RTP played a vital role in the successful upgrade and refurbishment of several 42-year-old General Motors Die Cast Buildings. The project involved replacing foundations for 2500-ton Die Cast Machines with ones designed for 4000-ton machines, which were positioned over a 30-foot-wide tunnel. Additionally, all process equipment was removed, and the concrete floor, support steel, piping, HVAC, and electrical systems were replaced.

RTP's actions encompassed a wide range of tasks and responsibilities to ensure a seamless and successful project execution. We assisted in developing the Plant Layout for the new equipment in the Die Cast South facility, optimizing space utilization and workflow efficiency. RTP's engineering team developed structural design drawings for various components, including foundations and inertia blocks for the 4000-ton capacity Die Cast Machine and the 200-ton capacity Rollover Trim Press. The design also included support beams spanning the 30-foot tunnel to accommodate the significant loads with limited deflection. Furthermore, RTP designed the tunnel roof/process floor, oscillating scrap conveyor foundations, incline scrap conveyor foundations, high load path and floor area for the die cart, and specified conduit and pipe embed sizes and locations for the die cast machines and automated cells. To aid in visualization and coordination, RTP provided 3D models of the work to the client for incorporation into the master plant 3D model.

Throughout the construction phase, RTP provided on-site assistance, particularly in addressing unknown abandoned foundations that were discovered during the process. Our team also prepared specifications for equipment purchase, facility refurbishment, and equipment installation, ensuring clear guidelines for the project. RTP conducted design reviews, offering comments on the building refurbishment to ensure quality and compliance with project objectives. We also reviewed building crane requirements, evaluating reach and tool path for changing 50-ton dies, and assessed the need for crane replacement. RTP ensured the proper placement of equipment near crane reach and travel path to avoid interference and optimize operations.

The project resulted in improved foundation structures, enhanced equipment capabilities, and modernized facility infrastructure.

RTP played a critical role in the design and construction engineering of a cutting-edge facility for General Motors (GM), dedicated to casting and pre-machining small gas engine blocks. This state-of-the-art facility included a range of equipment, including die cast machines with robotic cells, rotary furnaces with robotic cells, conveyors, and a CNC coolant system. RTP provided plant layout, robotic cell layout, installation scope requirements, drawings, and construction engineering assistance, ensuring the successful implementation of the project. 

RTP's actions encompassed several crucial tasks throughout the project. Our team actively participated in developing the Scope of Work for the involved Original Equipment Manufacturers (OEMs), establishing clear guidelines and expectations, and developed multiple concepts for robotic die cast cell arrangements, post-process line layouts, and plant layouts. We delivered comprehensive design drawings for various aspects of the facility, including the process layout of the robotic die cast cell, mechanical, piping, ductwork, and electrical utilities installations.

Throughout the project, RTP collaborated closely with fabricators and installation teams, contributing to the fabrication and installation of overhead casting cranes, fall arrest systems, and other safety features. Our on-site construction assistance engineering during the two-year installation period ensured precise fit and smooth implementation within the facility. Through close collaboration with OEMs, meticulous design, and construction engineering, RTP ensured the seamless integration of various systems, contributing to the overall success of the project.

RTP played a pivotal role in assisting General Motors (GM) with their die casting die storage project. GM required a solution to store eight different large 50-ton die casting dies in an upright position, optimizing floor space and reducing die changeover time. RTP provided conceptual designs, detailed design, and engineering support for the development of unique die stands that allowed for quick changes and assembly of the dies.

RTP's actions included several key tasks to support the project. We assisted in developing the Scope of Work for OEMs (Original Equipment Manufacturers) and created multiple plant layout concepts for evaluation by GM. Additionally, RTP developed various die stand assembly concepts and prepared detailed specifications and Scope of Requirements for OEMs and the installation contractor.

RTP's engineering team also created structural design drawings for various aspects of the project, including installation layouts in different plant locations, fabrication drawings for modular die storage stands, die preparation stands, die spacers, and quick-access tool storage racks. Our team provided specifications for forged T-bolts and certification of the fabrication process, and provided fabrication drawings for die storage and preparation stands, including those for specific areas like Die Cast North and Die Cast South. RTP also offered design assistance for motorized die transfer systems, including foundations, guide rails, electrical installations, and tool and bolt charts.

To ensure quality and compliance, RTP provided Professional Engineer (PE) certification for all die stands, spacers, and fasteners. We conducted on-site inspections at the fabrication shop to ensure adherence to specifications and provided on-site construction assistance engineering during the installation phase.

The project improved die changeover times and optimized floor space, enhancing GM's production capabilities and efficiency in the die casting process.

RTP played a pivotal role in the development and construction of a new GM die casting equipment facility, specifically designed for the production of aluminum transmission housing and cases. The project also involved redesigning underperforming subsystems and implementing safety enhancements.

Our team developed multiple concepts for robotic die cast cell arrangements and plant layouts, with consideration to the challenges posed by an older building with tight column spacing. Upon selection of a concept, RTP developed design drawings for various aspects of the project, including the process layout of the robotic die cast cell, mechanical and electrical utilities installation for the die cast machines and cells, safety enhancements, equipment installation jigs, and more.

Our team’s support was crucial throughout all phases of this project, including on-site construction assistance engineering during the installation phase, an extensive six-week on-site OEM review in Shenzhen, China. RTP also provided PE certifications for specific components, such as the shot rod changeout crane and davit arm attachment on the die cast machine.

Throughout the two-year project duration, RTP's expertise in engineering, design, and construction facilitated the realization of a state-of-the-art GM die casting equipment facility. The facility's advanced capabilities, enhanced safety features, and efficient production processes are a testament to RTP's commitment to excellence.