Key Takeaways and Challenges from Gold Plus Glass Industry Limited’s New Float Glass Manufacturing Plant

#### Key Takeaways:

1. Rapid Construction and Operational Efficiency:

- Gold Plus Glass Industry Limited partnered with EPACK PREFAB to construct a state-of-the-art Float Glass Manufacturing Plant within a stringent timeframe of 5 months.

- The project emphasized not just speed but also operational efficiency, aiming for seamless production processes and optimal use of resources.

2. Architectural and Engineering Excellence:

- The project featured sophisticated architectural designs by China Triumph International Engineering Co. Ltd. Shanghai, China.

- The construction included advanced features like a 350-meter crane beam, a heavily designed monitor for ventilation, a large valley gutter for efficient water drainage, and multi-legged pipe V-type bracings for stability.

3. Innovative Design Features:

- The plant design incorporated a dual sag rod system to prevent sagging in both the roof and walls.

- Continuous strut pipes and shear keys in the column base plates were implemented to enhance the building’s stability.

4. Effective Project Management:

- EPACK PREFAB ensured a streamlined approach to procurement, delivery, logistics, and inventory management.

- The project team coordinated closely with the production team to maintain smooth operations and adherence to quality standards.

5. Commitment to Safety:

- Rigorous safety measures, including training, daily inspections, and strict adherence to protocols, resulted in zero accidents and lost time injuries throughout the project.

#### Challenges:

1. Stringent Timeline Requirements:

- Completing the project within a narrow 5-month window required meticulous planning and execution. Maintaining daily productivity targets was crucial to meeting the deadlines.

2. High Daily Productivity Targets:

- With a total tonnage of approximately 6600 MT, achieving a daily erection rate of 90 MT and a daily sheeting works target of 3000 sqm was imperative. This required sustained high productivity and efficient resource allocation.

3. Seasonal Constraints:

- The project coincided with the peak monsoon and crop harvesting season, complicating labor availability. The scarcity of skilled labor during this period necessitated strategic management to avoid delays.

#### Solutions:

1. Parallel Erection in Modules:

- To meet the project schedule, work was divided into four modules, allowing simultaneous progress on multiple fronts. Extended work hours and concurrent erection of secondary members helped maintain structural stability and efficient time utilization.

2. Dedicated Teams and Equipment:

- Separate teams of engineers, safety officers, and quality engineers, along with strategically allocated equipment, enhanced coordination and resource utilization. This segregation ensured focused efforts on productivity targets without compromising quality or safety.

3. Dual Shift System for Sheeting:

- Introducing a dual shift system for the sheeting team maximized productivity and minimized downtime. One team provided sheets at height, while another shifted them to the fixing location.

4. Optimized Logistics with Pre-Punched Marking System:

- The logistics team used a pre-punched marking system to streamline material handling, ensuring precise unloading and stocking of materials. A dedicated logistics team at the site managed operations seamlessly, further boosting productivity.

#### Achievements:

- Despite facing several challenges, the project was delivered on time, demonstrating EPACK PREFAB's commitment to excellence, efficiency, and expertise in Pre-Engineered Building construction.

- The collaboration between Gold Plus Glass Industry Limited and EPACK PREFAB resulted in a successful project that met its objectives of operational efficiency and safety.