ENGINEERING DESIGN AND PROJECT MANAGEMENT CONSULTANTS

OFFICE: 301C, 3RD FLOOR, SHREEJI TOWERS, SARDAR PATEL

ROAD, BEGUMPET, HYDERABAD-500016, INDIA.
(https://www.proconstruct.co.in)
 EXPERIENCE OF PROCONSTRUCT TEAM
CLIENT NAME TYPE OF INDUSTRY
AUTOMOBILE AND TYRE INDUSTRY
Alstom E-locomotive Manufacturing Facility at Madhepura, Bihar, India. Railways
GE Locomotive Manufacturing Facility at Shahjahanpur, Uttar Pradesh, India. Railways

Ceat Tyre Manufacturing Facility at Ambernath, Maharashtra, India. Tyre

Ceat Tyre Manufacturing Facility at Sriperumbudur, Tamil Nadu, India. Tyre
MRF Tyre Manufacturing Facility at Arakonam, Tamil Nadu, India. Tyre
MRF Tyre Manufacturing Facility at Medak, Telangana, India. Tyre
Mahindra and Mahindra Automobile Manufacturing Facility at Zaheerabad, Automobile
Telangana.
Suzuki Automobile Manufacturing Facility at Hansalpur, Gujarat, India. Automobile

Sundaram Clyaton Auto Components at Mahindra World City, Chennai, Tamil Nadu, Automobile
India.
Federal Mogul Friction Plant at Chennai, Tamil Nadu, India. Automobile

Sh 2 of 5
INTEGRATED INDUSTRIAL FACILITY EXPANSION FOR SUZUKI MOTORS AT
HANSALPUR, GUJARAT

BUILT UP
• 10,02,270 SQFT.
AREA

• DESIGN & ENGINEERING

SERVICES • PROJECT MANAGEMENT
CONSULTANCY

TOTAL
PROJECT • RS. 2500 CRS.
COST

CONSTRUCTI
• RS. 350 CRS.
ON COST

• COMPLETED IN
STATUS
MAR’18.
 MANUFACTURING FACILITY
PROCESS

BLANKING PRESS WELD

BUMPER ENGINE PAINT

ASSEMBLY INSPECTION DISPATCH

 OVERVIEW

Step 1 RAW MATERIAL Step 7 CAR

PARK
Step 2 PRESS
Step 6
ASSEMBLY
Step 3 WELD

Step 4 PAINT

Step 5
BUMPER
ASSEMBLY SHOP (LINE-B) FLOOR PLAN
ASSEMBLY SHOP (LINE-B) SECTION
ASSEMBLY SHOP (LINE-B) SECTION
 ASSEMBLY SHOP COMPARITIVE STUDY OF LINE A & LINE B
MEMBER OTHER CONSULTANT OUR TEAM

LINE A LINE B
Foundations PAD Footings (Uniform Thickness) Stepped Footings (Change in Thickness)

Plinth Beams 400x750mm 300x600mm

Equipment Pits (Trenches) More Thickness & Reinforcement Optimized Thickness & Reinforcement
Columns RCC Steel Columns (Fast Track Construction)

N-Girders Typical sizes for all members (Verticals, Optimized member sizes based on design
Inclined) force

Jack Beams or Plate Beams Wider Flange widths & thickness Optimized thickness

Truss Rolled Steel Sections (More Weight) Tubular Sections of High Grade (High
Strength to Less Weight Ratio)
PAINT SHOP (LINE-B) FLOOR PLAN
 PAINT SHOP COMPARITIVE STUDY OF LINE A
& LINE B
MEMBER OTHER CONSULTANT OUR TEAM

LINE A LINE B

Foundations Pad Footings Pad Footings with reduced size

Plinth Beams 400x850mm 300x600mm
Equipment Pits (Trenches) More Thickness & Reinforcement Optimized Thickness & Reinforcement

Columns Heavier plate thickness Optimized thickness

Mezzanine Floors Typical sizes for all members (Verticals, Inclined) Optimized member sizes based on design force

Jack Beams or Plate Beams Wider Flange widths & thickness Optimized thickness

Truss Rolled Steel Sections (More Weight) Tubular Sections of High Grade (High Strength to
Less Weight Ratio)
WELD SHOP (LINE-B) FLOOR PLAN
 WELD SHOP COMPARITIVE STUDY OF LINE A
& LINE B
MEMBER OTHER CONSULTANT OUR TEAM

LINE A LINE B
Foundations Pad Footings Pad Footings with reduced size

Plinth Beams 400x700mm 300x500mm

N-Girders Typical sizes for all members (Verticals, Optimized member sizes based on design force
Inclined)
Jack Beams or Plate Beams Wider Flange width Optimized flange width
OUTCOME OF VALUE ENGINEERING IN SUZUKI PLANT AT BECHARAJI,
GUJARAT
Area SFT Structural Steel Saving Concrete Saving Total
Sl. No. Buildings
in Lacs (INR) (INR) Saving (INR)

1 Press Shop

2 Paint Shop

3 Weld Shop 8 14 Cr. 16 Cr. 30 Cr.

4 Assembly Shop

5 Bumper Shop

• Project completed in 2018

 DELIVERING BEST QUALITY OF
TRUSS ELEVATION BY CONVENTIONAL DRAWINGS
DESIGN

TRUSS ELEVATION BY OUR

TEAM
 DELIVERING BEST QUALITY OF DRAWINGS
GIRDER ELEVATION CONVENTIONAL
DESIGN

GIRDER ELEVATION BY OUR TEAM

BEST PRACTICE IN GUTTER DESIGN
SAMPLE OF PRECISE DETAILING
SAMPLE OF PRECISE
HIGH SPEED DETAILING
ROLLING SHUTTER
CONNECTION DETAIL
54mx78m FLOOR SLAB WITH SHRINKAGE STRIP
HIGHLIGHTED
SECTIONS SHOWING SUNKEN FLOOR BEAMS
 COST COMPARISON
COST COMPARISON BETWEEN CONVENTIONAL FLOORING AND
SEAMLESS FLOORING
Head Saw-cut floor Seamless Floor
4.0m x 4.0m to 6.0m x 6.0m Seamless throughout. Tied construction joints
Panel Size (depending according to practical requirements all
on thickness of floor) stitched into one single floor plate
Reinforcement Type and Steel Fibres Only - Dramix® 3D 80/60BG (15- Top Rebar Mesh with Dramix• 40 6S/606G
Range 20kg/m3 dosage) (2S-30 kg/m3 dosage)
Construction joint for day pour and Saw cut
Joints Needed No Joint openingsin the floor.ned construction joints
control joints

Illustration
(sample area of 40m x 60m)

Initial Investment Cost

Y Rs/m2 1.3 Y Rs/m2
(approximate)
Annual Recurring Cost (maintenance
0.03 Y Rs/m2 0.005 Y Rs/m2
of floor1 equipment etc)
Present worth of recurring expenses
compounded over a 20 year 0.38 Y Rs/m2 0.06 Y Rs/m2
operational life with 5% inflation
Total Present Worth Life Cycle Cost 1.38 Y Rs/m2 1.36 Y Rs/ m2
Cost per Kg
 COST COMPARISON
COST COMPARISON BETWEEN CONVENTIONAL PAVEMENT SECTION AND SECTION USING
STRATA WEB
Note:
The Below rates are considered as per the indicative rates and approx indicative transport cost
ROAD Conventional Design Strata ROAD Design
Layer Thickness Rate/cum Rate/sqm Layer Thickness Rate/cum Rate/sqm
PQC 200 6000 1200 PQC 200 6000 1200
PCC 100 4000 400 NP granular 375 300 112.5
GSB 200 2000 400 SW356-125 125 360
NPGranular material 225 300 68 Stratwrap 32
250gsm nonwoven geotextile 58
TOTAL 2068 TOTAL 1763
CHALLENGES FACED IN THE PROJECT
• COORDINATION WITH JAPANESE TEAM DUE TO ENTIRE DOCUMENTS ARE TO BE PROOFREAD AND APPROVED BY PMC COMPANY “KUMAGAI GUMI”
• ALIGNMENT WITH JAPANESE STANDARDS OF DETAILING TOOK SOME EXTRA TIME
CHALLENGES FACED IN THE PROJECT
• FAST TRACK CONSTRUCTION AND TIGHT DEADLINES
• CYCLONE “OCKHI” HIT GUJARAT IN NOV’17 DURING THE PRIME EXECUTION STAGES OF THE PROJECT DUE TO WHICH THE PROJECT
HAMPERED IN ACHIEVING ITS COMPLETION AS PER THE BASELINE PLANNING.
• DEPLOYMENT OF DESIGNERS TO SITE WAS MANDATED BY CLIENT WHICH WAS FULFILLED BY OUR TEAM.
• EXISTING FRAME ON COMMON GRID WAS FOUND TO BE INSUFFICIENT TO TAKE LOAD OF EXPANSION.
• STRENGTHENING WAS PROPOSED BY our team FOR THE EXISTING COMMON FRAME.
CHALLENGES FACED IN THE PROJECT
• LINE C REQUIREMENTS WAS PROPOSED IN THE LATER STAGES OF THE PROJECT AND HENCE ACCOMMODATED IN THE LAST STAGE.
TYRE MANUFACTURING FACILITY AT SRIPERUMBUDUR, CHENNAI, TN

BUILT UP
• 14,00,000 Sq Ft
AREA

• DESIGN & ENGINEERING

SERVICES • PROJECT MANAGEMENT
CONSULTANCY

TOTAL
PROJECT • RS. 2000 CRS.
COST

CONSTRUCTI
• RS. 300 CRS.
ON COST

• COMPLETED IN
STATUS
FEB 2020
 MANUFACTURING FACILITY PROCESS

STEEL BELT
RM WH FABRIC CORD
PREP.

RUBBER
CURING MILLING
COMPONENTS

ASSEMBLY INSPECTION DISPATCH

SITE PLAN
 SALIENT FEATURES OF THE PROJECT

Heavily loaded pipe rack

has to be designed
passing through all over
the site layout with a
maximum load of 2.4
MT/RM distributed over 7
tiers with 13 racks with a
width 4m and total height
of all tiers together 4.5m
with a walkable platform
in between and the pipe
rack was coinciding with
storm water drain layout
making one leg of the
pipe rack to be eccentric.
The pipe rack had many
intersections and level
changes and crossed the
road at many places for
which girders have been
designed.
 CHALLENGES
Piperack in CEAT is
unique in its feature as
per user requirement.
Piperack is ideally 4.3m
in width Outer to outer,
4m in Height between
Bottom tier to Top tier,
Maintenance is a
biggest challenge for
which our team
provided a solution of
intermediate
maintenance corridor
of 0.6m width.
As per the
loading condition
of piperack with
2400kg/rm of all
tiers put together
and Supporting
str. Weight of
additional
4100kg/rm =
6500kg/rm
 CHALLENGES

Column has been

Piperack Column is designed
fouling with eccentrically
Storm Water Drain for
entire stretch of 521rm
 CHALLENGES

Piperack vertical drops at multiple junctions provided for which the Girder
sections can be seen in the above.
CHALLENGES

Piperack junctions design for different

levels and branches of Piperacks
extended from main Piperack
 CHALLENGES

Piperack Intersections in plan

view for reference.
 REACH US AT:

SIDDHARTH RAJANA | Head-Projects | siddharth.r@proconstruct.co.in | +91-8939489797

MIRZA.K.BAIG | Head-Design | mirza.k.baig@proconstruct.co.in | +91-9030569343

Website: https//proconstruct.co.in