Our Engineering Process
Our process emphasizes engineering collaboration, detailed 3D CAD modeling, structural prototyping, and rigorous non-destructive testing before dispatch.
Design & Finite Element Modeling
Our design office uses advanced structural CAD software to calculate wind gust reactions, dynamic oscillation frequencies, deflection tolerances, and anchor bolt shearing stresses based on IS 875 wind velocity zones across India.
Certified Prime Steel Procurement
We source heavy-gauge structural plates directly from primary integrated mills (SAIL, JSW, Tata Steel) conforming to IS 2062 Grade E250 / E350. Each plate bundle is checked for silicon content to ensure optimal zinc adhesion during galvanizing.
CNC Plasma Cutting & Hydraulic Press Bending
Plates are precisely profile-cut using automated CNC torches into trapezoidal segments. The flat plates are then progressively cold-folded on tandem hydraulic press brakes into octagonal, polygonal, or conical hollow shafts.
Automated Seam Welding & Base Flanging
The open polygonal seam is joined utilizing automated submerged arc welding (SAW) machines ensuring deep root penetration and clean aesthetic beads. Base plates are welded using multi-pass CO2/MIG welding with reinforced gussets.
Hot-Dip Galvanizing & Acid Pickling
Poles and trays undergo a 7-stage chemical cleansing (degreasing, water rinse, hydrochloric acid pickling, rinsing, and pre-fluxing) before being immersed into molten zinc at 450°C to create an iron-zinc alloy metallurgical barrier.
Inspection, Bundling & Safe Logistics
Final QA clearance involves testing coating thickness (minimum 65 to 86 microns), thread inspection of door bolts, and balance checking. Poles are wrapped in high-density polyethylene packing before dispatch.
Have Custom Project Requirements?
Our engineering cell can review your customized BOQ or tender requirements.