QUALITY IS NOT AN END-GOAL; IT IS AN ON-GOING JOURNEY
435 KTPA Aluminium Smelter Expansion Project, BALCO, Korba
There is no magic formula to achieve and sustain Quality. It is all about rigorously following established processes to minimize errors, maximize quality, and ensure that every step is aligned to set high-quality standards. This is the formula that Project Head, Sanjay Saha and his team at the 435 KTPA Aluminium Smelter Expansion project for BALCO have adopted too and that they have succeeded in their effort is reflected in the project winning L&T Construction’s Quality Award 2024.
The team’s Quality process has found expression in the development of comprehensive project schedules and resource allocation plans, implementation of robust risk management & mitigation strategies, establishment of clear communication channels, stakeholder engagement protocols & continuous monitoring and improvement of project processes and procedures.
Our unwavering commitment to detailed quality checks, proactive issue identification, and strong communication with the entire team have ensured that every aspect of the build meets the highest standards resulting in a finished product that we are sure will exceed the expectations of both our customer and our management,” declares a confident Sanjay. The team’s Quality process has found expression in the development of comprehensive project schedules and resource allocation plans, implementation of robust risk management & mitigation strategies, establishment of clear communication channels, stakeholder engagement protocols & continuous monitoring and improvement of project processes and procedures.
“I have been driving project excellence in planning, coordination, and execution,” states Planning In-charge, Sujit Kumar Singh, “and as we progress with the project, I am committed to uphold the highest standards of quality, safety, and efficiency. Our team efforts have ensured seamless integration of various project components, resulting in timely completion of milestones and adherence to quality benchmarks,” he says, heaping praise on his team that has been performing
above par.
For a project that puts a premium on Quality, the Quality In-charge, V Balasubramanian (Bala), plays a key role. “Quality is not just an end goal, it is an ongoing journey that requires unwavering dedication from every team member, who have all demonstrated firm commitment to excellence,” he shares passionately. Attributing their success thus far to rigorous quality planning, inspection, and testing, he ticks off a few of their achievements like the implementation of robust quality control processes and procedures, conducting regular audits and inspections to identify areas for improvement, collaborating with cross-functional teams to resolve quality issues promptly, developing and delivering quality training programs to enhance team capabilities.
Sanjay, Sujit & Bala have been putting into practice what they preach and the Quality they refer to is evident in their project delivery.
Precision in pot shell assembly
To assemble pot shells, the team employed IS 2062 Grade 350 BR material, using semi-automated Gas Metal Arc Welding (GMAW) and Submerged Arc Welding (SAW) methods. “Of a total of 304 pot shells, 213 have been expertly produced, each weighing 56.607 MT, with rigorous specifications, that required a total weld length of 1.2 km per shell and a weld deposition of 0.8 MT, consisting of 507 detailed components,” explains Bala, adding that managing the welding distortion to ensure flatness called for both technical skill and a commitment to quality and craftsmanship, that has been roundly appreciated by their client.
Pot room civil works
The pot shell foundation, busbar columns, and precast column foundation demanded strict tolerance specifications (+0/-5 mm) that the team succeeded in achieving by optimizing their processes, with careful attention to detail, ensuring that each element integrated seamlessly into the overall structure.
Erecting precast columns & developing the RP-Slab casting machine foundation
“We set a benchmark within M&M by casting 704 numbers of 18-m tall precast columns, each weighing 28 MT, directly at site that reduced formwork costs and speeded up construction,” highlights Sujit. By using high early-strength cementitious (HES) grout, which sets in 6 hours compared to the traditional 24-hour grout, the project achieved significant time savings and improved productivity, effectively tripling output. Excavating a 24 m deep foundation pit for the RPslab casting machine foundation was tough, with operations hindered by lack of space. Implementing a 5-step sheet piling process to control water infiltration and avert soil failure, the team completed the works precisely and efficiently.
P&F Conveyor & Alumina Handling System
A new development was the introduction of the Power & Free conveyor system in the Anode Rodding Shop. An impressive 1,250 m overhead installation featuring a 960-m walkway, four loops, four drives, 150 carriers, and 110 stops, was efficiently erected, successfully tested and handed over to the Client. Another groundbreaking advancement was BALCO’s introduction of the Air Cushion Belt Conveyor, developed by Guiyang Aluminium Magnesium Design & Research Institute Co., Ltd. (GAMI) that replaced the conventional conveyor methods. “This innovative air cushion system, that marks a significant step forward in material handling, dramatically reduces friction and wear, while boosting efficiency and decreasing maintenance expenses,” points out Bala. The system spans 3.71 km and features 92 trestles, 12 transfer stations, 103 galleries, unloading stations, and three steel silos, each measuring 30 m in diameter and height.
Introduction of ACC Blocks
The team’s move to substitute conventional fly ash bricks with Autoclaved Aerated Concrete (ACC) blocks enhanced construction efficiency, minimised labour requirements and improved the overall quality of the buildings. “These blocks provide superior thermal insulation, reduce heat transfer and minimize energy consumption; their lightweight yet robust structure ensures reduced dead load on foundations and a more efficient structural design,” informs Sujit. ACC blocks are fire-resistant, non-toxic, pest resistant, and facilitate faster and more accurate construction.
Innovations like specialized Faraday cages for welding in high magnetic field areas and the Conquer Mobile App for real-time quality tracking have improved efficiency while modular erections reduce on-site construction time, minimize risks and ensure superior quality. Other tech solutions include real-time data analytics and documentation, Request-for-Inspection (RFI) processes and paperless observations on rework issues and resolutions.
Sustaining the workforce & vendors
To maintain the workforce at such a large-scale project, the administrative team provides essential services, including meals, snacks, mosquito control, routine medical checkups, and transportation to & from the labour colony. These initiatives have significantly improved workforce well-being, and in turn, project progress. Engaging with well-established vendors for prefabricated structures and bought-out components ensure that only high-quality resources are utilized, risks minimised, and project quality assured.
Site level Quality initiatives
Apart from stagewise inspections by field level inspectors & technicians, the team has checklists, work instructions, SOPs, internal quality review meetings, weekly reviews with BALCO, monthly Quality meetings with HQ teams, and daily checks and balances to ensure adherence to project specifications and standards. Continuous on-the-job training for employees & workers, recognizing ‘Quality Champs’, conducting regular walkdowns by the BALCO management & client representatives & frequent top management visits have ensured that Quality remains top of mind for all.
“By integrating these comprehensive quality initiatives, we are not only elevating project integrity but also fostering customer satisfaction by adhering to world-class quality standards,” says a determined Sanjay. “These measures serve as a blueprint for delivering durable, reliable, and value-driven construction projects.”