Manufacturing Solutions

Quality fabrication you can trust

Manufacturing of mechanical and fabricated equipment for heavy industrial applications involves precision engineering, strict quality control, and compliance with customer drawings, industry codes, and project specifications. Products are manufactured to meet the high reliability and durability requirements of continuous operations in power, process, and port handling environments.

1. Review of Customer Drawings & Technical Specifications

  • • Detailed study of GA drawings, fabrication drawings, and BOM supplied by customers
  • • Verification of material specifications, tolerances, welding symbols, and surface protection requirements
  • • Identification of critical components and special manufacturing processes
  • • Preparation of production route sheets and quality plans (QAP/ITP)

2. Procurement of Raw Materials

  • • Sourcing of plates, sections, forgings, castings, pipes, and hardware as per customer-approved specifications
  • • Verification of material certificates (MTCs) as per EN 10204, ASTM, IS, or equivalent standards
  • • Material identification, traceability, and storage control
  • • Procurement of bought-out items (gearboxes, bearings, couplings, pulleys, motors) when required

3. Mechanical Fabrication & Heavy Structural Manufacturing

3.1 Cutting and Forming

  • • CNC plasma/oxy-fuel cutting
  • • Shearing, bending, rolling of plates and sections
  • • Profile cutting for complex shapes used in material handling structures

3.2 Machining

  • • Turning, milling, drilling, grinding operations
  • • Machining of shafts, idlers, pulleys, bearing housings, flanges
  • • Precision machining for fitment-critical equipment

3.3 Welding & Assembly

  • • Welding using MIG/MAG, SAW, SMAW processes
  • • Fabrication of heavy structures such as conveyor frames, chutes, hoppers, trusses
  • • Assembly of mechanical sub-systems like gearboxes, housings, and drive units
  • • Compliance with WPS/PQR and qualified welders

4. Equipment Manufactured for CHP, AHP & Material Handling Systems

4.1 Mechanical & Fabricated Equipment

Conveyor Structures:

Stringers, galleries, trestles, head/tail structures

Chutes & Hoppers:

Crusher chutes, transfer chutes, loading/unloading hoppers

Storage & Discharge Systems:

Silos, bins, bunkers, surge hoppers

Handling Equipment:

Slide gates, diverter gates, feeders, vibratory equipment

Crushers & Associated Parts:

Rotor assemblies, breaker plates, liners, casing

Piping & Ducting:

MS/SS piping, ash handling pipelines, expansion joints, ducts

Boiler & Turbine Auxiliary Parts

For power plants

4.2 Rotating & Wear Parts

  • • Conveyor pulleys (drive, tail, snub, bend)
  • • Idlers & rollers (impact, return, carrying)
  • • Shafts, sprockets, couplings, gear/worm units
  • • Ceramic liners, wear plates, hardfaced parts

4.3 Process & Port Handling Equipment

  • • Ship loaders/unloaders components
  • • Grab buckets and tongs
  • • Stacker and reclaimer components
  • • Hydraulic and mechanical parts for bulk material flow

5. Surface Preparation & Painting

  • • Shot blasting / grit blasting to SA 2.5
  • • Application of primer, epoxy, polyurethane, or specialized coatings
  • • Galvanizing (HDG) for outdoor or corrosive environments
  • • Surface finish as per IS/ASTM/ISO standards

6. Quality Assurance & Inspection

  • • Preparation and implementation of QAP/ITP
  • • Stage-wise inspection including dimensional checks
  • • Welding inspection (VT, MT, PT, UT, RT as applicable)
  • • Material traceability and documentation
  • • NDT conducted by certified inspectors
  • • Final inspection with customer/TPI agency

7. Trial Assembly

  • • Pre-assembly of critical structures like conveyor frames, hoppers, or trusses
  • • Checking fit-up, tolerances, bolt alignment, and hole matching
  • • Marking and packing for site assembly

8. Packing, Transportation & Dispatch

  • • Preparation of packing lists and identification tags
  • • Use of protective packaging for machined and delicate items
  • • Arrangement of trailers/trucks for heavy and oversized equipment
  • • Ensuring safe loading and securing as per logistics requirements

9. Documentation Provided to Customer

Material Test Certificates
Welding documents (WPS, PQR, WPQ)
NDT reports
Dimensional reports
Surface preparation & painting logs
Final inspection / quality release notes
As-manufactured drawings (if required)

10. Optional Value-Added Services

  • Site installation support
  • Reverse engineering of damaged or obsolete parts
  • Design validation / drawing preparation based on provided samples
  • Supply of spares for O&M of power, process & port equipment