Dahej Special Economic Zone Chemical Process Plant
Trans-India Chemicals & Polymers Ltd — Dahej SEZ, Bharuch, Gujarat
High-Performance Structural Engineering
A high-tonnage structural steel project comprising multi-tier reactor support towers, 800m of multi-level inter-unit pipe racks, and a heavy machinery processing building designed for aggressive coastal marine and chemical environments.
The Requirement
Extreme corrosion protection against acidic vapor emissions and coastal salt spray, combined with heavy static and dynamic equipment loading up to 4,500 kg/m² on multi-level processing platforms.
Engineering Challenge
Managing complex dynamic torsional stresses from operating reactors, centrifuges, and vibrating screens while meeting stringent EN 1090-2 EXC3 fabrication and third-party inspection standards.
Engineered Structural Steel Strategy
Heavy built-up cruciform and box columns with heavy gusseted moment connections. All structural steel is treated with 100-micron hot-dip galvanizing and high-build polyamine cured coal-tar epoxy topcoats.
Design Details
- • Dynamic frequency analysis avoiding resonance with variable-speed industrial centrifuges
- • Multi-level pipe bridge modular units designed for fast tandem crane hoisting
- • Stainless steel 316 grade connection fasteners in high-corrosion zones
Fabrication
- • 100% Radiographic and Ultrasonic weld testing inspected by Bureau Veritas
- • Full trial assembly of complex 3D pipe rack intersection nodes at factory
- • Heavy steel plate cutting up to 65mm thickness on CNC plasma tables
Erection
- • Phased erection with zero disruption to adjacent active chemical operating lines
- • Specialized rigging using 150T mobile crawler cranes with computer-controlled load cells
- • Strict compliance with chemical plant work permit and zero-spark safety rules
Structural Metrics
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