It was an unprecedented project together with Techint E&C due to the methodology required in its design and execution since it had to fulfill high-security standards and not interrupt the production line, which continued working while the construction was being carried out.
This is what the progress of the project looked like in July. The work was completed in December 2021.
Together with Techint E&C, we carried out the remodeling of the ceiling of the shed with Pickling in the Ensenada plant, which consisted of the dismantling and replacement of 3 spans (segments found between the columns) nearly 150 feet long and 100 feet wide in total, and 55 tons in weight. The renovated ceiling has a surface area of 1.350 m2 and 14 LED lamps were installed on top of the new structure which improved the lighting on the operating site.
Pickling is the stage of the process where rust and superficial impurities are removed from the sheet while it is hot rolling, preparing it to be prepared for cold rolling.
The constructability analysis of the project began in 2016, with meetings between Ternium’s Engineering department and the Metalworking Project team of Techint E&C, with the goal of designing a rigid platform that would allow the bracing of the ceiling in different points, allowing them to perform a safe and controlled dismantling while the production line continued to function below it.
During the bidding process, the Metalworking Project team of Techint E&C developed an innovative idea, together with scaffolding equipment supplying companies, which consisted in linking two types of catalog systems of the supplier. One was the beam system for bracing the shuttering of highway bridges with great spans and the other was the system used to raise de ceiling panels of sports stadiums
The linking of both systems created a work and scaffolding platform that could be moved, using the same runway as the cranes of the shed as its own track, which were locked at the entrance and the exit of the track at free disposal for carrying out the Pickling. This new approach gave the company a better position, making it more competitive when it became time to allocate the project.
The works on the shed began in March 2021 The magnitude of the aforementioned required strong early planification, logistic design, and security requirements which were developed in an articulated manner with Techint E&C, alongside the companies PERI (scaffoldings) and Tecmaco (cranes). Previously, several teams were analyzed in order to perform the three main maneuvers of hoisting the ceiling panels together with Tecmaco. The concept of “modularization” was applied to assemble the ceiling spans at ground level, with the greatest amount of completion possible, minimizing the job needed to be done up high.
“A project of these dimensions required a volume of 1.800 m3 from the scaffoldings with a security platform. The crane used to mount the structures counted with a capacity of 350 tons. 50 people were simultaneously involved in the work”, noted Fernando Aranciva, Construction Engineer of Ternium’s Department of Engineering and Environment. (DIMA).
“It’s the first time that a mobile structure has been designed with these features, with the ability to slide on skates fulfilling the double function of being a work platform and a bracing one, supporting an entire load of a ceiling panel. Due to the methodology of support and the novelty of the structure, it was an unprecedented job in Argentina, both to our company as well as to PERI”, highlights Leandro Ezcurra, Construction Manager of Techint E&C.
“Another aspect which is worth highlighting is that the plant’s production duties were able to continue taking place at the same time as the construction, with all the required measures and precautions. The reach of the design of Engineering included the mounting of a roof structure for the production line underneath the mobile platform, as a rigid barrier to prevent possible drops of the material and therefore being able to continue the maintenance work and the production of the line in a safe manner” explains Adrián Medicina, Maintenance Manager of Ternium in Ensenada.
“We worked with a lot of intensity since the preparation and the training of human resources; with specific meetings with all of the project members in each sequence that marked a change in risk, to be able to meet the risk prevention objectives”, highlights Gerardo Alcorta, Chief of CMASS of Techint E&C.
“We work hard when it comes to security aspects, thinking about all the risks as early as possible and contemplating the acquisition of the equipment and elements in the bidding phase which subsequently allowed for the safe development of the job. Due to the high complexity from a preventive standpoint, we performed periodical meetings with the highest echelons of Ternium and Techint E&C until everything was well thought out”, mentions Marcelo Janicki, Construction Manager of Techint E&C
“The work environment that was created was exceptional, achieving a great synergy between all the areas involved in the project. This was essential to progress in time and form, and to fulfill the proposed objectives satisfactorily”, emphasizes Carlos Alfaro, Metalworking Projects Manager of Techint E&C.