Extension of Continuous Casting Plant, India

Customer Project

Structural Engineering Ingenieurbüro Mauss
Düsseldorf, Germany
Construction General Contractor
Düsseldorf, Germany

Oehmichen & Bürgers GmbH
Düsseldorf, Germany
Investor JSW Steel Ltd.
Mumbai, India

Length: ~ 50 m | Width: ~ 35 m | Height: ~ 24 m | Weight: ~ 908 t
Number of nodes: 1,741 | Members: 2,142 | FE: 11,966 | Cross‑Sections: 90

The continuous casting plant of the JSW ISPAT steelworks in India was extended by an additional level and completed by new plant components and stair towers. At the same time, the existing structure was reinforced to be able to absorb the additional weight of the new components as well as increased seismic loads.


The dimensions of the plant in the ground plan are about 33 m x 35 m with a height of 15 m. The upper level to be newly constructed of the continuous casting plant is specified as a casting platform and is designed for a load of 3 t/m2.

On the casting platform, there are control rooms, the emergency buckets, which collect the liquid steel in case of failure, as well as crane runways and further handling devices.

The supporting structure consists of steel girders with a span of up to 14 m. The biggest main beams have dimensions of h x w = 1200 x 600 mm with plate thicknesses of up to 60 mm. The structure is reinforced by diagonals against seismic loads.

Structural Analysis and Design

In order to realize the planning of the extension quickly and effectively, the possibilities of a digitization and data exchange between the different 3D planning and calculation programs were used from the start.

The existing construction was first captured with a 3D laser scanner and was displayed as 3D point cloud. It was transferred to an RFEM file using a construction program with the import/export function as an intermediate step.Thus the model was available as the basis for further testing.

The structural analysis was performed according to Eurocode 3 in the RF‑STEEL EC3 add‑on module.

For a detailed display of the results, the graphical tools of RFEM were used, for example to classify different categories of reinforcements and to display them in color in 3D graphics.

Programs Used for Structural Analysis

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