FLOOD GATE
Location: Khammam, India
Project: Laser Pack Industrial facility
Function: Industrial building located in the flood zone with past history of flood water rise to 9ft or lower from ground level.
VREcast Role: Vrecast lightweight system was designed to take flood loads and designed to use the gate for daily industrial operations. The gate was designed to be operated by only one person without any support from the motor to push and pull the gate.
PROJECT OVERVIEW
The flood gate utilizes VREcast’s lightweight composite wall panel system designed specifically for industrial facilities in flood-prone areas with historical water levels reaching up to 9 feet.
Key Design Features
Manual Operation Design:
- Single-person operation capability (no motor required).
- Sliding gate mechanism on overhead track system.
- Lightweight composite panels reduce operational effort.
- Plate (1/2″x7½”x20′-0″) installed above opening when gate is open.
Dual Functionality
- Flood Protection: Withstands flood loads up to 10 feet with engineered connections and waterproofing.
- Daily Operations: Smooth sliding operation for regular industrial access without mechanical assistance.
Panel Configuration:
- Panel 1: 9′-11″ width
- Panel 2: 7′-2½” width
- Panel 3: 7′-2½” width
- Total span: 20′-0″
Structural Components:
- Track System: Duragate CGS-345P galvanized track (52′-0″ long) mounted at top.
- Carriage System: Duragate CGS-350.8P carriages at 4′-0″ on center for smooth operation.
- Support Structure: 20″x20″ concrete columns with reinforced steel bars.
- Wall Panels: VREcast composite construction with 6″x2″-18GA bridging at 3′-0″ on center.
Sealing & Waterproofing:
- Thin rubber shut-off membrane for watertight seal.
- Masticord rubber shims (3/4″x7″x8″) between panel connections.
- Galvanized steel channels and connection plates.
Material Specifications: All steel components spray galvanized for corrosion resistance in flood conditions.
THE CHALLENGE
Laser Pack’s industrial facility in Khammam, India faced a critical dilemma. Located in a flood zone with historical water levels reaching 9 feet, the facility needed robust flood protection. But traditional flood barriers presented a major operational problem: they were heavy, cumbersome, and required multiple workers or motorized systems to operate.
The facility needed a gate that could:
- Withstand significant flood loads up to 10 feet
- Operate smoothly for daily industrial access
- Be deployed quickly by a single person
- Require no mechanical or motor assistance
- Maintain watertight integrity during flood events
Conventional concrete or steel flood gates were either too heavy for manual operation or lacked the structural capacity for both daily use and emergency flood protection.
ROLE OF VRECAST
VREcast engineered a revolutionary 10-foot-high, 20-foot-wide sliding flood gate system that solved both challenges simultaneously.
Our composite wall technology delivered:
Lightweight Construction, Heavy-Duty Performance
VREcast composite panels provide the structural strength to withstand major flood loads while remaining light enough for single-person operation—no motors, no crews, no complexity.
Dual-Purpose Design
The gate serves double duty: industrial access door during normal operations and emergency flood barrier when needed. One system, two critical functions.
Effortless Manual Operation
Engineered with a precision Duragate track and carriage system, the entire 20-foot gate glides smoothly on an overhead rail. One person can open or close it in minutes—crucial when flood warnings arrive.
Engineered Waterproofing
Rubber shut-off membranes and sealed panel connections create a watertight barrier that protects your facility when it matters most.
Built to Last
Galvanized steel components and corrosion-resistant materials ensure decades of reliable performance in harsh flood-zone conditions.
