Designing Steel Platforms for Industrial Excellence

Introduction Yas Tech services excel in designing steel platforms for commercial and industrial applications, delivering tailored solutions that enhance operational efficiency and safety. Our expertise spans various platform types, including milling platforms, storage platforms, and access platforms, serving industries such as manufacturing and automotive. This case study focuses on our design of a milling platform for a leading automotive parts manufacturer in Germany, highlighting our ability to address complex technical challenges and comply with stringent European regulations. Project Scope The project involved designing a steel platform to support advanced milling equipment for a German automotive parts manufacturer. The platform, integrated into an existing production facility, needed to ensure stability for heavy machinery, accommodate dynamic loads, and provide safe access for operators and maintenance personnel. Additional industrial platforms were designed for similar European clients, supporting diverse manufacturing processes. The designs adhered to Eurocodes and local building codes, ensuring safety and durability. Technical Challenges The project presented several technical challenges: 1. Load and Vibration Management: The milling platform had to support heavy equipment (up to 20 tons) and withstand vibrations from high-speed milling operations, which could affect precision and structural integrity. 2. Spatial Constraints: The platform needed to fit within the existing facility’s limited footprint, requiring precise coordination with the building’s layout. 3. Accessibility and Safety: Safe access for operators and maintenance, including walkways and handrails, was essential to meet workplace safety standards. 4. Regulatory Compliance: Designs had to comply with EN 1993 for steel structures and EN 1991 for load actions, alongside German safety regulations for industrial facilities. 5. Vibration Control: Minimizing vibration transmission to ensure milling precision required specialized engineering solutions. Regulatory and Industry Norms Compliance with European standards was paramount. We adhered to EN 1993 for steel structure design, ensuring material strength and stability, and EN 1991 for load calculations, including dead, live, and dynamic loads. Local German building codes mandated additional safety features, such as non-slip surfaces and emergency access points. Industry norms for milling operations, as outlined by manufacturing standards, emphasized vibration control and equipment stability to maintain production quality. Software Utilized Our team leveraged advanced software to deliver precise and compliant designs: • Tekla Structures: Enabled 3D modelling, Detailing and clash detection, ensuring seamless integration with the facility. • SAP2000: Used for structural analysis, simulating static and dynamic loads, including vibrations. • IDEA StatiCa: Facilitated robust connection design, critical for load transfer and durability. These tools streamlined design, analysis, and documentation, ensuring accuracy and efficiency. Solutions and Approach Our approach combined technical expertise with client collaboration: • Vibration Mitigation: We incorporated vibration-dampening mounts and conducted detailed analysis using SAP2000 to ensure milling precision, aligning with industry practices for high-precision manufacturing. • Structural Design: The platform featured reinforced steel beams and columns, designed with Tekla Structures to handle heavy loads. IDEA StatiCa ensured secure connections. • Safety Features: Walkways, guardrails, and non-slip surfaces were integrated to meet safety regulations, enhancing operator safety. • Regulatory Compliance: We conducted thorough reviews to ensure compliance with Eurocodes and local codes, coordinating with authorities for approvals. • Client Coordination: Close collaboration with the client’s team ensured the platform aligned with operational needs and facility constraints. Project Outcomes The milling platform was successfully designed, fabricated, and installed, delivering significant benefits: • Stability and Precision: The platform provided a robust foundation, minimizing vibrations and ensuring high-precision milling. • Enhanced Safety: Safety features reduced workplace risks, earning positive feedback from operators. • Operational Efficiency: Easy access for maintenance reduced downtime, boosting productivity. • Regulatory Adherence: Full compliance with EN 1993 and EN 1991 ensured regulatory approval and long-term reliability. The project was completed on time and within budget, with the client praising the platform’s quality and seamless integration. Similar successes with other industrial platforms for European clients further demonstrate our versatility. Conclusion Yas Tech Services is a trusted partner for designing steel platforms that meet the rigorous demands of industrial applications. Our expertise in addressing technical challenges, such as load management and vibration control, combined with our use of advanced software like Tekla Structures, SAP2000, and IDEA StatiCa, ensures exceptional outcomes. By adhering to Eurocodes and industry norms, we deliver safe, efficient, and compliant solutions that drive client success in manufacturing and beyond.