MANUFACTURED CAPITAL

To fulfil the growing requirement for superior quality structures, we have established The Manufacturing Unit (TMU) in Nagpur. A key pillar of our manufactured capital, the facility reiterates our commitment to sustainability and deploys advanced technology for developing superior quality structures.

Building Resilient Structures

With a focus on quality, safety and innovation, the state-of-the-art facility reflects our focus on excellence. It produces superior-quality transmission towers and structural steel fabrication products, and has cutting-edge galvanisation, shot blasting and painting facilities.

Key Highlights of FY2025

₹95.40 Cr

Value of Manufactured Capital

₹55 Cr

Investment in New and Upgraded Assets

83%

Capacity Utilisation

48 KTA

Galvanising Capacity

26%

Productivity Per Unit of Capital

36 KTA

Tower Manufacturing Capacity

₹422 Cr

Material Costs

12 KTA

Structural Steel Fabrication Facility

Waste Reduction and Recycling: TMU in Nagpur deploys quality checks at every stage of raw material procurement and the manufacturing process to optimise resource utilisation. We also strive to reduce scrap generation at the facility and recycle material off-cuts generated during the manufacturing process. In FY2026, we intend to maximise efforts for reducing scrap and surplus from our production process. TMU also has an ETP setup for handling waste generated from the galvanisation facility.

These efforts are not only expected to drive our sustainability agenda but also have an impact on the Company’s bottom line as well.

Leading with
Industry‑best Practices
JSOL Angul

Increase in Productivity through Flux-cored Arc Welding

To expedite welding in Coke Oven expansion projects without increasing cost or compromising quality, the project site team resorted to the use of Flux-cored Arc Welding (FCAW) in place of Shielded Metal Arc Welding (SMAW).

Benefits

  • Productivity increased from 2.40 to 2.65 units in comparison to SMAW
  • High deposition rate with improved quality
  • Relatively low metal wastage (Filler Wire)
  • Provides excellent weld penetration
  • Enables welding in all positions with the right filler metal
  • FCAW welding process is cost-effective in comparison to SMAW

Useful for

  • Coke oven expansion projects, fabrication and welding work
ONGC Kakinada

Waterproofing Improvements through HDPE Membrane Installations

Waterproofing is essential for the construction of fluidretaining structures like tanks, and workmanship significantly influences water-proofing quality. High-density polyethylene (HDPE) membranes are readily available in the market in various sizes. However, in-situ installation of HDPE membrane is prone to leakages due to poor quality of stitches. To solve this issue, HDPE membrane was fabricated at our factories, according to specific requirements for our project. The customised membrane was brought to the site and directly laid at the bottom of the tank.

Benefits

  • Ease of execution
  • Improved quality of work
  • Better client acceptance

Useful for

  • Projects aiming to minimise the risk of leakage from tanks
FGD Mundra

Improved Quality through Cement-Sand- Fly Ash Slurry Filling

Slurry filling using boom placers was found to be beneficial for backfilling structures, especially in non-approachable locations for components like Absorbers inside compartments and for congested areas between structures. This method proved to be effective in terms of ease of working, time and cost savings.

Benefits

  • Specialised technique offering several advantages, including efficiency, cost‑effectiveness, improved quality and versatility

Useful for

  • All places where space constraint is an issue due to its congested design
  • Infrastructure projects such as foundations, tunnels, roads, bridges and embankments
  • Projects requiring slope stabilisation and void filling
400 kV D/C Gonda Tonda

Enhanced Engineering through Advanced Boring Technique for High Water Table Region

Substructure work in high water table areas consistently presents a challenge. The 400 kV D/C Gonda Tonda project encountered significant seepage issues due to the high water table in the region. Boring was used for foundations with depths of 3 m and 3.5 m. This method involved deployment of horizontal and vertical pipes for dewatering during the boring process to keep the water level manageable.

Benefits

  • Ensured timely completion of substructure work on a critical stretch
  • Prevented cost escalation due to changes in boring method
  • Resulted in timely and cost‑effective performance

Useful for

  • All substructure works where there is a risk of high water table
National Maritime Heritage Complex Gujarat
ONGC Kakinada
765 kV D/C Narendra Pune TL (PKG III)

Biodiversity Conservation through the Deployment of Innovative Stringing Method

In Transmission Line projects, landowners often do not allow access to their land (Right of Way), leading to project delays. Stringing activity under such circumstances requires an innovative approach. The project team plans to use drones for stringing activities, and it is expected to be implemented in the Narendra Pune TL transmission project.

Benefits

  • Faster construction
  • Cost savings
  • Timely project completion

Useful for

  • Any project with ROW access constraints, shutdown issues and delays during stringing activities
765 kV Khavda IIIA

Improved Durability of Towers through the Use of Thread Locking Adhesive

In Transmission and Distribution (T&D) tower erection works, there is an inherent risk of corrosion at welding joints and painting is a time-consuming and costly activity. To mitigate this risk, we utilised thread locking adhesive instead of tack welding and painting in the Transmission line tower.

Benefits

  • The use of the adhesive prevents rust and damage of galvanisation due to tack welding
  • It also saves the painting cost

Project Teams that can benefit:

  • T&D projects
IOCL Gujarat Refinery

Vermiculite-based Fireproofing

Vermiculite-based cement is excellent for fireproofing structures and equipment, providing good bonding and superior properties compared to manual techniques. Vermiculite offers high-degree of fire protection, particularly in hydrocarbon industries, due to its low density and impressive insulation properties that make it a useful material, potentially leading to significant savings in steel weight. It is also more fire resistant and possesses heat and sound insulating properties, which make it better than conventional concrete.

Benefits

  • Useful for processes involving high-temperature and flammable materials, ensuring safety
  • Utilises specialised materials and meets regulatory guidelines
  • Maintains stability of the structure during fire and allows occupants to evacuate without fear of a building collapse

Useful for

  • Operation team, Maintenance team and Fire and Safety team of all OGH projects
Pune Metro Line 03

Increased Productivity through Specialised Precast Launching Girder

Due to space constraints for segment erection in metro projects, an innovative solution was required. We designed and fabricated a precast launching girder. This specialised equipment is used for precast girder launching for metro stations, even when construction is carried out in heavy traffic conditions.

Benefits

  • Productivity of girder erection increased by 50%
  • Manpower cost was reduced by 48%

Useful for

  • All metro project sites
Hyderabad Data Centre

Enhanced Equipment Lifetime and Project Timelines through Material Preservation Plans

A material preservation plan for electrical and mechanical equipment and panels helps expedite projects. Through regular maintenance, equipment lifespan can be extended.

Benefits

  • Prevents costly repairs and reduces downtime
  • Lowers risk of accidents and improves safety
  • Boosts performance and enhances productivity
  • Ensures compliance with industry standards and regulations
  • Retains asset value and can be useful for resale or upgrades

Useful for

  • Data centre projects
Chennai Metro UG 06

Value Engineering of Foundation Design

During the excavation phase, the team planned to optimise the construction process through value engineering. The initial design involved the use of sheet piles based on approved drawings. However, a detailed assessment of site conditions indicated that open excavation would be more effective. The proposed plan was accepted by the client and it not only enhanced productivity but also resulted in a cost saving of ₹55.58 Lakh.

Benefits

  • Increased productivity
  • On-time completion of work

Useful for

  • Metro underground projects
Chennai Metro UG 06

Expediting D-wall Construction

Typically, D-wall construction involves the use of a grab and trench cutter, particularly when working on rocky areas. However, after a thorough analysis of the soil data, the team adopted an alternative approach by combining a grab with a piling rig to cut through rock and remove debris. It helped accelerate the construction timeline and reduced unit cost associated with the D-wall work.

Benefits

  • Cost benefit

Project Teams that can Benefit:

  • Metro underground projects
Chennai Metro UG 06

Value Engineering of Foundation Design

During the excavation phase, the team planned to optimise the construction process through value engineering. The initial design involved the use of sheet piles based on approved drawings. However, a detailed assessment of site conditions indicated that open excavation would be more effective. The proposed plan was accepted by the client and it not only enhanced productivity but also resulted in a cost saving of ₹55.58 Lakh.

Benefits

  • Increased productivity
  • On-time completion of work

Useful for

  • Metro underground projects
Drone Stringing