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Project · Banking & Financial Services

Three 30-metre exhaust stacks for the Reserve Bank of India

ClientReserve Bank of India
LocationBelapur & Kharghar, Navi Mumbai · Nagpur
Capacity3 × 30 m stacks
ScopeTurnkey exhaust structures for six 1010 kVA sets

The brief

India’s central bank installed six 1010 kVA DG sets across three premises — and contracted Power Solutions to build what makes them compliant: three 30-metre exhaust stacks engineered to full statutory height. Institutional work at its most demanding: security-controlled sites, tender-grade documentation, zero tolerance for schedule drift. And the calendar made it harder still: the project ran through the COVID period, with the institution’s pandemic protocols layered on top of its security discipline — and was delivered under peak lockdown without a single COVID incident on any site.

What made it hard

  • Security-controlled premises — vendor access, material movement and personnel all under institutional protocol
  • Executed through peak COVID lockdown — screening, distancing and sanitisation norms enforced at every gate, on every crew, every day
  • Three 30-metre exhaust structures with aviation lamps and lightning arrestors, engineered and erected on live premises
  • Tender-grade BOQ discipline: fabrication, erection, civil works and documentation as one accountable bill

What we did

  1. 1Three 30-metre structural exhaust stacks with supports, aviation lamps and lightning protection
  2. 2Exhaust structures engineered to statutory height for the Bank’s six 1010 kVA DG sets — procured by the institution, made compliant by this scope
  3. 3Civil works and full commissioning documentation to institutional audit standard
  4. 4Delivered through the lockdown with zero COVID incidents across all three RBI sites

From the site

Unretouched photographs from our own site record of this job.

Concrete stack foundation pedestals with clusters of holding-down bolts and tie beams
Foundation pedestals with holding-down bolt clusters and tie beams, cast and cured before any steel arrives.
Steel reinforcement cages and timber shuttering for the stack foundation columns
Reinforcement cages and shuttering for the stack foundation columns.
Red dye-penetrant weld test applied to a lattice gusset joint
Dye-penetrant testing on the lattice gusset welds — every joint checked before the column leaves the ground.
Mobile crane erecting a 30 metre twin-flue lattice exhaust stack
Crane erection of the 30-metre twin-flue lattice stack at Nagpur.
Erected 30 metre lattice exhaust stack with a DG enclosure at its base
The erected 30-metre stack at Nagpur, DG enclosure at its base.
Mobile cranes rigged with a lattice stack section lying horizontal before the lift
Belapur — cranes rigged, a ground-fabricated section slung and ready for the lift.
Twin-flue lattice stack section suspended mid-air by crane above the standing base section
Belapur — a twin-flue section tailed up over the standing base.
Crane lowering a twin-flue lattice section onto the standing stack base
Kharghar — the upper section lowered onto the splice; height work is bolting, not building.
3 × 30 m exhaust stacks engineered and erected
6 × 1010 kVA client sets served
0 COVID incidents — delivered under peak lockdown

Services used

Turnkey ProjectsExhaust Stack Structures

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