The Problem
A tier-1 automotive supplier needed to install a new 12-tonne overhead crane on an existing production bay originally designed for 5-tonne cranes. The structural review showed inadequate capacity in 14 columns and 6 main beams supporting the crane runway.
The challenge: strengthen the structure without halting production in adjacent bays, and complete the work within the client's six-month line-installation window.
How We Approached It
After detailed structural analysis in collaboration with the client's design consultant, we specified a hybrid solution: carbon fiber wrapping for beams where section enlargement wasn't feasible, and concrete jacketing with rebar detailing and shear connectors for columns.
Execution was staged one column line at a time, with temporary crane rerouting and night shifts during the most critical column-strengthening operations. All work was completed while the surrounding facility remained operational.
Specification
- Beam strengthening: Mapei Carboplate E170 carbon fiber laminate, bonded with Mapei Adesilex PG1 structural epoxy
- Column jacketing: 75mm section enlargement with M40 grade concrete, 12mm main rebar at 150mm centres, 8mm stirrups at 100mm centres
- Shear connectors: 12mm headed studs at 300mm centres welded to existing column reinforcement
- Bonding agent: Fosroc Nitobond EP for new-to-old concrete interface
- Curing: Wet Hessian 7-day curing cycle per IS 456
The Result
The strengthening was completed on schedule, the new crane was installed and commissioned, and load testing confirmed the strengthened structure exceeds the 12-tonne design capacity with appropriate safety factors. Production throughput on adjacent lines was maintained throughout.
Need a structural upgrade?
Whether it's a crane load expansion, seismic retrofit, or column section enlargement, our engineering team can scope and execute the work without disrupting your operations.
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