Global presence
Project Overview
Wabtec, a globally renowned USA‑based leader in railway and metro manufacturing, required an efficient way to expand production capacity at their Rohtak facility. To support the installation of additional machinery and enhance workflow, our team delivered a high‑performance mezzanine flooring solution designed to increase usable vertical space without interrupting daily operations.
Client Requirements
- Create additional production space to accommodate more machinery.
- Ensure a 2‑ton running load capacity for industrial‑grade performance.
- Maintain complete safety compliance throughout execution.
- Achieve premium finishing with zero disruption to ongoing operations.
We engineered a robust mezzanine system using MS structural steel combined with industrial deck sheets for superior strength. Since the plant was fully operational, we implemented a strategic execution plan—working during night hours and break timings—to ensure complete safety and uninterrupted production. Every design decision focused on durability, load efficiency, and seamless integration into the existing facility.
Design Concept
& Planning
Construction & Execution
Fabrication and erection of MS steel structural framework. Installation of deck sheets,
bison board, and premium vinyl flooring for a clean and professional surface finish.
Safe and methodical on‑site execution using advanced tools
and dust‑control techniques.
Complete project delivery within a 2‑month timeline.
Executing structural work inside a running manufacturing plant required precision, safety, and intelligent planning. Challenges such as dust, cutting operations, and movement restrictions were efficiently handled using controlled work zones, safety tools, and advanced equipment. Our team ensured a safe, disturbance‑free environment while maintaining strict adherence to industrial safety standards.
Challenges & Solutions
Final Outcome
The completed mezzanine floor added significant usable space, allowing Wabtec to install additional
machines and boost production output. Delivered with high‑quality workmanship and strict safety compliance,
the mezzanine structure now serves as a durable, functional, and aesthetically polished asset within the facility.
Before & After
Client Testimonial
“Exceptional quality and smooth execution—even inside a running plant. The mezzanine floor has greatly enhanced our production space without causing any downtime.”
Key Highlights
- Premium, turnkey mezzanine solution with 2‑ton load capacity.
- Executed inside an active plant with zero downtime.
- High‑quality MS steel, deck sheets, and vinyl flooring for long-term durability.
- Intelligent night‑shift and break‑time planning for safe, efficient work.
Conclusion
This project represents a perfect blend of engineering precision, safety excellence, and efficient workflow management. By adding substantial operational space and enabling increased production, our mezzanine solution provided Wabtec with a long‑term, performance‑driven upgrade to their Rohtak facility.