Our Manufacturing Process

Your Project's Technical Path With Us

1. Conceptual Design and Structural Engineering

We collaborate closely with you to refine the statue's design, creating detailed 3D models using CAD software (e.g., SolidWorks or AutoCAD). Our structural engineers perform finite element analysis (FEA) with tools like STAAD.Pro to simulate load conditions.

Key Calculations Include:

  • Wind Load Analysis: Designed for wind speeds up to 47 m/s per IS 875 (Part 3):2015
  • Seismic Stability: Compliant with seismic zone standards per IS 1893 (Part 1):2016
  • Load Distribution: Safety factor of 1.5–2.0 for stability per IS 800:2007

Client Involvement:

  • Review and approve conceptual designs, 3D renderings, and preliminary structural reports
  • Receive FEA results detailing stress points and safety margins
  • Regular updates via virtual or in-person meetings

2. Fabrication and Assembly

  • MS Framework Construction: Fabricated in modular sections with stress-relief annealing. Dimensional accuracy verified using laser scanning (±1 mm) per IS 800:2007.
  • FRP Molding: Components molded with CNC-cut molds for precision (±0.5 mm). Hand layers ensure void-free lamination.
  • PU Coating Application: FRP surface is sanded, primed, and coated with PU in a dust-free environment. Curing controlled at 20–25°C for 24–48 hours.
  • Integration: FRP skin bonded to MS framework using high-strength epoxy adhesives and stainless steel fasteners.
  • Anchoring System: Secured to reinforced concrete foundation (M30 grade per IS 456:2000) with MS anchor bolts.

Client Involvement:

  • Review fabrication drawings before production
  • Receive video/photo updates of key milestones
  • Witness critical assembly and coating stages at our facility

3. Structural Stability and Safety Assurance

  • Load Testing: Simulated load tests applying 1.5x design loads per IS 800:2007
  • Dynamic Analysis: Vibrational modes modeled to prevent resonance, ensuring natural frequency above 1 Hz per IS 1893
  • Foundation Design: Engineered with factor of safety 2.0–3.0, using deep piles or mat foundations for low bearing capacity soils
  • PU Coating Durability: Protects FRP from environmental degradation, reducing maintenance needs
  • Safety Standards: Compliance with IS 800:2007, IS 456:2000, and local building codes

Client Involvement:

  • Receive structural stability report with load test results and compliance certificates
  • Joint review of foundation designs and site plans
  • Participate in on-site load testing or review third-party inspection reports

4. Quality Control and Assurance

Our ISO 9001-certified process guarantees excellence aligned with Indian standards:

  • Material Testing: MS, FRP, and PU coatings undergo rigorous checks with certificates provided
  • In-Process Inspections: Dimensional accuracy, non-destructive testing, and PU adhesion verified
  • PU Coating Quality: DFT (50–100 microns), adhesion (>4B rating), and gloss/color consistency verified
  • Final Quality Audit: Complete evaluation for structural integrity, PU coating performance, and aesthetic alignment
  • Documentation: Quality dossier including material test reports, inspection records, and certifications

Client Involvement in Quality Approval:

  • Progress reports and inspection data at each stage
  • Sign-off required at key quality checkpoints
  • Virtual or on-site quality audits available
  • Final acceptance test post-installation

5. Aesthetic Finishing

  • PU coating customized to your specifications (high-gloss, semi-gloss, or matte finishes)
  • Hand-sculpted features, CNC-engraved patterns, or embedded LED lighting options
  • Anti-graffiti or self-cleaning PU variants available
  • Gloss retention >80% after 5 years, color stability ΔE < 1.0

Client Involvement:

  • Approve aesthetic mock-ups and PU-coated samples
  • Pre-delivery inspection with opportunity for minor adjustments