- We are RDSO approved leading Designer and manufacturer of Steel Bridge Girders specialized in Open Web Girder, Plate Girder & Bow String Girder along with erection/launching at site. We comply & are approved by RDSO according to there latest STR fulfilling all perquisites and compliances .
- We have two fabrication units, both situated at Partapur Industrial Area Delhi Road Meerut having combined covered area of more than 30000 Sqm
- We have our own dedicated designing team who have a combined expertise for designing of fabrication drawing, assembling, drawing and preparation of launching scheme
- Our Units are operated with latest state of the art CNC machines.
- Our Facilities are capable of fabrication of 20000 MT per annum.
INFRASTRUCTURE
- Our both units are fully equipped with all the machinery and infrastructure required as per RDSO standard/as requested by our valued client for manufacturing and inspection and accuracy of the highest value.
- We have fully equipped Laboratory for both Chemical and Mechanical testing of material during Inspections.
- We have 10 Production Engineers, 15 Supervisors and 5 highly skilled dedicated Fabrication Teams having manpower of more than 250 people who can complete the work in record time with all quality and accuracy.
Some of our achievements
- Completion of fabrication of 2 - 120 meter OWGs with an accuracy achievement with error of less than 0.01 mm/meter
- Successful cantilever launching with centre closing over a 20 meter height of river Ganges of 2 – 120 meter OWGs
- Successful fabrication, and launching of more than 6000MT in 6 months simultaneously across 2 independent projects.
- Completion of single government work worth ₹57 cr.
GIRDER MANUFACTURING PROCESS AND INSPECTION
- We follow standard process as per RDSO standard for manufacturing and inspection of Girders ensuring quality and accuracy stated as below:
- Developing Fabrication Drawings, Quality Assurance Plan, and welding procedure Data Sheet as per GAD drawing and their approval.
- Layout of Girders for physical verification of drawings and template-ing.
Development of Fabrication Drawings, WPDS and QAP
- Prior to Fabrication, fabrication drawings are developed by our design engineers based on the general arrangement drawing of the Girders with Quality Assurance Plan and Welding process data sheet.
- These are submitted to competent authority for approvals and after approval layout process is being carried out in workshop.
MASTER AND JIGS
- Masters and Jigs are prepared by transferring intersection lines on Master gussets and detailing holes as per drawing on them.
- Drilling of holes is being carried out for manufacturing of Master Jigs for further production of similar gussets(if requested)
- Drilling of holes is being carried out for manufacturing of Master Jigs for further production of similar gussets(if requested)
- Drilling is generally done by CNC drilling machine On all structural members
CUTTING OF PLATES
- After inspection of Raw Materials, cutting of all plates used in fabrication of Girder components is being carried out with the help of CNC cutting machine for the plate to be cut in best accuracy size.
- It is ensured that plates are cut dimensionally and not cut undersize
WELDING INSPECTION BY RDSO/RITES/RAILWAY
- After final welding, Welding inspection is being carried out in workshop by carrying out following Welding Tests as per approved QAP:
Visual Inspection
Non destructive inspection (NDT)
- Magnetic Particle Inspection
- Ultrasonic Test
- Radiographic Test
- Dye Penetration Test (DPT)
Destructive Test
- Macro- Etching test
We have in-house testing facilities for conducting all these Tests.
SAW/MIG WELDING OF ALL COMPONENTS
- After cutting of all plates, fittings of Girder components on fixture with proper lines and level.
- Final Welding SAW/MIG as per approved fabrication drawings is done on Girder components by keeping them on fixtures
- Drilling of holes on these components is done after final welding.
- We use SAW/MIG wire and Flux manufactured by RDSO approved vendors.
- We have our own specially designed fixtures for SAW to ensure accuracy and speed
STRUCTURAL INSPECTION BY RITES/RDSO/RAILWAY
After welding approval, girder components are being checked dimensionally as per drawings. Following parameter are usually being checked by Inspection Authority:
- Overall Length of Members and gusset size.
- Depth of Girders
- Distance between center of bearings.
- Hole pitch and edge distance
- Overall width of the girder components
- Distance between Holes
- Straightness of the Girder components
TRIAL SHOP ASSEMBLY AND CHECKING OF CAMBER
- Trial Assembly of Girder is being done at shop after inspection with the help of Bolts and Drifts.
- For multiple Girder of same drawings, trial assembly of 1st span is sufficient to check the correctness of fabrication and Jigs/Templates or else directed.
- Proper camber as per drawing is given at all joints with the help of camber jacks for the final testing of Camber.
- After inspection of camber, the Girder is dismantled and stacked for painting/metalizing as per requirement.
- We have overhead Cranes (20 MT Capacity) for assembly of Girders which reduces time and hence increase our production capacity.
FINAL PAINTING/BLASTING AND METALIZING
- Before dispatch, Painting/Sandblasting, Metalizing is done on Girder components as per Bridge code (IRS B1:2001).
- Spray painting is done at our Paint shop to give best quality and long life.
- We use Iron Grit for Blasting to give desired roughness to the surface before Painting and Metalizing. We have separate Paint/Sand Blasting Shop for both the units to match the production.
- We also use Epoxy and International Paints if desired by the client
- We have overhead Cranes (20 MT Capacity) for assembly of Girders which reduces time and hence increase our production capacity.
ERECTION AT SITE
We have expertise in Launching and Erection of Open Web Girders /Plate by all method namely-
- Erection by Crane over Trestle/CC Cribs.
- Launching by Cantilever Crane method using Link Members
- Launching by Rolling method/ Girder Train Method by Joining 2-3 Girders by Temporary Link Members