Industry Overview
Steel grating is an open-grid structural product consisting of load-bearing bars arranged in one direction and cross bars positioned perpendicular to them. It combines high load-bearing capacity, low dead weight, transparency, durability, and safety, making it suitable for industrial and architectural applications. Electroforged steel gratings are manufactured by fusing square twisted cross bars into main load-bearing members using a high-current, high-tonnage welding process. The cross bars are set into the load members with a slight projection above the grating surface to improve slip resistance. Panels are generally manufactured to lengths of 6000 mm.
Gratings are widely used in refineries, power stations, steel mills, mines, oil platforms, logistics facilities, and industrial plants as flooring, platforms, walkways, shelves, drainage covers, and stair treads. Architectural applications include facade cladding, suspended ceilings, and sun shields. Bearing bars are available in flat, serrated, and I-type configurations, while cross bars are commonly supplied in square twisted forms. Depending on application requirements, steel gratings may be plain, serrated, untreated, galvanized, or painted. Their combination of strength, durability, light weight, and functional design supports diverse applications across heavy industry, infrastructure, and architecture.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 16 MT/Day |
| Land & Building (2000 sq.mt.) | Rs. 1.78 Cr |
| Plant & Machinery | Rs. 2.43 Cr |
| Working Capital for 2 Months | Rs. 3.48 Cr |
| Total Capital Investment | Rs. 8 Cr |
| Rate of Return | 22% |
| Break Even Point | 67% |
Content Index
- INTRODUCTION
- GRATING IS COMPOSED OF FOLLOWING MEMBER:
- BEARING BARS
- BEARING BAR TYPES
- SURFACE OF LOAD BEARING BAR IS PLAIN.
- CROSS BARS
- TYPES OF ELECTROFORGED GRATING
- (A) SERRATED GRATING
- (B) PLAIN GRATING
- ADVANTAGES OF USING ELECTROFORGED STEEL GRATINGS
- LIMITATIONS OF ELECTRO FORGE PROCESS GRATINGS.
- USES AND APPLICATION
- B.I.S. SPECIFICATION
- PROCESS FLOW CHART
- PROCESS FLOW CHARTMANUFACTURING PROCESS OF ELECTROFORGED GRATING
- ELECTROFORGED PROCESS
- FABRICATION OF GRATINGS:
- SPOT RESSISTANCE WELDING
- PRINCIPLE:
- SPOT WELDING:
- ADVANTAGES AND DISADVANTAGES
- ADVANTAGES:
- DISADVANTAGES:
- THE HOT DIP GALVANIZING PROCESS
- SURFACE PREPARATION
- CAUSTIC CLEANING –
- PICKLING –
- FLUXING –
- GALVANIZING –
- INSPECTION –
- QUALITY CONTROL
- INSPECTION & TESTING
- FABRICATION OF GRATING
- GALVANIZATION OF GRATINGS
- (1) RAW MATERIAL RECEIPT
- (2) ELECTRLFORGE WELDING
- (3) CROPPING OF WELDED RODS
- (4) CUTTING OF PANEL FOR REQUIRED SIZE
- (5) LOOSE PART MANUFACTURING
- (6) FABRICATION (WELDING)
- (7) FINISHING & GRINDING
- (8) SURFACE TREATEMENT
- (9) FINAL INSPECTION & DESPATCH
- MARKET POSITION
- KEY TAKEAWAYS
- BY TYPE - SEGMENT ANALYSIS
- BY APPLICATION - SEGMENT ANALYSIS
- GEOGRAPHY - SEGMENT ANALYSIS
- DRIVERS – STEEL GRATING MARKET
- ADVANCEMENTS IN TECHNOLOGY LIKE HIGH LOAD CAPACITY
- CHALLENGES – STEEL GRATING MARKET
- EMISSION OF CARBON DURING THE PRODUCTION OF STEEL GRATING
- MARKET LANDSCAPE
- ACQUISITION
- STEEL GRATING INDUSTRY
- PLANT LAYOUT
- SUPPLIERS OF ELECTROFORGED STEEL GRATING
- SUPPLIERS OF MILD STEEL ROD AND BAR
- SUPPLIERS FOR PLANT AND MACHINERY
- SUPPLIERS FOR ELECTROFORGED STEEL GRATING PLANT
- SUPPLIERS OF ELECTRO FORGED GRATING CUTTING MACHINE
- SUPPLIERS OF MULTI SPOT WELDING MACHINE
- SUPPLIERS OF EOT CRANES
- SUPPLIERS OF POWER TRANSFORMERS
- SUPPLIERS OF ELECTRICAL PANEL
- SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
- SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
- SUPPLIERS OF AIR COMPRESSORS
- SUPPLIERS OF PLATFORM WEIGHING MACHINE
- SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
- SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
- SUPPLIERS OF SHOT BLASTING MACHINE
Appendix
- 01. PLANT ECONOMICS
- 02. LAND & BUILDING
- 03. PLANT AND MACHINERY
- 04. OTHER FIXED ASSESTS
- 05. FIXED CAPITAL
- 06. RAW MATERIAL
- 07. SALARY AND WAGES
- 08. UTILITIES AND OVERHEADS
- 09. TOTAL WORKING CAPITAL
- 10. TOTAL CAPITAL INVESTMENT
- 11. COST OF PRODUCTION
- 12. TURN OVER/ANNUM
- 13. BREAK EVEN POINT
- 14. RESOURCES FOR FINANCE
- 15. INSTALMENT PAYABLE IN 5 YEARS
- 16. DEPRECIATION CHART FOR 5 YEARS
- 17. PROFIT ANALYSIS FOR 5 YEARS
- 18. PROJECTED BALANCE SHEET FOR (5 YEARS)
Frequently Asked Questions
Electroforged steel grating is an open-grid structural product manufactured by fusing cross bars into load-bearing members using a high-current welding process. The process creates a strong and stable connection between the bearing bars and square twisted cross bars. The resulting grating combines structural strength with relatively low dead weight and good transparency. It is commonly used for industrial flooring, platforms, walkways, drainage covers, stair treads, and other applications where strength, safety, and durability are required.
The main components of steel grating are bearing bars and cross bars. Bearing bars carry the primary load and extend in the direction of the grating span. Cross bars connect the bearing bars, normally at right angles, and provide structural stability. Bearing bars may be flat, serrated, or I-type, while electroforged gratings commonly use square twisted cross bars. The selection of bar type, size, spacing, and material depends on the required load capacity, operating conditions, safety requirements, and application.
Plain grating has a smooth load-bearing bar surface, while serrated grating incorporates notches to improve slip resistance. Plain grating is widely used for general flooring, sidewalks, ditch covers, and stair treads where standard surface conditions are suitable. Serrated grating is particularly useful in areas exposed to oil, moisture, or other slippery conditions because its notched surface provides improved grip. The choice between the two depends primarily on the required level of traction and the operating environment.
Electroforged steel grating is used across heavy industry, infrastructure, logistics, and architectural applications. Typical installations include refineries, power stations, steel mills, mines, oil platforms, industrial plants, logistics facilities, walkways, platforms, safety barriers, drainage covers, ventilation grates, stair treads, and shelves. Its combination of load-bearing capability, durability, transparency, and relatively low weight makes it suitable wherever a robust open-grid flooring or structural surface is required.
Electroforged steel gratings offer high load-bearing capacity, structural stability, durability, low dead weight, and good transparency. Their open-grid construction can provide practical drainage and ventilation characteristics while reducing material weight compared with solid flooring. Serrated versions can also provide improved slip resistance in demanding operating environments. The products can be supplied with different bearing bar configurations and surface treatments, including untreated, galvanized, or painted finishes, depending on application requirements and the desired level of protection.
Electroforged steel grating is manufactured by joining square twisted cross bars to load-bearing bars through a specialized high-current welding process. The production sequence generally includes raw material receipt, electroforge welding, cropping of welded rods, cutting panels to the required size, loose-part manufacturing, fabrication and welding, finishing and grinding, surface treatment, and final inspection and dispatch. The process is followed by quality control and inspection to ensure that the finished grating meets the specified dimensional, structural, and surface requirements.
Hot dip galvanizing is used to provide steel grating with a protective zinc coating that helps improve resistance to corrosion. The process generally involves surface preparation, caustic cleaning, pickling, fluxing, galvanizing, and inspection. Proper surface preparation is important because contaminants and oxides must be removed before the zinc coating is applied. Galvanized grating is particularly suitable for applications where the product may be exposed to moisture or corrosive operating conditions and where longer service life and reduced maintenance are important considerations.
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