CEMENT – Lead

LEAD serves the global cement industry with the Detailed & Review Engineering Services (Concept to Commissioning) collaborating with all the disciplines such as Process, Mechanical, Civil & Structural engineering.

At the civil and structural engineering stage it includes Analysis & Design of RCC and Steel Structures for all cement plant structures.

Analysis & Design of RCC and Steel Structures for all Plant & Non Plant Buildings
Crusher Building,
Conveyors Galleries & Trestles
Stacker & Re-claimer Sheds, Foundations etc
Raw Material Hoppers, Raw Mill Building, Pre-Heater Building, Kiln Piers, Cooler Building, DPC & Clinker tank,
Coal Mill Building & Hoppers
Cement Mill Building, Mill Foundations, RCC hoppers, Silos,
Packing Plant Building, Wagon Loading and Bulk Loading termials etc.
Raw Mill Buildings, Raw material Hoppers, Conveyors, Large Industries like power plants, cement plants, steel plants etc.
RCC Chimneys
Steel Stacks
RCC & Steel Bunkers
Vibration Analysis of Dynamically Loaded Equipment Foundation & Structures
such as Cooler Fans, Mills, TG Foundations etc.
Material handling structures like Transfer towers, Conveyors, DPC etc
Retaining Structures
Pile Foundations, Well Foundations, Sheet Piling & Coffer Dams
Joint Detailing of Steel Structures both Welded and Bolted
Settlement Analysis of Structure & Foundation
Underground RCC Tunnels
Architectural Design and Detailing
Design of Intake Structures
Structural Optimization Study & Recommendation
Retrofitting and Strengthening of Existing Structures

We also support the cement industry with structural optimization, retrofitting and strengthening of existing structures.

Our architectural support to the cement industry includes conceptual design, preliminary design, and preparation of tender drawings, detailed design for non plant buildings such as Administrative buildings CCR Buildings, Boundary Walls etc.

The mechanical engineering support for the cement industry includes

Developing lay outs
Developing General Arrangements of different departments
Developing Material Handling Systems
Developing Flow Sheets
Detailed design and fabrication drawings for different types of pressure vessels, pressure and utilities like piping, Bulk storage silos/tanks using national and other codes like Euro, ASME etc.,
Selection of materials for construction

Developing and Detailing of Utilities like,

Venting system (De-dusting systems)
Piping for compressed air and circulating / process water system
Fabrication details of material conveying chutes with BOM.
Details of supporting systems for above.
Engineering for Retro-fitting and system improvement.
Preparation of Technical Specifications of various Bought outs and main machinery for cement plants as per system requirement like, Material conveying equipment (Belt conveyors, Bucket Elevators, Screw conveyors etc.) Control equipment like various gates, (slide gates, rod gates dampers, Rotary valves etc.). Connecting equipment like Expansion Joints, Bellows etc. Piping, Dust collection Equipment, and Fans (Process as well as Auxiliary systems)
Developing compressed Air and Circulating water/ Process water distribution based on system requirement and also developing required piping layouts including piping sizing.
Fabrication details of steel stacks with BOM for both guided and self supported type.
Vetting of all suppliers Engg. /Spec. / Drgs.
Auto CAD is used in developing drawings and drafting standards are maintained at international level

equipment using national and other codes like Euro, ASME etc. We also offer support on selection of materials for construction.

At the start of the cement projects we coordinate with the main civil sub contractor, help in supervision and structural work and ensure quality control.

Ambuja Cements (for FL Smidth) Kodinar, Gujarat

Lime Stone Crushing and Screening System
Wobbler Crusher Building
Surge hoppers
Conveyors
Dump hoppers

Zuari Cements (for FL Smidth) Yerraguntla, AndhraPredesh

MRSS Building
Substation Buildings

Vikat Sagar Cement Pvt.Ltd. (for FL Smidth) Chatrasala, Karnataka

Cement Mill Hoppers Building
Cement Mill Load Center Building
Cement Mill Building
Mill Foundations
Conveyors and Transfer Towers
Substations Buildings

Heidelberg Cements (I) Ltd.,(for FL Smidth)

5000 TPD New Clinkerisation Plant, Narsingarh, Damoh, M.P. India)

321 Design of Raw mill Building & Associated Structures
461 Design of Coal Mill Building
Machine foundations for Raw mill, Coal Mill, Booster fan and Coal mill Fan.
Mill Foundations
Shed for Booster fan & coal mill fan
Steel staircases upto +47.80 m height
EOT crane girders
Steel platforms & miscellaneous structures
Design of Raw Material Hoppers, Conveyors & Transfer Towers
Design of OLBC Conveyers
Design of OLBC Substations (SS1 to SS4) Four Numbers
Design of Duct Supports
Material Handling Load Center ER-1
491 Substation (Cooler)
493 Substation (Coal Mill)
311 Raw Mill feed Conveyors

Expansion of Cement Grinding Unit at Imlai, Damoh, M.P

Clinker Transport MCC Room
891 MRSS Building
591 ER-5 Building

Expansion of Cement Grinding Unit at Jhansi, U.P. India

Clinker Transport MCC Room
MRSS Building
471 Transfer Towers (TT1)
471 Belt Conveyor BC 060 & 250
511 Conveyors & Transfer Towers

ACC (Wadi)

Miscellaneous Steel structures and structural audit of existing structures
K3 ESP modifications
Design of Duct Supports
Design of Fan Foundations
Design of bag filter supporting structures
DPC 1 & DPC4 installation after modification of clinker handling system
Installation of magnetic separator system for coal handling circuit
Integration of belt conveyor system for limestone crushers 2&3
Design of special platform for main chimney monitoring system (New Wadi unit)

DPC – 1A

Strengthening of existing DPC – 1A trestle

Power Plant fly ash silo

Strengthening of existing fly ash steel structure

Power Plant fly ash silo

Strengthening of existing fly ash steel structure

Clinker Tank

Strengthening of clinker tank roof

By pass arrangement for fly ash in cement mill building

Design of steel bin
Design of Bag filter venting & duct roofing
Design of supporting structure for steel Bin
Design of trestle for air Slide

Grate cooler

By pass arrangement at grate cooler to existing coal mill hot air duct
Design of steel structure at grate cooler

Coal Handling System

Design of steel Structure for connection L3/BC5 & L3/BC6
Design of Transfer Tower

Coal Handling System

Design of duct for VRM
Design of steel structure for new duct

ACC Sindri – Jarkhand

Coal Mill Building
Coal Dosing & Firing System

Cementos Argos – SA Antiqota, Columbia

Recirculation Building
Bucket Elevator Tower

Oman Cement Company, Rusayl

Cement Mill Substation

ACC (Thondebhavi)

Design of bag filter Supporting structure
Design of duct supports from wagon tippler bag filter
Design of wagon tippler structure
Design of Gypsum Storage System Modification

Proposal for Winch arrangement for pre-heater building
Design of steel structure for 5T Power winch

Clinker Handling
Design of steel Bin
Design of venting arrangement for steel bin
Design of steel structure
Vasavadatta Cement (Sedam)

Structural audit of steel structures of all 4 units (for FL Smidth)
Clinker Bulk loading system for UNIT IV
Integration of cement Mill 2 and unit 1 clinker stock pile
Redesign of DPC 1and strengthening of penta house and central shaft for integration with cement Mill 2 hoppers
Design of cable galleries
Monorail arrangements for critical handling of mill drives
Design of new higher capacity feed hopper for polycom
Clay separation system

Development of layout for Proposed 1.5MTPA Grinding Unit at HOTGI

Packing Plant at Sholapur

Packing Plant Building
Bulk loading system
Cement silo supporting structure
Empty bag godown
Administration and all miscellaneous. Buildings and other services including roads & drainage

Proposal for Bag filter arrangement for polycom

Strengthening of existing steel structure in entire Building
Designing of duct roofing for polycom

Proposal for Bag filter arrangement for fly ash bin

Designing steel structure for Bag filter
Design of Bag filter venting
Design of Duct roofing for Bag Filter
Design of Bag filter venting for fly ash ….. System.

Deccan Cements, Hyderabad

Design of wagon loading system (civil & Structural)

Parasakti Cements, Hyderabad

Gypsum shed and miscellaneous Structures
Precalciner Duct Supporting
Structure (Zambezi Cement)
Blending silo condition monitoring and design of rectification
Bucket elevator supporting Structure

India Cements, Vishnupuram

Community Hall and Auditorium for 1000 capacity and officer club

Mahi Cements (India Cements Ltd.)(for FL Smidth)

Design of Packing plant & Bulk Loading System

Proposal for Winch arrangement for pre-heater building

Design of steel structure for 5T Power winch

Clinker Handling

Design of steel Bin
Design of venting arrangement for steel bin
Design of steel structure

Proposal for Bag filter arrangement for fly ash bin

Designing steel structure for Bag filter
Design of Bag filter venting
Design of Duct roofing for Bag Filter
Design of Bag filter venting for fly ash ….. System

K. Lakshmi Cement Ltd. (for FL Smidth)

Work shop & Store Shed
Coal Mill Building and associated structures
Coal Mill Substation

Suvarna Karnataka Cements Pvt. Ltd, (for Vasavadatta Cement)

500 TPD clinker grinding unit
Design of Mill foundation
Raw Material of Hoppers
Modification fo cement silos and Packing plant
Design of Extension of Gantry Girder
Design of foundation for Dryer
Material handling System