01
Structural
Global and local analysis, stage-by-stage launch modelling, fatigue assessment on reusable equipment, connection design to limit state.
- STAAD.Pro
- MIDAS Civil
- SAP2000
- ANSYS
- IDEA StatiCa
Engineering
The method is the product.
A gantry is a lump of steel until somebody has proved it can put a span up in three days on your alignment, in your possession windows, with your crew. That proof is the thing IBEC actually sells. The steel is how we honour it.
- Engineers on staff
- 140
- Design centre
- Hyderabad
- Independent check
- Category III
- Disciplines
- 06
04How we work
The method is the product.
A gantry is a lump of steel until somebody has proved it can put a span up in three days on your alignment, in your possession windows, with your crew. That proof is the thing IBEC actually sells. The steel is how we honour it.
- 011 – 3 weeks
Method study
Before anything is priced, we work out how the structure gets built and what that costs in days.
We take the general arrangement, the span table, the site constraints and the programme, and produce two or three viable erection methods with an honest cycle time against each. Most of the value in a temporary works package is decided here — a method that saves a day a span across 180 spans is worth more than any discount on the steel.
Deliverables
- Comparative method statement, 2 – 3 options
- Cycle-time model per option
- Preliminary equipment schedule
- Programme impact and risk register
- 023 – 6 weeks
Scheme design
The chosen method becomes a machine: geometry, loads, load paths, reactions handed back to the permanent works designer.
Global analysis is built in the frame model at the same time as the erection sequence, so every stage of the launch is a load case rather than an afterthought. The reactions that the temporary works will impose on piers, pier caps and the deck are issued to the permanent works designer early enough for them to matter.
Deliverables
- General arrangement drawings
- Global structural model and stage analysis
- Reaction schedule to the permanent works designer
- Interface drawings for pier brackets and supports
- 036 – 12 weeks
Detailed design & independent check
Every member, connection, pin, cylinder and control interlock is designed, then checked by an engineer who did not design it.
Detailed design covers the structure, the mechanical systems, the hydraulics and the control logic together. A category III independent check is run in parallel by an engineer outside the project team, working from the brief rather than from the design, in line with BS 5975 practice. Nothing is released for fabrication until the check certificate is signed.
Deliverables
- Full calculation package
- Category III independent check certificate
- Fabrication drawings and weld procedures
- Hydraulic and electrical schematics
- 0412 – 24 weeks
Manufacture & trial assembly
Built at our own works, assembled complete, surveyed against the model and function-tested before it is allowed on a truck.
Material is traced from mill certificate to erected piece. The machine is assembled in the works to the extent the bay allows, dimensionally surveyed against the design model, and put through a full functional test of its hydraulics and controls with the client present. Problems found here cost hours; the same problems found on site cost weeks.
Deliverables
- Material traceability and test certificates
- Trial assembly dimensional survey report
- Functional test record, witnessed
- Erection, operation and maintenance manuals
- 05First 3 spans
Commissioning & site support
Our crew erects it, load tests it, runs the first spans with your team and stays until the cycle time is being hit.
IBEC supervisors run the first three erection cycles alongside the contractor crew, then hand over against a written competence check. A load test with instrumented deflection measurement is performed before the first production span. Spares and a response commitment follow the machine for the life of the contract.
Deliverables
- Erection and commissioning record
- Instrumented load test report
- Operator training and competence sign-off
- Spares schedule and support agreement
05Disciplines
Structure, mechanics, hydraulics, controls — one office.
A launching gantry is not a structure with a motor bolted to it. Splitting the disciplines across suppliers is how the interfaces get missed, so we do not split them.
02
Mechanical & hydraulic
Winches, cylinders, power packs, pin joints and bearings, sized against the duty cycle rather than the peak load alone.
- SolidWorks
- Automation Studio
- Inventor
03
Controls & instrumentation
PLC control of synchronised lifting and launching, with interlocks, load monitoring and an event log that survives a power loss.
- Siemens TIA
- HMI/SCADA
- Load cell arrays
04
Geometry & survey
Camber and pre-set calculations, match-cast geometry control, and daily deck survey reconciliation on cantilever work.
- Bridge geometry control
- Total station networks
- Point cloud comparison
05
Detailing & fabrication modelling
A single fabrication model feeding CNC profiling, so the shop cuts from the same geometry the designer analysed.
- Tekla Structures
- AutoCAD
- CNC nesting
06
Temporary works checking
Independent category II and III checks, both on our own schemes and as an external service to contractors on theirs.
- BS 5975 practice
- EN 12812
- Client TWC procedures
The independent check
The checker never sees the design first.
A category III check is not a second pair of eyes on the same calculation. The checking engineer works from the design brief, builds an independent model, and only then compares results. Where the two disagree, neither is right until the disagreement is explained.
Quality & safety- Who checks
- An engineer outside the project team, appointed by the design director rather than by the project manager. On client request, a third-party checker instead.
- What is checked
- Global stability at every stage of the launch, member and connection capacity, mechanism and hydraulic duty, control interlocks, and the reactions imposed on the permanent works.
- What is released
- Nothing goes to the shop floor without a signed check certificate. No exceptions, no conditional releases, no "start the plate while we finish".
- What is retained
- The full calculation package, the check certificate and the as-built survey are held for the life of the equipment and reissued on every redeployment.
06From drawing to gate
Everything we design, we can build.
The works exist because a 60 m truss with a 5 mm tolerance is not a risk a third-party shop will carry for you. Three hold points on the route out — nothing moves past them without a signature.
03Capacity
- 18,000 MT
- Annual fabrication capacity
- 900 t
- Heaviest gantry supplied
- 72 m
- Longest span erected
- 140
- Engineers on staff
Across two works, both rail-served
Self-launching overhead type
Precast segmental, span-by-span
Design, methods and site supervision
08Next step
Start with the method, not the price.
Send the general arrangement, the span table and the programme. The first thing you get back is a comparison of methods with an honest cycle time against each.
- Projects & tenders
- projects@ibec.co.in
- Telephone
- +91 40 4000 0000
- Response
- An engineer reads every enquiry. Expect a technical reply within two working days, not a brochure.