Piping Fabrication & Erection for Hot & Chilled Water Networks in HVAC Systems

At Struxon Integrated Solutions, we take pride in executing complex Mechanical, Electrical, and Plumbing (MEP) works with precision, efficiency, and uncompromising quality. One of our flagship ongoing projects is the end-to-end MEP mechanical works for Tata Electronics’ state-of-the-art electronics manufacturing campus in Hosur, Tamil Nadu.

With a 10-month delivery timeline, our scope covers complete process and HVAC piping, structural steel fabrication, and HVAC ducting with thermal and acoustic insulation—all engineered to meet the stringent requirements of high-precision manufacturing environments.

🔧 Piping Fabrication & Erection

Our piping systems are designed and executed to support both process and HVAC operations:

• Systems Covered

  • Hot water networks for process/HVAC reheat and utilities

  • Chilled/cooling water distribution to AHUs, FCUs, and process air handlers

  • HVAC header mains up to Ø450 mm with branch distribution

  • Comprehensive valve packages including isolation, motorized control, balancing, and instrumentation

• Materials & Fabrication

  • Mild steel/CS for chilled/hot water mains, with GI/SS in corrosive/hygienic areas

  • Bevel prep, full/partial penetration welds, and NDT on critical joints

  • Shop priming, finish coats, galvanizing, and color-coded identification

• Installation & Tie-ins

  • Alignment, slope control, and expansion provisions (loops/bellows)

  • Connections to pumps, AHUs/FCUs, heat exchangers, cooling towers, and makeup lines

  • Integration of gauges, flow meters, and DP switches for real-time monitoring

• Testing & Commissioning

  • Hydrostatic pressure testing, flushing, and passivation

  • Valve calibration, insulation, and leak/retention checks

  • Performance verification for reliable operation

🏗️ Structural Fabrication Works

To support large-scale piping and HVAC systems, we are also responsible for custom steel structures:

• Pipe racks for Ø450 mm mains and branches

• Cooling tower supports, access platforms, guardrails, and equipment frames

• Duct supports with seismic restraints and vibration isolation

• Skid frames and housekeeping pads for pumps and valve stations

Each structure is designed to ensure durability, accessibility, and safety.

🌬️ HVAC Ducting & Insulation

Precision air distribution is critical in electronics manufacturing facilities. Our HVAC scope ensures performance and efficiency through:

• Ducting

  • Optimized routing of supply, return, fresh-air, and exhaust ducts

  • Fabrication to project specifications with S-cleat/TDC/TDF/angle-flange connections

  • Incorporation of turning vanes, fire dampers, motorized dampers, and sound attenuators

• Insulation & Cladding

  • Mineral wool and closed-cell elastomeric insulation for thermal efficiency

  • Vapour barrier continuity to prevent condensation

  • External aluminium/PPGI cladding for plant room and outdoor durability

  • Fire-rated wraps/boards per fire strategy

• Testing & Balancing

  • Duct leakage testing and air-quantity measurement

  • TAB (Testing, Adjusting, Balancing) to achieve design airflow and pressure

  • Acoustic verification to meet NC/Rw criteria

📍 Project Impact

By delivering integrated piping, structural, and HVAC solutions, we are helping Tata Electronics build a world-class, high-reliability manufacturing facility. The project is not only about installing systems—it’s about creating an environment where precision manufacturing can thrive with reliable utilities, controlled environments, and sustainable operations.

✅ Client: Tata Electronics
📍 Location: Hosur, Tamil Nadu, India
⏳ Duration: 10 months — Ongoing