Project Overview
Dhanvi Infracon Pvt. Ltd. undertook a highly specialized industrial project for Cermet Sintered Technology LLP, a pioneering manufacturer of Stainless-Steel, High Alloy Metal, Sintered, and Silicon Carbide components. The requirement was a custom-engineered manufacturing plant tailored to support advanced metallurgical operations with stringent environmental and technical benchmarks. From structural layouts to utility integration, this project demanded an infrastructure that supported high-temperature processes, cleanroom capabilities, and heavy-duty machinery. Dhanvi Infracon managed the entire lifecycle—design, planning, execution, and quality control—with complete precision. This endeavor reflects our unwavering commitment to high-end industrial construction.
Key Features of the Project
- High-Strength Structure
- Designed to support the weight and vibration of industrial sintering and metallurgy equipment.
- Reinforced foundations and floors with industrial-grade concrete.
- Advanced HVAC & Filtration Systems
- Required for air purity during sintered material handling.
- Installed centralized ventilation with dust extraction and filtration units.
- Smart Utility Layouts
- Integrated plumbing, electrical, and gas systems for metallurgical operations.
- Safety circuits and emergency cut-offs built into the structure.
- Eco-Friendly Design
- Used fly ash concrete and energy-efficient insulation.
- Rainwater harvesting and solar backup provisions installed.
Technologies Used
- BIM (Building Information Modeling):
Enabled seamless coordination between design, civil, electrical, and mechanical works. - Laser Scanning & Site Layout Tech:
Provided real-time topography and ensured error-free layout execution. - 3D Concrete Printing for Molded Units:
Reduced human error and improved finish in non-linear structures. - IoT-Based Monitoring Systems:
Enabled real-time tracking of curing times, load balance, and indoor air quality. - Industrial Epoxy & ESD Flooring:
Essential for material-sensitive processes and machine safety.
Challenges Faced
- Sintering Environment Design Constraints
- The metallurgical processes required heat insulation and pressure management.
- We employed ceramic wool paneling and high-grade refractory bricks.
- Precision Machine Placement Coordination
- Required floor and baseplate leveling to micro-millimeter accuracy.
- Used laser-guided leveling tools to achieve the required standards.
- Managing Power Requirements
- Heavy load equipment demanded power substations within the premises.
- Installed dedicated transformer units and generator backup.
- Raw Material & Airborne Particle Management
- Dust control and material separation zones were mandatory.
- Designed with pressurized cleanrooms and isolation chambers.
- Schedule Compression
- The client needed rapid handover without compromising quality.
- Achieved delivery 3 weeks ahead of deadline with 24×7 shifts and micro-phase planning.
Advantages of the Project
- Delivered a world-class manufacturing facility capable of meeting both national and international metallurgical standards.
- Created a structure that is resilient, efficient, and scalable, allowing Cermet to expand in the future.
- Energy-efficient infrastructure with cost savings on utility usage.
- Employee-centric design with climate control, ventilation, and safety escape paths.
- Built-in systems for fire suppression, chemical containment, and noise isolation.
Disadvantages / Limitations
- High upfront cost due to specialized materials and tech.
- Complexity of operations increases long-term maintenance costs.
- Site-specific customization limits adaptability for future repurposing.
- Slight delay in international material imports impacted schedule buffers.
- Skilled labor requirement during construction led to recruitment from outside regions.
Future Expansion Plans
- Dhanvi Infracon has pre-engineered modular extensions for clean room expansion and automation integration.
- Provisioned for vertical expansion in the main plant to include robotics and AI integration in production.
- Underground tunnel system for waste management and material routing under consideration.
- Green certifications are being pursued for LEED Silver and GRIHA 4-Star Rating.
- Ready for Phase-II execution based on market demand and client input.
Construction Management Approach
- Agile Construction Scheduling – Broken into daily sprint goals with monitoring dashboards.
- Material Flow Optimization – Just-in-time delivery synchronized with structural progress.
- Zero Deviation QA/QC Policy – Third-party inspections conducted weekly.
- Digital Project Reporting – Drone monitoring, app-based tracking, and instant updates to the client.
- Team Strength – 60+ engineers, foremen, supervisors, and skilled laborers managed by a senior project manager.
Conclusion
This flagship industrial project by Dhanvi Infracon Pvt. Ltd. for Cermet Sintered Technology LLP stands as a testament to our ability to construct highly specialized and future-ready manufacturing infrastructure. It underscores our expertise in civil engineering, precision construction, project governance, and client satisfaction. The structure not only meets the functional requirements of a high-tech metallurgy unit but also provides scalability, safety, and sustainability. With such projects, Dhanvi Infracon continues to shape the future of India’s industrial landscape with unmatched quality and innovation.
