Silvan New Foundry Plant Project
Greenfield Steel Foundry - 50-ton Large Part Casting Capacity
Site Area
60,000 m²
Building Area
~40,000 m²
Casting Capacity
50 tons
Greenfield Foundry & Machining Complex
Silvan Sanayi A.Ş., one of Turkey's most established steel casting companies, invested in a new greenfield foundry and machining complex in the Dilovası IMES Industrial Zone to consolidate and expand production capacity. On a 60,000 m² site, the project delivers more than 33,000 m² of advanced manufacturing space in the first phase, with a planned second-phase expansion of approx. 3,000 m².
The plant is designed to cast large components up to 50 tons gross weight, supported by state-of-the-art moulding lines, increased melting capacity, dedicated heat-treatment facilities, and a CNC-equipped machine shop for medium and large-scale parts.
For Silvan, whose modern plants already serve global cement, mining, rail and heavy-industry clients, the Dilovası facility is a strategic platform to boost export competitiveness and operational efficiency. The project master plan balanced relocation of existing equipment from legacy sites with new high-tech investments, while maintaining production continuity and controlling schedule, quality, and cost risk.
The result is an integrated industrial campus that aligns long-term capacity growth with international quality and safety standards.
Project Details
Key project information
xPM / BMM Role
Owner's Project Management & Integration Partner
BMM/xPM was engaged as the owner's project management and integration partner from early concept through construction and commissioning. Our team prepared the comprehensive Project Management Plan and Master Plan schedule, coordinated all design disciplines, and established the governance structure, reporting standards, and contractor interfaces for the new plant.
We developed and maintained a detailed BIM-driven project model, structured monthly progress and variance reports for the executive board, and implemented performance dashboards integrated with Silvan's SAP ERP and MicroStrategy business-intelligence layer.
In parallel, we designed a dedicated document-management and collaboration platform to control drawings, contracts, and site records. Through this integrated control system, management could track physical progress, cost accruals, risk exposure, and contractor performance in near real time, protecting both schedule certainty and investment value.
Master Project Management & Governance
Comprehensive planning documentation
Integrated Master Planning & Scheduling
Critical path analysis
BIM Strategy, Plant Layout & Coordination
3D modeling and clash detection
Multidisciplinary Design Management
Architectural, structural, MEP, process interfaces
Procurement & Contractor Tender Support
Vendor evaluation and contracting
Construction Monitoring & Site Controls
Quality and progress oversight
Monthly Progress, Cost & Schedule Variance Reporting
Executive performance dashboards
Software & Systems Used
Integrated technology platform enabling model-based project control and executive decision support
BIM Tools
3D modeling and coordination
Scheduling
Project timeline management
Cost & Progress Control
Variance and accrual tracking
Industrial Project Consulting
With experience in large-scale industrial capital programs including foundry and manufacturing facilities, we provide project governance framework design, integrated project control, and executive decision support for complex industrial projects.
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