Every stage is specified.
Fabrication, pre-treatment, painting, assembly and testing — each held to a written standard, with surprise checks to confirm the process is being followed rather than assumed.
Process
From sheet steel to a tested assembly.
- 01
Fabrication
Panels are fabricated from 14 and 16 SWG CRCA sheet, designed to carry the load of the switchgear and busbar components at the specified short-circuit withstand capacity. Enclosures allow ample space for cable termination, straightforward maintenance access, and protection from live busbars and terminals. The foundation base frame is normally 75 × 75 × 4 mm MS channel.
- 02
Compartmentalisation
Built to IS 2147, with separate chambers for live busbars and live cable terminals.
- 03
Painting
Panels are preheated, then taken through a seven-tank process — degreasing, de-rusting, phosphating and cold water rinsing. A non-corrosive primer is applied, followed by two coats of synthetic enamel or epoxy in Siemens grey, shade 631 to IS 5. The panel is then oven-baked or powder coated to the client’s requirement. Surprise checks confirm the process is being followed.
- 04
Assembly
Every component is inspected against our quality standards and the technical specification before assembly. Aluminium and copper busbars are electrolytic grade, supported on non-hygroscopic epoxy or SMC insulators. Busbar joints are cleaned and greased to maintain conductivity and limit temperature rise; busbars are sleeved in PVC heat shrink for safety and phase identification. A separate earth busbar runs the length of the panel. Control wiring is 660/1100 V grade PVC-insulated flexible copper, neatly bunched. Switchgear assembly conforms to IS 8623 and IS 375.
- 05
Testing
Pre-assembly, in-process and final inspection are carried out with 1 kV meggers, a 2.5 kV high-voltage tester, continuity testers, multimeters, tong testers and an Elcometer for coating thickness.
Plant
Machinery.
- Hydraulic busbar bending machine (3 nos.)
- Hydraulic busbar cutting machine (1 no.)
- Manual cutting machine (1 no.)
- Hydraulic busbar punching machine (2 nos.)
- Bench drilling machine (2 nos.)
- Hand drilling machine (3 nos.)
Inspection
Testing equipment.
- 1 kV Agronic megger (2 nos.)
- 2.5 kV high-voltage tester
- Continuity tester
- Multimeters
- Tong tester
- Elcometer — powder coating thickness
Standards
What we build against.
| IEC 61439 | Low-voltage switchgear and controlgear assemblies |
|---|---|
| IS 2147 | Degrees of protection for enclosures |
| IS 8623 | Low-voltage switchgear and controlgear assemblies |
| IS 375 | Marking and arrangement of busbars and connections |
| IS 5 | Colours for ready-mixed paints — shade 631, Siemens grey |
Want to see the works?
Visit Vasai East, or send a specification and we will walk you through how we would build it.