Detailed Project Report on installation of unit for fabrication of shuttering/scaffolding material

INSTALLATION OF UNIT FOR FABRICATION OF SHUTTERING/SCAFFOLDING MATERIAL [CODE NO.3663]  


“Form work or shuttering is a temporary construction used as a mould for structure, in which concrete is placed & in which it hardens and matures”.


Definition of Formwork:

The term ''Formwork indicates a temporary structure erected to receive wet concrete and to hold it in place, till it is sufficiently hard and strong to be self-supporting without any deformation. The other synonymous terms used are: shuttering and centering. The formwork can be of different materials and different types depending upon the type of structure and site requirements, economy, safety and quality required in the finished work.

When concrete is placed, it is in plastic state. It requires to be supported by temporary supports and castings of desired shape till it becomes sufficiently strong to support its own weight. This temporary casing is known as the formwork or forms or shuttering.


COST ESTIMATION


Plant Capacity            23 MT/Day       
Land & Building (8000 sq.mt.)      Rs. 8.06 Cr         
Plant & Machinery                      Rs. 1.64 Cr     
Working Capital for 2 Months     Rs. 6.41 Cr
Total Capital Investment              Rs. 16.61 Cr
Rate of Return            24%                   
Break Even Point             51%            

        
      
INTRODUCTION    
DEFINITION OF FORMWORK:    
REQUIREMENTS OF GOOD FORMWORK    
IMPORTANCE OF FORMWORK:    
LIMITATIONS:    
TYPES OF SHUTTERING    
(A) SHUTTERING FOR COLUMN    
(B) SHUTTERING FOR BEAM & SLAB FLOOR    
(C) SHUTTERING FOR STAIRS    
BELOW IS A LIST OF COMMONLY USED STEEL SHUTTER MATERIALS:-    
A SHORT DESCRIPTION OF EACH MATERIAL IS GIVEN BELOW:    
THE MAJOR COMPONENTS OF A CONCRETE FORMWORK ARE LISTED BELOW    
COMPONENTS OF BEAM FORMWORK    
BEAM FORMWORK INCLUDES THE FOLLOWING COMPONENTS:    
COMPONENTS OF COLUMN FORMWORK    
THE COLUMN SHUTTERING OR FORMWORK INCLUDES
   THE COMPONENTS BELOW:    
TYPES OF FORMWORK    
1. CONVENTIONAL FORMWORK:    
2. MS FORMWORK:    
3. MODERN FORMWORK SYSTEMS:    
MODERN FORMWORK SYSTEMS:    
1. TABLE OR FLYING FORMWORK SYSTEMS:    
2. COLUMN FORMWORK SYSTEM:    
3. HORIZONTAL PANEL SYSTEMS:    
4. VERTICAL PANEL SYSTEMS:    
5. JUMP /CLIMBING FORMWORK SYSTEMS:    
6. SLIP FORMWORK SYSTEM:    
7. TUNNEL FORMWORK SYSTEM:    
TYPES OF FORMWORK MATERIALS    
(A) TIMBER FORMWORK:    
(B) STEEL FORMWORK:    
(C) PLASTIC FORMWORK:    
(D) ALUMINIUM FORMWORK:    
TYPES OF SCAFFOLDING    
THE DIFFERENT TYPES OF SCAFFOLDINGS WHICH ARE GENERALLY USED:    
SCAFFOLDING TYPES    
USES & APPLICATION    
(1) FLOOR FORMS    
(2) SLAB FORM    
B.I.S. SPECIFICATION    
PROCESS FLOW DIAGRAM    
FABRICATION PROCESS OF SHUTTERING/SCAFFLDING MATERIAL    
MAIN COMPONENTS TO BE MANUFACTURED    
(1) ACROW PROPS    
DIFFERENT ACROW PROP SIZES    
(2) SLAB FORMS STANDARD SIZES OF SLAB FORMS    
(3) FLOOR FORMS    
STANDARD SIZES OF FLOOR FORMS    
(4) H-FRAME SYSTEM    
H-FRAMES/WALL FORM SYSTEM/FLOOR SLAB FORM    
H-FRAME (CROSS BRACE)    
(5) H-FRAME SYSTEMS    
(6) STANDARD SIZES OF H-FRAMES    
(7) WALL FORM SYSTEM    
DIFFERENT SIZES OF WALL FORM SYSTEM    
PROCESS DESCRIPTION    
(1) SHEET METAL CUTTING OPERATIONS    
(A) SHEARING    
(B) BLANKING    
(3) BENDING    
(4) GRINDING    
(5) PAINTING    
MARKET POSITION/OVERVIEW    
CURRENT SCENARIO    
CLASSIFICATION    
FORM TYPES    
INSULATING CONCRETE FORMS    
WALL FORMS    
COM-SHELLS    
ARCHITECTURAL FORMS    
FORMLINERS    
DROPHEAD FORMWORK    
FLYING FORMS    
INFLATED FORMS    
CONCRETE CANVAS (CC)    
CONCRETE CANVAS SHELTERS (CCS)    
FABRIC FORMS    
SOME OF THE MAIN ADVANTAGES ARE;    
SLIPFORM    
NEW TRENDS    
SCAFFOLDING WITNESSES NEWER DEMAND TRENDS    
PRODUCTS & APPLICATIONS    
NEW DESIGN REQUIREMENTS    
MARKET HIGHLIGHTS    
MARKET RESEARCH ANALYSIS    
INDUSTRY INSIGHTS    
SEGMENTATION BY MATERIAL TYPE    
SEGMENTATION BY COUNTRY    
COMPETITIVE LANDSCAPE    
MARKET DYNAMICS    
MATERIAL TAKEAWAY    
REGIONAL TAKEAWAY    
PLANT LAYOUT    
SUPPLIERS OF SHUTTERING/SCAFFOLDING    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF HOT ROLLED SHEETS    
SUPPLIERS OF M.S. CHANNELS AND ANGLES    
SUPPLIERS OF M.S. FLAT    
SUPPLIERS OF M.S. PLATE    
SUPPLIERS OF M.S. PIPE    
SUPPLIERS OF DEGREASING CHEMICAL    
SUPPLIERS OF PICKLING CHEMICALS    
SUPPLIERS OF COATING POWDER    
SUPPLIERS OF PLANT AND MACHINERY    
SUPPLIERS OF POWER PRESS    
SUPPLIERS OF SHEARING MACHINE    
SUPPLIERS OF ROLLING MACHINE    
SUPPLIERS OF FLYPRESS    
SUPPLIERS OF BENDING MACHINE    
SUPPLIERS OF MECHANICAL PRESS    
SUPPLIERS OF SHEET LAVELING MACHINE    
SUPPLIERS OF PUNCHING PRESS    
SUPPLIERS OF CNC PLASMA CUTTING MACHINE    
SUPPLIERS OF MILLING MACHINE    
SUPPLIERS OF POWER HACSAW    
SUPPLIERS OF GRINDING MACHINE    
SUPPLIERS OF MIG WELDING MACHINE    
SUPPLIERS OF POWDER COATING MACHINE    
SUPPLIERS OF D.G. SETS    
SUPPLIERS OF EOT CRANE    
SUPPLIERS OF POWER TRANSFORMERS    
SUPPLIERS OF ELECTRICAL PANEL    
SUPPLIERS OF ELECTRIC MOTOR    
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS    
SUPPLIERS OF AIR COMPRESSORS    
SUPPLIERS OF AIR COMPRESSORS    
SUPPLIERS OF PLATFORM WEIGHING MACHINE    
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS    
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS    
SUPPLIERS OF SHOT BLASTING MACHINE    
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)