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Project · Automotive / Manufacturing

A 30-metre stack from bare earth to lamp at DAS Auto, Rajgurunagar

ClientDAS Auto

LocationRajgurunagar, Pune district

Capacity30 m stack

ScopeCivil foundation, ground fabrication and crane erection of a 30 m lattice stack

The brief

A 1010 kVA set at DAS Auto’s Rajgurunagar unit needed its exhaust at full statutory height — and this build became our most completely documented column: the raft and anchor-bolt cage in the open pit, ground fabrication running into the night, and the crane erection captured on film from first lift to final alignment.

What made it hard

Full civil scope: excavation, raft reinforcement and the holding-down bolt cage cast to template
Ground fabrication finished into night shifts to hold the crane date
Crane erection in ground-fabricated sections — work at height limited to splice bolting and alignment

What we did

1Isolated raft foundation with pedestals and anchor bolts, cast and cured to programme
2Lattice column fabricated complete on the ground, flue fitted up the centre
330 m self-supporting stack erected, aligned and fitted with ladder and rest platforms

From the site

Unretouched photographs from our own site record of this job.

Raft reinforcement and holding-down bolt cage in an excavated stack foundation pit — The raft reinforcement and holding-down bolt cage, set to template in the open pit.

Excavated foundation with raft reinforcement and anchor cage seen from the pit edge — The foundation from the pit edge — an isolated raft sized to the soil report and wind zone.

Night finishing work on a fabricated lattice stack section under floodlights — Ground fabrication running into the night to hold the crane date.

Telescopic crane lifting the complete lattice column off the ground, rain-cap elbow at its head — The lift — the ground-fabricated column leaves the ground in one piece, flue and platforms already fitted.

The lattice column hanging nearly vertical from the crane hook during tail-up — Tailed up to vertical — minutes from landing on the anchor bolts.

Erected lattice stack rising above a green Cummins DG canopy on rocky ground — The column up, the Cummins set below — exhaust taken from canopy to statutory height.

Erected 30 metre self-supporting lattice stack with ladder and rest platforms — The erected 30 m column — ladder, rest platforms and lamp, ready for the pollution-check point.

Completed 30 metre lattice stack beside the DAS Auto plant building with its signage — The finished column over the plant boundary — the DAS building behind.

Telephoto detail of the stack top: insulated riser, rain-cap elbow, caged ladder and platform — Top-section detail — insulated riser, rain-cap elbow, caged ladder and the top platform.

30 m self-supporting lattice stack

1010 kVA DG set served

2025 completed — the full build on camera

Services used

Exhaust Stack Structures Turnkey Projects

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