TWEKO has completed a full scope of works — from design and manufacturing to supply and installation — of a technological complex for abrasive blasting, painting, and drying of metal structures at a road and infrastructure production facility.

About the Client

LLC “VK “Autostrada” (Autostrada) is one of the largest Ukrainian contractors in road and infrastructure construction. The company specializes in construction, reconstruction, and major repairs of highways, bridges, overpasses, and complex engineering structures, working with large-scale metal components produced both in-house and by subcontractors.

The enterprise’s production facilities include dedicated areas for fabrication, surface preparation, and anticorrosion protection of oversized metal elements used in road and bridge construction. The extreme operating conditions — harsh climate and heavy mechanical loads — impose stringent requirements on surface preparation quality and the durability of paint coatings.

As part of expanding its own production capabilities, Autostrada initiated the development of a dedicated abrasive blasting and painting section capable of delivering a complete technological cycle for large-scale products while meeting all industrial safety, occupational health, and consistent coating quality standards.

Solution

To support abrasive blasting, paint coating application, and drying of large-scale products, TWEKO supplied and installed a complete equipment complex comprising an abrasive blasting chamber of the KASO series, model KASO-20, and a paint and drying booth of the IKFS series, model IKFS-20 KFS.000.00.00-ENERGY “D”.

Technical parameters, main component composition, and configuration of ventilation, heating, lighting, and power supply systems are provided below in accordance with the equipment technical documentation.

• • Abrasive blasting chamber of the KASO series manufactured by TWEKO — model KASO-20 with internal cabin dimensions 20,000 × 6,500 × 7,000 mm.
    The chamber is designed in a pass-through configuration with entry and exit gates at both ends, allowing unidirectional product movement through the chamber as part of the technological process.The chamber supports simultaneous operation of two abrasive blasting workstations and is equipped with a ventilation system based on FVU 30,000 filtration-ventilation units, as well as industrial-grade lighting.For safe work at height, two worker mobile elevating platforms are installed — one on each side of the working zone — providing convenient and secure access to all surfaces of oversized products.

    The chamber includes a complete abrasive transport and recovery system comprising a bucket elevator, abrasive separator, accumulation hopper, and mechanized scraper floor for collecting spent material from the working zone.

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    The cabin is constructed as a metal frame clad with sandwich panels. The design includes personnel service doors, and equipment operation is controlled from a centralized control panel.

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• Paint and Drying Booth
  Paint and drying booth of the IKFS series manufactured by TWEKO — model IKFS-20 with internal cabin dimensions 19,000 × 6,500 × 7,000 mm and external dimensions 19,163 × 11,360 × 7,640 mm.
  The booth is designed in a pass-through configuration with sectional entry and exit gates at both ends, enabling through-flow movement of products during painting and drying.The booth structure consists of a metal frame clad with sandwich panels. Internal components include industrial lighting and a ceiling framework with ceiling frames and filters.
  Worker mobile elevating platforms are provided on both sides of the working zone, ensuring safe and convenient access to all surfaces of oversized products.

  

  The ventilation system is based on supply and exhaust units, each with a capacity of 26,000 m³/h; the configuration includes four supply and four exhaust units, providing the required air exchange in the working volume.

  The working temperature inside the booth during drying can reach 80 °C. The lighting system is rated for up to 3 kW power consumption. The booth incorporates multiple filter types — pre-filters, ceiling filters, cardboard filters, and fiberglass filters — ensuring air purification at different stages of the process.

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Technical Specifications of the Complex

Design and Functional Features of the Complex

• Technological equipment layout.
  The complex comprises an abrasive blasting chamber, paint and drying booth, ventilation units, and auxiliary equipment installed within a single production layout in accordance with the project design.
• Working zone dimensions.
  Internal dimensions of the KASO-20 and IKFS-20 chambers allow processing of metal structures with significant length, height, and cross-section within the limits specified in the technical documentation.
• Abrasive collection and recovery system.
  The abrasive blasting chamber is equipped with a mechanized system for collecting and transporting spent abrasive, including scraper floor, bucket elevator, separator, and accumulation hopper.
• Ventilation and air exchange organization.
  The complex incorporates filtration-ventilation units and supply-exhaust systems with performance parameters as specified in the equipment technical documentation.
• Placement of heat-generating equipment.
  Heat-generating and ventilation modules of the paint and drying booth are located outside the cabin in accordance with the adopted design solutions.
• Access and maintenance provisions.
  The chamber design includes service doors, gates, lighting, and other elements required for performing technological operations and routine maintenance.
• Height access equipment.
  Worker mobile elevating platforms are integrated for safe execution of abrasive blasting, preparation, and painting operations within the working zones.
• Control systems.
  Operation of the main chamber units and engineering systems is managed from dedicated control panels provided in the equipment design.

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Result for the Customer

As a result of the project, the customer received a complete set of technological equipment enabling high-quality abrasive blasting, painting, and drying of large-scale metal structures within its own production infrastructure.

The supplied equipment forms an integrated technological complex that includes an abrasive blasting chamber, paint and drying booth, ventilation and auxiliary systems, and height access equipment. The composition, parameters, and configuration fully comply with the project and operational documentation.

Conclusion

The implemented project demonstrates TWEKO’s systematic approach to delivering comprehensive engineering solutions for industrial enterprises — from equipment design and manufacturing to installation and seamless integration into the customer’s production infrastructure.

The technical solutions adopted allowed the complex to be fully tailored to the actual conditions of the production site while meeting all requirements for industrial safety, occupational health, and future expansion potential. The coordinated operation of technological and engineering systems ensures process stability and predictable equipment performance.

If your company requires a customized solution for surface preparation, painting, and drying of large-scale products, the TWEKO team is ready to propose an optimal equipment configuration tailored to your production specifics and operating conditions.

Get a Commercial Proposal

In 2021, TWEKO completed a project to supply and install a painting and drying complex for the V.O. Malyshev Plant, a leading Ukrainian manufacturer of specialized military equipment. The complex significantly enhanced the efficiency of painting processes and the quality of product finishing.

In September 2020, the V.O. Malyshev Plant announced a tender for the supply of a painting and drying complex as part of the enterprise’s technical re-equipment program. The technical specification, approved by the chief engineer, outlined a full project cycle: design, manufacturing, delivery, installation, and commissioning.

In accordance with Ukrainian legislation, an open tender procedure was conducted. Based on its results, our company, Techservice VEKO and Partner GmbH, was selected as the winner. The client’s decision was based on our proposal’s compliance with all technical requirements and TWEKO’s reputation as a reliable supplier of comprehensive solutions.

Our competitive edge is driven by in-house production, experienced sales, design, and service department specialists, enabling prompt responses to project challenges and the implementation of changes at all stages. A comprehensive approach to design and flexibility in decision-making make TWEKO a trusted partner for technically complex and large-scale projects.

Project

The project for the V.O. Malyshev Plant is one of the most ambitious and technically challenging in our company’s portfolio. It involved not only the supply and installation of technological equipment but also a range of preparatory construction and installation works, laying a rail track, and setting up engineering utilities. A particular challenge was the development and manufacturing of a custom drying chamber capable of drying large and heavy products at temperatures up to 150 °C — the first of its kind implemented by our company.

Works and Equipment

Under the contract terms, TWEKO carried out:
1. Construction Works:

• Preparation of the floor and ventilation ducts for the painting chamber.
• Floor setup for the drying chamber.
• Laying a rail track and installing a traction winch.
• Manufacturing and installation of air ducts for air supply and exhaust.

2. Equipment Manufacturing and Installation:

• Painting and drying chamber with dimensions (L × W × H) — 11160 × 5660 × 5540 mm.
• Drying chamber with dimensions (L × W × H) — 9240 × 4740 × 4075 mm, drying temperature up to 150 °C, heated by electric heat exchangers.
• Rail transport cart with dimensions 6000 × 2300 × 1100 mm, load capacity of 15 tons.

The successful implementation of this project marked a significant milestone in TWEKO’s development. It allowed our team to gain invaluable practical experience and expand the company’s technical and production capabilities. Each new project enables us to raise the bar even higher.

Advantages

1. High-quality paint coating due to state-of-the-art equipment.
2. Optimized painting processes through a well-designed complex.
3. Reliability and compliance with stringent military production requirements.
4. Effective collaboration at all project stages.

TWEKO completed the full scope of work — from equipment manufacturing to installation and commissioning — with high quality and within the stipulated timelines. Specialists from the design and service departments promptly made necessary adjustments to the project in coordination with the client, ensuring compliance with the technical specifications and tender conditions.

Conclusion

This large-scale project is further proof that TWEKO can handle the most complex technical challenges at the highest level. We are ready to support any enterprise striving for technological advancement.

In 2018, the sales department of our company received a request for a painting and drying chamber and an abrasive blasting chamber from representatives of ZLMZ LLC. In the course of negotiations, lasting a year, we, together with ZLMZ, formed the terms of reference and drew up a detailed plan for the construction of the painting area as a whole. To implement this project, it was necessary, first of all, to carry out work on the design of a new paint area at the enterprise, to coordinate the project with local authorities, to conduct an environmental impact assessment, while observing the strictest fire safety rules…

The next stage after the design was the implementation of construction and installation work – it was necessary to dismantle a concrete base up to 1.5 meters deep, and then equip a foundation slab for installing equipment with built-in technological pits for ventilation and equipment operation, a rail track for supplying products to the working areas of the chambers…

The painting area of ​​production is a rather energy-intensive area. Since to ensure high productivity and safe working conditions, it is required to provide a colossal airflow in the painting chamber – up to 100,000 cubic meters/hour, while heating the air to a delta of 35 ° C in painting mode and up to + 80 ° C in drying mode – such a spray booth, with electric air heating, consumes up to 500 kW/h of electricity. The abrasive blasting chamber consumes up to 12 cubic meters/min, 8 atm, compressed air while consuming up to 50 kW of electricity per hour. The total energy consumption of the painting area reaches 700 kW/h. Naturally, to provide such a volume of electricity, it was necessary to lay a separate power transmission line from the TP, with a length of 240 meters, and this was also included in the scope of work performed by our company within the framework of this project.

The scope of delivery of the equipment included: a painting and drying chamber, an abrasive blasting chamber, two self-propelled rail carts, abrasive blasting machines, airless high-pressure painting machines, a compressor room with receivers and air dryers, a set of lifting-mobile platforms for painting large-sized items, a cabin for storage and making paints…

Paint area

A painting and drying chamber and a dead-end type abrasive blasting chamber are located outside the main production area, adjoining it with a front wall with a gate. Both chambers have an internal size of 16180x6000x5500 millimeters, and together with rail trolleys, they can efficiently handle products with dimensions up to 15000x4000x5000 millimeters and weighing up to 20 tons! Both chambers have excellent energy efficiency, as they are hermetically sealed and made of sandwich panels with a fireproof filler – mineral wool, 100 mm thick. The spray booth has three rows of sealed energy-efficient LED lighting fixtures that provide at least 800 lux of illumination inside the cab, which allows for the best possible paint application on a wide variety of products.

A set of lifting-mobile platforms built into the spray booth allow operators to move quickly inside the booth and handle products up to 6 meters high. The platforms move in three directions – along the entire length along the walls of the chamber, along the entire height of the chamber, as well as from the wall at a distance of up to 1500mm. The platforms are driven by compressed air, which makes them explosion-proof and can be used in a spray booth environment.

The abrasive blasting chamber (KASO) has a system for the automatic collection and regeneration of shots and debris. The scraper floor system is responsible for collection and transportation, which consists of five longitudinal and one transverse line, which moves the shot to the elevator pit with synchronous translational movements. Further, the elevator raises the shot to a height of 7 meters, from where it enters the drum-type separator. In the separator, the shot is sifted and cleaned of large contaminating particles, and fine dust is removed through the dust extraction channels to the filter unit. After passing through the separator, the shot automatically enters the storage hopper in which the abrasive blasting machines are arranged. Thus, the abrasive blasting chamber provides a fully automatic collection, regeneration, and supply of shots for reuse – a closed cycle. The dust removal system is responsible for ensuring safe and comfortable working conditions in KASO, which is represented by two highly efficient filter and ventilation units FVU-18, they promptly remove the dusty gas-air mixture from the chamber, filter it and release it into the atmosphere.

The compressor station is represented by a high-performance screw compressor Remeza VK120, with a productivity of up to 16,000 liters per minute at 8 atmospheres of pressure, and effective installation with an air dryer – freezer, 4 compressed air receivers with a volume of up to 1000 liters each.

The set of equipment includes the Wiwa Airless 140032 RS/F Phoe Airless Painting Machine, the CLEMCO SCWB Shot Blasting Machine – 2452, 200 liters. with a full set of operator’s suit and personal protective equipment. And to ensure fire safety, the painting area is equipped with an automatic powder fire extinguishing system, fire alarm, and its connection to local fire extinguishing services.

Probably, the production of equipment was not the most difficult in the implementation of this project, it was much more difficult to correctly draw up the terms of reference, carry out the design, design development, coordinate all the processes and stages of implementation: construction, laying communications, fire safety… At the same time, observing the strictest security rules labor that operates at the enterprise LLC “ZLMZ”, PJSC “Zaporizhstal” and throughout the Metinvest Holding. And also find reliable contractors, coordinate and organize their work, plan everything and invest in the schedule.

This project gave our company invaluable experience in the implementation of a difficult and complex object, moreover, for one of the largest enterprises in Ukraine – Metinvest Holding! The implementation of such a project once again confirms the ability of our company to create and implement the most complex technological complexes for the painting department of any, even the most demanding Customer.