manufacturing zincalume tanks (4 Tanks Per Day)

MANUFACTURING ZINCALUME TANKS

[EIRI/EDPR/4565] J.C.: 2782XL

Zincalume Water Storage Tanks are manufactured from steel sheet which has been continuously coated with zinc and aluminium to produce the excellent corrosion resistance that is commonly experienced by tanks that are exposed to the harshest of atmospheric conditions.

These tanks are fabricated using the highest grade of “Zincalume Steel” as MOC; which lasts up to four times longer than galvanized steel.

Aluminum in the coating provides barrier protection to the steel while the zinc element provides sacrificial cut edge protection. It is this double protection mechanism which accounts for Zincalume Steel’s superior corrosion performance.

This material provides customers with one in every of the foremost price effective, project specific choices for the storage of any water between the pH ranges of three to 12 and includes Potable Water, Irrigation Water, Fire Water with Water Reclamation. 

Zincalume steel is manufactured by an eternal hot dipped metallic coating process. The alloy coating of Zincalume steel provides glorious corrosion resistance and has been found to possess greater resistance to cracking and peeling.

Zincalume steel has an alloy coating of 55p.c Aluminium, 43.5% Zinc and 1.5% Silicon. The 150g/m2 (with choice of 200g/m2) coating weight is distributed equally on each surfaces of the coated strip. Metallic surface is coated with separate layers of special passivation resolution and resin.

Advantages of bolted steel Zincalume tanks:

• Eliminates the necessity for expensive labour, intensive site welding and at the same time dispenses with the need of elaborate and expensive re-enforced concrete base structures.

• Removes the chance of fire and explosion throughout erection, a explicit advantage on sites that store flammable products and liquids notably within the Oil & Gas Sector.

• Construction methods permit tanks to be erected at intervals days by a supervisor and team of semi-skilled labourers.

• Zincalume Bolted Cylindrical tank kits are reduced to one tenth of their total volume allowing a 100m? Tank to be packed onto pallets making a 10m? Cubic capability load that vastly reduces shipping costs.

• Standard panels are readily available ensuring speedy response to orders and delivery

• Zincalume pre-installed liner sealed tanks are easily re-located and can also have storage capacities increased by extending the height with minimal expense and disruption.

• Cost effective

• Easy and cheap to transport

• Fast Installations

• Relocating is easy

• Maintenance Free

• Flexibility in size

• Stronger structure

• Lighter Weight

 Zincalume water storage tanks Accessories

Panel of tank: 

Panels include, bottom panel, Roof panel, Side panel

Stays and Cleats: 

The stays and cleats are made of steel angle bar and steel plate

Bolts, Nuts and Washers: 

Hot Dipped Galvanised steel bolts, nuts and washers for internal and external

Jointing Materials: 

Non toxic PVC foam to be used for all jointing between tank panel flanges

Water Level Indicator: 

Mechanical Ball Float Type    

Ladder: 

Galvanised ladder for internal and external

Finish: 

(a) Hot Dip Galvanised conform to ISO equivalent

Internal Liner: 

A PVC Reinforced Liner that separates the water from the Tank Wall. Our liner is AS/NZS 4020 approved for use in contact with Drinking Water. Also they are perfect for hard water (bore water, chlorinated water or river water) applications.

COST ESTIMATION

Plant Capacity            4 Tanks/Day  

Land & Building (6500 sq.mt.)    Rs. 7.36 Cr    

Plant & Machinery                    Rs. 80 Lac 

Working Capital for 2 Months    Rs. 2.82 Cr 

Total Capital Investment          Rs. 11.30 Cr 

Rate of Return                          34%

Break Even Point                      48%

CONTENTS

INTRODUCTION

ADVANTAGES OF BOLTED STEEL ZINCALUME TANKS:

ZINCALUME WATER STORAGE TANKS ACCESSORIES

PANEL OF TANK:

STAYS AND CLEATS:

BOLTS, NUTS AND WASHERS:

JOINTING MATERIALS:

WATER LEVEL INDICATOR:

LADDER:

FINISH:

INTERNAL LINER:

USES AND APPLICATION

THESE TANKS ARE USED FOR VARIOUS APPLICATIONS LIKE

B.I.S. OF ZINC ALUMINIUM TANK

PROCESS FLOW CHART

PRODUCTION PROCESS

1. PROCUREMENT OF RAW MATERIAL

2. DECOILING

3. SHEET STRAIGHTENING (LEVELLER)

4. SHEARING

5. ROLL FORMING

6. PUNCHING

7. DIMENSIONAL CHECKING

8. FINAL CHECKING

9. DISPATCH TO SITE

10. QUALITY CONTROL

(A) DOCUMENT CONTROL

(B) PROCUREMENT AND MATERIAL CONTROL

(C) INSPECTION, TESTING AND VERIFICATION

(D) PROCESS CONTROL

(E) NON CONFORMATION CONTROL AND CORRECTIVE ACTION

MARKET POSITION

PRINCIPLES OF PLANT LAYOUT

STORAGE LAYOUT:

EQUIPMENT LAYOUT:

SAFETY:

PLANT EXPANSION:

FLOOR SPACE:

UTILITIES SERVICING:

BUILDING:

MATERIAL-HANDLING EQUIPMENT:

RAILROADS AND ROADS:

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

1. RAW-MATERIAL SUPPLY:

2. MARKETS:

3. POWER AND FUEL SUPPLY:

4. WATER SUPPLY:

5. CLIMATE:

SPECIFIC FACTORS

6. TRANSPORTATION:

A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES

7. WASTE DISPOSAL:

8. LABOR:

9. REGULATORY LAWS:

10. TAXES:

11. SITE CHARACTERISTICS:

12. COMMUNITY FACTORS:

13. VULNERABILITY TO WARTIME ATTACK:

14. FLOOD AND FIRE CONTROL:

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

1. DEPRECIATION:

2. FIXED ASSETS:

3. WORKING CAPITAL:

4. BREAK-EVEN POINT:

5. OTHER FIXED EXPENSES:

6. MARGIN MONEY:

7. TOTAL LOAD:

8. LAND AREA/MAN POWER RATIO:

PROJECT IMPLEMENTATION SCHEDULES

INTRODUCTION

PROJECT HANDLING

PROJECT SCHEDULING

PROJECT CONSTRUCTION SCHEDULE

TIME SCHEDULE

PLANT LAYOUT

SUPPLIERS OF ZINCALUME TANK

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF ZINC ALUME SHEET

SUPPLIERS OF GI NUT, BOLT AND FASTNERS

SUPPLIERS OF PLANT AND MACHINERY

SUPPLIERS OF FABRICATION MACHINERY

SUPPLIERS OF DG SETS

SUPPLIERS OF EOT CRANES

SUPPLIERS OF POWER TRANSFORMERS

SUPPLIERS OF ELECTRICAL PANEL

SUPPLIERS OF ELECTRIC MOTOR

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 JIGS AND FIXTURE

SUPPLIERS OF SUBMERSIBLE WATER PUMP

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)