Sanand Heavy Automobile Stamping & Assembly Plant
Apex Auto Infrastructure Ltd — Sanand Industrial Estate, Ahmedabad, Gujarat
High-Performance Structural Engineering
A heavy industrial manufacturing complex featuring four 36m-wide parallel production bays equipped with tandem 50-tonne and 30-tonne overhead EOT cranes for automotive stamping and robotic body-in-white assembly.
The Requirement
Extreme structural rigidity with strict deflection limits (L/1000 for crane runways) under heavy cyclic dynamic braking and acceleration loads, along with high-volume ventilation to dissipate heat from welding lines.
Engineering Challenge
Engineering heavy stepped columns (up to 1800mm depth) and surge trusses to carry dynamic crane loads without transmitting lateral vibrations into delicate robotic laser-welding cells on adjacent mezzanine floors.
Engineered Structural Steel Strategy
Designed composite box-column assemblies and heavy built-up crane runway girders with continuous high-strength friction-grip (HSFG) Grade 10.9 bolting. 1200mm continuous aerodynamic ridge ventilators and motorized intake louvers were integrated to achieve 14 air changes per hour.
Design Details
- • Dynamic harmonic vibration analysis in STAAD.Pro to prevent structural resonance with operating press equipment
- • Custom crane surge truss geometry absorbing lateral trolley braking forces
- • Heavy mezzanine deck carrying 2,500 kg/m² auxiliary stamping tooling loads
Fabrication
- • Heavy built-up plate girders up to 40mm thickness with 100% radiographic weld testing
- • Precision CNC line-boring of crane girder connection holes for exact rail alignment
- • Zinc silicate high-durability primer for enhanced corrosion resistance
Erection
- • Tandem heavy crane lifts utilizing 120-tonne hydraulic telescopic cranes
- • Sub-millimeter optical theodolite rail alignment across 250m long crane runway tracks
- • Rapid turnkey erection executed within 18 weeks
“The precision of Yatee's heavy fabrication is world-class. Our 50-tonne overhead cranes rolled across the 250-meter runway tracks with zero vibration from day one.”
Rameshwar Patel
VP – Projects & Plant Engineering, Apex Auto Infrastructure Ltd
Structural Metrics
Build a Similar High-Performance Facility
Our estimation engineers will provide a preliminary 3D model and steel tonnage calculation for your site location.
Request Similar Project Estimate