GES Museum — Lonavala – Veritas Engineers And Erectors

GES Museum — Lonavala

Veritas Engineers And Erectors> GES Museum — Lonavala

Project Overview:

Veritas Engineers & Erectors completed the fabrication and erection of the GES Museum Lonavala — a ship-inspired mono-structure commissioned by GES. Designed to resemble the merchant-navy profession, the museum features a circular deck, a mast-like central element and sweeping curvilinear members that evoke the profile of a ship anchored on land. The structure’s scale and distinctive maritime concept required precise fabrication and execution to realise the architectural vision.

Challenges:

Complex curvilinear geometry: Every structural member had unique compound curves requiring strict dimensional control.

Weather exposure & corrosion protection: The fully exposed structure demanded long-term corrosion resistance; hot-dip galvanizing was selected as the primary protection. Post-galvanizing, some fastener holes developed dried zinc deposits that needed sealing to ensure water-tightness.

Site logistics & lifting: Lifting long curved members and modular sections onto a circular elevated deck required detailed lift planning and temporary bracing.

Tight architectural tolerances: Joints and connections had to be smooth and nearly invisible to maintain the ship-like aesthetic.

Solutions:

3D-driven shop fabrication: CNC cutting and custom jigs allowed accurate shaping and pre-assembly of curved members, reducing on-site adjustments.

Modular pre-assembly: Large units were preassembled in shop and transported as modules to minimise high-altitude work and accelerate erection.

Corrosion protection workflow: All members received hot-dip galvanizing. Where galvanizing created dried zinc deposits in through-holes, we inspected and sealed affected holes using silicone-based washers of appropriate diameters to ensure durable, weather-tight connections.

Erection & lifting plan: Multi-point slinging, tag-line control and staged bracing were used for precise placement of curved members on the circular platform.

Quality control: Dimensional checks, fit-up verification and required NDT ensured compliance with specifications.

Results:

The GES Museum was delivered on scope and stands as a landmark structure that blends maritime-inspired architecture with robust structural performance. The hot-dip galvanizing combined with targeted sealing ensures long-term resistance to corrosion while preserving the clean, ship-like aesthetic.

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