GF Casting Solutions S.R.L.

Pitesti, Romania

New Die-Casting Foundry

Concept Design

Building requirements
August 28, 2019

www.projektingenieure.de
Scope: New die-casting foundry with 18.600m² 1)

Gate

Cast
Raw
Finished Parts Finish Parts (8 DCM) Melt

QS/Office

New plant: 18.600 m² Mainte-nance

Tool
shop

Parking lot

Site Pitesti: 52.600 m²

1) effective area

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Planning scope: = Phase 1, start with Phase 1a

Phase 1a Phase 1
4 DCM + Finishing 8 DCM + Finishing

Gate Gate

Finished Parts Ra Cast

Finished Finis w
Ra Cast Parts h Pa (8 DCM) Melt
Finis w
h Pa
(4 DCM) Melt rts
rts QS/Office QS/Office
Mainte- Tool Mainte- Tool
nance shop nance shop

Parking lot Parking lot

= Planning scope

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Future (possible) expansion: = Phase 2

Phase 1 Phase 2
8 DCM + Finishing 16 DCM + Finishing

Gate
Gate
Phase 1
Ra Cast Ra Cast (= planning
Finished Finis w Finished Finis w
h Pa (8 DCM) Melt Parts h Pa (8 DCM) Melt
Parts
rts rts
scope)
Parking
QS/Office lot QS/Office
Mainte- Tool
Ra
nance shop Finished Finis w Cast
Parts h Pa (8 DCM) Melt
rts

Infrastructure
Finish Tool Mainte- Tool
Parking lot shop nance shop

Phase 2

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Site and main buildings

Waste water treatment

Production building
Truck driveway Gate
(casting, finishing,
logistic)

Shipping area

Finishing and Receiving area

logistic building

Shipping area Driveway to

parking lot

Receiving area
Fence

Casting building

Waste collection Parking lot

Existing Expansion point

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Effective area phase 1a: appr. 15.800m²,
incl. appr. 3.620m² on 1st floor

159m
Gate
Effective area 1)
 Melt 1.500 m²
Empty  Cast 2.230 m²
24 m Finished Parts
 Buffer raw parts 560 m²
24 m Cast
Raw
Finish Part (4 DCM) Melt  Finish 1.000 m²
16 m s
QS/Office  Buffer finished parts 1.700 m²
Mainte- Tool  Maintenance 680 m²
24 m
nance shop
 Tool shop 1.200 m²
 QS/Office 1.000 m²
 Social (1st and 2nd floor) 1.270 m²
 Infrastructure (1st floor) 2.350 m²
 Empty space 2.250 m²

 Total 15.740 m²
Social area  Total, ground Floor 12.120 m²

16 m Social area
Infrastructure

1) Areas approx., incl. adjoining ancillary areas (driveways), incl. interior walls; excluding containers

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Effective area phase 1: appr. 18.600m² ,
incl. 3.620m² on 1st and 2nd floor

203m
Gate
Effective area 1)
 Melt 2.000 m²
 Cast 4.500 m²
24 m Cast
Finished Raw  Buffer raw parts 860 m²
24 m Parts
Finish Part (8 DCM) Melt
s  Finish 1.700 m²
16 m QS/Office  Buffer finished parts 3.000 m²
Mainte- Tool  Maintenance 680 m²
24 m
nance shop
 Tool shop 1.200 m²
 QS/Office 1.000 m²
 Social (1st and 2nd floor) 1.270 m²
 Infrastructure (1st floor) 2.350 m²

 Total 18.560 m²
 Total, ground Floor 14.940 m²
Social area

16 m Social area
Infrastructure

1) Areas approx., incl. adjoining ancillary areas (driveways), incl. interior walls

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Production hall: 12,5m or 8m high, with 40t (or 50t)
crane in 12,5m bays and differentiated HVAC

Phase 1a Phase 1
4 DCM + Finishing 8 DCM + Finishing

Gate Gate

Finished Parts Ra Cast

Finished Finis w
Ra Cast Parts h Pa (8 DCM) Melt
Finis w
h Pa
(4 DCM) Melt rts
rts QS/Office QS/Office
Mainte- Tool Mainte- Tool
nance shop nance shop

should be prepared
for future expansion
(Phase 2)
Parking lot Parking lot

12,5m high, 40t (or 50t) crane, high HVAC-req 8m high, no crane, low HVAC req.

12,5m high, 2 levels, no crane, medium HVAC req. Container

HVAC = heating, ventiliation and air conditioning

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Production hall: 12,5m or 8m high, with 40t (or
50t) crane in 12,5m bays (details)

Sectional view:

1 12,5 m

24 m 3 2 1

2 12,5 m
8m

3 8m

16 m 24 m 24 m

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Installations, ground floor (Phase 1a): As required
for different operations

shipping gate production x-ray measuring laboratory spare parts melting battery room tool shop
office office room magazine lab office
construction type lightweight lightweight lightweight lightweight lightweight lightweight shelf lightweight open lightweight
special aeration air-lock air suck-off
with WC? yes yes
numbers of floors 1 1 2 1 1 1 1 1 1 1
air-conditioned yes yes1) yes yes
floor coating acid resistant
floor drain acid neutralization
emergency shower boiler
floor cut yes
1) Quality requirements: “production-related measuring room” class IV acc. to VDI 2627

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Installations, ground floor (Phase 1): Gate and
shipping office moved

shipping gate production x-ray measuring laboratory spare parts melting battery room tool shop
office office room magazine lab office
construction type lightweight lightweight lightweight lightweight lightweight lightweight shelf lightweight open lightweight
special aeration air-lock air suck-off
with WC? yes yes
numbers of floors 1 1 2 1 1 1 1 1 1 1
air-conditioned yes yes1) yes yes
floor coating acid resistant
floor drain acid neutralization
emergency shower boiler
floor cut yes
1) Quality requirements: “production-related measuring room” class IV acc. to VDI 2627

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Installations, 1st floor (Phase 1): As required for
different infrastructure equipment

heating/ ventilation units electric stations compressed air stations

housing yes yes yes
F90 wall yes yes
soundproof yes

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Production process and equipment

For “gearboxes” and “engine blocks”

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Production process and equipment: Melting

Description:
Gas driven furnaces melt aluminum ingots and scrap.
Liquid metal is transported in ladles by forklifts to casting.
Aluminum ingots come without pallets, some may have a plastic cover.

Melting furnace Liquid metal forklift Ingot package

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Production process and equipment: Die casting

Description:
Casting cells keep liquid metal in electrical driven furnaces warm and
dose it into hydraulically driven die-casting machines. Those machines
press it with high forces into metal tools. After part is solidified, robots
take it out, cool it in water basins and trim it in hydraulic presses.
Hydraulic fluid is water-glycol (non-flammable).

Die-casting cell Die-casting cell Die-casting cell

(front view) (back view) (top view)

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Production process and equipment: Raw parts
buffer, finishing and finished parts buffer

Description:
Raw parts/finished parts buffer: Aluminum parts are stored in metal
mesh-bins, some of them with a cardboard layers between the parts.
Bins are stacked up to 4 high. Neither plastic bins nor wooden pallets
are actually planned to be used.
Finishing: Casted parts are unpacked from the bin and placed on a
conveyor. The parts are then machined and blasted. Finished parts are
next packed in a metal mesh-bins.

Gearboxes in metal mesh-bin Gearboxes in metal mesh-bin

(side view) (front view)

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Storage inside the building: Al-ingot in package,
raw and finished parts in metal mesh-bins

For details: see Autocad drawing

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Fire compartments: All sections <10.000m²,
finishing and logistics separated

FC 2 FC 1
5.940 m² 9.380 m²

FC 5
635 m²
FC 4
635 m²
FC 3 2.350 m²

FC Fire compartment

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Fire prevention

For details: see Autocad drawing

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Sprinkler: Necessary?

Possibility to avoid sprinkler due to:

• low fire load due to parts, scrap and ingots as well as
hydraulic fluids being non-flammable and very little use
of plastic, cardboard, etc.
• installation of a factory-wide fire alarm system
• installation of sufficient fire extinguishers
• training a part of the employees as plant fire department

But if local building codes require sprinklers:

installation of sprinkler possible

installation of sprinkler possible, but not recommended

installation of sprinkler strictly forbidden due to the risk of

explosion in the event of contact between liquid metal and
water

For details: see Autocad drawing

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Floor loading

min. 10 t/m²,
min. 5 t/m², and suitable for 5t forklifts,
and suitable for 5t plus special load conditions
forklifts

min. 2 t/m²,
and suitable for 2t forklifts

For details: see Autocad drawing

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Floor loading: Special load condition

Special load condition

(pictures: examples) Die repair – point load Die preheating station – point load
• Dies laying on 4 points on the floor • Dies waiting near casting cell

Scrap containers – point load

• Containers moving on flat steel
while being changed

Details tbd.

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Main cranes: 1x 40t (or 50t) crane per hall,
independent operation of cranes possible

For details: see Autocad drawing

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Doors and gates: placed and roughly dimensioned

Gate

Gates: Outer and inner rolling doors, appr. 5x6m² and 4x6m², details tbd.

For details: see Autocad drawing

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Office and social rooms: dimensioned for phase 2
298 employees, appr. 1200 m²

Phase 1a Phase 1 Phase 2

Total: 4 DCM 8 DCM 16 DCM
Personnel -
Industrial staff
Workplace - 32 48 79
Employee - 112 171 286
Office staff
Workplace - 8 10 12
Employee - 8 10 12

Office and social area m² 558 710 1.187

Office area m² 263 295 487
Social area m² 223 311 536
Canteen m² 72 104 164

Parking spaces
# parking space - 43 64 102
Parking lot area m² 864 1.272 2.040

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Industrial staff: 48 workplaces, 3 shifts

For details: see Autocad drawing

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Media: demands estimated

Phase 1a Phase 1
4 DCM 8 DCM
Power demand transformers [kW] 3.900 7.000
Power demand medium [kW] 2.000 3.600
Compressed air [m³/h] 3.200 6.200
Natural gas [m³/h] 700 1.000
Nitrogen [m³/h] 3 5
Cold water 15/19°C [kW] 100 100
Cooling water (CW) 28/32°C [m³/h] 200 400
CW pressureless return [m³/h] 200 400
Demineralized water
(Osmosis) [m³/h] 0,0 0,0
Public water [m³/h] 2,8 5,5
Soft water ?° [m³/h] 4,8 9,6
Waste water [m³/h] 1,5 3,1
Fresh air, winter [m³/h] 174.800 197.300
Fresh air, summer [m³/h] 258.600 281.100
Exhaust air hall, summer [m³/h] 230.600 236.700
Exhaust air mach., decentral [m³/h] 26.800 43.200
Exhaust air mach., central [m³/h] 1.200 1.200

Source: Infrastructure 723 GF Romania.xlsx

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Ventilation: 1,5 to 5 /h minimum air exchange
required, partially with AC

AE = AE = 5 / 2 x/h
1,5 / 1,5 x/h
a-c. air-conditioned

AE = 1,5 / 1,5 x/h

AE = 5 / 2 x/h air exchange summer / winter, per hour, related to 5m height

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Heating/Ventilation: heat recovery from equipment,
exhaust air directly blown to outside
exhaust exhaust
air air
supply Water Gas Option:
Summer
air
Cold Spotlight Spotlight
supply Water
air air-conditioned

Summer Hall ?
Winter
5m Winter

Exhaust
Compressed
Melting Machining QS,
air Blasting
Station furnaces center Prod.-Office
DCM

Infra 1st Floor Melting Casting Finishing Finishing Infra

Ground floor

air exchange, related to 5m height

? Useful?  Winter = 100% 2x/h Dimensioning of heating
 Summer >5x/h Dimensioning of supply air (and exhaust air)
Spotlight: black spotlight (gas) or ceiling collectors (hot water) in the workplace area, e.g. tool-shop
alternative: underfloor heating

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 Appendix

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 Some of the shown pages may contain an
outdated layout.
The binding layout is
“Layout 723 GF Pitesti 190828” .

The texts and graphics are intended for this

presentation; they do not represent a complete
documentation.

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