LTL Galvanizers - Brief Description.pdf

Hot Dip Galvanizing and
Steel Fabrication Plant
Largest Power Sector Engineering Organization in Sri Lanka
engaged in the Electrical, Mechanical and Civil engineering
fields.
LTL Galvanizers (Pvt) Ltd.

Corrosion Never Sleeps… Get it Galvanized…
than 3000 customer base.
• LTL Galvanizers (Pvt) Ltd. has Established in year 1991 by
Sri Lanka’s renowned and leading Engineering
Organization, LTL Holdings (Pvt) Ltd to complement their
construction activities.
• Today this subsidiary of LTL Holdings, owns and operates
ultra modern facilities for galvanizing, designing and
fabrication of steel towers and structures and serves all
major industries in Sri Lanka.
• Currently LTL Galvanizers (Pvt) Ltd. operates with a more
than 3000 customer base.
LTL
Galvanizers
(Pvt) Ltd.
Steel
Fabrication
Hot Dip
Galvanizing &
Metallizing

Our Products
Transmission
line towers
Telecom
towers
Substation
structures
Cross arms &
Line hardware
Nuts & Bolts Steel Buildings

Our Products
Hand Rails Highway Structures Pipes & Pipe Racks
Bridges Gas Conveyers Transformer Tanks

• Designing of Power Transmission Towers –
According to the ASCE-1097 standard
• Designing of Telecom Towers – According to
the EIA-222-G Structural standard
• Designing of Substations and other steel
structures. (Bridges, Steel Buildings, etc…)
Furnished Fabrication drawings are developed
utilizing state of the art computer software.
• PLS CAD – For Profile Designs
• PLS Tower – For Tower Designs
• MS Tower – For Tower Designs
• STADD Pro – For steel structures
Designs
Well trained Sri Lankan Design Engineers &
Draughtsman for all the design works.
• Designing of Power Transmission Towers –
According to the ASCE-1097 standard
• Designing of Telecom Towers – According to
the EIA-222-G Structural standard
• Designing of Substations and other steel
structures. (Bridges, Steel Buildings, etc…)
Furnished Fabrication drawings are developed
utilizing state of the art computer software.
• PLS CAD – For Profile Designs
• PLS Tower – For Tower Designs
• MS Tower – For Tower Designs
• STADD Pro – For steel structures
Designs
Well trained Sri Lankan Design Engineers &
Draughtsman for all the design works.
In-house Design Capabilities
Tower Testing

• Length: 7.0 m
• Width: 1.3 m
• Depth: 2.1 m
Bath Dimensions
• 5,000 kg/hr
Bath Capacity
• 13.5 m
Maximum length
can dip
Hot Dip Galvanizing Plant
Steel Bath
The Hot Dip Galvanizing Plant is equipped with state of the art
German machinery and technology.

• Length: 3.0 m
• Width: 0.8 m
• Depth: 1.2 m
Bath Dimensions
• 1,200 kg/hr
Bath Capacity
• 4600 C – 5600 C
Operating
Temperature
Range
Hot Dip Galvanizing Plant
Ceramic Bath (Centrifuge bath)

Why Hot Dip Galvanizing?
• The U.S. Federal Highway Administration (FHWA) released a break-through 2-
year study in 2002 on the direct costs associated with metallic corrosion in US
incorporation with NACE international.
• It was found that the total Direct cost of corrosion in US was B$276 / year that
is 3.1% of US GDP in 1998. Indirect costs were very much higher than this.
• The best solution for corrosion protection is Hot Dip Galvanizing because it
gives 03 types of protection to steel, Cathodic, Barrier and Zinc Patina.

LTL Galvanizers (Pvt) Ltd, incorporation with University of Peradeniya is planning to
conduct a corrosion cost study in Sri Lanka with the support of NACE International.
Cost of Corrosion Study – Sri Lanka

Galvanizing Process
Weighing Incoming Inspection Unloading Loading to frames
Pickling
(Surface cleaning by Hydrochloric
Acid)
Rinsing with water Fluxing – Zinc Ammonium Chloride
(Temporary protection until dipping)

Galvanizing Process
Quality Inspection Dispatch
Drying – by excess heat
(To remove moisture)
Dipping
(Dipping in molten Zinc –
450oC)
Quenching & Passivation
(passivation for prevent white rust)

Gamma
Delta
Zeta
75% Zinc
25% Iron
90% Zinc
10% Iron
Eta 100% Zinc
94% Zinc
6% Iron
The Gamma, Delta and Zeta layers are actually
harder than the base steel.
steel
Metallurgical Bond

Packing & Delivery
• All fabricated and galvanized products are checked for quality
conformance and packed according to the customer’s standards /
requirements.
• The items are placed on pallets, keeping some room to avoid moisture
trappings and tightened by coated metal strapping, to ensure the safe
arrival of the products at the final destinations. Each package is
numbered and packing lists ate prepared before delivery or shipping.

Packing & Delivery

Fabrication Plant
• 2,000 MT per Month
Total Capacity of the Plant

Quality Management System
ISO 9001:2015 Quality Management
System
• LTL Galvanizers (Pvt) Ltd has certified with
the latest ISO 9001:2015 for its compliance
with the standard requirements.
• The certification was awarded for design,
fabrication and Hot Dip Galvanizing of steel
structures for power transmission lines,
Electrical substations, telecommunication
towers, steel buildings and customer
supplied steel articles;
AND
• Thermal spray metallizing and painting of
storage tanks and steel structures.

ISO 14001:2015 Environmental
Management System
the latest ISO 14001:2015 for its
compliance with the standard
requirements.
• We have taken all the necessary steps to
minimize the Environmental impact that
can be happened due to the plant
operational activities and also to reduce
the carbon foot print.
• We are doing a sustainable business that
“meets the needs of the present world
without compromising the ability of the
future generations to meet their own
needs.”
Environmental Management System

OHSAS 18001:2007 Occupational Health
& Safety Management System
the ISO 18001:2007 for its compliance with
the standard requirements.
• We do all the necessities to assure the
work place safety of our employees.
• Frequent training programs , Work safety
instructions and all the required safety
gear have been provided to all the
employees.
• Recently we have awarded with the ‘Best
Workplace Safety & Health Risk
Management’ award at South asian
Partnership Summit (SAPS) event, Dhaka.
Health & Safety Management System

Member of American Galvanizers Association
• We have a strong
technical collaboration
agreement with the
American Galvanizers
Association (AGA).
• Also LTL Galvanizers
(Pt) Ltd. Is a member
of AGA

International Awards
Award for Best Workplace Safety
& Health Risk Management at
South Asian Partnership Summit
& Business Awards held in Dhaka,
Bangladesh - 2017

Only award given by American Galvanizers Association outside the USA & Canada in 2018

Only award given by American Galvanizers Association outside the USA & Canada in 2019

National Awards
Excellence in Engineering – Merit Award - 2018

For Past 20 years, more than 90 % of the
transmission line towers installed in Sri
Lanka have been Fabricated and Galvanized
by LTL Galvanizers

Local Projects Completed
Name of Contract Employer Project Scope Year
1
Kukule Ganga Hydropower
Project, Lot-5
Energie GmbH &
Co.KG, Germany 27km of 132kV, ACSR Lynx D/C
Transmission Line
Dec 2000
–
Dec 2003
2
Transmission Substation
Development Project - 2, Lot-
B (TSDTP-2)
Betonmast Energie
AS
35.3km of 132kV, ACSR Zebra D/C
Transmission Line from Balangoda -
Ratnapura, Kelanitissa - Kolonnawa,
Oruwala - Athurigiriya
June 2001
–
Jan 2003
3
Heladhanavi 100MW Thermal
Power Plant in Puttalam, Sri
Lanka
Lakdhanavi Limited 4.5 km of 132kV, ACSR Zebra D/C
Transmission Line from Puttalam SS to
100MW Heladanavi Power plant
Nov 2003
–
June 2004
4
Horana - Paragastota
Transmission Development
Project Lot-B
Lanaka
Transformers Ltd
20 km of 132kV, ACSR Zebra D/C
Transmission Line from Horana New
Substation to Paragastota T-off
Mar 2003
–
Jan 2005
5 Kelaniya - Kolonnawa
Transmission Line Project
Ceylon Electricity
Board
7.0 km of 132kV, ACSR Zebra D/C
Transmission Line from Kelaniya –
Kolonnawa
Apr 2004
–
July 2004
6
Power Sector Development
Transmission Project. PSDTP
Lot-B
Ceylon Electricity
Board
43km of 132kV, ACSR Zebra D/C
Transmission Line
Jan 2006
–
May 2008
Transmission Lines

For Past 20 years, more than 90 % of the Grid
Substations installed in Sri Lanka have been
Fabricated and Galvanized by LTL Galvanizers

Name of Contract
Employer/
Main Contactor
Project Scope Year
1 4 MW Asupiniella Mini Hydro Project
Nividu (Pvt)
Limited
Construction of 2 Nos. of 33kV
Outdoor Line Bays
Aril 2003
–
Oct 2005
2 40 MW Lakdhanavi IV Emergency
Power Plant Project Lakdhanavi
Limited
Construction of 0.4/33kV,
44x1.25MVA Generation
Substation
March
2005
–
June 2005
3
80 MW Emergency Power Plant
Project, Mwanza, Tanzania
Lakdhanavi
Limited
Construction of 0.4/33kV,
25x3.5MVA Generation
Substation
Nov 2006
–
Feb 2007
4
Yugadhanavi 300MW Thermal Power
Plant in Kerawalapitiya
Lakdhanavi
Limited
Construction of 220/14.5kV,
2x130MVA, 1x140MVA
Generation Substation
June 2007
–
Oct 2008
5 Vavuniya Grid Substation
Augmentation Project
CEB/LTL Holdings
(Pvt) Limited
Supply, Installation and
Commissioning of 132/33kV,
1x31.5MVA Transformer and
Commissioning of the
Transformer Bay
July 2009
–
Oct 2009
Grid Substations

Name
Employer/
Main Contactor
Project Scope Year
Kittanpahuwa Bridge
(Cable Projects)
Ceylon Electricity
Board
Colombo city Electricity Distribution
Development project package –B
supply & Installation of 132kV U.G.
cable system
2010
Dematagoda Bridge
Ceylon Electricity
Board
Colombo city Electricity Distribution
Development project package –B
supply & Installation of 132kV U.G.
cable system
2010
Bridges

Recently Completed Local Projects
132 kV Transmission Line – Ukuwela - Pallekale
220 kV Transmission Line – Upper Kothmale
132 kV Transmission Line – Galle - Matara 132 kV Transmission Line – Puttlam - Maho
33 kV Transmission Line –
Hambanthota

Project Name Employer Project Scope Tower Qty.
Total
Weight
(MT)
Clean Energy Network Efficiency
Improvement Project – ( Mannar –
Vavuniya – Anuradhapura)
Ceylon
Electricity
Board
220 kV Transmission Lines - 121.6
km
372 4700 MT
Clean Energy Network Efficiency
Improvement Project – ( Thulhiriya –
Molagoda/ Polpitiya – New Polpitiya /
Athurugiriya - Padukka)
Ceylon
Electricity
Board
220 kV Transmission - 34.1 km 124 1374 MT
Supply and Delivery of 33 kV Double
Circuit Towers Tender No:
DD3/P&D/ICB/2015/029/B
Ceylon
Electricity
Board
33 kV Double Circuit - 37.1 km 106 460 MT
Supply and Delivery of 33 kVTower
Structures
Tender No: DD1/P&D/ICB/2014/081/D
Ceylon
Electricity
Board
33 kV Double Circuit Towers- 18.9
km
54 187 MT
ADB- Clean Energy and Access
Improvement Project, Part 2: Puttlam-
Maho – Ukuwella Pallekele, Galle-Matara
Ceylon
Electricity
Board
132kV Transmission Lines
95.7 km
310
2632 MT
ADB-Clean Energy Access Improvement
Project , Part – 7: Habarana -
Walachchenei
Ceylon
Electricity
Board
132kV Transmission System in the
eastern Province
100km
320
2718 MT
Transmission Lines

Name of Project Employer
Project Scope Total Weight
(MT)
CEB grid substation in Katunayake,
Ambalangoda , Aniyakanda
CEB/TCP/DGM/CBAAKGS/2014/12
Ceylon
Electricity
Board
Construction of New 132/33kV GS 55 MT
Clean Energy and Access
Improvement Project, Part 6:
Network Capacity Augmentation for
Renewable Energy Project
Ceylon
Electricity
Board
Augmentation of Existing 132/33kV GS at
Badulla, Balangoda, Nuwaraeliya,
Seethawaka, & Construction of New
132/33kV GS at Mahiyanganaya
255 MT
Augmentation of Grid Substations
for Absorption of Renewable Energy
Project- (AGSAREP) Phase I- Lot A
Ceylon
Electricity
Board
Augmentation of GS at Ratmalana, Ratnapura
& Wimalasurendra Power Station
85 MT
132 kV
Gantry -
Kilinochchi
Grid Substations

Power Plants
300 MW Combined Cycle Power Plant - Kerawalapitiya

Power Plants
Steel structures of 300 MW Combined Cycle Power Plant - Kerawalapitiya

Power Plants
24 MW Power Plant for CEB – Jaffna (Northern Province)

Steel structures of 24 MW Power Plant - Jaffna
Power Plants

Other Steel Buildings
Work shop building – Sri Lanka Railways

Central Storage Building – 300 MW CCPP Kerawalapitiya

Spherical structure made for Chandra Engineers
Verele Japanese
Restaurant at
Anantara Peace
Haven – Tangalle
Resort

Place : Hambanthota
Height: 60m
Weight : 14.71 MT
Established Year : 2005
Place : Malvana
Height: 40m
Weight : 8.12 MT
Telecom Tower Projects for Mobitel
Place :Beliatta
Height: 70m
Weight : 24.68 MT
Place :Morranthuduwa
Height: 60m
Weight : 14.71 MT
Total No. of Mobitel towers Completed = 150

Galvanized Exports
• Galvanizing of Gas conveyers for
world’s largest Gas conveyer
manufacturer, Kosan Krisplant. These
conveyers are exported all over the
word including European countries.
• This is a continuing business.
• Galvanizing of Fences and solar panel
mounting structures for MIC Lanka. All
the fences are exported to Japan.
• This is also a continuing business.

Overseas Projects
33 kV Transmission Line – Uganda

Overseas Projects
Name of Contract Employer
Total
Weight
(MT)
Uganda- In relation to the Construction of Government Priority
Rural electrification projects in Lawala, Kaberamaido, Kobolubulu,
Amolatar & Kelle Port , Lawala- Otuboi, acinip and Lawala, Dokolo
The Government of the
Republic of Uganda
420 MT
Rural electrification projects in Kitgum, Palabek amd Lira, Apala,
Aloi
Republic of Uganda
Rural electrification schemes in Busia, Manafwa and Mbale
districts
Republic of Uganda
Rural electrification schemes in Soroti, Pallisa,Bukedia and Tororo
Districts
Republic of Uganda
Bangladesh - Komila Power Plant Project Lakdhanavi-Bangla
Power Limited
100 MT
Bangladesh - Rajshahi Power Plant Project Raj Lanka Power
Company Limited
100 MT

Overseas Projects
Project Tonnage
(MT)
Tanzania Transmission Line Project LOT 20 327.359
Tanzania Transmission Line Project LOT 21 248.218
Uganda – West Nile Transmission Line Project LOT 01 168.152
Uganda – West Nile Transmission Line Project LOT 02 12.028
Uganda Transmission Line Project LOT 03 7.91

Overseas Projects
HE the Prime Minister of Bangladesh at opening ceremony of power plant

Power Plant Projects in Bangladesh
Overseas Projects

Special Jobs Done

Special Jobs Done
‘Verele’ Japanese Restaurant for
Anantara Peace Haven Tangalle
Resort
Reefer Access Gantry Structures for
Hambantota Port

Monopole communication Tower for Ivory coast
03 Pieces and the Base
Maximum diameter = 1145 mm
Total Height of the Tower = 30 m
Total Weight of the Tower = 9435 kg
Special Jobs Done

LTL Galvanizers (Pvt) Ltd. LTL Galvanizers (Pvt) Ltd
THERMAL SPRAYING (Metallizing)
The most effective and resilient coating for protecting steel
structures, such as bridges, available today.

Electric Arc Wire Spray Metallizing
A thermal spray process in which, an arc is struck between two
consumable electrodes of a coating material. Compressed gas is
used to atomize and propel the material to the substrate.

Abrasive Blasting
Zn/Zn-Al Spraying
Application of Primer
Application of top Paint Coats
Metallizing Process

Why Metallizing?
1. Best alternative for re-painting of already fixed structures.
2. Life cycle cost is lower than that of painting.
3. There is no limit for the shape and size of the structure as in Hot
Dip Galvanizing.
4. Higher bond strength when comparing with painting.
5. Higher service life comparing with painting.
6. No limit of coating thickness as in Hot Dip Galvanizing.
7. The most versatile and effective coating for protecting steel
structures, such as bridges, available today.

Some ongoing and Completed Projects
Pipe bridge for
National water supply
& drainage board.
Location - Kalpitiya
Metallizing

Some ongoing and Completed Projects
Steel girder at CGR Work Shop
Metallized and
painted
condensate
storage tank –
Yugadanavi
Power Plant
Kerawalapitiya
Sample Metallizing at Aluthgama
Railway bridge

• Thermal Spraying of Zn and Zn/Al alloy will be done in accordance with the ISO
2063:2017 standard.
• Metallized coating thickness will be greater than the minimum coating thickness as
mentioned in TableC.1 of ISO 2063:2017-1.
• Metallized coating thickness and thickness of sealer coats can be customized according
to the requirement of the customer and according to the Environmental conditions
where item is installed.
• Adhesions tests of coating can be done if requested by the customer.
• Painting over metallized surface will be done under the guidance of a certified paint
specialist and in accordance with the table A.8 of ISO 12944-5:2007.
• Pre-Preparation, metallizing, painting and testing will also done in accordance with the
applicable NACE and SSPC standard requirements.
Quality Assurance

Future Strategies
• Manufacturing of Galvanized monopole towers in Sri Lanka
There is a potential market in Asian countries
for Power Transmission Hexagonal monopole
towers

• Manufacturing of Galvanized solar panel mounting structures and provide
complete solution with installation.
Future Strategies

• Acquiring/putting up a new fabrication plant in India
Future Strategies
If we have a steel fabrication facility in India, we may be able to fabricate towers for a
much lower cost than in Sri Lanka.

Future Strategies
• Putting up a new Hot Dip Galvanizing plant in Hambanthota
This will help in catering the future industrial development in
Hambanthota area,.

Sustainable Manufacturing
• Using Resources Efficiently
– Zero direct Discharge of
process water
» Use rinsing water
to prepare fresh
acid baths
» Use quenching
water to prepare
rinsing water baths
– Use waste heat for
drying furnace without
using electricity or gas
burners
– 100% cut down
electricity usage for flux
heating by using non-
heating flux
– Reduce HCl consumption
& Lime consumption by
improving acid
preparation
methodology
• Minimizing Pollution
– Zero discharge of effluent
water to the Environment
» Use proper Effluent
Treatment Process
– New Experiments to
reduce pollution
» Get support of
Department of
Agriculture to find
the possibility of
using solid sludge
generated as an
ingredient of
coconut fertilizer.
– Periodic monitoring of
Stack emissions, Ambient
Air Quality, noise levels
and Treated water quality
and do necessary process
adjustments.

Contractor for Turnkey Construction Projects
• LTLG is capable of handling turnkey construction projects.
• Our professional and highly qualified team will ensure
every phase of a project; Design, Fabrication, Galvanizing
and Installation, completed on time exceeding customer’s
expectations.
• We will earn customer’s vote of confidence and patronage
with our design competence, timely performance,
and competitive bid for the actual work.
Blocks 03 & 04, LINDEL,
Sapugaskanda, Sri Lanka

THANK YOU !

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