Industrial
Proton EV Factory Steel Structure Optimisation
Reducing steel tonnage, simplifying structural framing, and improving construction efficiency through engineering-led optimisation without compromising structural performance.
Tanjung Malim
Dec 2025
Steel Structure Optimisation
Steel Members Reduced from 2,500+ to Approx. 1,500
Executive Summary
The Proton EV Factory project required a comprehensive engineering review to reduce construction costs while maintaining structural safety and performance. Rather than simply reducing material quantities, Sanki re-engineered the steel structure through Finite Element Method (FEM) analysis, member optimisation, and framing simplification. Standard steel sections replaced uncommon profiles, while the structural configuration was simplified, reducing the number of steel members from over 2,500 to approximately 1,500.This engineering-led value optimisation improved constructability, reduced material and installation costs, simplified site coordination, and helped the main contractor achieve its project budget without compromising design requirements.
1.0 Engineering Design for Constructability
Engineering analysis identified opportunities to optimise the original steel structure while maintaining the required structural performance and safety.
Finite Element Analysis (FEM)
Reviewed structural behaviour, load distribution, member utilisation, stability, and connection efficiency to optimise the framing system.
Steel Tonnage Optimisation
Reduced unnecessary steel weight by improving load paths, optimising member sizes, and removing redundant structural components.
Performance Maintained
Delivered a lighter steel structure while maintaining compliance with project requirements and structural performance.
2.0 Material and Construction Optimisationng
Engineering decisions considered both structural performance and practical construction efficiency to reduce overall project cost.
Economical Steel Sections
Replaced uncommon steel sections with commercially available standard members to reduce procurement cost, fabrication complexity, and material wastage.
Simplified Structural Framing
Redesigned the framing arrangement to reduce installation members from over 2,500 to approximately 1,500.
Improved Constructability
Fewer structural members simplified fabrication, transportation, lifting, assembly, and on-site coordination.
3.0 Construction Efficiency and Project Value
The optimised design delivered measurable construction benefits that improved productivity throughout project execution.
Faster Installation
Reduced lifting operations, alignment work, bolting activities, and overall installation time through simplified framing.
Lower Site Costs
Reduced manpower, crane operating duration, temporary works, and installation equipment requirements.
Improved Constructability
Simplified the erection sequence, improved site safety management, and supported faster project completion while meeting budget objectives.
4.0 Project Outcome
Through engineering-led value optimisation, Sanki reduced steel tonnage, selected more economical steel sections, and simplified the structural framing without compromising safety or performance. The redesigned system lowered material and construction costs, improved installation efficiency, and helped the main contractor achieve its budget target while maintaining construction quality and structural integrity.
