Hot dip galvanizing and the laboratory
Fabrication and plant
Galvanized steel, packed and despatched
Site work — civil, erection and installation
Installed and in service
The stores and the office
These are working photographs of the plant, not a studio shoot. Where people appear, they are in the protection the job calls for — helmet, gloves and high-visibility vest at the kettle and at the machines, face shield and gloves in the laboratory. Frames that did not meet that standard were left out rather than tidied up, and nothing here has been edited beyond cropping. If you want to see something that is not on this page, ask us — buyer visits, vendor audits and third-party inspections are welcome at Jangalpur.
Hot dip galvanizing and the laboratory
The kettle at Jangalpur, and the gauge and the bench that decide whether a batch is released. Galvanizing is done on our own floor — there is no sub-contractor in the chain.
The galvanizing lineJigged members on the line above the pre-treatment and galvanizing tanks. Degrease, pickle, flux, dip, quench — every batch takes the same route through the same 7 metre kettle.
Operators at the zinc kettleWorking the kettle at 450 °C. Helmets, high-visibility vests and gloves on the kettle floor; the lifting beam and jig are our own.
Reading the coating thicknessDry film thickness taken on galvanized cleats with a Coatmeasure M1 gauge, batch by batch, against IS 2629 and IS 4759. The standards set a minimum coating, not a ceiling — readings above our stated 75–85 µm band are normal on heavier sections.
Wet analysis in the laboratorySample preparation in the works laboratory, in face shield, gloves and coat. Our laboratory is not NABL-accredited; where a specification calls for NABL type-test reports we arrange that testing with an accredited laboratory against the order.
The spectrometer roomThe optical emission spectrometer sits in its own controlled room. Steel chemistry is checked here before a heat goes into production.
Fabrication and plant
Cutting, forming, pressing and grinding — what the steel passes through before it ever reaches the kettle.
CNC plasma cuttingProfile cutting on the CNC plasma table. Cutting to the drawing is where a tolerance is either held or lost, and everything downstream inherits it.
The cutting head at workThe plasma head following the programmed profile. Nesting is done from the drawing so offcut is minimised on long runs.
The press brake bayThe 80 tonne by 2500 mm CNC press brake. Both operators in helmet, high-visibility vest and gloves.
Hydraulic press — operator stationAn operator at the hydraulic press control station, in helmet and high-visibility vest.
Grinding a weldDressing a weld on a fabricated plate section. Helmet, eye protection and gloves; welding is to IS 816 and AWS D1.1, inspected to IS 822.
Fabricated frames in the shopA run of fabricated frames laid out in the shop before galvanizing. Volume work is set out in rows so the count and the mark numbers can be checked against the bill of materials.
Proto assembly in the yardA tower prototype assembled in the yard before release to production — the check that every member, gusset and hole in the drawing actually fits together.
Fabricated sections in marked baysFabricated tower sections held in numbered floor-marked bays, awaiting galvanizing. Housekeeping is what makes a mark number findable six weeks after it was cut.
Galvanized steel, packed and despatched
Sorted, bundled, crated and marked — the point at which an order stops being steel and becomes a consignment.
Galvanized poles and mountsGalvanized tubular poles with fabricated brackets, bundled in the yard. Line hardware is small and cheap; the coating is what decides how long it lasts on the line.
Galvanized angle and cleatsPunched and galvanized angle sections, banded into bundles. Steel to IS 2062, galvanized to IS 2629 and IS 4759.
Angle bundles on the paved yardGalvanized angle and flat sections bundled and stacked on the paved yard, sorted by section before loading.
Channels and angles, sortedGalvanized channels stacked behind the angles. Sections are kept separated by size so a part load can be picked without breaking every bundle.
Bundled members inside the shedGalvanized members bundled and laid out under cover, each bundle chalk-marked with the section and the quantity.
Bundled members on standsGalvanized members and poles bundled on stands in the yard. Stock is kept off the ground so the coating is not sitting in standing water.
Palletised channel membersGalvanized channel members stacked and palletised in the despatch yard at the end of the shift.
Channel members in the yardGalvanized channel members in the yard between galvanizing and despatch.
Tower base sectionsGalvanized tower base and leg sections. The bolt pattern, the gusset and the coating all come off the same floor.
Galvanized bracket assembliesBracket and cleat assemblies after galvanizing, waiting to be counted and bundled against the bill of materials.
Painted frames ready for despatchNot everything is galvanized. Painted fabricated frames, hessian-wrapped at the bearing faces, ready to load.
Closing a packing crateGalvanized cleats being loaded into a wooden crate, in helmet and gloves. Export consignments are packed, marked and documented to the buyer’s instructions.
Packing to the crate listPieces going into the crate against the packing list, so the count on the document is the count in the box.
Crated for despatchCrates packed and closed in the yard. The works is on NH-6, about 22 km from Kolkata Port.
Crates and loose members in the yardCrated and loose consignments in the despatch yard, marked up by order before loading.
Site work — civil, erection and installation
Since 2005 we have also taken tower work at site on a turnkey basis — foundation, erection, painting and the equipment that goes with it.
Foundation excavation and reinforcementExcavation and reinforcement for a tower foundation. Civil, erection and painting at site have been part of the offering since 2005.
Shuttering and pedestal castingShuttering set for the foundation pedestals, with the stub template held to level and line before the pour.
Equipment shelter on a finished baseThe equipment shelter and standby set installed on their cast plinths at a completed tower site.
Installed and in service
The same steel, some years on, doing the job it was fabricated for.
Telecom tower in serviceA lattice telecom tower in service, in aviation marking, carrying a microwave dish and its platform. We have manufactured telecom towers since 1995.
Rooftop telecom towerA rooftop tower in service. Hamilton poles have been supplied to the Department of Telecommunications since 1987.
Module mounting structures on siteGalvanized solar module mounting structures erected in the field, on cast foundations.
Steel channel sleepers on a bridge deckGalvanized steel channel sleepers bolted through to the girder on a bridge deck. We have manufactured steel channel sleepers for Indian Railways since 2001.
A track panel on channel sleepersRail laid and fastened on galvanized steel channel sleepers, gauge held by the fastening assembly at each seat.
The fastening assembly, close upThe galvanized fastening at a single sleeper seat. On a bridge deck the coating is the whole of the corrosion protection.
The stores and the office
The two parts of the works a buyer’s auditor asks to see, and the two most companies do not photograph.
The consumables storeBought-out components and consumables in the stores, each bay carded with the part number and quantity it holds.
The works conference roomThe management team at Jangalpur. Buyer visits, vendor qualification audits and third-party inspection by SGS, Bureau Veritas, TÜV, DNV or Intertek all start in this room.