556 7.4 Manufacturing Phase To meet the schedule, manufacturing was distributed among four specialized providers such as crushing/screening stations, skid-type chassis, trusses and drives, and auxiliary components and chutes. The precision of the modular design made it possible to dispense with integral pre-assembly, validating the interoperability and dimensional fit of components manufactured independently in different geographical locations. This approach guaranteed final compatibility on-site, optimizing logistical and shipping times. 7.4.1 Factory Modularizations The stations and conveyors were manufactured as welded assemblies on workshop and delivered to the site considering the transport restrictions and applying modularization concept whenever possible. The execution recorded no deviations from the engineering, validating the technical feasibility of the model and compliance with manufacturing specifications. 7.4.2 Pre-assembly and Assembly in Factory The integral pre-assembly was performed only for the first unit to validate tolerances, omitting the subsequent ones due to design replicability. The skid-chassis were 100% pre-assembled due to their interface complexity (Figure 7). Conveyor components (trusses, head and tail sections) were shipped pre-assembled to ensure bolted connections in the field, while secondary structures underwent individual dimensional controls. The technical delivery concluded in September 2024, meeting the contractual milestones. Figure 7 - Main structure of pre-assembled station 7.5 Pre-Assembly on site The execution consisted of an external pre-modularization of macro-modules lasting 145 days, finalized in January 2025, followed by the final integration between August 2024 and May 2025. The installation was divided into two plant shutdowns: 48 days for the first line and 61 days for the remaining two. The interval between shutdowns facilitated the operational ramp-up and the optimization of the assembly through the transfer of lessons learned.
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