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Headworks Ships Gargantuan Mahr Bar Screens to Mumbai

April 4, 2012 download pdf

Colossal, enormous, gargantuan. Words like these are only used to describe items that are physically or metaphorically of great magnitude. Headworks® Inc. is known for manufacturing the largest and most robust screens in the industry, but a recent shipment to Maharashtra, India, may set a new record for the largest pair of Mahr® bar screens Headworks has ever shipped outside of the United States.

Each screen is comparable in height to a five story building, measuring 50 feet (15.25 meters) in height and 11 feet (3.45 meters) in width. An unprecedented amount of raw materials were purchased for the sole construction of the two screens, including:

  • 48,947 pounds (22,202 kilograms) of stainless steel sheet and plate metal;
  • 15,248 pounds (6,916 kilograms) of screenfield bar; and
  • 400 feet (122 meters) of chain.

Custom crates were manufactured for the transportation of the screens for their voyage from Houston to India where they will then be installed at the intake of the Shahad River, 60km northeast of Mumbai. The installation is being handled by Crystal Industrial Syndicate Pvt. Ltd.

Headworks was awarded the contract last fall by STEM Water Distribution & Infrastructure Company to manufacture the two bar screens. Heavy debris from the Shahad River has been blocking and clogging the intake structure and transfer pumps at the local Water Treatment Plant. A manual screen was installed with hopes of reducing maintenance issues, but large debris including the carcasses of small animals made the working conditions unsanitary for the operators.

STEM needed an improved screening system and hired Tandon Urban Solutions (formerly Tandon & Associates) to specify a solution. The conditions demanded a bar screen with 10mm spacings that could withstand flows of up to 1,650 MLD. Although the total capacity of the WTP is 900 MLD, the increase in flow capacity will support future expansions of the facility.

“Some manufacturers didn’t think it could be done,” explained Gerald Seidl, Senior Vice President of Headworks Inc. “Headworks, on the other hand, manufactures some of the largest screens in the world and we are thrilled to be presented with an opportunity to showcase our strengths with screens of this magnitude in India.”

Both screens are scheduled to be installed post-shipment this spring.

About Headworks
Headworks Inc. is a leading engineering and manufacturing company supplying wastewater screening and MBBR/IFAS biological treatment solutions to municipal, industrial, and marine facilities around the world. The team of professionals at Headworks is committed to innovating and refining our processes in order to design and manufacture the best products in the industry. With these goals in mind, Headworks has become the benchmark in our industry for providing robust, reliable solutions.

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