Cutting & shearing
CNC Plasma Cutting Machine
Cuts webs, flanges, stiffeners and gusset plates from plate to the nested CNC programme.
- Operation
- Automatic, CNC
- Cutting thickness
- 20 mm recommended, 32 mm piercing
- Bed size
- 4,000 mm × 15,500 mm
Manufacturing
The works
One roof, every process.
Every DSI building is made under one roof at Chhattar, on the Rajkot–Morbi highway: plate in at one end, numbered, painted members out at the other, from a 15,000 square metre works with a fully enclosed, automated production line.
Work done under a roof is work that can be measured. Plate is cut on CNC plasma and shears, built-up sections are welded on an automatic pull-through line, holes are drilled and punched to the detailing model, and every member is shot-blasted and primed before it is bundled for the erection sequence. Purlins, girts, roof and wall sheet, standing seam panels and deck sheet are roll-formed on the same floor, so the frame and its skin leave together.
The shop runs to management systems certified by TÜV SÜD for quality, environment and safety, with inspection hold points recorded against every mark number. What follows is the capacity, the certifications and the machines, one by one.
Annual Fabrication Capacity
15,000MT
Fully enclosed, automated production line
Manufacturing Facility
15,000Sq. Mt.
At Chhattar, Rajkot
Established
2018
8+ years of building
Projects Delivered
230+
Since 2018
Process
From plate to dispatch.
Nine things the shop does to every building, in the order they happen on the floor.
- 01
CNC Cutting
Profile and plate cutting to drawing geometry, with nesting to reduce offcut.
- 02
CNC Drilling
Hole positions driven from the detailing model so bolt groups line up at assembly.
- 03
Automatic Welding
Submerged-arc welding of built-up sections for consistent, repeatable weld profiles.
- 04
Built-Up Section Fabrication
Tapered I-sections assembled from plate so depth follows the bending moment diagram.
- 05
Surface Preparation
Blast cleaning to the specified surface profile before any coating is applied.
- 06
Coating & Painting
Primer and finish systems selected for the operating environment, with film thickness recorded.
- 07
Quality Inspection
Dimensional and weld inspection at fixed hold points, documented against each mark.
- 08
Material Handling
Crane-served bays and staging areas that keep members moving through the shop in sequence.
- 09
Dispatch Management
Bundling and loading planned around the erection sequence, not around truck convenience.
Certifications
Three systems, certified by TÜV SÜD.
Quality, environment and safety, each run as a management system that is audited by an independent body. The certificates themselves are below.
- Certified scope
- Manufacturing and supply of pre-engineered building and fabricated steel structure
- Validity
- to Subject to successful completion of annual periodic audits
- Certification body
- TÜV SÜD South Asia Private Limited
ISO 9001:2015
Quality management system
Certified by TÜV SÜD
The international standard for a quality management system: a documented way of working that starts from what the customer needs, controls every process that delivers it, checks the result, and corrects the process when something goes wrong.
What the standard requires
- Documented procedures from enquiry to handover, with responsibilities fixed
- Control of design, purchasing, production and inspection as defined processes
- Traceability of material and records against each order
- Internal audits, management review and corrective action
- Measurement of customer satisfaction and continual improvement
How it works on the DSI floor
- Incoming plate and sections are checked against mill certificates and the material schedule
- Six inspection hold points on every member: material, dimensions, welds, blast profile, coating thickness and final release
- Measuring instruments are calibrated and records are kept by mark number
- Non-conformances are recorded, contained and closed with a corrective action
ISO 14001:2015
Environmental management system
Certified by TÜV SÜD
The standard for managing the environmental impact of an operation: identifying where the work touches air, water, land and resources, meeting the law that applies, setting objectives to do better, and proving it with records.
What the standard requires
- Identification of environmental aspects and their impacts
- Compliance with applicable environmental law and permits
- Objectives, controls and monitoring for waste, emissions and resource use
- Emergency preparedness for spills and releases
- Audits, management review and continual improvement
How it works on the DSI floor
- Plate is nested on the CNC cutter to cut offcut, and steel scrap is segregated and recycled
- Abrasive is reclaimed inside the enclosed shot-blast machine rather than blown into the yard
- Paints, solvents and their containers are stored, used and disposed of under control
- Energy and water use are monitored against targets
ISO 45001:2018
Occupational health and safety management system
Certified by TÜV SÜD
The standard for keeping people safe at work: finding the hazards in every task, reducing the risk before the work starts, involving the workers themselves, and learning from every incident and near miss.
What the standard requires
- Hazard identification and risk assessment for every activity
- Worker consultation and participation in safety decisions
- Operational controls, permits and emergency plans
- Training and competence for the task in hand
- Incident investigation, audits and continual improvement
How it works on the DSI floor
- PPE is standard in the shop and on site: helmets, eye protection, harnesses at height and safety footwear
- Lifting plans, exclusion zones and temporary bracing are agreed before a member leaves the ground
- Machine guarding, hot-work control and fume and dust management on the cutting, welding and blasting lines
- Every crew is briefed on the method statement for the work in front of it
Six hold points on every member
The quality system in practice: a member does not move to the next stage until the check for the last one is recorded against its mark number.
Material Inspection
Incoming plate and sections checked against mill documentation and the material schedule.
Dimensional Accuracy
Member length, depth, camber and hole position verified against the shop drawing.
Welding Quality
Weld size, profile and continuity inspected; procedures and welders qualified to the project specification.
Surface Preparation
Blast profile and cleanliness confirmed before coating is applied.
Coating Inspection
Dry film thickness measured and recorded across each coated member.
Final Quality Check
Fit-up, marking and completeness verified against the packing list before release.
Plant & machinery
Machines on the floor.
Cutting & shearing
CNC Shearing Machine
Straight cuts in plate and sheet to programmed length, for flange strips, cleats and flashings.
- Operation
- Automatic, CNC
- Cutting length
- 6 m
- Thickness
- Up to 20 mm
- 3 units
Cutting & shearing
Shearing Machines
Three semi-automatic shears for lighter plate, sheet and trim, sized so the CNC shear is kept for heavy work.
- Operation
- Semi-automatic
- Cutting lengths
- 3 m, 3 m and 1 m
- Thickness
- 14 mm, 4 mm and 12 mm
3 units on the floor
- 3 m × 14 mm
- 3 m × 4 mm
- 1 m × 12 mm
Bending & pressing
CNC Press Brake
Bends sheet into flashings, trims, closures, gutters and brackets to the programmed angle.
- Operation
- Automatic, CNC
- Capacity
- 80 tonnes
- Sheet thickness
- 0.5 mm to 3 mm
Bending & pressing
Mechanical Power Press
Presses and blanks small fittings, cleats and washers in volume.
- Operation
- Manual
- Capacity
- 150 tonnes
- 3 units
Drilling, punching & threading
Hydraulic Punching Machines
Punches bolt holes and slots in cleats, plates and cold-formed sections faster than drilling.
- Operation
- Semi-automatic
- Capacities
- 240, 100 and 60 tonnes
- Tooling
- Single punch, four-punch and slot
3 units on the floor
- Punch hole, 240 tonnes
- Four-punch hole, 60 tonnes
- Slot hole, 100 tonnes
- 2 units
Drilling, punching & threading
Radial Drill Machines
Drills bolt holes in end plates, base plates and flanges where punching is not suitable.
- Operation
- Semi-automatic
- Hole diameter
- Up to 50 mm
- Bed and reach
- 1 m × 1 m bed, 1 mm to 600 mm thickness
2 units on the floor
Drilling, punching & threading
Hydraulic Thread Rolling Machine
Rolls threads on sag rods, bracing rods and anchor bolts, which are stronger than cut threads.
- Operation
- Semi-automatic
- Rod diameter
- 10 mm to 12 mm
Welding
PHI Pull-Through Automatic Welding Line
Welds web to flanges on built-up tapered sections in one continuous pass, both sides at once.
- Operation
- Semi-automatic
- Travel speed
- 0.5 to 1.8 m/min
- Welding power
- 90 kVA
- 13 units
Welding
MIG Welding Sets
Fit-up, stiffeners, end plates, cleats and every weld the automatic line does not reach.
- Operation
- Manual, three-phase
- Rating
- 10 kVA
- Travel speed
- Up to about 1 m/min
13 units on the floor
Surface preparation
Shot Blasting Machine
Blasts every member to the specified surface profile before the primer goes on.
- Operation
- Automatic
- Conveyor speed
- 0.5 to 5 m/min
- Abrasive throughput
- 2,400 to 4,000 lb/min
- Air volume
- 18,000 m³/h
Roll forming
C/Z Purlin Roll Forming Machine
Forms the cold-formed Z and C purlins and girts that span between the frames.
- Operation
- Automatic
- Material thickness
- Up to 2.5 mm
Roll forming
Roof & Wall Sheet Forming Machine
Roll-forms the trapezoidal roof and wall sheet from coil, in single lengths to order.
- Operation
- Automatic
- Sheet thickness
- 0.6 mm
Roll forming
Standing Seam Roll Forming Machine
Forms the clip-fixed standing seam roof panel with no fastener through the sheet.
- Operation
- Automatic
- Sheet thickness
- 0.6 mm
Roll forming
Deck Sheet Forming Machine
Forms the profiled deck sheet that carries the concrete slab on a mezzanine floor.
- Operation
- Automatic
- Sheet thickness
- 1.6 mm
Next step
See the works for yourself.
Clients and consultants are welcome at Chhattar to walk the floor and see their steel being made. Ask for a visit, or send us the building and we will send you the programme.
Survey No. 169/P4/P1, At, Rajkot - Morbi Hwy, Chhattar, Gujarat 363650