Detailed Project Report on electroforged steel grating manufacturing plant

ELECTROFORGED STEEL GRATING MANUFACTURING PLANT

[CODE NO.3837]  

Grating is open grid assembly of metal bars, in which the bearing bars, running in one direction, are spaced by rigid attachment to cross bars running perpendicular to them or by bent connecting bars extending between them.

Grating is a structural element that has a high load-bearing capacity with a low dead weight and a high level of transparency. The positive-fitting connection of the bearing bars and cross bars with the surround make the grating not only a very stable, but also visually attractive product. The applications are very diverse, as grating is used everywhere in industry and architecture. As an extremely robust, safe yet light platform flooring, the grating is indispensable in all areas of heavy industry.

Grating is installed in refineries, power stations, steel mills, mines and on oil platforms. Grating is being used increasingly more in the logistics industry as platform flooring and shelves. Architects and building owners appreciate the grating as a product which is both aesthetically pleasing and functional, be it used as a decorative facade cladding, a suspended ceiling or sun shield.

Steel grating is a kind of open steel member with its bearing bars & cross bars jointing at their intersections either by welding or by locking.

Electroforged Steel Gratings are made using the electroforging process. In this process, the sqaure twisted rods (Cross Members) are fused into the main load bearing members at using a special welding machine at very high current and tonnage. The Cross Members are properly set-in the Load Members such that it projects out of the grating top member by only a little more than 1 mm. This improves the slip resistance during walking. Electroforged Grating Panels are generally manufactured to 6000 mm lengths.

Grating is composed of following member:

BEARING BARS

Load carrying bars made from steel strip or slit sheet or from rolled or extruded aluminum and extending in the direction of the grating span.

Bearing bar types

Steel grating is made up of bearing bar and cross bar as certain distance by welding or pressure locked. Bearing bar have the types: flat type (also called plain type), serrated type, I bar type (I plain type and I serrated type). According to the bearing bar materials, there are carbon steel bars, mild carbon steel bars, stainless steel bars and so on.

Flat type bearing bars are made from steel strip or slit sheet or from rolled steel. These are produced using high quality steel materials which exhibit good hardness, ductility and tensile strength. Our bearing bars provide extremely good level support for floor joists. They have excellent finishing and based on clients’ need we provide them with untreated, galvanized or painted bearing bars. 

Surface of Load Bearing Bar is Plain.

Commonly used size: 25 x 3mm 

Commonly used pitch: 23mm 

Applications: flat type bearing bar gratings are the most widely used gratings, available for flooring sidewalk, all kinds of ditch cover, stair tread etc.

Serrated type-bearing bars delivers excellent performance in application areas, which are slippery, oily, moisture filled. They form a sort of anti-slip grating with their non-slip notches offering them a very good grip. They are made using mild carbon steel or stainless steel materials. We offer variety of serrated products in this category such as, normal serrated, serrated interrupted, serrated trapezoid, serrated carrier bar and serrated carrier bar with cross bar. For inclined gangways with a pitch of 10-25 degrees, we also provide grating with tread strips. 

Notches are made on tip of the Load Bearing Bar to improve skid resistance.

Commonly used size: 25 x 5mm, 30 x 3mm, 30 x 5mm, 32 x 5mm, 

40 x 5mm, 50 x 5mm 

Commonly used pitch: 23mm, 30mm, 34mm, 35mm, 40mm, 41mm, 

45mm, 50mm.

Advantages: Serrated type bearing bar gratings are best non-skid property & safety compared with plain grating.

I type bearing bar is one among the highly demanded product in our range. Features such as high strength, cost-efficient production processes and ease of installation are incorporated in all of our mild steel grating products. Because of its high strength and durability, these bar gratings can withstand extreme loads, quite comparable to solid floorings. Our products have wide range of applications such as Walkways, Platforms, Safety barriers, Drainage covers and Ventilation grates. Standard panels available for this product are in 6 × 1 meter at any size of bearing bar/cross bar and at any center distance as per load design.

Features: I type bearing bar is lighter, not substantially weaken the case of load capacity more economical and practical comparing with plain grating.

CROSS BARS 

The connecting bars, made from steel strip, slit sheet, or rolled bars, or from rolled or extruded aluminum, which extend across the bearing bars, usually perpendicular to them. In the Electroforged Steel Gratings, Cross Bars are generally of the Square twisted type. Where they intersect the bearing bars, are welded, forged to them. 

Commonly used size: 6mm Square Twisted, 8mm Square Twisted 

Commonly used pitches: 38mm, 50mm, 75mm, 100mm

COST ESTIMATION

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%

• 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 – A:

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)