Design For Accessibility: Getting it right from the start
Company presentation fabricator feb20_2016
1. 20 Feb 2016
CA, USA
Presentation
to
Bechtel
National Bank of Kuwait
2. Established in 2002
An ISO 9001: 2008 certified company
Executed 200+ projects
A team strength of 250 Engineers
Offices in California, USA, Bangalore & Mysore, India with 350 work stations
Projects executed for Fabricators, Engineering Companies, General Contractors
and EPC Contractors
Project size up to 40,000 tons, simple to complicated structures executed to the
satisfaction of our customers
Experience in Power, Petroleum, Chemical, Airport, Manufacturing, Commercial &
Architectural structures
Experience in designing and detailing projects in seismic zones
Have not lost a single customer in last 10 years
Consistently 70%+ revenue through repeat business from existing customers
Projects executed in US, Mexico, Middle East, Hong Kong & India
About US
3. 250 Engineers
30 Connection Design Engineers
120 BIM/3D modelling Engineers
100 Engineers in checking and Quality Control teams of which 30 Engineers
with experience in Fabrication and Erection
Support Functions
In-house software development team
Support and admin staff
Sales and pre-sales team
Partners
Professional Engineers
MEP firms
Our Team
4. Software expertese
Trimble/Tekla Structures – 62 licenses
DESCON
STAAD
AutoCAD Rivet
3D Max
In house developed Tools
iConnect – Connection design suite ASC, LRFD – 9,13 & 14 th Editions
iSoft – In house developed automation tools running on Tekla Structures
iManage – Project Management & workflow automaton tools
Software & Automation Tools
5. ISO 9001 2008 certified company
Matured Process – in use for over 9 years and continuously improved to handle
changing environments
Process Tracks
Critical aspects of project
Traceability – Revisions, RFIs
Process Helps in
Allocating right people for the projects based on employees’ skill certification
and experience
Identifying training needs
Improving efficiency
Improving Quality
Ensures checks and controls at every stage
Timely delivery of Projects
Process
6. Services offered to Fabricators
Connection Design services and stamping of Connection Designs services
BIM Development and Maintenance
3-D Modelling of both Structural and Miscellaneous Steel
Detailed Shop Drawings and CNC files for Fabrication
Coordination with joists, decking, grating & facades service providers
Review and stamping of shop drawings
Project Estimation and take off services to assist Fabricators in bidding
7. A single source for connection design and detailing services
A great partner for Design Build / Design Assist projects and Material take off
On-demand, scalable resource mobilization leading to quicker delivery cycles with
no long term commitment from the customer
Access to 3D Modeling software, custom applications and tools (over $2 million in
investments) and trained professionals
On Schedule, Error free drawings delivered at a very Competitive Price through
a combination of on-site and offshore resource utilization
On demand customer support during Fabrication and Erection stage
Benefits to Fabricators
8. Projects & Case Studies
Project Name Owner Location
Engineering
Consultant
Tonnage
Plant Scherer
Southern Company
Juliette, GA,
USA
Worley Parsons 40,000
(Units 1 to 4)
Kemper County IGCC Project Southern Company
Kemper County,
MS, USA
Southern
Company
24,500
Dow Poly 5 Dow Chemical Company
Freeport, TX,
USA
Dow Chemicals 20,000
IOC Paradip
Indian Oil Corporation
Limited
Pardip Valdel 20,000
Dow LHC9 Stick Builds
The Dow Chemical
Company
Houston, TX,
USA
FLUOR 5,000
Plant Bowen (Unit 3&4) Southern Company
Cartersville, GA,
USA
Southern
Company
4,500
Oak Grove Power Station Texas Utilities
Robertson
County, TX,
USA
Neil & Gunter 4,900
La Cygne Generating Stations (Unit 1&2) Kansas City Power & Light
La Cygne, KS,
USA
Sargent &
Lundy
9,000
Plant Daniel Southern Company
Jackson County,
MS, USA
Southern
Company
3,300
9. Projects & Case Studies
Project Name Owner Location Engineering Consultant Tonnage
Dow LHC9 Pipe Rack
The Dow Chemical
Company
Houston, TX, USA FLUOR 2200
Williams Generating Stations
South Carolina Electric
& Gas
Berkeley, SC, USA Stantec 1300
Plant Scherer Baghouse Structure Georgia Power Co., Juliette, GA, USA Worley Parsons 1500
Wateree Generation Stations
South Carolina Electric
& Gas
Richland County,
SC, USA
Stantec 1900
Plant Miller Alabama Power
West Jefferson, AL,
USA
Advatech 2900
USGC Petrochemical - ISBL
Chevron Phillips
Chemical Company
Baytown, TX, USA JGC-FLUOR 2000
Brandon Shores Generating Station
Constellation Power
Source Generation
Baltimore, MD, USA Wheelabrator 1600
Altamira Line 2 - C6774 Dupont
Wilmington, DE,
USA
Dupont 1600
Shawnee Fossil Fuel Plant
Tennessee Valley
Authority
West Paducah,
Kentucky
Stantec 1400
10. Projects & Case Studies
Project Name Owner Location
Engineering
Consultant
Tonnage
Chana 2 & Thailand
Power
Thailand Siemens 1,600
Wangnoi 4
Mount Storm Power
Station
Dominion West Virginia Mill Creek 450
Clifty Creek
Indiana
Kentucky
Electric
Corporation
Madison,
Indiana
6,000
Bangalore
International Airport
BIAL Bangalore STUP 6,000
Baggage Handling
System
BIAL Bangalore Vanderlande 800
UT, Dallas, Brain
Performance
Institute
UT Dallas Dallas
Datum
Engineers
800
11. Fabricator Engineering Company
About the Project
The Shawnee Fossil Plant is a coal-fired power plant owned and operated
by the Tennessee Valley Authority located near Paducah, Kentucky. Our
scope included SCR support structure
Tonnage 1400 Tons
Scope
Design of connections as per Seismic Zone D,
Review and Stamping of Connections
3 D Modelling & Detailed Shop Drawings
Case Study - Shawnee – Fossil Fuel Plant
Shawnee 1/3
12. Our services
1. Connection design as per AISC 341 -02
Basic seismic resisting system is OCBF (ordinary
concentrically base frames)
Complex Vertical Braces and Trusses as the brace
loads posted were amplified loads
Total connection types included 60 truss connections,
60 Brace connections and 130 special connections
2. Preparation of 3 D models in Tekla
3. Providing detailed shop drawings & CNC outputs
Benefits
1. Turnaround time – designed, reviewed, stamped, modelled and
released shop drawings for approval in 8 weeks.
2. One stop shop – Fabricator did not have to invest time in co-
ordinating between the designer and detailing company
3. Faster completion of the project due to reduced coordination
time and RFIs
Shawnee – Fossil Fuel Plant
Shawnee 2/3
14. Fabricator Schuff Steel Company Engineering Company FLOUR
About the Project
Dow is currently expanding its production facilities on the Gulf Coast in
Freeport, Texas and Plaquemine, Louisiana with its Gulfstream Program.
Tonnage 20,000 Tons
Scope
Design of connections
Review and Stamping of Connections
3 D Modelling & Detailed Shop Drawings using Model based inputs
Case Study - Dow Chemicals
Dow 1/6
15. Our services
Connection Design
3 D Modelling – over 100 sequences
Completely Model based detailing – Inputs from Dow as an STP model,
Revisions through STP, BFA comments through XSR files. No paper drawings were
received in this project.
Benefits
Design and detailing done at one location
Multiple sequences and coordination among various sequences
Impact analysis was carried out in less than 24 hours
Effficiently managed multiple revisions based on site requirements up to 9
revisions (in few sequences) which impacted sequences already detailed/
fabricated/erected. Suggested Field modifications wherever required and
coordinated with earlier sequences to address the impacts
Dow Chemicals
Dow 2/6
16. Model based Detailing Process
RFI’s were reviewed by the client using model viewer.
UDA report in .xsr format were given by the client along with loads wherever
connections need to be designed by iCAD.
All the connections applied in model were tracked using connection codes.
After completing the modeling activities and updating all the RFI responses in
model, the assembly drawings and E-plans were generated, edited and checked
as per customer standards.
Models along with the assembly drawings, E-plans and Fabtrol reports were
submitted for approval (OFA).
Dow Chemicals
Dow 3/6
17. RFI’s were tracked using member UDA in the model.
Dow Chemicals
Dow 4/6
18. BFA (Back From Approval) Drawings
Approver comments were received through .xsr file and the same was imported in to
Tekla model using GUID number for future reference.
Dow Chemicals
Dow 5/6
20. Fabricator Engineering Company
About the Project
Retrofitting two WFGDs complete with Absorber Island, limestone
preparation, and gypsum dewatering systems, with complete flue duct and
structural steel components to integrate the WFGD system into the existing
power plants.
Tonnage 3300 Tons
Scope
Design of connections as per Seismic Zone D,
Review and Stamping of Connections
3 D Modelling & Detailed Shop Drawings
Case Study - Wateree & Williams Generating
Station
Wateree 1/4
21. Our Services
1. Designing Connections as per AISC 341 -02
Basic seismic resisting system is SCBF (Specially
concentrically base frames)
Designed and 3 D modelled connections for retrofitting
WFGD (wet flue gas desulphurization) to the existing structure.
2. Preparation of 3 D model in Tekla
3. Preparation of Detailed shop drawings & CNC outputs
Benefits
1. Quicker Turnaround time – designed, reviewed, stamped, modelled and
shop drawings under one roof
2. Fabricator did not have to invest time in co-ordinating between the
designer and detailing company
3. Faster completion as both Design and Detailing carried out parallelly
Wateree & Williams Generating Station
Wateree 2/4
24. General Contractor Larsen & Toubro Engineering Company STUP
About the Project
The Bangalore airport expansion involved four new link bridges, walkways,
support structure for escalators and Travelator
Scope
Structural design of Fixed Link Bridge, Connection Designs and developing
Detailed Fabrication Drawings
Our Services
1. Developed a STAAD model USING the given preliminary load model
2. Designed specific connections to suit tubular structural steel and architecturally
exposed (aesthetic) steel
3. Got the designs reviewed by another external consultant in addition to Airport
Design team due to Airport regulation requirements
Case Study - Bangalore International Airport
BIA 1/2
25. 4. Visited the project site periodically to understand the site conditions and modified the design
based on the studies carried out.
5. Was responsible for interacting with other agencies, resolving RFIs and approval of designs
6. Developed custom work sheets for validating the STAAD outputs.
Benefits
1. Acted as single firm responsible for design, validation, site co-ordination and approvals
2. Co-ordinated amongst other trades to ensure there is no clash/fowling in the site
3. Ensured timely completion of project through deployment of resources as needed
4. Faster turn around of shop drawings & RFIs as design and detailing was carried out under
one roof
5. Customer did not have to deploy any of their key resources in this project
Bangalore International Airport
BIA 2/2
26. EPC Contractor Vanderlande, Netherlands
About the Project
Design of Baggage handling support structures at Bangalore International
Airport. This is a suspended structure based on site needs and required
a very high precision.
Scope
1. Member Design, Connection Design, 3D Modelling and shop drawings
2. Coordination with Airport Authority for review and approval of designs
Our services
1. Site visits to understand the site conditions
2. Incorporated site conditions in the design as the structure was fitting to an
existing concrete structure
3. Designed Connections
4. Developed 3 D Models in Tekla Structures and prepared Shop Drawings
5. Got the design reviewed and approved by the Airport Authority of India
Case Study - Baggage Handling System
BHS 1/2
27. Tools used
STAAD, In-house designed connection design worksheets and Tekla
Structures
Benefits
1. Entire Structural Design, Connection Design and Detailing works were
carried under one roof
2. Customer did not assign any of their design resources.
3. Coordinated with Fabrication and Erection companies
4. Coordinated all the approvals from Governmental Agencies
5. Assisted customer in executing the project with very few resources
Baggage Handling System
BHS 2/2
28. EPC : Siemens
Scope
Design of all connections in the two power plants
Develop 3 D model to validate clash with pipelines in PDMS
About The Project
These two Power plants were designed by SIEMNS for Electricity Authority
of Thailand. The steel sections involved Japanese and Thailand sections
Tonnage 1600 Tons
Scope
1. Connections were designed as per ASIC standards. Standard
connection design software could not be used because of the load combinations for
the given sections was very high as Siemens looked at optimising the steel
Case Study - Chana 2 & Wangnoi 4 Power Plant, Thailand
Chana 1/2
29. 2. Connection concepts were developed by us and approved by Siemens
3. Designed the connection work sheets for the approved concept
4. Designed 1000 plus connections
5. Provided detailed Calculations for all the connections
6. Resolved Detailer and Fabricators RFIs
Tools Used
STAAD, In-house developed connection suite & Tekla Structures
Benefits
1. As modelling was done and validated with PDMS, there were no design revisions
during fabrication and erection.
2. We were able to ramp up resources as required thereby ensuring timely
completion of project
3. In many cases steel connections were modified to accommodate pipelines at
design stage
4. With very few resources Siemens was able to complete the job
5. Our core strength of AISC knowledge was very help full to Siemens Asia
Chana 2 & Wangnoi 4 Power Plant, Thailand
Chana 2/2
30. UDH 1/3
Fabricator Indiana Bridge Inc.
About the Project
This is a complex building with hip and Valley roofs & Curved roofs.
Because of the complexity, it involved coordination with lot of other
vendors to ensure there are no issues at the site.
Scope
Developing 3 D Model & Detailed Shop Drawings
Coordination with HVAC, Joist, Deck & Skylight vendors
Benefits
Lot of interferences with other desciplines were brought to the notice of
the Architect which led to revisions in the roof slopes at an early stage to
avoid costly field fixes.
In spite of being complex architectural building, the fabrication and
erection went of smoothly as we were able to identify the problems
early and suggest possible solutions.
This project was awarded the best BIM Model award by an independent jury
in Tekla BIM competition 2015
Case Study - Hoover Dining Hall
33. Fabricator Schuff Steel Company
About the Project
The Brian Performance Institute - a new 62,000-square-foot facility will
bring together the latest research and training techniques designed to
improve cognitive skills and health. Brain training rooms, event spaces and
other clinical offerings will be in an elliptical, three-story glass structure
connected to a rectangular building filled with administrative offices.
Tonnage 800 Tons
Scope
Providing Connection Designs
Detailed shop Drawings for Structural and Miscellaneous Steel structures
Case Study - UT Dallas, Brain Performance Institute
UTDBPI 1/3
34. Work Carried Out:
1. Design of specific connections as per AISC 13th Edition, ASD method.
2. Created 3D model of elliptical structure using Tekla structure software - version
20.1 by interpreting design drawings supplied by customer, produced 2D shop
and erection drawings for fabrication and erection
3. Provided weekly BIM model to General Contractor to co-ordinate with MEP, Civil,
Joist, Fire safety, Deck suppliers
4. Identifying Architecturally exposed structural steel and design & detail steel as
per AESS requirements.
5. Model Coordination with Joist, Steel deck, architectural stair, monumental stair
and Mechanical equipment's.
UT Dallas, Brain Performance Institute
UTDBPI 2/3
36. Fabricator NAFCO Steel
About the Project
Mount Storm Power station is a coal fired power station owned by
Dominion located in West Virginia. Mount storm power station has
three different building units namely Head house-A, Head house –B and
Storage transfer tower.
Tonnage 450 Tons
Scope
Structural Steel Connection Design
Develop 3D Model and Detailed Shop Drawings
Case Study - Mount Storm Power Station
MSPS 1/3
37. Our Services
Designed the connection using LRFD 14th edition
150 varieties of connections designed along with connection calculations
3D Modeling and Shop Drawings
Benefits
Timely delivery of drawings was very critical to this project
Customer realized the need for Connection Design services after 3 weeks
in to the project but could not extend the schedule due to Liquidated
Damages clause. We took the responsibility of Designing the Connections
without affecting the final Drawing delivery schedule
Reduction in RFIs as Design and detailing were under one roof and faster
turn around
Mount Storm Power Station
MSPS 2/3
39. Our Automation Tools
APPLICATION NAME DESCRIPTION BENIFITS
MEMBER CHECKS -
132M17
Checks the Assembly Name, Assembly Prefix,
Part Prefix, Material Grade and generates a
report for the wrong ones.
Used in QC. Helps the user to check part prefix,
assembly prefix, material grades before
generating the drawings to improve quality.
GUSSET ON CENTER -
2A02
Verifies that Gussets are exactly placed to the
center of BEAM/COLUMN/BRACES
Used in QC to ensure gussets are to the center of
the Main Member.
ASSEMBLY NOT LINKED -
3A03 and PARTS NOT
LINKED - 22P03
Checks to ensure assemblies are linked to the
respective multi drawings and parts are linked
to respective G-Sheets. Generates reports of
Assembly/Parts that are not linked.
Assemblies and parts will not be missed out in
the MULTI DRAWING and PART DRAWING.
K-ENCROACHMENT
VERIFICATION - 32C03
Checks the material encroachment in to K-
Value/K1 Value and generates a report when
there is encroachment.
Used in QC which helps to ensure there are no
material encroachment into the k/K1 value.
HANDRAIL
VERIFICATION - 47HR02
Checks the parameters of Handrails Like Height,
P-end Distance, Max Post to Post Spacing, Max
length, Profile etc.
Used in QC which helps to verify the handrail
parameters are correct and reduces checking
time.
SIMILAR BOLT QTY. ON
BOTH ENDS - 41B04
Checks if the GAGE and No of Bolts are same on
both the ends of the Braces
Used in QC. Helps to check the connection design
requirement through automation.
WASHER
ENCROACHMENT -
59W03
Checks the Washer encroachment into K-
Value/K1 Value and generates a report when
there is encroachment.
Used in QC to ensure there is no washer
encroachment in the model.
40. Our Automation Tools
APPLICATION NAME DESCRIPTION BENIFITS
COORDINATION
CHECKING OF BOLTS
Checks if the location of bolts are correct
between two or more coordinating tekla
models.
Used in QC to check if the location of bolts at the
coordinating locations are correct.
BENT PLATE
VERIFICATION - 74P10
Checks Bent Plate Radius, washer
encroachment into the bent plate radius.
Used in QC. Helps to verify if the bent plate radius is
correct and there are no washer encroachment into
the bent plate radius.
WORK POINT CHECKING
- 130P17
Checks the work points intersection between
BEAM To BEAM, BEAM To COLUMN, BRACE To
BEAM and COLUMN
Used in QC to check if work points are proper.
VERIFYING SHEAR
PLATE IS ONE SIDE OF
BEAM - 116C13
Verifies whether shear plate is on the same
side of beam.
Used in QC to check if shear plates are one side of the
beam.
SET BACK
VERIFICATION - 60C07
Verifies the set back value for the members
like Beams, gussets, Haunch plate etc.
Used in QC to check if set back value is proper at all
the locations.
BOLT CHECKS - 241B12
Checks the bolt errors which may occur in the
TEKLA STRUCTURES
like 1) Bolt parts are not proper
2) GAP between bolt parts
3) Multiple bolts at same location, etc
Used in QC to ensure that bolt errors do not exist in
the model.
GAGE VERIFICATION -
8C01
Validates the bolt GAGE for W, Wt, Channel
and L section profiles.
Helps in ensuring the bolt gages are proper.
EDGE DISTANCE - 7B03
Checks the EDGE DISTANCE of the bolt with
respect to bolt Dia.
Ensures that the required edge distance exists for all
the bolts.
CONNECTION DESIGN
CHECKING - 125C15
Checks the connection design parameters Like
profile, No of bolts, weld Length, Hole To Hole
Spacing etc for Beam To Beam connections,
Beam to Column connections, Vertical Brace
connections, Horizontal Brace Connections.
Quality and efficiency based application to ensure
quality.
41. Our Automation Tools
APPLICATION NAME DESCRIPTION BENIFITS
BATTEN PLATES - 73C10
Automatically insert the batten Plates(Spacer
plates) for the 2L braces in the model.
Efficiency based application helps in reducing the
time of placing the batten plate in the model .
DELIVERABLES -
110D08
This generates customer related deliverables
from Tekla, Like
1) bolt report, 2) .nc1, 3) .dxf, 4) .kISS, etc
Also generates customer specified outputs as
per the requirement like 1) DXF Splitter: Dxf
separately for different Plate Thickness
2) NC File Splitter - To create NC files for
Different hole Dia
3) .KISS File With Out Bolt and .KISS with Cost
code information.
Generates customized outputs as per the customer
requirement. Since the generation is automatic, helps
in efficiency and quality
DRAWING CHECKS -
158DWG12
This application is used to check the
1) RD start point are correctly called out in the
drawing.
2) Used to check the Precision and dimension
format check.
Quality based application, which helps to ensure RD
start points are correct for the members (Especially
for skewed and sloped member) and also the
precision and dimension format used for the entire
drawings are right.
AUTO DIMENSIONING -
98DWG06
Providing the Dimensions automatically for the
VERTICAL BRACES, HORIZONTAL BRACES,
BEAMS
Helps in eliminating the editing errors.
COPE AND BLOCK OUT
REPORT - 61C09
Extracts CopeX and CopeY (Left Top, Left
Bottom, Right Top, Right Bottom) and Flange
Cuts (X and Y) for the W-Section Members.
Quality related application which helps to verify that
copes and cuts are with in the limit of design. The
application is also useful to checker to ensure that
flange cut details are called out in the detail drawings
BO - APPLICATION -
16B09
Generates hole report for each member from
the model.
The holes will be cross verified with the drawing
output, to ensure that holes are correctly called
out in the drawings.
Quality related application, which helps the checkers
while checking the drawings and also useful in
identifying the wrong hole Sizes used in the model
E-PLAN VS ASSEMBLY
LIST - 189EPLAN01
Checks and generates a report for the
assemblies which are not called out in the E-
PLAN.
Ensures all the assemblies are called out in the E-
Plan.
