Factory Complex for Semco Electric Pvt. Ltd., MIDC Chakan, Pune.
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Project in Brief : Semco Electric Pvt. Ltd. manufactures electrical accessories. It is 100% Export Oriented Unit. The company is already having one unit running at Jaipur and two more in Chakan Industrial belt. The new factory complex is spread over 9.5 acres of land. The main plant building is on 182m long X 84m wide plinth. A 10M high common wall divides the plant building in two parts. On one side of wall is Machine shop which is 105m long and 84m wide and it occupies 8820 sqm. of area. On the other side of wall is Pressure Die-Casting shop (PDC) and the central store. PDC is spread over 4704 sqm and it comprises of two bays of 84mx28m. On the west of PDC is central store spread over 1764 sqm. (84m long X 21m wide). |
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Abutting the south wall of main plant building is workers' facility block, on 84m long X 7m wide plinth. It is two storied building. A dinning hall, two entrance foyers, two workers' change rooms and two toilet blocks are on the ground floor. An office block and the training centre are (294sqm.) on the first floor. The entry to main plant building is through two entrance foyers (94sqm each). Next to each entrance foyer is one change room (66 sqm. each) and one toilet block (33 sqm. each). The dinning hall (196 sqm.) is in the midst of two foyers and has a capacity for 80-100 persons to dine at a time.
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The utility building (550sqm) includes a switch gear room, compressor and DG room. The services comprise pipe and cable bridges, water supply lines, sewer lines, storm water drains and roads. Concrete roads & pathways alone cover approx. 6500 sqm of area. The under ground water tank (GSR) and pump house occupies almost 350sqm of area. The GSR has six compartments to hold process water, firewater, hot & cold water (255 KL combined). Machine foundations include foundations for heavy-duty pressure die casting machines, DG sets, compressors, cooling tower and many other. Switchyard, the underground diesel tank, effluent treatment plant and security office also form part of the project. |
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The Machine Shop has an average height of 9.5m. Columns are in RCC and extend upto tie (8.0m) level. Excluding peripheral columns 8820sqm shop has only 12 interior columns to support the roof. Large column-less area provides more flexibility in planning machinery layout. Peripheral brick masonry walls also extend upto tie level. North light structural steel girders and trusses form roof framing. Cold roll formed purlins span across roof trusses. The roof covering is of cold roll formed Galvalume sheets. The shop receives good natural light till late evenings through large window openings in peripheral walls and north light glazing in the roof. In spite of large area the air ventilation also is fairly good. This is due to provision of large window openings and fairly good height of building. |
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On the west of machine shop are the PDC Shop and the Store . The general construction is similar to machine shop except for the height. It has an average height of 11.5m. The height of this shop has been raised in view of generation of (molten) aluminium/zinc fumes. Roof extractors have been provided on the rooftop to take out these fumes. Aluminium louvers in the lower portion of windows create natural air draft and assist the roof extractors in removing the fumes. The die-casting shop, like machine shop, has large window openings. It also has a north light roof with Galvalume sheets on top.
PDC shop will have 46 PDC machines when it will operate to its fullest capacity. For quick changing of heavy dies four semi Golieth cranes, each of 3mt capacity run all along 84M length of the shop.
The Shop Floor in all the shops is in 150mm thick Tremix concrete laid over 150mm thick hardcore. There is neither the reinforcement in concrete nor there is any PCC below the floor. 'Ashford ' treatment is given to the top surface to impart non-absorbent property to the floor as well as to improve the abrasion resistance of the floor. A three-ton capacity forklift movement has been considered while designing the floor.
The Utility Block is 55 M long & 10m in width. It is located in the Southwest corner of the plot. The switch gear room occupies front 20m portion. The next 15m are apportioned for two numbers of 380KVA DG sets. And the last 15m are for compressors and air receivers. A provision has been made to accommodate three numbers of 450cfm screw compressors.
The switch gear room is entirely in RCC with roof slab at 4m level. The DG and compressor rooms have RCC columns upto tie level (7m). The peripheral brick masonry walls also extend upto tie level. Both side sloping roof has Galvalume sheets on top. Large window openings have been provided for proper ventilation. On the radiator side of DG aluminium louvers are provided in the lower portion of windows for proper air circulation.
The Switchyard is located south of utility block. Currently only one transformer of 750KVA has been installed in the switchyard with a future provision for one more transformer of the same capacity. The metering kiosk is located in the Southeast corner of the plot. From there HT underground cable runs all along the south compound wall upto the transformer yard.
All the electrical supply cables from switchgear room in utility block enter the main plant building through a cable bridge in the Southwest corner. These cables continue to run through over head cable trays all along 182m long south wall of main plant building. In PDC shop the main distribution panels are located just below the over head cable trays. From these panels the cables run through under ground MS pipes to sub distribution panels and respective machines. In machine shop the electrical power is fed to individual machines through over head bus trunking system.
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Utility Services include compressed air lines, diesel lines, LPG lines, liquid die coat lines, cold water supply lines, hot water return lines, drinking water lines, fire hydrant line etc. Compressed air lines, diesel supply lines, LPG lines, liquid die coat lines in PDC shop run over ground all along the column line in pipe trays at a height of about 3.5M above finished floor level. These lines finally run down vertically along the columns and continue under floor before getting connected to individual machines. All other service lines in PDC shop like effluent lines, cold water supply and hot water return lines run throughout under the floor. In machine shop there are only two service lines. The effluent line runs below the floor level and the compressed airline runs over head. |
The Diesel Storage Yard occupies around 200sqm of ground space. It is located near the west boundary of plot. Two numbers 24KL diesel tanks have been installed in an underground RCC pit. The diesel is pumped from these underground tanks to a overhead day tank located in the Southwest corner of the main plant building. From their the diesel flows under gravity to respective (aluminium/zink) melting cum holding furnaces.
Ground Service Reservoir (GSR) and Pump House is spread over 350 sqm of area; out of which 60% area has been occupied by pump house alone. GSR is almost underground. Pump house is partially underground and partially over ground. GSR has six compartments; two for holding fire water (45KL each), two for process+domestci water (45KL each), one hot well (40KL) and one cold well (35KL). Hot and cold wells are one above the other.
Two number cooling towers are located on top slab of GSR. The cold water from cooling tower basin flows under gravity into cold well below. From cold well cold water is pumped and circulated around PDC machines and in the process becomes hot. The hot water is collected through hot water return lines into hot well and pumped onto the cooling tower.
The underground pump house accommodates around seventeen large and small pumps including firewater pump and jockey pump. In order to ensure positive suction the pump house raft slab has been kept well below that of GSR.
Effluent Treatment Plant is in the Southwest corner of the plot and occupies almost 28mx18m of ground space. Effluent from Machine shop, paint shop and PDC shop is treated here and it is used for gardening. ETP structures are partly underground and partly over ground. The ETP structures include reaction tanks, oil and grease trap, neutralisation tanks, settling tanks, aeration tanks, clarifiers, sludge drying beds etc.
All Internal Roads are in 150mm thick Tremix concrete over the base layer of 150mm thick hard core. No reinforcement is provided in road concrete except dowel bars at joints. There is no PCC either. Built in RCC curbing is provided on either sides of the road. Pathways are in 80mm thick pre-cast concrete pavement blocks.
The loading platforms are in the front and the unloading platforms are in the rear. In front of loading and unloading platforms sufficient space has been left for turning and docking of 40 feet containers. Dock levellers have been provided in the loading and unloading platforms for height adjustment, which helps in easy loading and unloading of packing from containers
Gate Office is square (6.3m X 6.3m), single storied building supported on four circular columns with flat slab on top. Peripherally brick masonry walls are only upto sill level. Full height aluminium glazed windows above sill level provide better all around visibility.
| Client | : | Semco Electric Pvt. Ltd. |
| Project Cost | : | Rs. 12.5 Crores (Approx.) |
| Structural Steelwork | : | 700MT (approx.) |
| Services Rendered | : | Architectural, Structural, Electrical Engg & Project Management |
| Year | : | 2000-01 |
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