Successfully launching a new industrial facility requires more than just mechanical capability; it demands a global partner who can deliver seamless, end-to-end services, from heavy rigging to final commissioning. For a rapidly expanding metals leader in India, Beck & Pollitzer provided the full spectrum of industrial installation services necessary to bring a new, state-of-the-art aluminium rolling and casting plant online.
This project, undertaken for our partner, the Asian Aluminium Manufacturing Specialist, in Kathua, Jammu, represented a massive undertaking. Over a sustained 610-day period (1 year and 7 months), a dedicated on-site team of 230 highly skilled workers and 25 supervisors and engineers executed the complex installation and commissioning of all production machinery.
Managing mega-scale installation and rigging
The project’s scale was defined by the sheer size and sensitivity of the core equipment. Our expertise in heavy machinery rigging was immediately crucial for handling:
- The 1,400-tonne Cold Rolling Mill (CRM).
- The 1,300-tonne capacity of four combined Casting Lines.
- Associated finishing equipment, including the Roll Grinder, Slitter, and Cut-to-Length (CTL) lines.
Our comprehensive mechanical scope included the unloading, unpacking, final positioning, and assembly of every component. We utilised heavy lifting resources including mobile cranes up to 300 tons to ensure the safe and precise placement of the main Mill and Caster housings, a hallmark of our unwavering commitment to safety and procedural excellence.
Precision engineering for quality output
The functional success of an aluminium mill is entirely dependent on the precision engineering of its foundations and systems. Our teams executed the precise levelling and anchoring of all main machinery to exacting OEM specifications. This precision extended to the intricate utilities, which included:
- Piping systems: Fabrication and erection of crucial Hydraulic, Lubrication, and Rolling Oil piping, utilisng specialist welding techniques (Argon/Walform fittings) and leak testing by DP and pressure testing.
- Structural integration: Comprehensive installation of 110 tonnes of steel plate cladding, platforms, and maintenance supports for the CRM area, ensuring structural integrity and maintenance access.
- Electrical systems: Complete installation of main power cables, dedicated cable trays, and electrical panels within the Equipment Control Room (ECR), followed by rigorous I/O testing and loop checking.
From installation to successful commissioning
Following the mechanical and electrical build-out, Beck & Pollitzer provided dedicated commissioning support, collaborating closely with OEM teams (including Mino, Bruno Presezzi, and Kame Pomini) to complete final testing and power-on protocols. The successful, integrated delivery across all mechanical, electrical, steel structure, and piping domains ensured the plant achieved full operational status as required. This successful outcome, underscores Beck & Pollitzer’s capacity for providing integrated, global industrial services that launch world-class manufacturing capacity.
Planning your next greenfield project or major plant build-out? Partner with Beck & Pollitzer for expert, single-source management of heavy rigging, precision installation, and commissioning. Contact us to mobilise our global expertise for your project.
