of any ElectroMech equipment. A
fact attested by several repeat orders received from all major
industrial groups not only in India, but also in the Middle East and
Africa as well.
Latest technology - highest reliability
ElectroMech which enjoys undisputed leadership in the segment
of Industrial Cranes in India, achieved the ISO 9001 certification
in 2003 and won an Exporter Award in 2005. Recently,
ElectroMech has achieved the prestigious Welding Approval
Certificate from Germanischer Lloyd (GL) and the latest
ISO 9001:2008 certification from BVC.
The company has been consistently growing year-on-year at
a rate higher than the industry average. The vision of
ElectroMech is to achieve a leadership position in India in terms
of sales, number of cranes sold, sales network, service network
and manufacturing capacities.
The team
The team at the helm of ElectroMech consists of qualified
technocrats with collective experience of more than one hundred
years in the industry. More than 500 motivated experts are
engaged in the manufacturing of more than 1000 cranes, hoists
and other similar lifting equipments every year.
Global presence
The span of ElectroMech capabilities has ever been widening.
After achieving a position of market leadership in India,
ElectroMech is also spreading its wings to soar high in the global
markets. A substantial chunk of ElectroMech's revenues comes
from exports.
Our subsidiary, ElectroMech FZE in Dubai is dedicated to
provide pre and post-sales service to our customers in the Middle
East and support hundreds of installations across different
countries like UAE, Qatar, Oman, Saudi Arabia and Iran. In
addition to the Middle East, ElectroMech also has its equipment
base across countries like Afghanistan, Bangladesh, Finland,
Kazakhstan, Kenya, Maldives, Mexico, Sri Lanka, Sudan and
Sweden. The list of countries keeps on growing with every
passing year.
3
BEST OF

Compendium 2009 to 2014

New corporate office & plant expansion at Pune

ElectroMech has at present a vast plant at Pirangut near
Pune which is spread over an area of 18 acres, with
covered manufacturing area of 10,000 sq. m. It is one of
the largest crane manufacturing facilities in India.
A spacious, new corporate office building is under rapid
construction in the same premises. The new office would
house all our departments such as Marketing, Sales,
Projects, Service, Vendor Development, IT, Finance, etc.
In the next few months, we will be shifting to this
new corporate office which would occupy a vast area
of 1200 sq. m.
We are also proud to mention that alongside our present
manufacturing plant, a massive plant expansion is
underway. On its completion, ElectroMech will have
its entire mega manufacturing facilities spread over
18,000 sq. m.
June 2009

On the fast track

Expanding and modernizing
our manufacturing facilities

With the modest beginning of a 12m x 66m (792 sq.m.)

shop in 2004, we have been expanding by leaps and
bounds. Just after one year, in 2005, we built two massive job having a maximum size of 50m long x 8m wide x 5m
shops, 12mx66m and 30mx66m. This expansion was to tall, advanced material handling equipments, etc.
cater to the rapidly growing demand for ElectroMech
Once completed, the total built-up area will be nearly
cranes from various industry segments - automobile, light
18000 sq.m. on 18.5 acres of land and will facilitate
& heavy engineering, electrical, domestic appliances,
production of 2000 cranes every year and will be one of
infrastructure projects, railways, shipyards and
the best fabrication facilities in India for industrial cranes.
progressive SMEs. Anticipating the future demand for our
advanced-technology, high-quality and safe cranes, we New office building
started construction of a 30m x 200m shop which was
opened for production in April 2008. The entire ElectroMech team in Pune is now located in
a single premises at Pirangut. The office expansion plan
The demand is constantly growing, not only from India,
is on the verge of completion. The three-floored building
but also from other countries in Europe, UAE, Africa and
accommodates 19 executive cabins, 23 cubicles,
South East Asia. To meet this upbeat demand, the next
118 workstations, 10 meeting rooms, large conference
shop of size 36m x 200m is in construction stage and will
hall, training center and a spacious lounge. The
be inaugurated by April 2010. Shop # 7 (the new shop)
inauguration is planned by January 2010.
which is under construction, will be equipped with a shot
blasting equipment, paint booth suitable for painting a December 2009

4
If we have one idea and you have one idea;
when we exchange, both of us have two ideas each!
At ElectroMech, we perfectly During these conferences,
preach and practice this.
That's the reason we are
ElectroMech top leaders of ElectroMech
personally shared various
organizing marathon sessions
of ElectroMech Knowledge
Knowledge Forum developments. Also, our
new initiative, Cranedge -
Forum all across the country dedicated to crane
for knowledge and idea maintenance and services
exchange. Through these was introduced, which
conferences, we are inviting received special
our clients for knowledge- appreciation from all
sharing on ElectroMech crane industry leaders. Gaining
technology, its applications, an insight into the
customization to meet specific technology, capability and
requirements and worldwide presence of
manufacturing practices ElectroMech helped the
followed by us. At the same audience in further
time, we are keen to reinforcing their trust in
understand your activities ElectroMech.
and specific requirements as Our approach of offering customized solutions using
well as your expectations from ElectroMech. standard building blocks was of special interest to some of
The activity kick-started on 28th August at Taj Palace, the delegates. They have categorically mentioned that
New Delhi. The event was attended by leading this is a unique offering where ElectroMech scores over
consultants, representatives of PEB companies and some the competition.
of our key clients. Subsequently, it was also organized in
Chennai at Marriot on October 23, 2009.
December 2009

Prestigious order from Impregilo S.p.A., Italy

for tunnelling projects in Abu Dhabi
ElectroMech FZE has won a prestigious order for 30MT Double Team ElectroMech is
Girder Gantry cranes from Impregilo S.p.A., Italy. Impregilo is a thankful to Impregilo
leading Italian engineering and general contracting group in management for their
construction, marine, infrastructure and environmental sectors. trust and confidence
The state-of-the-art Gantry cranes with reach up to 90m deep and looks forward to a
and with a hoisting speed of 30m/min, will be used in one of the long-term association
complex tunneling projects for Abu Dhabi Government. It will and working on more
involve simultaneous use of multiple earth pressure balance challenging projects
tunnel boring machines to excavate and at the same time case in the future.
the tunnel with precast concrete sections. The supply and July 2010
execution will be in two phases.
ElectroMech has been active in the Middle East for several years
and has supplied number of cranes to a wide cross-section of
industry. The addition of an international construction major
such as Impregilo to our clients' list further demonstrates our
manufacturing and project execution capability on the global
platform.
5
BEST OF
Compendium 2009 to 2014
Cargotec project
Bon voyage to the first Jib Arms and
Foundations for Deck Crane
After a rigorous evaluation of manufacturing capabilities
and competency of the manufacturing team, a top level
delegation of Cargotec selected ElectroMech as their
manufacturing partners. And the first prestigious
contract for manufacturing 48 Jib Arms and Foundations
was awarded to us. The delegation included Mr. Olli
Isotalo (President, Cargotec), Mr. Pasi Lehton Gunnar
and Mr. Daniel Forsberg.
6
Once the contract was finalized, a separate team was
formed at ElectroMech under the leadership of Tushar
Mehendale (Managing Director) and AVR Murty (CEO).
This special task force comprised Harish Gonepavaram
(Business Development Manager), T Srinivas Raju
(Group Leader-Production), Ajit Bhosale (GM Quality),
NVS Murthy (Welding specialist), Ajay Dharmadhikari
(Head Purchase), Raghunath (Production), Nilesh
Railkar (Design) and Satish Shirtode (CNC shop).
 The next step was to equip
ourselves with the right
technologies to meet the
stringent quality norms and
time line as well. For this,
we have set up a separate
manufacturing shop
equipped with a fabrication
bed, SAW machine set up,
FCAW machines, wall
travelling cranes, bevel cutting machines, special
fixtures for the fitment and full welding of jib arms.
The equally important part of this project was the WPS
Mr. Daniel Forseberg and Mr. Mattson Mattias of
MacGREGOR on 18th April 09 and the first set of Jib
Arms and Foundations was ready for final inspection in
September 2009.
After a stringent quality check by MacGREGOR team,
Cargotec management has expressed satisfaction
about ElectroMech's world-class manufacturing
capability and service of global standards. Team
ElectroMech is thankful to them for their trust in us and
we look forward to a long-term association and
opportunities to work on more challenging projects in
the future.
December 2009

(Welding Procedure Specification) approval as per

EN 15614 and Welder Qualifications as per EN 287.
This part was completed in the presence of ABS
(American Bureau of Shipping) surveyors as well as
GL (Germanischer Lloyd )
Once fully equipped with the technology, state-of-the-
art machines and well-trained and certified team, the
project went full steam ahead. Cargotec project
manufacturing shop at ElectroMech was inaugurated by

7
BEST OF
Compendium 2009 to 2014
More bays. More cranes. More smiles.
In spite of the recent blow of recession, ElectroMech
expansion has been at its peak. We are about to finish
with the 36m span x 200m long fabrication shop. The
shop is being equipped with advanced material handling
equipments and other facilities. While promising best
product quality to our valued customers, ElectroMech has
invested in procuring blasting equipments, paint booth
systems, semi-automated welding machines, etc.
Execution of the same is in progress. Starting with its own
8
factory, ElectroMech has developed a cost-effective
solution for contact-less material handling trolleys. Nine
numbers of the same are being installed in the factory.
Looking at the increasing demand for ElectroMech
cranes, Chennai plant execution will commence shortly.
This plant will boast of the capacity to manufacture 200
cranes of up to 250MT lifting capacity.
Enhanced infrastructure, capabilities and production will
certainly ensure more smiles.
 GL approval for welding and ISO 9001:2008

Welding Quality
MacPILER, the first Hatch Cover Lifting
equipment successfully manufactured
at ElectroMech was totally inspected
and approved right from the raw
material stage to the final assembly
and testing by the leading classification
society, Germanischer Lloyd (GL),
Hamburg, Germany.
However, as per the GL requirements,
before production, it was mandatory to
get the Manufacturing Workshop
approved to attest the availability
of the necessary infrastructure,
calibrated welding equipments,
measuring instruments and
competence of manpower involved to
produce the products of desired
quality.
One of the key elements in this shop approval process was Welding Procedure
Specification (WPS) Approval and qualifying the welders as per the GL rule
book, based on DIN Standards.
After a rigorous shop audit, documentation review and all essential tests,
GL (Hamburg) issued ‘Approval for Welding’ certificate to ElectroMech.

One more feather in our cap

ElectroMech has already been an ISO 9001:2000 company. Now, we are
pleased to announce that ElectroMech is now certified for ISO
9001:2008 standard with UKAS accreditation. A stringent audit was
conducted by Bureau Veritas Certification at various locations such as
ElectroMech works, Sales and Service offices in Chennai and Delhi and at the
customer site in Coimbatore, in order to confirm the scope of certification
finalized as “DESIGN, MANUFACTURE, SUPPLY, ERECTION,
COMMISSIONING AND RELATED SERVICES FOR CRANES, HOISTS,
WINCHES AND CUSTOMIZED MATERIAL
HANDLING SOLUTIONS”.
Implementation of ISO 9001:2008 has been
the second important step for ElectroMech
after successful implementation of SAP
ECC 6.0 to improve overall business
New shop-floor processes, enhance customer satisfaction by
under completion
meeting requirements in more efficient manner
and improving the quality of products to have a
better competitive edge. Now, ElectroMech
aims to be an ISO 18001 and ISO 14001
company to have a systematic approach to put
emphasis on safety, occupational health and
environment-related aspects.
Congratulations to the entire ElectroMech team
for the remarkable achievements. July 2010
9
BEST OF
Compendium 2009 to 2014
Cheers! On the docks!
First MacPILER despatched
On 12th Feb. 2010, ElectroMech marked a historic
moment by delivering the first MacPILER (RC20) to
Rongcheng Shipyard, China. It is a hatch cover lifting
equipment used on the bulk carriers and has a handling
capacity of 44 Tonnes. MacGREGOR (Finland) has
placed an order of 10 such equipments on ElectroMech.
Rc20 was the first complete equipment produced by
ElectroMech while adhering to all stringent norms
related to welding safety and corrosion protection for
the Marine Application and class approval by
Germanischer Lloyd (GL). Before the delivery of this
equipment, functional testing of the
entire MacPILER was carried out at
100% SWL and load testing was
carried out at 125% successfully in the
presence of the GL and MacGREGOR
representatives.
During the product realization stages
of the entire equipment, it was
subjected to all stringent quality
requirements of various European
10
Standards and GL Rule Book. MacPILER comprised
massive fabricated structures, mechanical sub-
assemblies, electrical drives and PLC programing for
smooth functioning. From the safety point of view,
special testing was carried out for lifting hooks and wire
ropes in the presence of GL surveyors. The operational
testing of the MacPILER was carried out on a special
test rig which simulates the long travel on the actual
ship.
The equally difficult task was the shipment of MacPILER
without causing any damage. However, ElectroMech
team, through its vast experience
and immense efforts, made the
stuffing process successful in
minimum number of containers.
Overall project activities carried out
for the production of first MacPILER
enriched the experience of
ElectroMech and added a new
dimension to the field of material
handling equipments.
July 2010
 Glad to serve. Pleased to hear.
Customers appreciate our service efficiency

“ I want to thank you all for your timely and continuous
support in resolving some of the issues related to crane
erection, maintenance and repair, which we were facing in
the last couple of days.
We extremely appreciate the efforts of both your teams,
“Even though we started the XP Shop Crane installation
project late due to some major constraints, we ended up
with good speed. Your team, especially Mr. Dinesh More,
put in very good efforts to finish the same on time.”
l

Cranedge and ElectroMech, in sorting out all the issues in Shankar Malge - Project In-charge
the shortest span of time and with least follow up JCB Manufacturing Ltd., Pune
(especially rigorous phone calls).
Once again thank you and looking forward to expecting the
same kind of Service & Support in the future as well.”
l

Mr. Raju Prasad of SIEMENS LTD. Energy Sector,

Power Transmission Division, Gas Insulated
Switchgear(GIS), Aurangabad

“Thanks for the extensive support for the supply and

erection of the crane.”
l

T. S. Sampath Kumar - Manager-Purchase

Gamesa Wind Turbines Pvt. Ltd., Chennai

“I really appreciate your efforts in trying to help us to get

the module repaired. This type of cooperation and timely
help in overcoming our problems really raises our
confidence in you. We look forward to your cooperation in
the future as well.”
l

Vijay Arora - Plant Head

Mahindra Intertrade, Nasik
“Your erection team has performed to more than our
satisfaction level. They understood the emergency of
cranes for our machine erection work and completed the
erection of three cranes in a very professional manner.”
“Just gone through EMPOWER newsletter Q2 2009-10. We
are very happy to note that you have launched a new
company in Jebel Ali, Dubai and has become a global
company in true sense, sooner than expected. Hearty
congratulations to you and your team for this well-
deserved success. Probably we noticed the spark in you in
early days and built relationship, which we are very proud
of.”
l

l
Sanjay Tikle, Plant Head
Vaskar Mitra - Vice-President, Mechanical Mahindra Steel Service Centre Ltd., Maval
Nahar Polyfilms, Bhopal

July 2010, December 2012

11
BEST OF
Compendium 2009 to 2014
ElectroMech FZE
spreads its wings
in Africa and Qatar
We have recently forayed into the African
market with our association with Zenith
Steel Fabricators, Kenya. Zenith Steel
is one of the largest steel fabricators
operating in the East and Central African
regions with offices in more than seven
countries. They will be supplying cranes
using ElectroMech crane kits and their
expertise in steel fabrication.
Prestigious installations in Abu Dhabi
Italian construction
and civil engineering
company, Impregilo
S.P.A. has landed a
contract with Abu Dhabi
Sewerage Services Company (ADSSC) to
build the first of the three lots of the
Strategic Tunnel Enhancement Program
(STEP) in Abu Dhabi. STEP involves
construction of a 40km gravity tunnel to
collect waste water from the Abu Dhabi
Island and mainland, and convey it to the
treatment plant in Al Wathba. The new
project involves construction of the first
15km of the tunnel, with an excavated
diameter of 6.3 meters, and six access
Kondapalli Power project
Lanco Infratech Ltd. is one of India’s top
business conglomerates and among the fastest
growing. It has subsidiaries and divisions across
a synergistic span of verticals. These include
construction, power, EPC, infrastructure,
property development, and renewables. A
member of the UN Global Compact, Lanco
Infratech Ltd. is recognized for its Good
Corporate Governance.
Lanco Kondapalli Power Ltd. (LKPL) is an
Independent Power Project (IPP) located at
Kondapalli near Vijayawada in India. Set up at a
cost of around `12,400 million (US$275
million), this Combined Cycle Power Project
operating on natural gas as primary fuel is being
developed in various phases.
LKPL has taken up the implementation of a 2 x
371 MW plant under its stage III expansion
project. The ultimate capacity of the Lanco
Kondapalli Power Plant after completion of
Phase III will be around 1500 MW.
12
The first lot of crane kits has been
dispatched to Kenya recently and we
expect to increase our business in this
region in the coming years.
Our presence in the Qatar market will
be further enhanced through a new
channel partner, Construction
Development Company (CDC).
CDC is one of the leading Industrial
groups in Qatar. CDC’s trading arm
will be responsible for marketing and
shafts to depths of between 40 and 50
meters. Impregilo has also been
awarded the third and final lot of the
contract which includes between 40
and 50 meters. Impregilo has also been
awarded the third and final lot of the
contract which includes construction of
10km of 7m diameter water tunnel.
Impregilo selected
ElectroMech FZE as its
partner for installation and
commissioning of Gantry
cranes required on this
project. ElectroMech FZE has
successfully commissioned
the first lot of 30MT, 90m lift
July 2011
Expectedly, LKPL paid a great deal of attention
to every piece of equipment being selected
for this project. Considering the magnitude and
critical time frame for the project, along with
quality and reliability of the equipment, equally
important was the manufacturing and project
execution capability of the partnering
companies. When the tender for various hoists
and cranes, which included challenging TG hall
cranes was floated, 5 companies participated in
the bid. Mr. Minocha- CEO, Mr. RNS Tomar- Vice
President and Mr. Bimal Sen- Asst. General
Manager personally interacted with each of the
bidders to evaluate their capability and
credentials. This helped ElectroMech in
understanding the finer details of the project
requirements and demonstrating our ‘solutions
approach’, thus winning the trust of the
Lanco team in our capabilities. Through these
discussions and interactions, ElectroMech
shone through, convincing the Lanco team to
opt for our cranes.
providing local service and installation
support to ElectroMech projects.
These new tie-ups underline our
commitment and endeavor to serve our
customers in the Middle East and
Africa in the best possible manner. The
localization of our after-sales service
support and structural fabrication
activities in these territories will enable
us to provide turnkey solutions to the
customer at competitive prices.
Double Girder Gantry Cranes. All the
cranes will be put in 24x7 operation
working on one of the most challenging
projects in the region. These
installations further demonstrate
ElectroMech’s capabilities in executing
large scale projects on a global
platform.
The complete scope includes
Ø 150/25T x 25m DG Crane for Steam Turbo
Generator building
Ø 90/20T x 15m - 2 Nos. DG Crane for Gas
Turbo Generator building
Ø 50/25T x 25m DG Crane for Steam Turbo
Generator building
Ø 20/5T x 9.6m DG Crane for Clarified Water
Pump house
Ø 12T x 11.4m DG Crane for Boiler Feed Pump
building
Ø 5T x 8.5m DG Crane for Gas Insulated
Substation building
We sincerely thank Lanco Infratech Ltd. for
awarding this prestigious project to
ElectroMech.
July 2011
 Pivotal role in Mumbai's
unique water supply project
ElectroMech supplies tunnel mucking cranes and
special hoisting equipment for lowering and assembling
of Tunnel Boring Machine.

Clients : Ø Soma Construction Company Ø Unity-IVRCL Ltd. (A joint venture company)

Mumbai - the business capital of India - the city of dreams ElectroMech has supplied special tunnel mucking cranes for both
for millions - has been growing exponentially. This growth isthe phases where shafts of 140 meters are to be excavated at
taking place in a narrow, long stretch of the costal land. 4 different locations. ElectroMech has also provided cranes of
The existing 21 million and growing population naturally 105MT for lowering the Tunnel Boring Machine up to 100meters
needs adequate supply of water for today and tomorrow. below the ground level. Additionally, a special type of crane,
The Tansa Dam situated around 75km from Mumbai is the major which will be installed 100 meters below the ground level is
source of water supply to Mumbai since it provided to assemble the
was built in 1892. The existing pipeline Tunnel Boring Machine. This
which carries this water to Mumbai was crane has four winches
laid down in the British era. Over decades, MCGM has undertaken a very ambitious operating in tandem for
the pipeline has rusted and eroded due to precision work, which is
water supply project by building a new
which bursting and leakages are quite required for the Tunnel
underground leak-proof tunnel which is
frequent. Naturally, it interrupts the water Boring Machine assembly.
8.3km long. This prestigious project
supply, creating shortage. 32MT Goliath cranes are
has been awarded to Soma Construction
To avoid this, MCGM (Municipal deployed at the entry and
Company (Phase I) and to a Joint Venture exit points of the shafts,
Corporation of Greater Mumbai) has
undertaken a very ambitious water supply
of Unity Infraprojects Ltd. and IVRCL Ltd. where high-speed hoisting
project by building a new underground (Phase II). ElectroMech has supplied equipment, incorporating 3.4
leak-proof tunnel which is 8.3km long. The special tunnel mucking cranes for both meter long rope drums
tunnel is being constructed at the most the phases where shafts of 140 meters rotating almost non stop lift
critical part of the supply system over a are to be excavated at 4 different the muck at 40 meters /min.
stretch of 15km from Gundovali village locations. A special type of crane is The criticality of the cranes
(near Bhiwandi) to Bhandup. The provided to assemble the Tunnel Boring operating on these projects
construction work of this prestigious lies in 'Continuous operation
Machine. This crane will be installed 100
project has been awarded to two without any down time' and
meters below the ground level.
construction majors namely, Soma ElectroMech’s proven track
Construction Company for Phase I record on several
(Gundovali to Thane) and to a Joint infrastructure projects makes
Venture of Unity Infraprojects Ltd. and it an ideal choice to ensure
IVRCL Ltd. for Phase II (Thane to that uninterrupted work.
Bhandup).
July 2011

13
BEST OF
Compendium 2009 to 2014
Connecting places - Connecting lives
Roads, highways and bridges form a network that unites the
nation, brings people together and expedites communication.
Bridge construction has undergone revolutionary changes over
the years. Advanced, gigantic construction equipment and the
use of precast and pre-fabricated components have reduced
much of the cumbersome manual labour and has increased the
speed of construction significantly. ElectroMech, with its proven
expertise in material handling, is also a part of this construction
revolution.
Soma Enterprises Ltd., the infrastructure construction
company is an esteemed user of different types of ElectroMech
gantry cranes on a number of major projects for varied
applications. ElectroMech has always stood up to Soma's unique
requirements and expectations. As a result,
Soma puts its complete trust in the capabilities
of ElectroMech, thrusting newer challenges
our way, which we have always lived up to.
This recent, new challenge was not an
exception. ElectroMech was to supply bridge
building girders 60 meters in length. The
girders were required at the site of a bridge
14
Bridge Building Girders
construction at Cochin in Kerala. The task, apparently simple,
demanded great precision and manufacturing using special jigs
and fixtures. Transportation, material costs, operational
simplicity and actual joining of pieces posed several challenges
for ElectroMech, which braced against them successfully and
provided the client with the best solution.
The solution was devised in the form of separate pieces of
girders, precisely manufactured, each of 15 meters in length.
Accurate positioning of pieces of girders was ensured using
special fixtures at ElectroMech plant. Arrangement of nuts and
bolts for joining them eliminated the need of any welding on the
site. Such girders can conveniently be used and reused for
constructing bridges quickly, using advanced technique.
The bridge building girders supplied by
ElectroMech offer great operational simplicity,
re-usability, accuracy and ease of
transportation. All this results into
considerable reduction in the turnaround time
of the project, hard work, material costs and
risks.
July 2011
Installation at Amtek Auto Ltd.
A challenge for our problem-solving ability
Client : Amtek Auto Ltd.
No. of cranes: 6 nos.
Location of crane installation: Dharuhera (Rajasthan)
About Amtek Auto Ltd.
Amtek Auto Ltd. is headquartered in New Delhi and is one of the
largest integrated automotive component manufacturers in
India with a strong global presence. The company has world-
class manufacturing facilities in India, Europe and North
America. Amtek Auto has significant expertise in forging, gray
and ductile iron casting, gravity and high-pressure aluminum die
casting and machining and sub-assembly. The company also
manufactures components for non-auto sectors such as
railways, specialty vehicles, aerospace, agricultural and heavy
earth moving equipment.
This article talks about an interesting event which is not related
to any special requirement of cranes, but a very unusual logistic
challenge. We recently supplied Double Girder EOT cranes (6
nos.) to the Dharuhera, Rajasthan plant of Alliance Integrated
Metaliks which is a part of the Amtek Group.
The challenge
The site had a restriction in the form of a very sharp turn within
the factory premises that would not allow a trailer longer than
60ft to turn around that bend and enter the site. This posed a
problem to most of the suppliers, including ElectroMech, whose
equipment needed to be transported over long distances on 80 ft
trailers. At one point, it looked like the only option was to
AMTEK
engineer the girders so that they could be transported in two
pieces and then attached using a bolted flange joint at site. Of
course, other equipment couldn’t be broken down like this.
The solution
While anticipating and realizing the challenge posed by the site
conditions, our installation team, backed by our experience of
having transported cranes to the most treacherous locations in
the Himalayas was ready with a simple, but ingenious solution.
They simply transferred the girders to a specially arranged trailer
just outside the site entrance, allowing the girders’ easy entry.
Although this may sound simple, surprisingly, this solved their
major problem of bringing in the other machinery as well. The
Amtek team, impressed with our job, asked us to repeat the
entire procedure, capturing a video of this procedure to be
displayed to their other vendors who supply bigger machinery to
them. After witnessing the entire process, the client was
confident that it will solve their major problem and will surely
help other vendors in easily bringing their machinery inside the
plant.
Several such challenges on site help ElectroMech to hone its skills
and develop problem-solving ability to be truly called a Solutions
Company.
March 2012
15
BEST OF
Compendium 2009 to 2014
A challenge
100m beneath the ground
The project
Carrying components for a 1km long
TBM (Tunnel Boring Machine) through
a shaft and assembling it in a tunnel
100 meter beneath the ground was the
challenge posed to ElectroMech by the
ElectroMech has construction giant, Soma Enterprises Ltd.
As usual, we handled it swiftly while
designed a unique
demonstrating a well-orchestrated
crane with
performance along with Soma’s
triple girder design engineering team.
and four 25MT crabs.
It all began when Soma was awarded
With the use of the the challenging contract to excavate
4-crab arrangement, an underground water tunnel for
it becomes extremely Brihanmumbai Municipal Corporation
easy to assemble (BMC) - the city’s civic body.
the longer parts Mumbai is the fourth most populous
of the TBM. city in the world with a population of
20.5 million people. Providing water
16
uninterruptedly to such a large
population and industries around the city
has always been a challenge for BMC. To
effectively meet this challenge of today
and future, the Government of
Maharashtra sought help from the
Government of India under its
Jawaharlal Nehru National Urban
Renewal Mission (JNNURM). This entire
project would replace the outdated
pipelines which have been providing
water to Mumbai from the Tansa
reservoir.
The INR 2235 crore project is divided
into two parts, one being awarded to
Unity-IVRCL joint venture and the other
to Soma Enterprises Ltd. Interestingly,
ElectroMech has also supplied tunnel
mucking cranes to Unity and IVRCL.
The challenge
As per Soma’s project plan, the first
phase involves completing the tunnel
from Kalher to Kapurbavdi. Accordingly,
work started at Kalher, where a shaft of
100m depth and 10m diameter was dug.
The entire tunnel will be approximately
100m beneath the ground. For
excavating the tunnel, Soma had two
options. The first was conventional rock
drilling and blasting, and the other was to
use a modern Tunnel Boring Machine. By
November, 2011, Soma completed the
digging and concreting of the 100m deep
shaft and excavated a 1km long tunnel
at this depth using the conventional
method. For further work, Soma decided
to use a modern TBM and chose
Herrenknecht, Germany to hire the TBM.
A TBM is a mammoth machine, 1km in
length, 100MT in weight and consisting
of thousands of components, each of
which had to be lowered into the tunnel
through the shaft individually. Some of
these components are close to 100MT
and assembling this machine on site is
a herculean task. Once assembled, it
appears like a train with the only
difference of the cutter head at the front
instead of an engine. It excavates the
tunnel just like an earthworm.
The solution
For handling this challenge successfully,
ElectroMech was involved at two critical
stages. The first stage involves lowering
hundreds of components into the tunnel
through the 100m deep shaft. Second
was to assemble the complete TBM
inside the tunnel itself. Soma selected
ElectroMech as its trusted partner to
meet these handling requirements based
on their previous experience with
ElectroMech’s competency in the field.
ElectroMech modified a previously
supplied 120MT Gantry crane at the
opening of the shaft. This crane served
two purposes. Firstly, it acted as a shaft
mucking crane for removal of overburden
while digging the shaft of 100m depth
and secondly, it helped in lowering
hundreds of components of the TBM into
the tunnel.
The most challenging task
was lowering an 11m
long, 95MT component
through the 10m diameter
shaft which required an
ingenious solution.
To tackle this requirement,
we designed a special
attachment beam on which
two 30MT chain pulley
blocks and two wire rope
slings were fitted. Using
this arrangement, the
component could be
precisely tilted to a pre-
determined angle and then
lowered through the tunnel.
Another interesting feature is the multi-
layer rope drum with a guiding
mechanism, necessitated by the 100m
height of lift and total wire rope of almost
2.5km. The same crane was also used for
routine up-down movement of workforce
for which a 15MT auxiliary hoist was
provided.
The second challenge was the actual
assembly of the TBM. To handle this
demanding application, ElectroMech
designed a special crane with unique
triple girder design and 4 crabs of 25MT
each. With the use of the 4-crab
arrangement, it became easy to
manoeuver and assemble the longer
parts of the TBM. The crane movement
also needed precision as the alignment
and matching of the TBM parts is very
crucial.
By meeting both these challenges
successfully, ElectroMech is indirectly
playing a crucial role in BMC’s ambitious
24x7 water supply project.
March 2012
17
BEST OF
Compendium 2009 to 2014
150/30MT Double Girder Crane
At PEL, ElectroMech cranes
will integrate the handling of
transformers through various
processes and assembly
stations from incoming raw
material to the dispatch bay.
ElectroMech has supplied
14 cranes ranging from 5MT,
8.5m span to 150/30MT,
30m span.
18
Prime Electric installation -
Successful handling of a new challenge
ElectroMech has achieved another
milestone by adding Prime Electric Group -
a leading manufacturer of Transformers to
its client list. The plant has recently been
commissioned and all ElectroMech cranes
are operational, helping them achieve the
required handling task.
Introduction
Prime Electric Limited (PEL) is one of
India’s largest transformer manufacturers,
catering to the requirements of Indian and
international markets for power utilities,
EPC companies, substations, power
generation, transmission and distribution
companies and large industries from
various sectors (steel, cement, petroleum,
petrochemicals, etc.) using bulk power.
PEL is one of the most significant activities
of the Prime Group. The rich experience
of the Prime Group in addressing the
most exacting needs of the power sector
and through its range of eco-friendly
(low noise), aesthetically designed, extra
high voltage power transformers up to
1000MVA/500kV. PEL's production
capacity, projected to 35000MVA,
makes it one of the largest manufacturers
from India, producing world-class extra
high voltage power transformers for users
across the globe. PEL’s 100 acres
manufacturing location is at Nayudupet
Special Economic Zone in Nellore district
of Andhra Pradesh.
 ElectroMech solution
ElectroMech has supplied 14 cranes
ranging from 5MT, 8.5m span
to150/30MT, 30m span. ElectroMech
cranes ensure complete integration of
handling on the shop-floor while
covering every process station and
reaching every corner. These cranes
cover the handling requirements
existing at various places on the
shop-floor including handling of raw
material such as steel coils and copper
plates, various assembly stations,
core winding stations, vacuum
chamber, oil filling station, testing
room and finally, the dispatch bay.
ElectroMech is proud to be associated
with Prime Electric Ltd. for one of their
largest transformer manufacturing
facilities in India.
March 2012

30/10MT EOT crane in huge transformer core winding handling bay

A challenge for ElectroMech

The task assigned at Prime Electric is
challenging in several aspects. ElectroMech Application
cranes are expected to integrate the handling ElectroMech cranes are used in
of transformers through various processes and handling and lifting of transformers
assembly stations from incoming raw material and their parts in the assembly line.
The complete scope of supply includes:
to the dispatch bay. As the transformers pass
through the assembly, their weight gradually
increases, the heaviest transformers weighing Ø 150/30MT, 30m span, 16m lift x 3 nos
as much as 300MT. Two 150MT cranes are used Ø 50/10MT, 30m span, 17m lift
in tandem with a specially designed lifting Ø 30/10MT, 30m span, 17m lift
beam to lift these large transformers. Ø 30/10MT, 15m span, 11m lift
ElectroMech cranes cover the entire length and Ø 15MT, 15m span, 11.4m lift
width of the shop-floor, providing maximum
Ø 15MT, 10m span, 11.4m lift
coverage by reaching every nook and corner.
Ø 10/2MT, 20m span, 11.4m lift x 2 nos
The most critical part of the process is filling of
Ø 10/2MT, 10m span, 11.4m lift
oil in assembled transformers. For this, the
transformer is to be lowered into a vacuum Ø 5MT, 30m span, 22.7m lift

chamber where it is completely dried to make it Ø 5MT, 30m span, 11.7m lift
moisture-free. Here, precision positioning Ø 5MT, 10m span, 11.7m lift
using the cranes is very important. After this,
the transformer is filled with oil and to be
moved without any spillage due to jerks.
Hence, the cranes should be able to handle the
load ensuring absolutely jerk-free movement.

19
BEST OF

Compendium 2009 to 2014

Handling challenges successfully in Iraq

Our global customers trust us for our solutions ability and With the successful execution of this project, we now look forward to new
approach us to meet challenges in handling with our hoist challenges in Iraq and the Middle East region.
or crane solutions. This is true not only in case of December 2012
completely new projects, but ElectroMech is also their
trusted partner when it comes to refurbishment,
retrofitting or modernisation of existing cranes, where
Refurbishing of double girder trolleys at Diala State Company in Iraq
they know for sure that ElectroMech can handle the job
swiftly and ably.
One such challenging requirement was successfully
handled by us for Diala State Company in Iraq. Diala is
engaged in the assembly and manufacturing of large
capacity distribution and power transformers and is one of
the largest transformer manufacturing companies in Iraq.
The project involved supply and retrofitting of completely
new hoisting units and refurbishing the old cranes with
new electrical systems. With our expertise in such
projects, we refurbished four units of Double Girder
trolleys of 100/30MT, 50/20MT, 15/10MT and 15/7MT
capacities.
This was a very challenging project considering the unrest
in Iraq and the critical time frame requirement of the
customer. However, our engineer, Santosh Tambe took on
the assignment, and with admirable courage and project
execution ability, completed the task in the given time
frame to the fullest satisfaction of the customer.

20
 ElectroMech crane features on cover page
of HOIST magazine, UK

HOIST
is a prestigious international
magazine from UK. ElectroMech
is featured in it as a leading
Asian player. Our Tunnel Boring
Machine assembly crane appears
prominently on its cover.

Hoist magazine, published from UK, is a prestigious magazine

dedicated to the Hoist and Crane industry worldwide. In the
April 2012 issue of this magazine ElectroMech is featured as a
leading Asian player in this market. The photograph of our TBM
assembly crane supplied to SOMA for Mumbai water tunnel
project appears prominently on the cover of this magazine
highlighting its uniqueness and our solutions capability.
Hoist Magazine is published by World Market Intelligence - a
premium information and marketing solution company focused
on the provision of high-quality information and software
solutions to drive business success. This is the only international
magazine with news and information focused on overhead
cranes and industrial lifting equipments. The magazine reaches the same issue. It highlights the uniqueness of crane solutions
almost 19,000 users and distributors of lifting equipments from supplied to these projects and the challenges fulfilled by them.
various countries across the globe. This news signifies our growing footprints in the global market.
The April 2012 issue of this magazine focuses on the emerging With the encouragement and best wishes from our clients, we
South Asia market in which it has extensively covered Indian look forward to several such news in the near future.
crane industry from various perspectives.
The article mentions Mr. Tushar Mehendale's views on the
importance of tie-ups and how ElectroMech’s strategic
partnerships are a significant part of the ElectroMech growth
strategy.
Mr. Tushar Mehendale has highlighted the entry of ElectroMech “We have always been a firm believer in tie-ups with
in the new market viz. the nuclear sector with the order for market leaders which allow both the partners to
cranes for critical handling applications at Kakrapara Atomic effectively leverage each other's strengths and
Power Project set up by the Nuclear Power Corporation of India. derive synergies".
The cover of the April 2012 issue shows the ElectroMech crane
supplied to SOMA for Mumbai water tunnel project. This unique Mr. Tushar Mehendale, Managing Director, ElectroMech
project has also been described in detail in a separate article in

December 2012
21
BEST OF

Compendium 2009 to 2014

ElectroMech inks JV agreement

ElectroMech has diversified into the tower ElectroMech reach out to the booming real estate sector with
cranes business by signing a Joint Venture Zoomlion's world-class leading tower cranes.
agreement with Zoomlion. The joint venture The real estate sector itself has seen a paradigm shift over the
plant will realise USD 50 million in annual sales past decade with modern techniques of construction
becoming more common across the sector. Not only metros,
over the next five years.
but tier II towns are witnessing previously unseen levels
of development and the skylines of cities like Mumbai and
Delhi are rapidly changing with skyscrapers becoming the
On the 21st of August, 2012, ElectroMech entered into a Joint
norm. This isn't surprising, given escalating land prices
Venture agreement with Zoomlion Heavy Industry Science
and Cushman & Wakefield’s estimate of the shortfall in
and Technology Development Co. Ltd., to manufacture, sell
residential units from seven major cities alone touching
and service Zoomlion's complete range of tower cranes in
1.3 million. With these changes comes the demand for
India.
quicker time to market for projects, which is pushing the
This strategic alliance aims to combine the advanced
demand for related equipment. Mumbai alone accounts for
technology and manufacturing expertise of Zoomlion with
approximately 70% to 80% of the demand for new tower
ElectroMech's strong base in India and its strengths in sales
cranes and this is only expected to grow as project approvals
and service to provide top class Zoomlion tower cranes to
are becoming a speedier process.
Indian customers.
Zoomlion is China's leading construction machinery
ElectroMech specialises in designing, selling, manufacturing,
manufacturer with the world's most comprehensive product
erecting and commissioning of a diverse range of products in
chain. The company has maintained an average CAGR of
the industrial cranes product spectrum and counts amongst
over 60% since establishment and now manufactures
its clientele all leading infrastructure construction companies
13 categories, 66 series and over 640 varieties of leading
in India. This Joint Venture aims to leverage ElectroMech's
products, to which it owns complete intellectual property.
relationships within the infrastructure majors and expand
With annual sales of over 8 billion USD in 2010, Zoomlion
our product offerings to them. Moreover, this will see

22
 is the 7th largest construction equipment manufacturer in the Commenting on this association Mr. Tushar Mehendale,
world. Tower cranes are one of the most competitive products Managing Director, ElectroMech said, "It is a fine time for
of Zoomlion among its diverse product lines. Their technical Chinese machinery producers to invest in India's heavy
superiority and tremendous manufacturing strength make machinery industry, as India has planned to invest USD one
Zoomlion the leader in the Chinese tower crane market. trillion on infrastructure construction over the next five years.
In June 2011, Zoomlion acquired the world's most advanced Last year, India's tower crane industry saw total revenue of
topless tower crane technology from JOST, thereby entering into USD 93 million. Industry insiders expect the sector to maintain
the global high-end an annual growth rate of more
tower crane market and than 20% in the next decade."
leaping from a leading Mr. He Wenjin, Vice-President
Chinese enterprise of Zoomlion Heavy Industry
i n t o a n a d va n c e d Science and Technology
international Development Co. Ltd. said,
enterprise. Currently, "The joint venture will be
Zoomlion manufactures Zoomlion's first directly-
three series; hammer- invested overseas plant, with
headed, luffing-jib and Zoomlion holding a 70% stake
topless tower cranes and ElectroMech owning the
and over 40 models of remainder."
tower cranes ranging He further added that the
from 63tm to 5,200tm. On August 29, 2010, Zoomlion developed Hong Kong-listed Zoomlion has a long-term strategy in the
the world's largest horizontal jib top slewing self-raising tower Indian market and plans to invest USD 100 million to bolster its
crane -D5200. business development in India in the next few years. He said
the two partners hoped the joint venture plant, which will

with Zoomlion
specialise in tower crane production, will realise USD 50 million
in annual sales in five years. Mr. He Wenjin also mentioned that
Zoomlion will continue looking for overseas merger and
acquisition opportunities in the future.
December 2012

23
BEST OF
Compendium 2009 to 2014
Being on the right track
ElectroMech has proved to be
a reliable partner to several
EPC companies. Hardly any
large scale infrastructure
project is complete without
ElectroMech. In keeping with
this tradition, we have supplied
several cranes for the Chennai
Metro Rail project, handled by
Gammon India and Soma
Constructions, reasserting our
successful track record.
Metro rails are the new lifelines of
modern India. With the ever-growing
population of Indian cities, rapid mass
transportation systems are the need of
the hour. A metro rail is best suited for
this purpose with an added advantage of
economy in commuting. After their
successful implementation in Kolkata,
Delhi & Bangalore, several other cities
such as Chennai, Mumbai, Pune are
following suit.
ElectroMech continues to play a pivotal
role in several metro rail projects by
installing cranes for precast segment
yards and in flyover construction activity.
A railway track is an essential
24
requirement for a metro rail and the present at several flyover projects,
congested nature of most Indian cities precast segments yards, highway
necessitates an elevated structure over construction and other infrastructure
existing roads. projects in India.
Hence, most of the routes of the metro
rail track consist of flyovers. These The current project
flyovers are necessarily built using
Recently, ElectroMech supplied several
modern construction techniques
consisting of pillars and precast
cranes for the Chennai Metro Rail
project. This is being jointly executed by
segments, which allow quick, precise and
Gammon India Ltd. and Soma
reliable construction.
Constructions Ltd., both of whom are
For using this method of construction, ElectroMech clients.
precast segments are manufactured in
a central precast segments yard which is
usually located far away from the
construction site. These precast
segments are then carried to the project
location. They are then lifted and
precisely placed to form the track length.
ElectroMech's experience at metro
rail projects
ElectroMech is looked upon as a reliable
partner by several EPC companies for
their metro rail projects. ElectroMech has
Cranes for casting yards
supplied a 60 Ton launching girder hoist
to Gammon India for the Delhi metro rail Gammon India and Soma both have
large casting yards on the outskirts of
project. We have also been a part of
Chennai where precast segments are
Bangalore metro rail project by supplying
manufactured and then transported to
two 120 Ton gantry cranes to Navayuga.
project sites. ElectroMech Gantry Cranes
ElectroMech cranes are conspicuously
are used in these casting yards for
 efficient and safe handling of precast
segments. These gantry cranes
practically cover the entire length and
breadth of the yards, reaching every
corner. They are used to handle precast
segments through various stages of
manufacturing and then for moving them
to the stocking area. ElectroMech gantry
cranes are also used for loading of
precast segments onto trucks.
These cranes are reliably performing
round-the-clock for continuous handling.

Cranes on flyovers
ElectroMech is synonymous with
handling solutions. Obviously, for any
challenging requirement, industries look
at us with great expectations and trust.
One such challenging requirement at the
Chennai metro rail project was to
construct a parapet wall using precast
cemented blocks. ElectroMech was quick
to respond to this unusual requirement.
The solution came in the form of a
7MT gantry crane running on top of the
flyover, with overhangs on both sides.
With this arrangement, it was very easy
to lift precast segments and position
them precisely to form the parapet wall.

Photo courtesy : Infrawindow.com

ElectroMech marks its presence

at the Chennai Metro Rail project
The same crane was used to build
platforms on the elevated track of the
metro rail.
By meeting the requirements of
Gammon India and Soma successfully at
the Chennai Metro Rail project,
ElectroMech has reasserted its
successful track record once again.
December 2012

ElectroMech clients

25
BEST OF
Compendium 2009 to 2014
ElectroMech receives a single largest order
from a steel plant - BMM Ispat Ltd.
BMM is a Rs.2000 crore company with a focus on market
orientation and optimal usage of technology to achieve process
efficiency and value addition. BMM has always believed in its core
value - 'potential in tonnes' and hence continues to transfer the
benefit derived from sustained growth to all its stakeholders. The
unique value proposition that defines the very fabric of the BMM
culture is the firm's belief in unleashing this 'potential in tonnes'
in terms of its human capital, continuous growth and consistent
transfer of benefits to its stakeholders.
The BMM Group has two manufacturing facilities -
n BMM Ispat Limited - Located at Danapur, Hospet, Karnataka
n BMM Cements Limited - Located at Gudipadu, Yadiki
Mandalam, Anantapur District, Andhra Pradhesh
Current capacities at BMM ISPAT Limited are
n Beneficiation plant - 2.60 million tonnes per annum
n Pellet plant - 2.40 million tonnes per annum
n Sponge iron plant - 0.73 million tonnes per annum
n Induction furnace - 0.10 million tonnes per annum
n Rolling mill - 0.09 million tonnes per annum
n Power plant - 165 MW
l frame and the lower trolley frame. The slewing bearing is
BMM Ispat Ltd. has embarked upon an expansion project to set
up an Integrated Steel Plant of 2.00 million tonnes per annum in
two phases and a Power Plant of 70 MW.
During the summer of 2012, senior executives from BMM visited
the ElectroMech factory in Pune for capacity evaluation. They
were very impressed with our plant facilities, systems, design
facilities and our ability to achieve on time performance. After
thorough evaluation, they have placed an order on ElectroMech
for 15 cranes for their Steel Melting Shop and Rolling Mill which
will be a part of the new 1.25 mtpa Steel Plant.
26
An interesting challenge in this order from BMM will be the supply
of Cranes with Rotating Trolleys.
This is achieved in two ways :
n Via slewing wheels
n Via slew bearing for the 12.5t cranes
Rotating Trolley on slewing wheels
This trolley consists of two parts viz. the upper trolley
frame and the lower trolley frame. The main hoisting machinery
is mounted on the upper trolley frame which has slewing wheels
that run on a circular rail track fitted on the lower trolley frame.
This will be used to rotate a spreader beam with magnets
attachment through 270 degrees with a slewing speed of 2 rpm.
The magnets are capable of handling hot billet bundles at
6000C and are designed for 60% duty cycle (having class H
insulation with temperature rise limited to class B). These
magnets are equipped with a battery back up system for
15 minutes. This crane will normally be used for stacking of
billets, loading/unloading of billets/bars.
Rotating Trolley on slewing bearing
This trolley consists of two parts viz. the upper trolley
fitted in between these two frames. The main hoisting machinery
is mounted on the upper trolley frame. This will facilitate the
spreader beam (having magnets attachment) to rotate through
270 degrees with a slew speed of 2 rpm.
l
This is the single largest order for ElectroMech from a steel plant.
The entire project is expected to be completed by the end of
2013. We sincerely thank the entire BMM team for their trust in
our solutions capability and look forward to a successful
completion of the project.
December 2012
 When productivity
takes a new turn
The rotating crab at Valmont makes
tasks easier; enhances productivity.
The company
Valmont is a world-renowned company manufacturing street
lighting poles, traffic signal poles, utility poles, communication
poles and poles to light up large sports complexes and stadiums.
In India, Valmont has a large manufacturing plant at Indapur
(Maharashtra). The plant is designed in such a way that the
entire production process follows a linear path right from the raw
material arrival to the dispatch bay. The plant employs state-of-
the-art manufacturing facilities.
The challenge
Valmont uses 11 ElectroMech cranes throughout their
manufacturing plant. They are being used at various stages in
manufacturing, right from the unloading of steel coils from
trailers and placing them on the conveyor. The requirement from
an EOT crane at the last stage of manufacturing was most
challenging. Here, the poles, completely ready for despatch, are
carried by the conveyor. At this point, they are to be lifted and
placed on the trailers. But, the direction of the trailer is
perpendicular to the conveyor. This necessitates lifting and then
rotating of poles by 90º. Conventional cranes pose limitations in
rotating the poles automatically and also placing them precisely
on the trailers.
The solution
The engineering team at ElectroMech perfectly understood this
problem. Using the conventional solution was ruled out because
of its limitation of automatically turning the pole to change its
orientation. It would have been very cumbersome, involving lot
of labour to do the job if a conventional crane was used.
Considering this aspect, our design engineers designed a special
crane with a rotating crab. Such a design allows extreme
flexibility. It can rotate the object by 360º clockwise or anti-
clockwise. This special design consists of two hoists of 10Ton
capacity each mounted on a rotating crab of a double girder
crane. The span of the crane is 17.6m and the height of lift is
7.6m. It can lift a load up to 120Ton. When ready-to-despatch
poles come out of the shed along the conveyor system, they are
lifted using this crane, turned by 90º to bring them in line with
the trailer and then carefully placed on the trailer.
The result
This ingeniously designed system resulted in a tremendous
amount of saving in labour, time and enhanced productivity of
the despatch area. Team ElectroMech thanks Valmont for
involving us in this challenging project and proving the real
solutions ability of ElectroMech.
December 2012
27
BEST OF
Compendium 2009 to 2014
The company
CMI Fpe is a global leader in designing, manufacturing, erection
and commissioning of Cold Rolling Mill plants. In India, they have
large plants at Taloja and Silvassa, where they manufacture
various equipments required in Cold Rolling Mills. These two
units are equipped with high precision, ultra-modern machinery,
and all the assembly activities conform to high quality standards.
In the entire plant, emphasis is laid on automation where
handling of various components and parts during the assembly
impacts the productivity of the plant.
The challenge
CMI Fpe’s Taloja plant consists of several manufacturing
bays. With the growing demand for their equipment and
machinery, the company has also constructed another plant
beside the existing one. With this new addition, the
manufacturing activity is carried out in one plant and the
assembly in the other plant. For handling requirements
in a particular bay, the company uses EOT cranes. However,
the inter-plant handling of high tonnage machinery from one
bay to another and intra-plant movement of components
and semi-assembled machines weighing up to 150Ton posed a
great challenge.
Transfer trolley
Adding flexibility to handling
CMI Fpe benefits from our new transfer trolley system
for intra-bay and intra-plant handling of loads
28
The solution
The ElectroMech solution for intra-bay and intra-plant transfer
and handling of loads came in the form of a transfer trolley. This
is a specially designed trolley operating on ground rails. It
consists of a platform of size 9m x 3.5m with 8 wheels, capable of
handling 225Ton shock load. It traverses on a 112 m long set of
rails which efficiently integrates various bays and also two plants
in the premises. Handling is made extremely easy with a pendant
control, and a load of 150Ton at a time can be transported at a
speed of 40m/min. Power supply to this transfer trolley is
through a spring operated cable reeling drum. To ensure safety,
power cables run through a cable tray which is 6 inches below
the ground.
The result
This highly efficient and safe system has made handling
extremely efficient. Previously, for the same job the company
was using a trailer, which has now become redundant. All the
bays and two plants are conveniently connected to operate
without requiring any special skill. The transfer trolley system
from ElectroMech is a new development ideally suitable for intra-
bay and intra-plant handling of heavy loads. This is a completely
in-house development introduced in the market after
successfully using it in our own plant for more than 3 years. The
system is also proving its worth at Prime Group, Reniguntta plant
and Enpro Industries, Pune.
December 2012
 Solutions Service Satisfaction
Receives a major order from
Air Liquide Group of France
Air Liquide Group is a major player in the oil & gas sector as well
as health & environment with operations in over 80 countries. It
is the world leader in gases for industry, health and environment.
The Group offers innovative solutions based on continuously
enhanced technologies for cold box manufacturing which is used
in Air Separation Units / Cryogenic Air Separation Units (ASUs).
In a major breakthrough, our subsidiary, ElectroMech FZE, Dubai
bagged a major order worth approx. INR 200 million for
29 EOT Cranes from the French multinational, Air Liquide
Group. The order was received against tough competition from
several multinational companies.
Our complete scope is for the manufacture, supply, erection,
commissioning, testing and certification of 29 EOT Cranes.
The cranes to be supplied are:
Ø 150MT DGEOT - 2 nos. Ø 20MT DGEOT - 11 nos.
Ø 10MT SGEOT - 14 nos. Ø 10MT DG Gantry Cranes - 2 nos.
These cranes will be installed in their plant in RAK Maritime City
which is the latest and most advanced maritime free zone to
open in the United Arab Emirates. The Air Liquide Group plant is
spread over 36 acres and the facility will be used for the
manufacturing of fabricated metal products, structures, tanks,
reservoirs and containers or in short cryogenic vessels.
This challenging project will be completed during FY 2013-14
successfully.
September 2013
29
BEST OF

Compendium 2009 to 2014

Nuclear Power Corporation of India Limited (NPCIL) is a Public Ø Gantry Cranes - 4 nos.
Sector Enterprise under the administrative control of the Ø Manually Operated Cranes - 6 nos.
Department of Atomic Energy (DAE), Government of India. It Ø Chain Hoists - 4 nos.
was established in 1987 with the objective of operating atomic
Among these, one of the most challenging requirements was
power stations and implementing atomic power projects for
that of the 60MT Single Failure Proof Crane to be installed in the
generation of electricity. It is responsible for design,
reactor building.
construction, commissioning and operation of nuclear power
reactors in India.
For the 3rd and 4th units of its Kakrapar Atomic Power Project
near Surat in Gujarat, NPCIL sought a competent and
experienced crane manufacturer with the capability to design,
manufacture and commission 29 EOT cranes according to the
critical requirements of the project while being able to adhere to
stringent quality norms. The cranes are to be installed at crucial
locations in the reactor building, reactor auxiliary workshop and
mechanical workshop of the nuclear plant. The scope of the work
also includes the designing of three critical Single Failure Proof
Cranes (SFPs).
ElectroMech - Selected as a most reliable project partner
The order was received after a thorough technical and
commercial evaluation of the bid, which was followed by a
factory visit by a cross-functional team from NPCIL to evaluate
our infrastructure and capabilities to execute the order. Satisfied
with the capability and competency of ElectroMech, NPCIL
placed the package order on ElectroMech in the month of August
2011. The total scope of the work includes design, manufacture,
inspection, assembly, shop testing, packing & forwarding, safe
delivery to site, unloading, storing, handling at site, erection, Technical specifications of the 60MT Single Failure Proof
final testing commissioning and handing over of cranes as per Crane
NPCIL specifications.
Ø Crane SWL: 60MT Ø Span: 21m Ø HOL: 38m
This order includes:
Ø Class of duty: M7 Ø Operation: Cabin, Radio Remote Control
Ø Single Failure Proof Cranes - 3 nos.
& Pendant Ø Crane weight: 80MT Ø Crab weight: 30MT
Ø Double Girder EOT Cranes - 6 nos.
Ø Hook: 60MT Ramshorn Type Single Failure Proof Hook
Ø Single Girder Underslung Cranes - 6 nos.

30
In a major international bid, ElectroMech won an order to supply 29 EOT
cranes to Nuclear Power Corporation of India (NPCIL) for their Kakrapar
Atomic Power Project (KAPP) near Surat in Gujarat. This order includes
3 Single Failure Proof (SFP) Cranes.

Story of unfailing commitment to deliver

first Single Failure Proof EOT Crane to NPCIL
What is a Single Failure Proof Crane?
A Single Failure Proof Crane has redundant systems &
mechanisms built into it, so that should one system or
mechanism fail, the backup system ensures that the work cycle
is completed. In the case of these cranes, it means that if a load
carrying system or mechanism suffers a failure, the full load is
taken by the backup or redundant mechanism. This, in turn,
prevents any major catastrophe in case of failure of any load
carrying component in the system.
Application
The first crane supplied is mainly to be used for handling Primary
Coolant Pump Motors, which are located exactly above the
reactor. The secondary application is for erection, maintenance
related activities of all the equipments within the reactor
building.

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BEST OF
Compendium 2009 to 2014
Why is this required?
This crane will operate at the top of the Reactor Building dome,
directly above the reactor which is the heart of a nuclear power
plant. The location of the crane thereby demands a very high
level of safety, necessitating the need for a Single Failure Proof
Crane.
How is this achieved?
The required redundancy is achieved by using two independent
load paths through two rope drums. Both the rope drums are
driven by separate gearboxes and motors, synchronised to
ensure equal displacement of wire rope in each load path. Each
load path is designed to hold the rated load. Both the wire ropes
reevings are taken on alternate pulleys to maintain equilibrium of
load in case of failure of one rope system. The hooks used are of
dual design with dual attaching points thereby if one attachment
fails, the other load path continues to support the load without
excessive drop or swing.
32
Project challenges
Design
One of the biggest challenges for the designers was that this
Single Failure Proof Crane for the 700MWe reactor was to be
made with the same dimensional constraints as a regular EOT
crane. Moreover, the span of the crane for the 700MWe reactor is
21m as compared to 10m for a crane in the 500MWe reactors.
This made the design and arrangement of the crane components
a daunting task while meeting the dimensional requirement.
Finally, after months of painstaking efforts, dozens of proposals
and several brainstorming sessions, our design team along with
the NPCIL design team narrowed down to a double-decked
arrangement of the trolley mechanism. The design of this trolley
having a height of approximately 6.5m and sitting on top of the
reactor building was successfully undertaken by our design
team. This new concept was endorsed by the NPCIL team, so
much so that the same concept will be adopted in unit 7 of their
Rajasthan Atomic Power Plant as well.
Seismic Design
Design to ensure structural integrity during a seismic event was
called for. The crane structural needed to be designed for Safe
Shutdown Earthquake (SSE) and Operating Base Earthquake
(OBE) standards as per the furnished Floor Response Spectra.
For the design and qualification of the plant the Safe Shutdown
Earthquake (SSE) standard is adopted. In simple language, this
means, in the eventuality of an earthquake it must be possible to
shut down the plant and equipment safely. Similarly, the intensity
of the Operating Base Earthquake (OBE) is related to the
production period of the Nuclear Power Plant. After an OBE, it
should be possible to shut down the plant safely and further
operation of the plant and equipment should be possible after
checking and a certain amount of repair work.
The Floor Response Spectra is tabulated data that gives the
acceleration forces that may act on the crane in the event of an
earthquake. These acceleration values are a function of
equipment frequency and the elevation (i.e. crane location)
amongst many other factors. By using this data given by NPCIL
for the particular site location, the structurals of the crane were
qualified accordingly.
The ElectroMech design was reviewed by the NPCIL design team
and handed over to a third party for analysis using software to
simulate more virtual conditions. Finally, after 12 months of
detailed engineering and analysis, the structural design was
approved.
Procurement, Quality and Production
The special design called for use of special / non-standard
materials. For example, MS plates of grade E350 instead of
Single Failure Proof EOT Crane for NPCIL
conventional grade E250 were used for girder fabrication, square
tubes were used for trolley fabrication and caliper brakes were
used, to mention a few. WPS PQR were re-established to meet
the customer requirement as per ASME. Above all, a stringent
quality plan was followed whereby material at each stage of its
production cycle - from raw material to finished component, was
tested to meet the highest quality standards. Obviously, this
couldn’t be achieved without a very efficient procurement,
quality and production team.
Setting new records at ElectroMech
Ø First Single Failure Proof EOT Crane supply by ElectroMech
Ø First supply to a nuclear power plant by ElectroMech
The first Single Failure Proof (SFP) Crane was manufactured and
despatched in March 2013. This was tested for full load and
overload in our factory before despatch in the presence of a
specialist team across NPCIL, QS Pune and NPCIL Mumbai.
Several tests were conducted by simulating even the rare
possibilities and our cranes satisfactorily passed all of them. The
remaining 2 Single Failure Proof Cranes will be supplied during
this financial year.
September 2013
07
33
BEST OF
Compendium 2009 to 2014
CMI FPE trusts our solutions capability
ElectroMech develops Pot handling crane with unique design by using 2 hoists on a single beam
CMI FPE Limited - formerly
Flat Products Equipments
India Ltd. was incorporated
in 1986. The company, over
the last 22 years, has acquired a
global leadership position in the design,
manufacture, erection and commissioning of cold rolling mill
complexes and auxiliary equipments for the cold rolling industry
and the metal processing industry. The Belgian Group CMI
(Cockerill Maintenance & Ingénierie) completed the acquisition
of Flat Products Equipments India Limited in 2008 and has now
been renamed CMI FPE Limited. The principal activities of the
company comprise manufacturing and installation of cold rolling
mills complexes, processing lines, chemical processes, thermal
processes and automation equipments for ferrous and non-
ferrous industries worldwide. As of today, CMI FPE Limited has a
global footprint across Asia, Africa, Middle East, Europe, North
America, South America and Russia.
The challenge
CMI FPE is currently working on a steel mill project for JSW Steel
Ltd. at Tarapur, Thane. While working on this project, a big
challenge was posed by the handling requirement at the
galvanising plant. The company was looking for a Pot handling
crane of suitable design to be fitted exactly above the zinc pot.
34
What is a Pot crane? Working and uses
These types of cranes are placed above the pots in galvanising
plants. It is primarily a maintenance crane, used to maintain and
replace the galvanising equipment such as rolls and slits when
required. The space constraint is high, and precise hook
positioning is required as the hook needs to be positioned exactly
above the zinc pot.
ElectroMech solution
Having experienced our solutions capability previously, CMI FPE
approached us to design a unique solution for their current
challenge. The end client, JSW steel further attested this
decision.
After carefully studying the process and the requirements, our
design team developed a solution which was a perfect fit for their
requirement. The design is very different from a conventional
DG EOT crane.
The crane has 2 hoists of 7.5MT capacity each, mounted on
cantilever beams hanging on the crab. The hoists were modified
to suit this particular handling requirement. This design has been
made for the specific application, considering the critical end
approach requirements. The crane offers a span of 8m and lifting
height of 18m. The overall system, in spite of the customised
design, proved to be an economical solution for the client. This
crane was under commissioning at the time of going to print.
September 2013
Prestigious order from Mazgaon Dock Limited
Intelligent design for overcoming space constraint to handle heavy loads

Mazagon Dock Limited, Mumbai, an ISO 9001:2008 company is Keeping this in mind, extensive engineering has been done to
one of the leading shipbuilding and offshore fabrication yards in optimise the crane dimensions, to ensure maximum and
India. The yard was established in the 18th century, and over 200 effective space utilisation.
plus eventful years, has earned a reputation for quality work and l
established a tradition of skilled and resourceful service to the ElectroMech solution
shipping world in general and the Indian Navy, Coast Guards & After a thorough assessment of various crane manufacturers in
ONGC in particular. India, Mazagon Dock Limited selected ElectroMech to design,
After 1960, Mazagon Dock grew rapidly to become a premier manufacture and commission the cranes for this new submarine
warship building yard in India, producing sophisticated warships manufacturing unit.
for the Navy and offshore structures ElectroMech has designed 3-tier
for the ONGC. It has grown from a cranes to suit the client
single unit, small ship repair requirement. This type of design
company, into a multi-unit and will ensure compact construction
multi-product company, with a of the cranes to fit into the limited
significant rise in production, use of space available. We will be
modern technology and supplying 7 heavy-duty cranes.
sophistication of products. The The client being a Defence
company’s current portfolio of organisation, the manufactured
designs spans a wide range of cranes will be undergoing close
products for both domestic and monitoring and quality checks
overseas clients. from the officials of the Defence
Ministry.
The challenge The order will be executed during
Mazagon Dock is in the process of the year 2014 and we are
expanding its facility to manufacture submarines for the Indian confident of meeting the expectations of the client.
Navy. This is a very prestigious, challenging and critical project
for the Indian Ministry of Defence. Handling requirements in this Details of the order l

plant vary from a few tonnes to as high as 300 tonnes. Needless

to say, safe handling of these critical components is of utmost
importance. The frequency of utilisation and the operating
speeds are very high. Further complicating these challenges is
the fact that space availability is a great constraint in this plant.
Ø 150/30MT Semi-Goliath Cranes, Span 16m, HOL 22m-2 nos.
Ø 60/20MT Semi-Goliath Cranes, Span 23m, HOL 22m-1 no.
Ø 30/10MT DG EOT Cranes, Span 41.5m, HOL 32m-2 nos.
Ø 30/10MT DG EOT Cranes, Span 41.5m, HOL 27m-2 nos.
September 2013

35
BEST OF
Compendium 2009 to 2014
hermax Ltd., headquartered in Pune, has been providing
T engineering solutions for decades to the energy and
environment sectors. One of its biggest divisions
supplies boilers to the power sector. The company recently
entered into a joint venture with Babcock & Wilcox (USA), a
global leader in the power generation industry, to manufacture
super critical boilers for the power sector. The Thermax Babcock
& Wilcox (TBW) plant is spread over 100 acres of land at Shirwal
near Pune. The manufacturing facilities are split into 3 units; a
25,000 sq.m Section shop, a 16,000 sq.m Panel shop and a
18,000 sq.m Header shop.
ElectroMech has been supplying cranes to all of Thermax
factories as well as their projects. The Thermax factory in
Chinchwad, Pune has several cranes from ElectroMech and these
are used for various applications like loading, unloading,
handling, assembly work, etc. Satisfied with their past
experience of using ElectroMech cranes, TBW approached
ElectroMech at the planning stage itself to discuss the crane
requirements for this new plant.
How project costs can be saved by
Energy Solutions
At the new TBW plant, 34 ElectroMech cranes with capacities
ranging from 10MT to 50MT integrate the entire handling
operations on three shop-floors. This covers handling right from
raw material storage to the final despatch, including several
fabrication and assembly stations.
The interesting part of this entire project was the involvement of
ElectroMech right from the project conception and designing
stage of the plant building. Consideration of overhead cranes in
the plant is crucial in determining the overall specifications of the
building. This is because overhead cranes run on gantry girders
that are supported by the building structure. In addition to the
Photo courtesy: Vogel Business Media India Pvt. Ltd.
36
building structure and roof itself, the entire load of the crane as
well as the job being handled is borne by the factory columns.
Involving us at the factory planning stage is beneficial to a client
as the structural engineer can optimise the factory building
based on the wheel loads and crane dimensions provided by us.
This also allows us to provide inputs on the workflow, so as to
optimise the choice of cranes to keep costs low while achieving
maximum resource utilisation.
Saving on project costs
The work of the TBW factory building started almost two years
ago and following a consultative approach, ElectroMech
designed a solution that was economical, had advanced
features, matched speed, technical specifications and other
parameters of the crane such as the geometries, wheel loads,
etc.
An apt example of the benefit of involving us during the planning
stage is seen in the plant’s section shop. The highest capacity
crane is 50MT, which would logically require the entire factory
building to be designed for the loads exerted by this crane.
A testi
However, during detailed analysis of the client’s work flow, it was
apparent that the 50MT job would never traverse the entire
length of the shop floor. This allowed the structure to be
optimised so that only the necessary portion has been built to
take the load from the 50 MT crane. Safety limit switches ensure
that the 50 MT crane does not travel with its full load to other
parts of the shop. This solution gave TBW substantial saving in
their structural cost for this shop.
Reduced maintenance
ElectroMech advised TBW to opt for a power supply system,
especially for the outdoor duty gantry cranes, that is more
 reliable and has zero maintenance compared to what is used lean manufacturing philosophy dictates its reduction. By taking
traditionally. Typically, for a gantry crane, one uses cable reeling cognisance of what needs to be done on a shop-floor, arranging
drums. The cable reeling drum mechanism itself can prove to be processes accordingly and by optimising speeds and geometries
problematic in some cases as it increases maintenance. Again, of cranes, material handling time can be drastically reduced. This
because we were involved with the customer from the needs to be planned in the early stages of the project to derive
beginning, we were able to factor in, at the time of construction maximum advantage.
itself, a way to use regular shrouded bus bar for supplying power
to the outdoor gantry cranes. By this, we have eliminated a lot of
hassles which might have arisen in the future had we resorted to
the cable reeling drum concept. This approach has also led to
further reductions in the project cost.
Power saving
Thermax has always used conventional cranes of the older
generation of technology, based on the older Russian designs in
their older plants. Cranes from ElectroMech used at the super
critical boiler plant are more compact, efficient and lighter in
weight. These cranes are reliable with practically no breakdowns
and minimal requirement in regular maintenance. These cranes
are also inverter-driven. Hence, there is better control on various

y involving ElectroMech at plant designing stage

imony at Thermax Babcock & Wilcox Ltd., Pune
parameters like smoothness of operation, precise control on
speeds. Energy efficiency is further enhanced as cranes take only
as much power as is required. If one were to combine the total
power consumption of all the cranes used throughout the TBW
factory, it would be observed that there is a reduction of at least
15-20 percent over conventional cranes.
Faster handling. Higher profits. Higher safety
Divisional Manager-Manufacturing, Thermax
Babcock & Wilcox Energy Solutions Pvt. Ltd.,
Mr. Rajeev Sondur seconds the fact that including
ElectroMech from the start provided numerous
benefits. He said, “The company was able to fine
tune our plant layout to ensure maximum space
utilisation and save on our asset costs.”

ElectroMech has also supplied TBW with unique solutions like

wall travelling cranes. On a shop-floor, with respect to the
principles of lean manufacturing, waiting time is one of the prime
sources of waste. Wall travelling cranes allow workers to service
workstations individually without using cranes on the top.
Waiting time for the crane is thus eliminated and productivity of
the individual workstation is enhanced.
This is a much better solution than a semi-gantry crane, in which
one end carriage runs on the gantry girder, while on the other
side a leg runs on the floor. Having an end carriage running on
the factory floor, creates a safety hazard due to the possibilities
of collisions with men, machines and material. Rail tracks or
supports would also be needed on the ground, increasing the
civil cost. Wall travelling cranes have no legs and travel in the air
independently on their own supporting structure integrated with
the factory building, thus enabling efficient and safe layout of the
workstation. Integrating wall travelling cranes into the layout
was only possible because ElectroMech was involved in the
project from the factory planning stage.
Customer satisfaction
Though material handling forms a critical part of any workshop,
Adding further value is the ElectroMech factory, which uses
almost every type of crane that we manufacture, acts as a
showcase. This allows customers to experience a new solution
that we may recommend to them, building their faith in the
usefulness of the product.
We are indeed very thankful to the TBW team for reposing their
trust in our solutions approach and capability and for involving
us at the project planning and building designing stage.
Challenges
Thermax Babcock & Wilcox (TBW) wanted a material
handling system that was technically proven, matched
their applications and was cost-efficient.
Solution and Results
Wall travelling cranes were suggested by ElectroMech
to TBW for carrying out their operations effectively;
various zone protection systems were introduced
which helped them save their structural cost. Inverter
drives were used to save on power consumption.
September 2013
37
BEST OF

Compendium 2009 to 2014

A ‘plate’ full of challenges

One crane with 2 hoists avoids swing and allows higher span of Long Travel
JSW Steel Ltd. is a well-known name in steel manufacturing in As always, out-of-the-box thinking by ElectroMech design
India. For their Tarapur plant, they were looking for a suitable engineers provided a unique solution for this project challenge.
system to handle steel plates and long steel beams. These steel We designed one 20 MT DG EOT crane with 2 hoists of 10 MT
plates and beams, on coming out from capacity each mounted on it. The hoists
a rolling mill are stacked adjacent to are placed 1 meter apart. This allows
the mill. The client was looking for a hooking at 2 different points and the
Customised solution for
suitable handling system which can possibility of jerks is completely
JSW Steel Ltd.
efficiently handle and shift these eliminated. Specially modified hoists
plates to a nearby location. which work in tandem were used for
JSW engineers approached this application. The use of only one DG
ElectroMech to develop a suitable EOT crane allows a higher span for long
system for their unusual requirement. traverse, making optimum use of
When our team studied the available shop-floor area, thus meeting
requirement, we discovered several the client's requirement. Also during
challenges in the requirement. First of routine operations, only one crane
all, the long plates and beams operator is required instead of two
necessitated hooking at two points to needed by the conventional system. Of
avoid swinging. The heavy loads up to course, using one crane of this type
20MT demanded use of double girder instead of two conventional DGEOT
cranes. The simplest solution would cranes has also reduced the equipment
have been to provide 2 Double Girder cost to the client.
EOT cranes which operate in tandem. The JSW team was extremely satisfied
But the space constraint in the plant ruled out the possibility of with our ingenious solution and the delight further enhanced
using 2 DG EOT cranes as this would reduce the long traverse when we commissioned the system within just 6 weeks from the
span which would not have met the client's requirement. confirmation of the order.
September 2013
38
 A high-lift, high-speed crane in operation at an HCC Hydroelectric Power Project in Punatsangchhu, Bhutan

Award-winning solution
Mr. AVR Murty, CEO, receiving the award on behalf of ElectroMech
for tunnelling operations
‘Manufacturing today’ award for ‘Excellence in Innovation’ in the SME category
ElectroMech is proud to have been awarded for our innovative
solution provided for the execution of the Mumbai water
supply project. ElectroMech, India's largest industrial crane
manufacturer and customised material handling
solutions provider was awarded the 'Excellence in
Innovation' award in the SME category for its
s p e c ia l is e d Tu n n e l Mu ck in g Sy s te m a t th e
‘Manufacturing Today awards 2012’, conducted by
‘Manufacturing Today’, an ITP Publication group
magazine.
Commenting on the occasion, Mr. Tushar Mehendale,
Managing Director, ElectroMech said, "We are very
pleased to receive the award for our path-breaking
innovation. This award testifies that we continue to align
our innovation approach to meet our customer
expectations. This unique Tunnel Mucking System is a
boon for projects which require rapid removal of
overburden from tunnelling or shaft excavation and has
its own benefits as a special purpose crane. We will
remain committed to our customers and continue to
offer the best products."
ElectroMech's clients for its high-speed, high-lift Tunnel
Mucking Systems include several leading infrastructure
majors such as Gammon, HCC, Unity, Patel Engineering,
SOMA and IVRCL on sites in India and across the globe.
ElectroMech's unique Tunnel Mucking System has proved to be
an innovation in various critical projects for rapid removal of
overburden from tunnelling or shaft excavation. The recent
installations for the Mumbai water supply project
involved ElectroMech's tunnel mucking crane under the
government's Jawaharlal Nehru National Urban Renewal
Mission (JNNURM). The INR 2235 crore project was
divided into two parts. The construction work of this
prestigious project was awarded to two construction
majors namely, Soma Construction Company for Phase I
(Gundovali to Thane) and to a Joint Venture of Unity
Infraprojects Ltd. and IVRCL Ltd. for Phase II (Thane to
Bhandup). Interestingly, ElectroMech supplied tunnel
mucking cranes to both the companies, thus playing a
crucial role in BMC's ambitious 24x7 water supply project.
September 2013
IVRCL & ElectroMech teams
39
BEST OF
Compendium 2009 to 2014
Our customers reaffirm our positioning.
A recent customer satisfaction survey by Nielsen reveals the fact *.
Customer satisfaction is a top priority for ElectroMech. Every
action, effort and the organisational energy are directed towards
keeping our customers satisfied. It is of course important to keep
track of changing customer expectations and where we stand
while fulfilling them. To achieve this, we interact with our
customers on several platforms such as conferences, exhibitions
and customer visits by our sales team. This customer-centric
approach has helped us win the trust of thousands of crane users
in India and abroad. Satisfied with the ElectroMech experience,
our existing customers invariably approach us for their new
requirement of cranes. At the same time, new customers, some
of them users of other brands of cranes, who are looking for
better solutions, service and experience approach us as
well.
To further augment our efforts, a more systematic approach
in this direction was recently initiated by conducting a pan-
India survey among our customers through Nielsen, a
premier global market research organisation. The survey
findings are very encouraging and have provided insight
and clues for further improvements to excel in our field of
operations.
According to this survey, the attributes about ElectroMech
most appreciated by our customers were:
Ø The overall performance of our products
Ø Domain knowledge and skill set of team members
while understanding customer requirements
Ø Our ability to provide customised solutions which are
most relevant for a particular application
Ø Professional and ethical practices followed by the
company
Ø The technical competency of our team of engineers
Ø Our customer-oriented approach
Over the years, we have evolved as a leading and capable
'Solutions provider'. For this, we always ensure strong technical
and design support to our customers. To provide the most
pertinent solutions, our R&D team is constantly exploring ways
to improve our products and deliver a better customer
experience. Apart from this, we lay a great emphasis on adopting
most modern manufacturing practices which ensure high quality
and reliability of our cranes. This, in turn, translates into a
greater benefit for our customers. According to them, the
following are the important benefits with our crane systems.
Ø Safety features of equipment
Ø Smoothness and low noise levels of equipment
Ø Necessary safety and statutory regulations followed by our
installation team
* Source: Nielsen Survey February 2013 (sponsored by ElectroMech)
40
Apart from the above, customers have appreciated our systems
during and after the tendering process. According to them,
Ø Accuracy, completeness and timely submission of technical
documentation are highly satisfactory
Ø Interaction, courtesy and politeness of the sales team are
appreciable
Ø Majority of our customers also admired our ability
to provide 24x7 service support
Ø ElectroMech deploys a well-trained and skilled team
of engineers and technicians on the field to provide numerous
trusted services
Survey highlights
Ø ElectroMech is mainly known for providing
customised solutions, technical competency,
excellent product performance and customer-
centric approach.
l
Ø 9 out of 10 customers will definitely
recommend our cranes and services to other
businesses.
l
Ø ElectroMech has the highest recall amongst all
the crane brands in India.
A very encouraging comment received in response to the
question, “How likely are you to recommend ElectroMech and
Cranedge Service to a business associate?” For calculating
the Net Promoter score on a scale of 0 to 10 - ElectroMech was
rated 9.
Also, when the customer was asked for a 'top-of-the-mind' recall
we were happy to know in terms of awareness ElectroMech is
the leading brand name for EOT cranes in India.
At ElectroMech, we have taken cognisance of all the feedback
from our clients and are implementing certain changes to
increase customer satisfaction. For example, Radio Remote
Controls have been made standard across our range of cranes
based on customer feedback during this survey.
We thank all our customers for participating in this survey
and provide us with their valuable time and feedback.
September 2013
 News from
ElectroMech FZE
Mr. Rohan Warty joins as CEO, ElectroMech FZE
ElectroMech is very happy to announce that Mr. Rohan Warty has
been appointed as the CEO of ElectroMech FZE from 1st April,
2014. Prior to taking on this new assignment, Rohan worked with
ElectroMech as General Manager - Sales & Marketing from 2003
to 2013. During his tenure at ElectroMech India, he was
responsible for developing the Sales & Marketing functions of the
company from scratch and he successfully delivered a consistent
growth in the company’s order bookings. He was also actively
involved in the operations of the company and has a thorough
knowledge of the entire business.
A qualified Mechanical Engineer, Rohan has also attended
various executive management programmes of premier
institutes in India.
Rohan’s vast experience of working in the crane industry and
exposure to companies engaged in manufacturing capital goods
have armed him with the right arsenal of tools to lead
ElectroMech FZE into a new era of excellence and growth.
We wish him all the best in his new assignment.
July 2014
41
BEST OF

Compendium 2009 to 2014

2 nos. 80MT, 32m span cranes

working in tandem at the casting yard

Being a part of the

ambitious Kochi
Rapid urbanisation in India has led to the need for rapid mass About Kochi
transportation systems in our expanding cities. Several metros
Kochi is a cosmopolitan city in Kerala with a bustling commercial
and large cities in India are responding well to this demand by
port and the financial capital of the state, with a population of
undertaking metro rail, BRTS and monorail projects. Designing
more than 2 million. More than 600 years ago Kochi merchants
such mass transportation around the existing infrastructure
began trading in spices with the Arabs, Dutch, Phoenicians,
in the city and the limitations posed by narrow roads are
Portuguese and Chinese. This helped Kochi to prosper and
challenging tasks indeed.
become the gateway to old India. Since 2000, Kochi has
Metro rails with their enormous flexibility and speed are gaining revitalised its economy with a focus on tourism, information
fast popularity in urban India and several projects are underway technology and the port. Today, it is one of the major tourist
in tier I and tier II cities. After cities like Mumbai, Delhi and destinations in India.
Bangalore, Kochi is the first tier II city in India to start the
execution of a metro rail project.

42
 Giving speed to
life in metros

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Metro - Railways Transfer
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About the project

The Kochi metro-rail is expected to be the fastest constructed metro rail project in the
country. This INR 5182 crore project will consist of 22 stations from Aluva to Petta. The
metro rail at Kochi will run on elevated viaduct tracks mounted on pre-stressed U/I concrete
girders with pile/open foundations. The construction work of the 25 kilometre long
elevated viaduct track for this project has been assigned to construction and infrastructure
majors such as Larsen & Toubro, Soma and a joint venture of Era Infra and Chengdu
Ranken. After a grand inauguration of its site in June 2013, Soma soon initiated the
construction of the first metro station at Kaloor.

Challenges
In order to ensure quick and timely completion of the project, Soma set up a casting yard
near Eloor in Kalamaserry to manufacture pier caps, pier bases, U beams and I beams.
Soma was looking for different types of cranes to cover its 300m long manufacturing bays
and handle the various precast segments. A detailed analysis of the handling requirements
in this huge casting yard by ElectroMech revealed that in order to meet the timelines, in all 5
cranes would be needed. Four of these are needed in the casting yard and one for dispatch.
All of them were expected to handle heavy loads, to be precise in operations and cover long
bays. In addition, two cranes in a bay would often have to work in tandem. In order to cut
down the project cost, Soma wanted to explore the possibility of modifying and reusing
existing cranes from other completed project sites.

metro rail project

43
BEST OF

Compendium 2009 to 2014

1 Load testing of 50T, 28m span cranes

2 Handling of inner structures
3 Placing inner structures over outer structures for manufacturing beams
4 Handling of moulds while preparing concrete structures
5 Concrete pouring process for manufacturing beams and piers
1 and heavy girders, bars and rods used for manufacturing of
2 cranes efficiently and precisely handle and place huge inner
Solution
Team ElectroMech welcomed this tough challenge and designed
a solution which is both technically feasible and economically
viable. Two pairs of cranes were required to handle voluminous
concrete structural products required for viaducts and metro
tracks. These cranes are also used to handle and store
machinery, moulds, concrete girders, foundations and all other
finished products.
In the first bay, two gantry cranes of 50MT with 28m span and
12m height of lift work in tandem. These were originally 50MT,
20m span cranes used by Soma at another project. The
modification was carried out by our subsidiary company
Cranedge, whose expertise in crane modifications has been
proven and appreciated by several clients. In another bay, two
more 80MT cranes modified from Soma’s earlier Chennai metro
project site work in tandem and handle a load of 160MT. These
moulds and steel bar skeletons inside outer moulds - an activity
which demands high accuracy. The cranes also handle precast
pier base caps in a similar process. The cranes were also modified
by Cranedge from their original specification of 120MT with 22m
span to 80MT with 32m span.
By way of ingeniously modifying the existing cranes, a substantial
cost saving has been achieved at this project of Soma’s.
Number of cranes: 4 July 2014

Cranes 1&2 Cranes 3&4

SWL 80MT 50MT

3
Span 32m 28m

Height of Lift 10m 12m

Application Handling of Handling of

moulds and moulds and
finished products finished products
(U-beams, Pier (I beams)
caps, Pier bases)

Speciality Modification of Modification of

existing cranes existing cranes
from 120MT, from 50MT,
22m span to 80MT, 20m span to 50MT,
32m span 28m span

4 5

44
 Glad to be a part of a
critical infrastructure project
Tunnel completion ceremony at Unity-IVRCL site in Mumbai Ù
IVRCL team visiting the ElectroMech stall at bC India Ø
Unity - IVRCL JV celebrates
completing the boring of 8 km long tunnel
As you know, Municipal Corporation of Greater Mumbai (MCGM)
has planned an ambitious project of an underground tunnel for
drinking water supply to its citizens. This is the first of its kind
project in India worth INR2235 crore. As mentioned in earlier
stories of EMPOWER, ElectroMech played a pivotal role in this
project through its cranes supplied to Unity - IVRCL and Soma for
tunnel mucking and TBM assembly.
Out of this entire ambitious project, the joint venture of Unity
and IVRCL was awarded with a contract to complete a stretch of
15km from Gundovali to Bhandup. Recently, they have
successfully completed the tunnelling of the first phase of this
challenging contract. In this phase, the length of the tunnel is
8.3km with an inlet of depth of 108m and 11.8m diameter at
Kapurbawdi. At the outlet near Bhandup, the diameter is 11.8m
and the depth 125m. This is one of the deepest raw drinking
water tunnels in Asia. The uniqueness of this project is that it
used the highly advanced Tunnel Boring Machine which reduced
the entire project execution period from 5 years to 18 months.
The underground boring and construction of 8.3km long tunnel
at the depth of 100m was a high-risk project which demanded
technical expertise to complete the job without any untoward
incident. All facilities for safety, communications, lighting,
ventilation, dewatering, wet/dry mucking and its disposal had
been perfectly planned for the smooth completion of the project.
In this project, the astonishing excavation speed of the
mammoth TBM had to be matched by suitable equipment for
speedy removal of muck from 100m depth. High speed
ElectroMech gantry cranes had been chosen as the most reliable
equipment for the challenging wet/dry muck removal cycle. Two
gantry cranes of 32MT capacity, 18.7m span, 140m lift and
hoisting speed of 40m/min. were installed at two ends of the
proposed tunnel. Also, safety features like load limiter with
display, limit switches for motion restriction had been
incorporated.
With the help of efficient muck removal using an ElectroMech
gantry crane, Unity - IVRCL has set a new Indian record of drilling
57.38m length (finished diameter of 5.5m) of an underground
tunnel in 24 hours. According to the statement by Unity Infra and
IVRCL, they have also set a record by achieving 2 million safe
man-hours and maintained zero lost time and accidents in a
project of such type and size. The boring of the entire length of
8.3km was also completed in a record time of 180 days.
Team ElectroMech is proud to be a part of this achievement by
providing a perfect solution and ensuring zero down time of the
crane. This is a further testimony to our claim of providing the
most pertinent
solutions, which are
safe and reliable. PR OJ M D
July 2014
45
BEST OF
Compendium 2009 to 2014
Completing installation of 29 cranes
in record time at Air Liquide, UAE plant
Air Liquide is a reputed international company headquartered in
France. It is a major player in production of gases for industry,
health and environment. It offers advanced technologies for cold
box manufacturing used in Air Separation Units. Recently, Air
Liquide has set up a vast manufacturing plant in RAK Maritime
City in UAE. The plant will manufacture machinery, fabricated
metal products, structures, tanks, reservoirs, containers and
related equipment needed for setting up gas manufacturing
plants. For their requirements of quality cranes to integrate shop
46
handling, Air Liquide approached ElectroMech FZE and placed an
order for 29 cranes of different types. These cranes were
recently supplied and commissioned in their UAE plant.
The Air Liquide facility at Ras Al Khaimah is spread over 36 acres
and has 6 different shops. The 29 cranes of different types with
varying capacities have to handle critical parts and components
during various processes. At the raw material yard, 2 gantry
cranes handle large and heavy steel plates during unloading,
storage and shifting to the main plant. These plates further pass
 Working together
to create a record

Load testing of 150MT double girder crane

at the Air Liquide facility in Ras Al-Khaimah, UAE

Project Achievement Certificate awarded to ElectroMech by Air Liquide

through processes such as cutting, bending, rolling, welding,
fabrication and testing in different shops to form the end
product. The gas plant machinery thus manufactured ultimately
reaches the despatch bay. This end product, i.e. the entire gas
plant machinery consists of 2 parts each, weighing about 300MT.
Here, at the despatch bay, two cranes of 150MT capacity each,
work in tandem to lift a load of 300MT. Two such parts of 300MT
each are then assembled together forming a combined load of
600MT. This is the most challenging part of the project, apart
from a few cranes, which are installed in two tier construction.
Responding to the urgency of the customer, ElectroMech team
completed the entire erection and commissioning of all the 29
cranes in record time by working for almost 16 hours a day in
temperatures as high as 450 Celsius. Full load trials of these
cranes have been recently completed and the customer team
has expressed its satisfaction while appreciating our effort to
complete the job ahead of schedule.
July 2014
47
BEST OF

Compendium 2009 to 2014

Displaying the prowess

of our solutions capability
in a true blue steel plant

15MT, 28m span double girder crane installed in the quenching & cooling unit

About BMM Ispat Ltd.

BMM Ispat Ltd. is an INR 20 billion company, part of the
renowned BMM group. Their plant at Danapur, Hospet,
Karnataka is a true blue steel plant manufacturing high-quality
steel products. As a part of a new brownfield project, the
company is planning to expand the existing capacity, for which
ElectroMech is supplying 13 cranes in the first phase. This facility
is being constructed to expand the product range and to include
a semi-automatic process, which will increase production.
BMM Ispat approached ElectroMech during the summer of 2012
and after a thorough evaluation of our proposal, placed an
order for 13 cranes to be used at various stages of their
manufacturing process. Through a detailed understanding of
their workflow and several interactions between both the teams,
cranes of most efficient design, effectively matching the
application requirements were selected.

48

20/5MT, 34m span double girder crane installed in the despatch bay
The processes and challenges
BMM Ispat’s plant is spread over a vast area of 50 acres (approx.
200,000sq.m.) and the entire manufacturing process is divided into
four stages.
Steel melting shop
The first area is called the steel melting shop, which
handles all the operations from the melting of raw
material to forming of billets of desired shape and size.
Here the metal is processed in the molten form and
handled by ladles. The formed billets are to be rotated in
90° and are to be transferred on the idle rollers to take
them to two different storage locations.
Furnace and rolling mills
The second phase of the entire process consists of a
furnace and rolling mills and includes handling of long
metal billets of an average length of 12m each. The
process is initiated by passing the billets on to idle rollers
installed besides the furnace. The rolling facility is spread
over 200m length and the preheated billets are passed
through various horizontal and vertical rolling mills to give
them the desired shape. The dies of the presses are
required to be changed frequently to suit the particular
product to be rolled, which includes rolled angles, TMT
bars, metal rods and I-beams.
Quenching and cooling
The third phase is the quenching and cooling
process. This is a well-equipped and
technologically advanced process cycle
performed using a plant manufactured by
Siemens, Italy. The products are rapidly cooled,
which produces a harder material and prevents
low temperature processes such as phase
transformations in the material. Further cooling is
then done and the product is then prepared to
undergo the final finishing process.
Despatch area
The fourth and final phase includes the despatch
of the finished products. The despatch yard is
spread over 380m long and 50m wide area. This
consists of parking bays for trucks and a railway
track for loading on railway carriages. The
despatch area has to store and handle long rods
and beams. Rotating crabs are used to control the
angle of long metal bars and other similar
components in the despatch bay.
BMM Ispat was looking for a competent partner who could
understand the challenges and design a complete
material handling system to integrate the various
processes. The objective was to ensure safe, quick and
precise handling and appropriate manoeuvring during
loading at the despatch bay.
49
BEST OF
Compendium 2009 to 2014
Displaying the prowess
of our solutions capability
in a true blue steel plant
ElectroMech solutions
ElectroMech responded to BMM Ispat's challenge with some
unique ideas. Detailed analysis, design iterations and trials
resulted in an integrated solution that has proved to be fool-
proof, achieving the intended task swiftly.
A total of 13 cranes were designed to handle the material
through various processes right from the steel melting shop to
the placement of bars and rods on railway carriages.
Steel melting shop
In the steel melting shop (SMS) where billets are formed, a total
of 4 cranes with rotating trolleys assist in the manufacturing and
storage of the billets. Two cranes of 20MT each covering a span
of 32.8m and another two 20MT cranes with 27.2m span cover
the manufacturing and storage of the billets before they are sent
for further processing. Since these cranes are part of a process
and in constant use, these are designed for class 4 duty. The
ambient temperature in the steel melting shop is approximately
600 Celsius, requiring all the components of the crane to be able
to withstand such high temperatures. Hence, a slewing wheel
type of arrangement was selected to be able to work in this area.
An air-conditioned cabin is also provided for the operator.
50
12.5MT, 34m span double girder crane
with 360° rotating crab installed in the despatch bay
Furnace and rolling mills
The furnace is served by a 10MT crane with 22m span, which also
has a rigorous initial application of installing the furnace and
rollers. Once the installation of the furnace is completed, the
crane will be used for replacing the rollers and for regular
maintenance applications. Once the billets are transferred to the
furnace for heat treatment purpose, they pass through idle
rollers where they are re-heated. Two cranes serve this area; one
crane of capacity 25/5MT with 28m span and another of 20/5MT
capacity and 34m span. Since the dies have to be changed
depending on the product to be manufactured, the 25/5MT
crane is in constant use. All these cranes are designed for class 3
duty.
Quenching and cooling
Rolling is followed by the quenching and cooling of rolled items.
The material to be handled in this stage is in the form of bundles
and the same continues till the despatch of the final product.
Here, two 15MT, 28m span, class 3, double girder cranes are
installed to assist the installation of the machinery during plant
set up stage and later on will be used to handle the material
being processed at this bay.
 Despatch
Once the processing of the material is complete, it moves towards the despatch bay. The
despatch bay is 380m in length and is entirely covered by 3 nos. 12.5MT, 34m span, class 3
duty cranes. Like in the case of the steel melting shop cranes, these cranes also have 360°
rotating crabs, however, the mechanism used here is a slewing bearing. This mechanism was
narrowed down upon after many discussions between the design team of ElectroMech and
BMM team. There were two types of rotating mechanisms that were finalised. One that
operates with the help of gears and the other by using rails and wheels. The first one is used
for continuous operations and hence the maintenance had to be kept to the lowest possible.
The latter crane was operated under normal working conditions hence easy accessibility and
simple mechanisms had to be provided. Since the despatch bay is in continuous operation,
the cranes installed here are used rigorously for loading of finished components. The other
two cranes will be used to load and unload materials onto despatch vehicles into the
respective parking areas.
The client team and ElectroMech team worked closely to develop a suitable system and
commission it in the stipulated time span. BMM Ispat management appreciated the efforts
and complimented ElectroMech team for its customer-centric approach.
July 2014

25/5MT, 28m span

double girder crane
installed in the
rolling mill unit

Total no of cranes: 13
SWL (DG EOT) Span Height of Lift Class of duty Application
12.5MT (360° rotating crab) 34m 12m III Despatch bay
12.5MT (360° rotating crab) 34m 12m III Despatch bay
12.5MT (360° rotating crab) 34m 12m III Despatch bay
25/5MT 28m 16.5m III Mill bay (rolling mill)
20/5MT 34m 16.5m III Mill bay (rolling mill)
15MT 28m 16.5m III Mill bay (Quenching & cooling)
15MT 28m 16.5m III Mill bay (Quenching & cooling)
10MT 22.4m 16.5m III Furnace
20MT (360° rotating crab) 32.8m 11.5m IV SMS area (Billet storage bay)
20MT (360° rotating crab) 32.8m 11.5m IV SMS area (Billet storage bay)
20MT (360° rotating crab) 27.2m 11.5m IV SMS area (Billet storage bay)
20MT (360° rotating crab) 27.2m 11.5m IV SMS area (Billet storage bay)
25/5MT 18m 11.5m III Oxygen plant
51
BEST OF

Compendium 2009 to 2014

Setting wheels of
the automobile
industry in motion

The automobile industry in India has witnessed a lot

of action over the past decade. Almost every major
international brand of repute assembles or manufacturers
its vehicles in India. Several have also made India an export
hub. Along with the large automotive names, an umpteen
number of suppliers to these brands have also set up shop
in India.
ElectroMech has a significant presence in this market
through crane solutions provided to a number of companies
in the automotive segment. Auto industries have to follow a
specific standard and process during manufacturing.
Hence, the cranes need to be very precisely designed and
tailor-made to cater to the individual requirements.
The main application areas of EOT cranes in the automobile
industry are:
Ø Handling press components
Ø Die handling through EOT cranes or transfer trolleys
Ø Chassis handling systems / cabin drop arrangements
Ø Vehicle interiors
Press components typically require double girder cranes
ranging from 35MT-50MT for their handling. Precise
positioning and smooth movement are required for this
application, which are ensured by equipping these cranes
with micro-speed facility in all motions.
For die handling, an additional auxiliary mechanism needs
Die tilting operation at Bajaj Auto Ltd., Aurangabad
to be installed on the cranes. This is especially for the die
tilting process for maintenance or changing of dies. Also, for
die inter-bay transfers, we recommend die transfer trolleys

- the safest way to handle dies for linear movements.
The 'cabin drop' requirement and chassis handling are a few
other special applications. These are lighter applications
(2MT capacity), but require tandem motions / synchronous
motions of the hoists. Lifting of chassis is achieved with
2 hooks with adjustable hooking positions.
Considering the various options of crane systems in
different load capacities available with ElectroMech, a
number of leading automobile manufacturers and tier 1 &
tier 2 suppliers trust us for their handling requirements.
Here are a few of our satisfied customers.
52
Omnipresence ac
Amtek Auto Ltd.
Amtek is a leading manufacturer of high precision iron and steel
forgings and aluminum castings. They also manufacture various
products from piston rods to precision engine components.
ElectroMech has supplied more than 40 cranes for different
applications across their various plants in India. ElectroMech cranes
are applied under various conditions right from installing the
machinery, loading and unloading of parts to maintenance of
machinery.
 20/10MT, 8.8m span semi-gantry and 35/10MT, 21.3m span double girder cranes
at Bajaj Auto Ltd. for handling and tilting of dies

80MT transfer trolley at

Mahindra & Mahindra Ltd.

cross the automobile industry

AMW Motors Ltd.
AMW manufactures heavy vehicles required in mining, power,
roads and highways and many infrastructural projects. They
have a plant at Bhuj in Gujarat for manufacturing vehicles for a
wide range of applications. ElectroMech has supplied 2 cranes to
handle axles and in vehicle assembly area.
Apex Auto Ltd., Bangalore
The company manufactures components used in heavy
construction machinery such as dozer frames, rotating frames,
dozer blades, loader buckets, crawler frames, etc. The handling
requirements of their plant are taken care of by 20 ElectroMech
cranes. Their shop-floor is equipped with single girder cranes,
double girder cranes and wall travelling cranes to cover the
complete process of manufacturing.
53
BEST OF
Compendium 2009 to 2014
EletroMech double girder cranes in 2 tier
arrangement at an automotive ancillary unit
Omnipresence across the auto
Automobile Corporation of Goa Ltd. (Jejuri)
ACGL is a leading bus body manufacturer with a plant at Jejuri
near Pune. We have supplied 2 cranes, which are used in the
pressing unit for handling of moulds. Here, the massive loads of
dies of bus doors, front and rear body are to be handled, for
which our cranes are used round the clock.
Bajaj Auto Ltd.
ElectroMech cranes are installed in the four wheeler
manufacturing facility of Bajaj Auto at Waluj near Aurangabad.
Three ElectroMech cranes are being used in the press shop for
handling of dies of various components, transfer and tilting of
dies as well as for the maintenance of machinery. Out of these
three cranes, two double girder cranes are in continuous
54
operation for loading dies on a series of press machines on the
shop- floor and a semi gantry crane assists in the maintenance of
dies and die-tilting mechanism.
FCC RICO Ltd.
FCC RICO Ltd. is a joint venture between FCC, Japan and Rico
Auto Industries, India. This company is a supplier of clutches
for Honda motorcycles. In their plant, 5 ElectroMech cranes are
being used to handle the dies and machinery used for
manufacturing clutches.
Force Motors Ltd.
At their Pithampura plant, one single girder EOT crane of 10MT is
installed in the press shop for handling of dies.

omobile industry
GE Stamp Ltd.
The Chakan plant of GE Stamp is involved in the stamping and
welding of multiple parts used in an automobile. Their main
production is of stampings for Volkswagen car doors. We have
supplied 6 cranes for the efficient and precise handling of dies
and press components.
Hero Motocorp Ltd.
For their factory at Neemrana, Rajasthan, we have supplied
2 cranes and a 5MT hoist, which is installed in the measurement
and testing laboratory to handle the components being tested.
Honda Motorcycles & Scooters India Pvt. Ltd.
ElectroMech has supplied one crane at their factory in Alwar for
loading and unloading of various parts of vehicles.
Mahindra & Mahindra Ltd.
At the factories of Mahindra in Kandivali and Chakan, total 11
cranes are supplied for handling of dies. 50/15MT cranes
supplied to the body shop, where stamping of vehicle doors is
done, are of special design. Apart from this, several smaller
cranes are being used on engine assembly line.
MAN FORCE TRUCKS Pvt. Ltd.
This company was in requirement of 2 cranes of 10MT each to
handle chassis, vehicle body which were to be used for vehicle
assembly. The main application of the cranes would involve the
placing of body on vehicle chassis for heavy commercial vehicles.
Hence, 2 cranes of 10MT each and a span of 12m with 9.9m
height of lift were selected.
Maruti Suzuki India Ltd.
ElectroMech has supplied 3 cranes to the Gurgaon plant of Maruti
Suzuki. The cranes are used in the testing facility for handling
material testing instruments and parts to be tested. These
cranes are also used in the training facility and electrical
assembly area.
Renault-Nissan Automotive India Pvt. Ltd. (Chennai)
A 2MT single girder EOT crane is installed in the 3D room to
handle dies and stampings of parts.
Roki Minda / Uno Minda (MINDA Group)
Minda Group is a leading auto ancillary group in India. Their joint
ventures with various companies like Roki Corporation of Japan
and Stoneridge Instruments of USA have helped them gain a
strong position for automobile parts like driver instrument panel,
automotive lighting, intake manifolds, etc. Our cranes installed in
Minda are spread over various locations like Pune and
Neemrana. We have supplied 6 cranes to this auto ancillary
major for applications such as handling of dies during loading
and unloading and maintenance purpose.
Tata Motors Ltd.
More than 100 ElectroMech cranes of different types are proving
their worth on shop-floors of Tata Motors - the largest
automobile manufacturer in India. Our cranes are installed in
various plants in Pune, Lucknow, Pantnagar and Ahmedabad.
They are being used for a variety of applications such as sub-
assembly of multiple parts (chassis, axle), paint shop, assembly
shop, stockyards, etc.
Volkswagen India Pvt. Ltd
We have supplied 2 jib cranes to their Chakan plant, which are
used in measurement room and have a very specific application
of handling multiple parts during measurement and quality
check. Apart from this, hoists are used in the body shop to
handle various parts during the assembly of car bodies.
Volvo India Pvt. Ltd.
Two cranes are supplied to Volvo India, Bangalore plant, which is
one of the biggest manufacturers of buses in India. Our cranes
are being used to handle bus bodies in the body shop.
With these existing credentials in the automobile industry, Team
ElectroMech is all set to handle bigger challenges such as
integrating handling on press shops, body shops, paint shops
or even the entire automotive plant. July 2014
55
BEST OF

Compendium 2009 to 2014

Thinking differently ‘Innovative 100'

gets rewarded
award
ElectroMech has always been a
leader in innovation and has
stepped forth to meet every
handling challenge, be it in
i n fra s t r u c t u re p ro j e c t s o r
manufacturing establishments.
The solutions provided by
ElectroMech have always been
unique and engineered to
perfection. Over the years, these
innovations have been
appreciated across several
factories and projects across
India and the world. These
projects and their success is the
real award that ElectroMech takes
pride in, but along the way
recognition from other
We were the only company that was able to rise
organisations goes a long way in
to the challenge of achieving a 325m height of lift
encouraging us to take on more 32MT, 18.7m span, high-speed, high-lift
tunnel mucking crane supplied to Unity-IVRCL JV
for two hydroelectric power projects; HCC’s
challenges.
Punatsanchhu project in Bhutan and Gammon’s Parbati
About the award project in Himachal Pradesh.
‘Innovative 100’ is an award instituted by 9.9 Media to honour the
most innovative companies in the mid-sized industry segment. For the first phase, for the tunnel from Gundovli till Kapurbavdi in
This award is a representation of innovative achievements in Thane, Soma had decided to use a modern Tunnel Boring
technology, products and processes followed in the industry today Machine (TBM). A TBM is a mammoth machine, 1 km in length,
and to be followed for years to come. It identifies and brings 100MT in weight and consisting of hundreds of components.
forward innovative mid-sized organisations and their leaders who, ElectroMech was first posed with a challenge of lowering these
through their innovative actions, have introduced breakthrough components down the tunnel through the 100m shaft. This in
changes in the Indian industry and possess a potential to itself was a challenge as the shaft was 10m in diameter, while the
revolutionise the business world. longest component of the TBM was 11m. This called for a special
ElectroMech was recognised and honoured with this award for the lifting attachment for the 120MT tunnel mucking crane which
successful development of the Tunnel Mucking system. This was designed and manufactured by ElectroMech to carry the
material handling solution, specific to removing of overburden components safely down the shaft to the tunnel.
from tunnelling operations has been successful across several The second challenge posed to ElectroMech was the installation
projects in India and abroad. We were the only company that was of this mammoth machine 100m below the ground level. A
able to rise to the challenge of achieving a 325m height of lift for 4x25MT triple girder crane was assembled 100m beneath the
two hydroelectric power projects; HCC’s Punatsanchhu project in ground to successfully install the Tunnel Boring Machine and
Bhutan and Gammon’s Parbati project in Himachal Pradesh. complete the project ingeniously.
About the award winning solution ElectroMech’s unique innovation in the form of the Tunnel
The INR 2235 crore Mumbai water supply project under the Mucking systems has proven to be successful in various critical
Jawaharlal Nehru National Urban Renewal Mission (JNNURM) projects for rapid removal of overburden from tunnelling or
involved construction of a tunnel from Gundovli to Thane in the shaft excavation. This award testifies that ElectroMech continues
first phase which was awarded to Soma and from Thane to to align to its 'Innovations Approach' to satisfy customers'
Bhandup in the second phase, which was awarded to a joint expectations. Earlier, ElectroMech had also won the
venture of Unity Infraprojects Ltd. & IVRCL Ltd. 'Manufacturing Today Award for Excellence in
Innovation' for the same innovation.
July 2014
56

60/12MT, 28m span gantry crane
for flyover construction
Gammon India is amongst the largest construction and
infrastructure companies in India and ElectroMech has over a
decade-long business relationship with the infrastructure giant.
Gammon was recently awarded a project to construct a flyover
in the Pimpri-Chinchwad area of Pune. This flyover will be from
Yashopuram in Chinchwad and will connect to the auto-cluster
across Pune-Mumbai highway.
Three ElectroMech cranes cover the handling requirements of
this entire project. A 60/12MT gantry crane is used to construct
the flyover. The main hook with an SWL of 60MT is used to lift the
precast concrete blocks and place them precisely on the top of
the pier. The 12MT auxiliary hook of this crane is used to install
and dismantle all supporting structure for the flyover and the
concrete structures. This also ensures that the workers have
easy access to the entire structure of the flyover.
Apart from the main flyover construction work, two other cranes
of SWL 15MT and 60/12MT are used in the precast yard in
After globetrotting,
proud to be a part of a
project in our hometown
Gantry cranes for
flyover construction
in Pune
Chinchwad. These cranes ensure smooth handling of moulds
and precast segments during manufacture and are also useful
for loading of precast segments on trucks.
Crane details
Ø Capacity: 60/12MT / Span: 19.5m / Height of lift: 15m
Ø Capacity: 60/12MT / Span: 28m / Height of lift: 15m
Ø Capacity: 15MT / Span: 19.5m / Height of Lift: 12m
A Special mention is that these cranes were originally supplied to Gammon
India in 2009 for their Godavari Bridge project. We are glad to see our cranes
going strong for yet another infrastructure project!
ElectroMech-Gammon relationship
ElectroMech crane solutions are instrumental in the construction
of several of Gammon’s projects, including Parbati hydroelectric
project, Godavari bridge, Munger project, Parvati bridge project,
Delhi metro, Chennai metro, Kolkata metro and Bangalore metro
projects, where Gammon is playing a major role in construction.
July 2014
57
BEST OF
Compendium 2009 to 2014
Sharing knowledge. Winning trust
ElectroMech kicked off its series of Knowledge Forums with the
first edition in Mumbai at Hotel Leela on 25th April and the
second in Chennai at ITC Grand Chola on 20th June. The Forums
aim at building on the solutions offerings available from
ElectroMech through an exchange of ideas with customers. The
Forums brought to the forefront how ElectroMech solutions can
add value to customers' projects by bringing the stakeholders on
a common platform and communicating insights from both. The
proceedings of the Forums were enjoyed and appreciated by the
audience of 60+ delegates for Mumbai and 80+ delegates for
Chennai, which included the company's key clients, partners,
consultants and engineering media.
The clients for Mumbai figured reputed names such as Siemens,
Tata Power, Pratibha Industries, HCC, Mott MacDonald, IVRCL,
ESSAR Projects, Dodsal, Pan Gulf Technologies, Steiner India
and many others. The Chennai forum was attended by esteemed
clients like L&T Construction, L&T Hydrocarbons, BGR Energy
Systems and Boilers, Hyundai Motors India Limited, VGN Infra,
Caterpillar, Hanil Automotive India and many others.
The Knowledge Forums were addressed by Mr. Tushar
Mehendale, Managing Director of ElectroMech, who gave the
audience an insight into the company's operations and its focus
areas for future growth as well as the innovative solutions over
the years.
Mr. Arun Bishnoi, Director Sales, ZEIPL offered the clients a walk
through of Zoomlion tower cranes in India and the ‘Made for
India’ cranes developed by the joint venture especially for
Indian markets.
Mr. Raj Shrivastav, CEO, Cranedge, elaborated upon the
objective of the services subsidiary of ElectroMech, as it aims
at catering to the void in the market for professional offerings in
the after service of cranes.
The Knowledge Forums proved to be admirable successes as the
attendees expressed their curious interest in ElectroMech and
Cranedge. The clients showed an overwhelming response to
these Forums and some of them shared their positive
experiences with ElectroMech and Cranedge.
ElectroMech
Knowledge Forum
58
“We are happy to have partnered with ElectroMech as it
delivered perfect solutions for our precise requirements, and also
stood by us during our lean patch as we were affected by the
global recession. We are thankful to ElectroMech.”
- Gurudatt Pandit - DGM Procurement (Equipment),
Hindustan Construction Company, Mumbai
“ElectroMech's valuable inputs for a project we were bidding for
added value to our proposal - ultimately we won the contract.
The timely and consistent support from ElectroMech Mumbai
sales team vindicated its positioning as a solutions provider.”
- Harshawardhan Deshpande - Chief Engineer,
Civil & Structural, Mott MacDonald, Mumbai
“ElectroMech Sales team in Chennai has always supported us in
our need. Whenever we require solutions for our handling
requirements, the Chennai team is always present. It has always
supported us to ensure a safe and secure working environment.”
- J. Srinivasa Babu - General Manager (Operations),
Prabha Auto Products, Chennai
“Cranedge has always been an excellent team for service and
maintenance of our cranes. The team has done a brilliant job and
has planned every detail well with our team to benefit our
cranes.”
- A. Julien Christopher Amirtharaj - Managing Director,
Bay Forge Limited, Chennai
These reactions of the delegates represent the typical feelings of
all members of the audience. Similar views were expressed by
them during personal interactions of the management and the
delegates.
ElectroMech intends
to hold more such
sessions of the
Forum in the future
to achieve greater
c u s t o m e r
satisfaction.
July 2014
Mr. Tushar Mehendale addressing the delegates of the
ElectroMech Knowledge Forum at The Leela, Mumbai
 ONCE AGAIN!
Excellence in Innovation
Team ElectroMech receiving the ‘Manufacturing Today’ Award at the Manufacturing Today Conference & Awards, 2013

Honoured with coveted

Manufacturing Today Award for Innovation
The prime reason for ElectroMech being synonymous today with While working on this project, it was not only the application
'solutions' is the obsession of our team members for innovation. which was critical, but the stringent design specifications and
Our customers have repeatedly vindicated this by way of their highly demanding requirements of the user were a challenge to
appreciation and repeat orders. To enhance this joy of our design team. After evaluating several options, a double-
appreciation, this year again ElectroMech has decker crane where two rope drum
been honoured with the Manufacturing Today arrangements are placed one above the
'Excellence in Innovation' award. This award other, was selected. Such an arrangement
is instituted by 'Manufacturing Today' not only saved space, but also provided larger
magazine, which is a part of the renowned hook approach areas. All these requirement
ITP Publications group. challenges and our innovative solution were
We received this award for the indigenous taken into consideration by the jury team
development of a Single Failure Proof Crane while selecting us for the award.
(SFP) for Nuclear Power Corporation of India While commenting on the award, Mr. Tushar
Ltd. (NPCIL). SFP cranes are installed at Mehendale, Managing Director said,
extremely critical locations in a nuclear power “Innovation is a tradition and a way of life at
plant such as the reactor dome directly above ElectroMech. It not only keeps us ahead of
the reactor and the spent fuel storage bay. competition, but also gives our team
Clearly, safety is of utmost importance in immense satisfaction of accomplishing the
Award winning Single Failure Proof Crane
these areas. To avoid any accidents, the designed and manufactured by ElectroMech impossible. Our biggest awards come from
for Nuclear Power Corporation of India Ltd.
crane is provided with redundant safety our customers when they repeatedly
mechanisms to ensure safety. This is approach us for new requirements and such
achieved through a dual wire rope and drum arrangement as well awards further encourage our team to excel in what they are
as redundant mechanisms for critical systems. doing.” July 2014
59
BEST OF

Compendium 2009 to 2014

60
BEST OF

Compendium 2009 to 2014

Launch of CRANEDGE
New service brand from ElectroMech for reliable maintenance of cranes
of all makes
At ElectroMech, customer service
has always been the topmost
priority. In fact, the ethos at
ElectroMech is that, first and
foremost we are a service-oriented
company. Be it pre-sales service or
services provided to our customer
during the execution of the order or
post-sales service.
Post-sales service for cranes is an
area where we find several lacunae
in the Indian industry. Although
ElectroMech has always had the
reputation of addressing the customer's issues on priority, we
found that owners of cranes from other brands have not been so
lucky in getting their problems addressed.
Furthermore, as the customer's scope of work changes, the
hoisting requirements also change. Hence, it becomes
imperative for customers to find an able partner who can help
them in modernizing or retrofitting their existing equipment to
suit their new requirements. Some factory owners in India have
equipment which is quite ancient and finding spares and
expertise to keep such equipment running in optimum condition
becomes a harrowing task.
In today’s scenario of lean manufacturing systems, where
productivity levels are being continuously monitored and
downtime on the shop-floor can translate into huge losses, it is
extremely important to ensure that all the machinery involved in
various processes runs perfectly. Cranes are an essential part of
several processes on the shop-floor.
Hence, undertaking proactive
preventive maintenance activities
on cranes becomes a topmost
priority.
For addressing all the above
pressing issues, it becomes
extremely important to have a
partner that has a rich experience in
the crane industry and which has a
pan-India network to cater to
different installations all across the
country.
Therein lies the case for Cranedge.
At ElectroMech, we have spun off a set of service offerings under
the brand name of Cranedge to address all the above-mentioned
pain areas. We aim to leverage our rich experience of more than
three decades in this industry and our existing national service
network to provide an enhanced range of services to our clients.
Under the umbrella of Cranedge, we will be undertaking Annual
Maintenance Contracts for cranes of any make in any corner of
the country. We will also attend to breakdown calls from our
customers in the shortest possible time. In addition to this, we
aim to provide to our customers spares support for different
crane brands. Our engineers will also be able to evaluate
requirements for modernizations and retrofitting of existing
cranes at the customer end in order to increase their life and
enable our customers in deriving maximum value of their
investment. Please visit www.cranedge.com for further
details about our service offerings or write to
enquiry@cranedge.com for more information.

June 2009

Get your edge.

Get Cranedge.
Ø Inspections
Ø Spare Parts
Ø Emergency Breakdown Repairs
Ø Formal Proactive Predictive
Maintenance Program
Ø Modernizations

62
Raj Shrivastav is appointed
as CEO of Cranedge
Cranedge, an ElectroMech initiative, is an organization dedicated
to offer a host of services required by crane users. These
services include maintenance, supply of spares, repairs,
relocation and modernization of cranes.
This newly formed company will now be working under the able
leadership of Raj Shrivastav, a Chemical Engineer from
Jadhavpur University. His last assignment was with Sandvik Asia
Ltd. as a Vice President (Mining & Construction).
Raj brings in with him 30 years of Marketing, Sales and Service
experience with European and Indian manufacturers in Capital
Equipment required in steel, power, chemical, mining &
construction industries.
Besides working as CEO of Cranedge, Raj will also represent
ElectroMech as a Business Head for the steel & construction
Raj Shrivastav, CEO
verticals.
Cranedge India Pvt. Ltd.
December 2009

63
BEST OF
Compendium 2009 to 2014
Cranedge passes the litmus test with two giants
1 Caterpillar India Ltd.
On a pleasant October morning last year in Pune, Cranedge Help
Desk was flooded as usual with calls. A few minutes later there
was a moment’s quiet. Just as the person at the desk reached out
to pick up her coffee mug, the phone rang. Glancing at the Caller
ID, she noticed the Chennai STD code. The
caller politely introduced himself and
asked to be connected to a decision
maker at Cranedge. He was quickly
put through to Mr. Raj Shrivastav,
our CEO. Pleasantries were quickly
exchanged and the conversation
was short and crisp.
An immediate conference call
ensued between our Technical
Services Team at Pune and our
Chennai Office. Anxious to know
why they were summoned at such
short notice, our Pune and Chennai
team came on line, expecting the
worst. In fact, what they heard set
their adrenalin rushing. The purpose
was explained to them very simply:
"Ensure zero down time of the cranes
installed at CAT, Chennai works for the next 3
months – starting within the next day". This was a
huge business opportunity and actually a litmus test for
Cranedge since the world’s largest construction equipment
manufacturer CAT had turned to us for critical help! Only a few
hours were available at hand for preparation. Quickly, a mission-
specific core group was formed. Tasks were listed out and
deadlines set. Everyone was made aware and mentally prepared
for a long-haul operation which would stretch for the next couple
of months.
The scorching sun and dusty locale did not deter team Cranedge.
The march began towards Melnallathur, in Tiruvallur district of
Tamil Nadu, about 45km from Chennai. At 14:30 sharp, the
Cranedge team was in front of a large gate of the massive factory
whose facia read, 'Caterpillar India Ltd.' The team was already
briefed on the new task - Ensuring zero down
time of their cranes installed in the
assembly shop of heavy construction
equipment till, at least, the end of
64
December 2009. Caterpillar was heavily booked with orders and
only uninterrupted production round the clock could help meet
their target. Elaborate discussions were held with the CAT
production team and Cranedge maintenance team to ascertain
and reconfirm their production cycle and the crane usage
cycle - all of which was highly demanding. This ruled
out the possibility of any major repairs. Cranedge
team quickly carried out the Health Assessment
of cranes. The crane history sheets were
analysed with clear identification of
the associated working risks. A
resource plan and daily
maintenance and preventive plan
were worked out in consultation
with CAT team to ensure 100%
up time. This also called for
arranging spares immediately.
Minimum essential quantities of
parts were organized and our
engineers were deployed on two-shift
basis at the works. A core team
consisting of CAT and Cranedge engineers
was formed to focus on these cranes. The first
target was achieving at least 120 shifts without any
breakdown! We started an exercise in routine and preventive
maintenance. With a constant vigil and monitoring of the crane
operations, the core group worked round the clock at times, to
ensure that not a single hour of production time was lost.
January 01, 2010. The Cranedge team proudly submitted a blank
paper to CAT management. It was titled 'Downtime record of
cranes on assembly shop II'. Indeed, by the end of December 09,
Cranedge could successfully achieve its target, but more
importantly, CAT production team could accomplish their
commitment to the management of meeting the targeted
production, ensuring zero down time for the last three months on
the shop-floor and being well within their cost target for usage of
spares.
However, the real appreciation for the Cranedge team came in
the form of an extended service contract further till the end of
March 2010. Once again, the highly motivated and professional
Cranedge team was entrusted with a new challenge!
July 2010
CATERPILLAR & its logo are the trademarks of Caterpillar
 2 Pipavav Shipyard Ltd.

Pipavav Shipyard Limited (PSL), an integrated picked up the gauntlet and went
shipbuilding facility, is one of the largest in ahead.
Asia. The shipyard complex is located on the In consultation with the
South Western coast of Gujarat, about 130km operations & maintenance
from Bhavnagar to its east, and Diu about departments of the customer,
90km to its west. C ra n e d g e d e p u t e d e x p e r t
Spread over an aggregate area of 198.92 engineers to be located at
hectares (approximately 491.53 acres), the pla nt. Cr i tica l s pa re s
comprising a SEZ unit spread over 95 requirement was evaluated and
hectares (approximately 234.75 acres), it has organized. Working on a sixteen-
more than 100 cranes delivered by all leading hour basis, Cranedge drew up an
Indian crane manufactures. The plant was action plan for each of the cranes.
commissioned by mid 2009 and PSL The daily maintenance and weekly

cranedge
immediately realized the crucial role cranes preventive protocol was defined
play in shipbuilding. and followed meticulously to avoid
In October 2009, needing strong after market any major breakdowns.
services, PSL turned to ElectroMech to After initial hiccups, the plan got
support 61 of their critical Double Girder, Semi working and it proved to be a huge
Gantry and Goliath Cranes. Pipavav learning experience for the young
demanded minimum down time till March 2010 and upkeep of organization.
cranes of all makes such as ElectroMech, and its competitors, The customer’s confidence in Cranedge was further
cranes ranging from 3.5MT up to 150MT SWL. Cranedge, the demonstrated when they asked us to continue maintaining the
latest initiative of ElectroMech had just been launched with a cranes beyond March. It is a privilege to be associated with
mission to offer professional services for cranes of all makes. This giants like Pipavav and it is a firm resolve to improve
was the moment of truth. Sensing the big moment and realizing performance to establish Cranedge as a leading organization
that Pipavav had confidence in ElectroMech, we at Cranedge providing all services for overhead cranes.
July 2010

cranedge

PIPAVAV and its logo are the trademark of Pipavav Shipyards Ltd.

65
BEST OF
Compendium 2009 to 2014
Partners in progress
i
Cranedge at
Bharati Shipyard Ltd.
Shipbuilding in India
Global shipbuilding investment has reached an all-time high and
order books are full to the extent that International yards are
refusing to accept orders for delivery before 2012. The
overworked European and East Asian yards have inadvertently
offered India an entry point into this lucrative market. Hence,
India has started on a solid footing, with its focus on the offshore
segment, followed by bulk carriers and containers, ranking it
ninth by investment in the shipbuilding sector. Going by the
present growth trends, the industry, with a current order book of
$3.7 billion, is projected to grow at a compounded annual growth
rate (CAGR) of 30 per cent, burgeoning to $22.1 billion by 2020.
Proposed capacity additions by various shipyards are expected to
move the country up in the global rankings and India can surely
compete on costs and deliver quality ships
on schedule by leveraging its vast pool of
skilled manpower.
About Bharati Shipyard Ltd.
Bharati Shipyard Ltd. (BSL) is the foremost
privately operated shipyard in terms of
shipbuilding facilities in India. BSL has
earned its reputation by constructing a
large array of specialized sophisticated
vessels for diverse offshore, coastal and
the marine market sectors. The BSL
product range includes highly
maneuverable and power-packed offshore vessels including
AHTS, PSVs and MSVs of varying bollard pulls, Tractor and ASD
66
tugs, state-of-the-art dredgers, deep sea fishing vessels, cargo
and container ships, tankers and Ro- Ro Vessels.
Bharati has four shipyards under operation - Goa, Ratnagiri,
Ghodbunder near Mumbai, and Kolkata - and has invested about
$150 million. Currently BSL has an order book of about $980
million and seventy-five per cent of these orders are for export.
Bharati shipyard is undertaking a Greenfield project at Dabhol
spread over 300 acres of land on the banks of the river Vashishti
wherein most modern infrastructural facilities for shipbuilding
are being created. The Shipyard is designed by First Marine
International of UK. The yard will have capacity to build among
other vessels, Jack-up Drill Rigs, Offshore Structures and ships
up to 100,000 DWT. For this, BSL had
purchased a shipbuilding yard from
Swan Hunter (NE) Ltd., Newcastle, UK
with all equipment in as-is-where-is
condition and moved it to their new
site in Dabhol.
Swan Hunter (NE) Ltd. is a renowned
shipbuilder in Europe existing since
1880, operating out of a 40 acre yard
in Wallsend, on the banks of the river
Tyne. The yard is now owned by the
N o r t h Ty n e s i d e C o u n c i l a n d
shipbuilding activities have ceased
there. However, Swan Hunter
continues to provide engineering, design and management
support to the shipbuilding and offshore industry.
 A new challenge for Cranedge
Shortly before the summer of 2010,
cranedge
Cranedge received a request from BSL,
who needed an all-encompassing
solution to erect and commission two
used cranes that had been procured by
them. The Cranedge team held an
internal review and planned their visit to Dabhol on the Konkan
coast where Bharati Shipyard Ltd. is located. The equipment,
which included 7 cranes had been in storage for 10 months and
initially BSL required Cranedge to refurbish and erect two
55/10.10MT Morris make EOT cranes. As a first step to erecting
the cranes, team Cranedge proposed to undertake a detailed
health check up of the cranes, constituting an inspection of
mechanical and electrical assemblies. This approach was
immediately accepted by the BSL senior management. The
inspection and health check up of the cranes was conducted over
a seven-day period and on 8 June, 2010, the Cranedge team
submitted a report along with an offer for the overhauling along
Cranedge - scope of work at Bharati Shipyard Ltd.
n 55/10/10MT, 30m span, 23m height of lift DG EOT
Crane - 2nos
Make-Herbert's MORRIS, England. Year of manufacture -1969
Complete overhauling, assembly, erection, commissioning,
electrical circuit modifications were done as per our logic to
start the 55/10/10MT crane
l
n 30MT, 30m span, 23m height of lift DG EOT Crane - 1no
Make-Carruther, England. Year of manufacture -1969
Complete overhauling, assembly, erection, commissioning
All spares related to overhauling were supplied by Cranedge.
with various components which
needed to be replaced. The report
recommended cleaning, servicing
and lubrication of all the major
components such as gearboxes and
motors of both cranes. Electricals and
the electrical panel were to be refurbished and several
components such as limit switches, cable trolleys and wire ropes
which were either damaged or missing were to be replaced. In
addition to these corrective measures, the report also suggested
the addition of features such as gravity limit switches, radio
remote controls and anti-collision devices to the cranes.
Impressed by the Cranedge approach, BSL entrusted Cranedge
to supply all the parts and spares required to bring the cranes
into operational readiness.
Once the initial order had been executed to BSL's satisfaction,
they engaged ElecrtoMech to refurbish the remaining 5 cranes,
certainly making us partners in their progress.
July 2011
n 10MT, 29m span, 21m height of lift DG EOT Crane - 1no
Make-Carruther, England. Year of manufacture-1969
Complete overhauling, assembly, erection, commissioning
l
n 10MT, 29m span, 21m height of lift DG EOT Crane - 1no
Make-Demag. Year of manufacture -1982
Complete overhauling, assembly, erection, commissioning
l
n 6MT & 8MT - Deck Cranes on Floating Dock -
Supply of CRD with CRD cable, installation at site and
commissioning
67
BEST OF
Compendium 2009 to 2014
ElectroMech - Cranedge
Fighting nature’s wrath
A damaged crane was
reconditioned after reverse
engineering, design,
manufacture and supply of
damaged parts, assembly
and load testing.
The task was completed
in a record time.
Repaired crane being load-tested
68
In June 2009, an 80/20MT EOT crane that Nilanchal Ispat Nigam
Ltd. (NINL) had purchased from another OEM fell victim to
nature’s wrath, when the cyclone Aila packing winds of over
180km/hr blew the crane away.
The crane was amongst others that were erected at their site in
Kalinganagar Complex, Duburi, near Cuttack-Jajpur road and the
project was nearing commissioning. The crane which weighed
almost 150MT, fell from a height of 22 meters and was severely
damaged under the impact of its own weight.
The crane required extensive rework to bring it back to
operational level, however, the OEM was unwilling to take up the
job and who could be better than ElectroMech to execute it!
ElectroMech, with the support of its service subsidiary, Cranedge
India Pvt. Ltd. (a company specializing in crane services and
refurbishment) took up the challenge.
A special team was formed, led by Mr. Omkar Majumale to
complete this daunting task.
The scope of work consisted of complete
dismantling of the damaged crane at NINL Duburi,
transporting it to ElectroMech Pirangut,
completely reconditioning the crane which
included reverse engineering, design,
manufacture, repair or replacement of damaged
parts, assembly, load testing and transporting it
back to NINL Duburi .
The crane was badly damaged and to add to the woes, the crane
was not stored properly which led to rusting and accumulation of
dust. Undeterred, our team took it as an opportunity to explore
new horizons. Throughout the project, the team remained
focused, complemented each other and completed the work
within the given time frame without compromising on the quality
and safety norms.
March 2012
The damaged crane The crane after repairs

69
BEST OF

Compendium 2009 to 2014

Gestamp
Gestamp saved
saved 60%
60% through
through
re-engineering
re-engineering and
and reallocation
reallocation of
of

70
 Gestamp Automotive is an international group dedicated to the
design, development and manufacture of metal components and
structural systems for the automotive industry. Today, Gestamp
Automotive is present in 22 countries and has 95 production
centres (49 plants in West Europe, 15 plants in East Europe, 8
plants in North America, 9 plants in South America, 14 plants in
Asia) and 13 R&D centres, and has over 25,000 employees. One
such plant of Gestamp Automotive India is in Chakan, near Pune
in India.
This plant presently has 5 ElectroMech EOT cranes on their press
shop, which are performing extremely well and to the
satisfaction of the customer for the last 5 years. However, there
was a change in the handling requirement due to an increase in
the production and die maintenance activity.
The cranes being used presently are -
n Bay 1 (Blanking line) 32/16MT DGEOT Cranes-2 Nos.
n Bay 2 (Line 1) 50/15MT DGEOT Crane-1 No.
n Bay 3 (Line 2) 50/15MT DGEOT Crane-1 No.
n Bay 4 (Line 3) 50/15MT DGEOT Crane-1 No.
utilised and a 50/15t crane was not essential in Bay 3 (Line 2) as
die handling demanded no more than 30t capacity. Hence, the
following suggestions were made to the client.
n One new 32t crab would be added to the existing 32/16MT
blanking line crane
n Shifting of another 32/16MT crane in bay 3 (Line 2) as the
total die capacity in line 3 was not more than 30MT
n Shifting of existing 50/15MT crane from Bay 3 (Line 2) to
Bay 2 (Line 1) to meet their requirements
The most interesting part of the proposal was that the entire
investment in the project was just 40% of the cost of a new
crane. The client was definitely impressed with this ingenious
solution and opted for it. After making all the initial preparations,
the required cranes were re-engineered and reallocation of
cranes was done based on the client's requirement. This was
quite a herculean task, but with the help of a large team of
engineers and contractors we completed this task in just 6 days.
We sincerely thank team Gestamp Automotive India for involving
us in this challenging project and trusting our solutions providing
capability.
December 2012

Cranedge team conducted

a thorough audit of all their cranes.

existing
existing cranes
cranes
Suggestions were made to the client,
which proved greatly worthy.

With the change in the production requirement and die Project highlights
maintenance activities, Gestamp required 2 cranes of 50/15MT
in Line 1 bay. Hence, they approached Cranedge for their
following requirements. Phenomenal saving of 60% of
n Dismantling of 32/16MT crane from blanking line (Bay 1)
investment in a new crane.
n Upgrading one existing 32/16MT crane to 50/16MT capacity
Proper utilisation of cranes.
n Re-erection of modified 50/16MT crane in Line 1 (Bay 2)
n Upgrading one existing blanking line crane to 32/32MT The problem related to production
capacity is solved successfully in minimum
possible time.
Based on the above enquiry, Cranedge evaluated the possibility
of converting 32/16MT to 50/16MT crane and found that
technically this modification was not feasible.
A completely new crane for Bay 2 was then considered, however
this option proved to be beyond their allocated budget for this
upgrade. The client approached Cranedge again for solving this
problem. Looking at the challenge involved in the project, the
Cranedge team decided to conduct a thorough audit of all the
cranes on the shop-floor. A careful study of the optimum usage
pattern revealed that the Blanking line 32/16t crane was not fully

71
BEST OF

Compendium 2009 to 2014

Crab

Before After

Gearbox

Before After

Wheel block

Before After
72
 A new lease of life
to a worn out crane of HCC
The Hindustan Construction Company (HCC) specialises in
engineering and construction of complex infrastructure projects
and has executed a large number of India's landmark
infrastructure projects. HCC has been awarded some major
contracts by Delhi Metro Rail Corporation (DMRC) and for the
execution of these projects, they require various material
handling equipments.
One such 25MT double girder gantry crane at their Mundka site,
supplied by a European manufacturer was lying unused for
several years. When the need for such a crane arose on a new
project site, the HCC team intended to assess the possibility of
refurbishing and using this crane. Knowing that the Cranedge
team of experts is well versed with cranes of all makes, HCC
approached us to carry out the task. The Cranedge team first
conducted a Crane Health Assessment to evaluate the possibility
of reusing the crane by refurbishing and bringing it back to the
original condition without compromising on safety and
performance.
The Crane Health Assessment report prepared after thorough
evaluation and analysis revealed that most of the components
were completely rusted and moving components were jammed
because of rust and grime. This included key components and
various sub-assemblies such as the crab assembly, wheel
assemblies for long travel & cross travel, rope drum, lower block,
etc. A few control panel covers and the wiring inside the panel
was completely missing. The gearbox was in a relatively good
condition, but needed cleaning and oil change, whereas the
operator cabin was in a completely derelict condition.
For refurbishing this crane properly, we decided to bring the key
parts such as the crab assembly, long travel wheel blocks with
motors and the operator cabin to our Pimpri, Pune factory. The
entire work was completed to great satisfaction of the client and
trials and tests of major components were conducted in our
factory for rigorous performance.
Another factor that demanded attention was that the crane had
been supplied by the OEM with motors compatible with 60Hz
power supply. However, these kind of motors typically overheat
when subjected to the standard Indian 50Hz power supply. On
Cranedge’s recommendation, Variable Frequency Drives were
added for all motors to avoid overheating.
The HCC team was extremely happy with the solution and
services of Cranedge. HCC was able to save a considerable
amount of money thanks to the methodical approach and proper
engineering solutions from Cranedge to grant a new lease of life
to the completely worn out crane. The modification of the
existing trolley has resulted in a huge direct saving for HCC both
in terms of costs and time. Had HCC procured a new trolley to
match the application and fitment on the crane, it would have
cost them at least 4 to 5 times more! At the same time, the
modification undertaken by Cranedge has saved the customer at
least 12 weeks of valuable time which, when calculated over the
project time line is a significant and crucial saving.
September 2013
73
BEST OF
Compendium 2009 to 2014
Expect global standards
of service
Cranedge is the services subsidiary of ElectroMech devoted to
offering complete after-sales services to cranes of all brands,
globally. In its short span of existence, Cranedge has earned a
special reputation for itself through its rapid response,
knowledgeable understanding of the customer's problems and
provision of fast and perfect solutions in the form of its excellent
service. It is a matter of great pride for us that Cranedge has
recently been certified as a 'Development Member' of the Lifting
Equipment Engineers Association - LEEA of UK.
The LEEA, founded in 1944 in Great Britain, is a leading, global
representative body of all those involved in the lifting industry
worldwide. The honourable members of LEEA work in every
aspect of the lifting equipment industry, from design,
manufacture, refurbishment, repair, hire, maintenance and use
of lifting equipments. For over half a century, LEEA has been
engaged in training personnel, setting standards, providing
technical and legal advice and developing examination and
licensing systems. LEEA represents its members in public and
private bodies, government departments, and nationally and
internationally recognised professional and technical
institutions.
74
Cranedge conducts comprehensive
Crane Health Assessments
Now a member
of LEEA, UK
Cranedge is now a proud member of LEEA. Member companies
of LEEA conform to very high standards in the aspects such as
the knowledge, technical information and competence of the
technical team. The members have to follow standard operations
and maintenance methods; calibration methods of tools and
tackles; maintain up-to-date records and documentation and
adhere to high health and safety standards at site. Competence
building, training, testing and certification of the technical team
are mandatory.
Member companies of LEEA assure their customers of prompt,
professional response from a knowledgeable team; clearly
defined, multi-layered contact point information; high-quality
work execution, consistent supply of quality, standard products
from standard suppliers. Such companies are regarded as top-
notch companies in the segment.
Being a member of LEEA, now Cranedge is also pledged to all
these attributes and our customers will be benefitted from this
high standard of service.
July 2014
A World of Satisfaction

Sweden

Finland

Kazakhstan

Uzbekistan
China

Iraq Afghanistan
Iran
Algeria Kuwait
Mexico Bahrain Bhutan
Saudi Arabia Dubai, UAE Bangladesh
Qatar India
Yemen Oman
Sudan
Philippines
Ghana
Nigeria
Sri Lanka
Somalia
Uganda Maldives
Kenya

Indonesia

South Africa ElectroMech FZE, Dubai

ElectroMech, India

Installations across the world

 Solutions Service Satisfaction

ElectroMech Material Handling Systems ElectroMech FZE

(India) Pvt. Ltd. Corporate Office
l

Corporate Office & Plant LOB 19 1002, P. O. Box 263019,

Gat No. 316, At post Kasar Amboli, Tal. Mulshi, Jebel Ali Free Zone, Dubai, UAE
Dist. Pune 412 111 INDIA Tel. : +971-4-8857466
Telefax : +91-20-6654 2222
Fax : +971-4-8857655
E-mail : cranes@emech.in | www.emech.in
E-mail : contactus@emech.ae | www.emech.ae

India branch offices

Ahmedabad : 099043 53700 Bengaluru : 099008 15071 Chennai : 099406 57525, 093812 23925
Delhi : 097177 79432 Kolkata : 098740 64646 Mumbai : 090110 99418

For private circulation only. In-house publication of ElectroMech Material Handling Systems (India) Pvt. Ltd., Pune. © copyright 2014 Concept & design : www.kaleidoscopeB2B.com
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Compendium 02/1014/ 1k / KaleidoscopeB2B.com