Our client, Renfe, contacted us to discuss the installation of a paint booth for the railway repair workshop in Villaverde.
During our visit, they shared their concerns with us, and we also took the opportunity to view the location they had in mind for the installation. We were able to observe how the parts are handled, as well as their dimensions and weights, the details of which they would later provide us with.
- Passage for the overhead crane; limited space for the ductwork, which must not interfere with the overhead crane.
- They need to be able to access the interior of the cabin via the overhead crane to position the parts.
- They need to be able to access the interior using a heavy-duty scissor lift so that they can handle the part inside and carry out the painting work in an ergonomic manner.
- They want to comply with the strictest environmental regulations; therefore, they are asking us to adapt to the most demanding standards.
- They do not want to use fossil fuels for drying and heating the cabin.
- He wants to keep the civil engineering work to a minimum for the installation.
- Pneumatic top access for overhead crane.
- 15-tonne parts handling table, movable via rails.
- Exhaust air filter.
- Heating system using endothermic radiant panels.
- Advance dashboard.
- Air recirculation system for drying.
- Drive unit located outside the plant to optimise floor space.
Having analysed the data at our disposal, we have proposed the construction of a paint booth measuring 236,22 x 196,85 // 177,16 (width x length x height), which will feature a removable access door.
These dimensions are dictated by the parts that our client requires to be handled comfortably inside the booth. As the client does not wish to undertake any structural work, we propose a side air outlet which will also be fitted with two air purifiers to filter the air in three stages before it is discharged to the outside. In addition to the purifiers, we must adapt the air outlet ducts to comply with the regulations applicable in their autonomous community, taking VOC measurements as specified in those regulations.
As for the access points for the equipment to be painted in the oven booth, we have installed a top access panel that opens pneumatically, providing ample space for a bridge crane and leaving a clear area measuring 39,37 x 118,11 inches, which facilitates access using single-point or multi-point chains to ensure comfortable working conditions. Furthermore, as required, we sought a table from our suppliers for moving and handling heavy loads. This 15-tonne table is capable of moving along rails from outside to inside the booth and, once inside, allows the workpiece to be moved vertically from 27,56 in to 59,05 in, as requested by the client. Furthermore, this system is connected to the booth to comply with the safety regulations required for equipment operating inside it, ensuring proper and risk-free operation at all times.
As for the booth’s airflow, a vertical lateral flow system has been chosen, allowing us to apply the process to any type of part under optimal working conditions, guaranteeing finishes that meet the customer’s requirements.
The exhaust air filtration system ensures a high level of filtration by equipping the chamber with a 5-stage exhaust air filtration process, as well as large filter surfaces that ensure high machine uptime and minimise the need for maintenance.
This cabin features high-efficiency LED lighting, as well as electrical control via our ADVANCE control panel, which allows for detailed temperature control by sector across groups of radiant panels that heat the oven cabin. This technology differs from standard convection heating in that it heats the material of the part to be dried directly, resulting in significant savings in power consumption.
This solution is designed to ensure we meet each and every one of the client’s requirements in a timely and appropriate manner, whilst also complying with the highest standards implemented by Renfe regarding: access control, provision of preventive documentation, verification, and the qualifications of our staff on a specific management platform. We would like to take this opportunity to thank everyone involved at Renfe, as well as our team, for their impeccable management of the project.