Plettenberg

Novelis intends to install a new Continuous Annealing (CAL / Durchlauf-Glüh-Linie), integrating it into an existing plant. To this end, internal budget calculations and the elaboration of a variant selection had to be verified, independently. Group-IPS was contracted die to its experience in similar projects to supplement limited Novelis resources in performing the following tasks:

• Elaborate three possible options for the CAL-line in order to independently validate preconceptions and choose a layout / building configuration option.
• Make an informed proposal on which permitting route to take incl. a permitting roadmap.
• Perform a logistic analysis, streamlining especially the storage situation withing the plant.
• Produce an integrative plan layout to clear the gate of approval.

The described steps were to be performed within 3 months, with all works and decisions driven by time-to-market considerations.

The biggest challenge was the large amount of work in very little time. As a result, decisions had to be taken fast with absolutely no tolerance for revisions. The constrain was compounded contradictory construction imperatives: The site is located very close to a river and was partially build on a former river-end. Therefore, special considerations had to be made in terms of available building space, earth works and foundations. At the same time, fire engineering and time to market considerations would influence building preferences.

The project phase was completed in time and budget despite the fast track imperative, thus securing the Start of Production target and enabling further project phases, which will be executed with Group-IPS as General Contractor.