Project Overview: Dhanvi Infracon Pvt. Ltd., a reputed name in the construction industry, successfully undertook the comprehensive design and construction of Bhavani Industries India LLP’s advanced manufacturing facility. Bhavani Industries specializes in cold, warm, and hot forging processes, precision machining, heat treatment, and hard machining operations. To meet these sophisticated industrial requirements, Dhanvi Infracon delivered a facility that emphasizes mechanical strength, safety, smart layout, and future scalability. The result is a robust, high-performance workspace tailored for modern metallurgical and machining excellence.
Facility Highlights:
- Total Area: 1,25,000 sq. ft.
- Structural Framework: RCC and Pre-Engineered Building (PEB) hybrid
- Flooring: Vibration-resistant epoxy and concrete flooring with load-bearing capacity of up to 10 tons/m²
- Utilities: Overhead cranes, pit-based press systems, oil mist collectors, and high-pressure air & gas lines
- Functional Segments: Forging bays, machining zones, heat treatment chambers, grinding & finishing labs, gear shaping units, quality inspection labs, and corporate administration block
- Advanced Infrastructure: Water cooling systems, fire safety with heat-sensor alarms, integrated ETP & STP units, and isolated vibration-prone machinery zones
Key Technologies & Systems Implemented:
- Pre-Engineered Building (PEB) Technology: Enabled fast and efficient construction with heavy-load bearing steel structures.
- Vibration Isolation Foundations: Specially designed RCC foundations for heavy forging and grinding machinery, ensuring operational accuracy.
- Advanced HVAC and Ventilation Systems: High-efficiency extraction and air handling units to control temperature during forging and hard machining.
- Trench-Based Utility Routing: Underground and surface trenches for safe movement of utilities such as hydraulic lines, air compressors, and oil lines.
- Heat Treatment Room Insulation: Fire-resistant walls and insulated doors with automated exhausts for safety in case hardening and induction processes.
- Smart Lighting and Surveillance: LED low-heat high-bay lights, motion sensors, and 24×7 CCTV monitoring system.
- High-Capacity Power Infrastructure: Substations with transformer vaults and backup diesel generator rooms.
- Fire Protection System: Gas-based and sprinkler fire suppression systems around high-risk heat treatment and forging zones.
Construction Challenges & Solutions:
- Heavy Equipment Foundations: Challenge: Creating stable foundations for massive forging and press equipment. Solution: Reinforced deep pile foundations with anti-vibration slabs.
- High-Heat Environments: Challenge: Designing heat-insulated rooms for forging and heat treatment. Solution: Rockwool-insulated walls, fire-rated panels, and dynamic airflow design.
- Underground Cabling and Safety: Challenge: Risk of cable and utility damage. Solution: Laid structured, reinforced concrete ducts with removable slab covers.
- Timeline Constraints: Challenge: Tight completion timeline with phased machinery movement. Solution: Parallel workflow management and 24×7 on-site engineering teams.
- Precision Equipment Setup: Challenge: Needing floor-level accuracy. Solution: Laser-level flooring techniques with pre-alignment coordinates.
Advantages of the Project:
- Tailor-made infrastructure for complex metallurgy operations
- Excellent thermal and structural performance
- High-grade safety and energy efficiency
- Adaptable for future technology integration
- Efficient workflow-based layout reducing turnaround time
Future Expansion & Strategic Plans:
- Phase 2 – CNC Expansion Block: Planned construction of additional 30,000 sq. ft. CNC and robotic machining wing.
- Solar Power Integration: Proposal for a 200 kW rooftop solar system under Net Metering Policy.
- Export-Grade Product Assembly Wing: An assembly and inspection bay for international shipments with ISO-specific certifications.
- Training & Innovation Centre: A collaborative R&D and training facility for precision metallurgy and forging simulation.
- Green Building Certification Goals: Targeting IGBC Silver certification through water recycling and sustainable design.
Project Outcome: The project delivered by Dhanvi Infracon stands as a testament to smart industrial construction, combining cutting-edge construction techniques with a deep understanding of Bhavani Industries’ forging and machining workflow. The success of this project highlights Dhanvi Infracon’s ability to adapt, innovate, and deliver results under challenging specifications and timelines.
Conclusion: Dhanvi Infracon Pvt. Ltd. has once again proven its position as a leading industrial infrastructure partner. The Bhavani Industries India LLP project not only meets the current demands of manufacturing excellence but also lays the groundwork for future innovation, scalability, and international competitiveness. From concept to commissioning, this project reflects unmatched precision, planning, and performance.
