Project Overview
Dhanvi Infracon Pvt. Ltd. took immense pride in delivering one of the most technically advanced construction projects for Classic Electrocoating Pvt. Ltd., a company housing the highest capacity plant for Powder Coating and Electro Colour Anodising in India. The project demanded state-of-the-art infrastructure and intricate planning, requiring modern civil construction to accommodate high-end machinery and process flow. From heavy-duty flooring and ventilation systems to chemical-resistant treatments, Dhanvi Infracon ensured that every detail aligned with the company’s cutting-edge processes. The emphasis was placed on environmental safety, worker efficiency, and space optimization. As a turnkey solution provider, Dhanvi’s role extended from conceptualization and structural planning to complete civil execution.
Key Features
- Heavy Load-Bearing Foundation:
Designed to support high-capacity electrocoating machinery and large chemical tanks, using M30 and M35 grade concrete. - Advanced Ventilation Systems:
Integrated for air purification, temperature regulation, and safety within the coating chambers. - Anti-Corrosive Industrial Flooring:
Epoxy and polyurethane-coated flooring that withstands chemical exposure and wear from equipment movement. - Energy-Efficient Lighting and Power Management:
Installation of smart energy grids and LED-based lighting to reduce power load. - Segregated Zones for Safety:
Strategic separation of raw material handling, production, waste disposal, and office areas.
Technologies Used
- Building Information Modeling (BIM): For detailed structural planning and visualization.
- Pre-Engineered Building (PEB) Structures: For faster erection and lower steel consumption.
- Green Building Concepts: Use of solar panels, water harvesting, and natural lighting.
- SCADA Systems for Utility Monitoring: Integration of SCADA for power, air, and water systems.
- Chemical-Proof Surface Treatment: Anti-corrosive epoxy treatments in the coating and anodizing areas.
- Fire Detection and Suppression: Intelligent fire safety systems using addressable panels and water-mist technology.
Challenges Faced
- Handling Complex Chemical Requirements:
The plant required specially lined storage rooms for acidic and alkaline materials, which needed reinforced, chemical-resistant structures. - Meeting Environmental Regulations:
Compliance with GPCB norms, effluent treatment setups, and air quality systems was compulsory. - Tight Deadline Pressure:
The client needed to go operational within 8 months. Dhanvi worked in double shifts to stay on track. - Precise Machine Foundation Layouts:
Equipment placements required accuracy to the millimeter, coordinated with machine suppliers and mechanical teams. - Extreme Weather Conditions:
Unpredictable rainfall during monsoon delayed structural roofing. A temporary roofing structure was used to proceed with interior work.
Advantages of the Project
- Seamless coordination between civil, mechanical, and electrical teams.
- Boosted client productivity with efficient layout design.
- Enhanced brand visibility due to architectural appeal and functionality.
- Long-term cost-saving through energy and water optimization.
- Minimal downtime with structured workflow zones and storage systems.
Disadvantages & Limitations
- Initial cost overhead due to high-grade material and technology integration.
- Dependence on multiple vendors led to coordination delays in the early stage.
- Limited space expansion scope due to zoning restrictions.
Future Plans by Classic Electrocoating Pvt. Ltd. (Supported by Dhanvi)
- Expansion of Warehouse & Dispatch Unit: Dhanvi is already planning the second phase construction.
- Introduction of Robotic Coating Booths: Structural space for automation is already allocated.
- Dedicated R&D Wing: A separate block for innovation labs is in the blueprint.
- Solar Farm Installation on Roofs: Roofs designed to support 100 KW panels.
- Rainwater Reuse Facility: Implementation in Phase II for increased sustainability.
Construction Management Highlights
- Agile Project Management: Tools like Primavera and MS Project used for timeline control.
- Real-time Site Monitoring: Use of drone mapping and CCTV for progress validation.
- Vendor & Contractor Management: 24×7 coordination among 10+ subcontractors under Dhanvi’s leadership.
- Transparent Reporting: Weekly client meetings and status dashboards.
- Quality Control Checks: 4-tier QC process including third-party audits.
Conclusion
The Classic Electrocoating Pvt. Ltd. project represents the fusion of innovation, engineering excellence, and construction brilliance by Dhanvi Infracon Pvt. Ltd. With this plant, Dhanvi not only met but exceeded the expectations for an industrial facility capable of housing India’s highest-capacity powder coating and anodizing unit. The project stands as a hallmark of durability, adaptability, and futuristic planning. It highlights Dhanvi’s ability to handle technically intensive and large-scale projects while ensuring sustainability, compliance, and structural integrity. This achievement further strengthens Dhanvi’s reputation as a leader in industrial construction for advanced manufacturing facilities.
