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Zamil Steel relied only on Tekla to expertly deliver the Bangalore Metro Rail Depot

Image courtesy - Telge Projects

“Tekla Structures enabled us to complete the project successfully on time in spite of the manifold challenges and complexities. At the engineering stage, all possible clashes and other departmental co-ordination were tackled with ease. The execution team did not encounter on-site issues with other project departments. We easily modelled all complicated sheeting joint & transitions in Tekla. Roof monitor feature was used to double check any water leakage issues.” 
Mr. Vasudev Rao, Director - Engineering, Zamil Steel 

Company overview

Established in 1977, Zamil Steel specializes in the design, fabrication and supply of Pre-Engineered steel Buildings (PEB). Over the past 44 years, it has grown from a local, single-division company into a leader in the growing field of steel fabrication in Asia, Africa and Europe. The company has supplied over 90,000 buildings to more than 90 countries worldwide, from Panama and Mexico in the West to the Philippines, China, Japan, Australia and South Korea in the east. In India, the company is headquartered at Kharadi, Pune.

Construction of the pre-engineered steel buildings for Hebbagodi metro depot in Bangalore

Pamika Commercial and Estates Pvt. Ltd. deputed Zamil Steel to construct the Hebbagodi metro depot for Bangalore Metro Rail Corporation (BMRCL) in Bangalore. The scope of the contract included the design and detailing, fabrication, supply and erection of pre-engineered steel buildings for metro depot with an area of 22,000 sqm., having 65M width x 171M length and a total tonnage of 1600MT.

Hebbagodi metro depot PEB project with manifold challenges

  • The customer’s requirement of having multiple functions such as repairing the metro bogies, internal cleaning of bogies, inspection bay for bogies & pit wheel lathe; under one roof was in itself a challenge
  • Co-ordination with other Civil, Mechanical, Electrical, Instrumentation departments was a daunting task. Further, the project had all non-standard purlin connections, non-standard roof monitor, nonstandard bracing arrangement making the execution even more complex.

The above challenges demanded the project to be executed in 3D environment only as each potential clash needed to be resolved in the design/detailing stage itself. In addition, as the metro rail bogie were to pass through the depot, the project team had to keep the way clear of any hindrance.

Choosing Tekla Structures for the successful delivery of the metro depot project in Bangalore

Considering the complexity and the need for coordination with all departments, the project team relied on Tekla Structures for the successful delivery of the metro depot project.

  • Tekla enabled the project execution team to import previously approved cross section and foundation drawings in Tekla as reference object. This import facility increased the modeling speed of the project.  In addition, the client’s equipment plan was also imported in Tekla to examine there are no clashes with another department’s structure.
  • Further models of reference Metro Rail bogie were built in Tekla to enable the project team to check bogie movement clashing, catwalk length and staircase access
  • Accurate, as-built 3D models generated on Tekla Structures enabled the team to have successful meetings with the Lead Design and Detailing team on project progress. The team could not only give real time update on the project but could also incorporate feedback immediately in the model itself. The Designer’s requirements were discussed and resolved on the spot thus speeding up the detailing cycle time and meeting the project schedule.
  • The project team followed the US detailing format of assembly drawing separate + single part drawing separate detailing. Using Tekla export NC file/DXF file the complex gusset plates were fabricated on CNC machine omitting the manual error chances. This helped ensure an efficient fabrication process thus reducing the overall fabrication time.
  • The project is a non-standard project and for clarity during the erection stage separate erection drawing as per erection sequence were generated. The GA drawing filer command speeded up the drawing filtering and erection process. The project team created separate GA drawings as per erection sequence that helped in erection activities such as the roof rafter drawing, purlin drawing, side wall bracing details drawings, platform joist arrangement drawing, chequered plate drawing, etc.
  • 3D IFC files were generated for the erection team. Also, Trimble Connect’s visualization capabilities facilitated the erection team to view the entire project enabling them to plan their erection sequence and material accordingly.  It also helped in crane location fixing. In addition, any gaps within the erection drawings could be easily rectified just by referring the Tekla IFC Trimble Connect model.