The Solvent Extraction Plant building is a steel structure measuring 46.4m x 66.4m and rising six storeys high, with the deodouriser section extending two additional floors. The design prioritised efficiency, safety, and flexibility, which are essential for industrial buildings. Steel was chosen as the primary material over reinforced concrete (RCC) due to its quicker construction timeline and adaptability, crucial in process plants where changes are frequent.
One of the main challenges arose when the client initially wanted the building fabricated in India but later opted for local fabrication in Nigeria. Concerns about the fabrication practices in Nigeria were addressed by appointing an independent quality consultant who ensured high standards. Due to the unavailability of certain sections, equivalent sections were fabricated using plates, and the design adhered strictly to Euro Codes.
Innovative steel design and construction techniques played a significant role in the project’s success. The structure was planned for assembly at the site in a knocked-down condition, with transportability carefully considered. The structural members were coated with high-quality epoxy to withstand chemical vapours present in the plant environment. Load data from the client and vendor supported the development of a STAAD model, which accounted for fixed column bases, applied loads, and platform live loads. Cross braces were strategically placed for improved stability, while industrial louvres were included to enhance cross ventilation.
The structural design involved meticulous planning, with detailed member parts and assembly drawings created for fabrication. The entire structure was analysed for strength and serviceability using multiple load combinations as per Euro Codes. An iterative approach was employed to optimise member sections while minimising inventory and reducing wastage. For service areas, a combination of gratings and chequered plates was used, and service hatches and railings were included as per safety standards.
The erection procedure was carefully coordinated with all stakeholders, and the shipping list was prepared to account for transportation limitations. Splices were strategically proposed, and hand railing connection details were meticulously incorporated to ensure precision and structural integrity.
“At a few locations, the equipment layout was changed and so the loading changed. This loading was considerably higher. Our team had to do a re-analysis, modify the Tekla Model and extract afresh the DWGs. This last-minute change put the team under enormous pressure. The client would request for RCC slab over some parts (for ex. In the electrical panel room) and our team had to submit details on priority. Though it was a deviation from the initial design, we had to support in interest of the project requirement. The cross bracings which were approved in the initial stages were objected to at two locations (fouling issue) at the time of final detailing (an afterthought for the process consultant) but accordingly, corrections were required to be made. However, all in all, it was a great feeling to have worked in a foreign country.”
– Suneel Voditel, Technical Director, Techture Structures Pvt Ltd
