Detailed Project Report on roofing sheet (metal) manufacturing
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ROOFING SHEET (METAL) MANUFACTURING [CODE NO.3618]
Galvanized Corrugated Sheets are manufactured using best grade steel and is widely applied in construction industry. Galvanized Corrugated Sheets have excellent corrosion resistance, these Sheets have become the most preferred material for various construction purposes, particularly roofing and walling. The demand for corrugated iron sheet depends mainly on the performance of its end-user (i.e. the construction sector or more specifically the building construction sector). Therefore, the demand for the products under consideration is a derived demand, which depends directly on them performance of its major end – user.
The construction sector of the country has undergone tremendous changes and development in recent years. The contribution of the construction sector to the GDP during the period 2001 – 2010 have been growing at annual average growth rate of 13 percent which is above the average annual growth rate of real GDP during the period under consideration (11.4 %), indicating a rise in the share of the construction sector within the overall economy. Moreover, during the GTP period (2010 – 2015), the construction sector is expected to grow at annual average growth rate of 20%.
COST ESTIMATION
Plant Capacity 60 MT/Day
Land & Building (7000 Sq.Mtr) Rs. 4.39 Cr
Plant & Machinery Rs. 5.85 Cr
Working Capital for 2 Month Rs. 19.19 Cr
Total Capital Investment Rs. 31.11 Cr
Rate of Return 35%
Break Even Point 48%
INTRODUCTION
USES AND APPLICATIONS
PROPERTIES
APPLICATIONS
B.I.S. SPECIFICATION
MANUFACTURING PROCESS
(1) PROCESS OF GALVANIZING
HOT-DIP GALVANIZING
METHODS OF HOT DIP GALVANISING
(A) BATCH PROCESS
(B) CONTINUOUS PROCESS
HOT-DIP GALVANIZING ON CONTINUOUS LINES
(A) PREPARATION OF BLACK COILS
(B) CLEANING
(C) ANNEALING AND COOLING
(D) ZINC BATH MANAGEMENT AND ALLOYING REACTIONS
COATING WEIGHT [MASS] CONTROL AND MEASUREMENT
POST TREATMENTS
(A) TEMPER PASSING
(B) LEVELING
(C) CHEMICAL TREATMENT
(D) INSPECTION
(E) OILING AND RECOILING
(2) COLOURING PROCESS OF G.I SHEET
COATING PROCESS 28
TESTS CONDUCTED FOR QUALITY CHECK OF THE COATED STEEL
(3) CORRUGATION PROCESS OF G.I COLOURING SHEET
PROCESS FLOW CHART
QUALITY CONTROL
VARIOUS QUALITY CONTROL TEST INCLUDE
PLANT DESCRIPTION
1. CONTINIOUS GALVANISING LINE
GALVANIZING BASICS
ZINC
WHY ZINC IS ONLY USED:
SALIENT FEATURES
LINE DIAGRAM OF CGL
COMPONENTS OF LINE:-
DEGREASING SECTION
FURNACE SECTION
PRE HEAT FURNACE:-
RADIANT TUBE FURNACE (RTF):-
SOAKING ZONE:-
JET COOLING:-
ZINC POT:-
COOLING TOWER
Q-TANK
(2) COLOUR COATING LINE
COMPONENTS:-
MARKET OVERVIEW
FEW INDIAN MAJOR PLAYERS ARE AS UNDER
INDIAN GALVANIZED STEEL INDUSTRY
APPLICATIONS OF GALVANIZED STEEL PRODUCTS
SECTOR CONSUMPTION PATTERN
APPLICATIONS OF METAL ROOFS
PROBLEMS WITH METAL ROOFS
LOW ACCEPTANCE
LIMITED COLOUR PALETTE
COST
UNWILLINGNESS TO TAKE ONUS OF QUALITY/SAFETY
OUTLOOK
METAL ROOFS AND ITS INSTALLATION
MATERIAL FOR METAL ROOFING
CHOOSE YOUR METAL ROOFING
ADVANTAGES OF A METAL ROOF
INSTALLING A METAL ROOFS
B. PROCESS IN INSTALLING A METAL ROOF
CHALLENGES OF INSTALLING METAL ROOFING
ROOFING MARKET
GLOBAL ROOFING MARKET: SNAPSHOT
RISING DEMAND FOR ECO-FRIENDLY ROOFING COULD SHAPE ROOFING MARKET
ASIA PACIFIC LIKELY TO SUSTAIN STRONG POSITION IN GLOBAL ROOFING MARKET
INDUSTRY INSIGHTS
HOUSEHOLD SIZE
RESIDENTIAL DENSITY
INCOME DISTRIBUTION
HOUSING CONDITION AND OBSOLESCENCE FACTOR
HOUSEHOLDS PER ROOM AND CONGESTION FACTOR
SLUMS
HOUSING SHORTAGE AND NEED
PROPOSED HOUSING POLICY
PRIVATE SECTOR PARTICIPATION
ROLE OF GOVERNMENTAL
HOUSES OF DIFFERENT INCOME CATEGORIES
GROUP HOUSING SCHEMES
URBAN VILLAGES
CONCEPT OF CITY WITHOUT SLUMS
URBAN RENEWAL
AREA FOR RENEWAL
GUIDELINES FOR URBAN RENEWAL1
HOUSING & SLUMS
HOUSING
SLUM POPULATION
BASIC SERVICES FOR URBAN POOR (BSUP) PROGRAM IN JAMMU
ISSUES
MIGRATION
FUTURE HOUSING DEMAND
PROPOSED HOUSING POLICY
HOUSING FOR URBAN POOR:
DETAILED EXPORT DATA OF ROOFING SHEET
ROOFING INDUSTRY STATISTICS AND TRENDS
CURRENT MARKET
MAJORITY OF CONTRACTORS ARE CENTERED IN THE FOLLOWING STATES:
INDUSTRY LEADERS
HIGH PERFORMANCE PVC SINGLE PLY ROOFING
INDUSTRY MATERIALS
ROOFING INDUSTRY COMPLAINT TRENDS
THE MOST POPULAR DOCUMENT REASONS FOR COMPLAINTS ARE:
PROCESS FLOW CHART FOR CONTINIOUS COIL GALVANISING LINE
PROCESS FLOW CHART FOR COLOUR COATING LINE
PROCESS FLOW CHART FOR CORRUGATION LINE
PLANT LAYOUT
MANUFACTURERS/SUPPLIERS OF ROOFING SHEET
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF M.S STRIP COILS
SUPPLIERS OF ZINC INGOT 110
SUPPLIERS OF CASTIC SODA
SUPPLIERS OF HYDROCLORIC ACID
SUPPLIERS OF DEGREASING CHEMICAL
SUPPLIERS OF COATING POWDER
SUPPLIERS OF PAINTS
SUPPLIERS OF PLANT AND MACHINERIES
INDIAN SUPPLIERS OF CONTINIOUS GALVANISING LINE
FOREIGN SUPPLIERS OF CONTINIOUS GALVANISING LINE
INDIAN SUPPLIERS OF COLOUR COATING LINE
FOREIGN SUPPLIERS OF COLOUR COATING LINE
INDIAN SUPPLIERS METAL CORRUGATED ROOFING SHEET LINE
FOREIGN SUPPLIERS OF METAL SHEET CORRUGATION LINE
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 PLATFORM WEIGHING MACHINE
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
SUPPLIERS OF JIGS AND FIXTURE
SUPPLIERS OF SUBMERSIBLE WATER PUMP
SUPPLIERS OF COOLING TOWER
SUPPLIERS OF EFFULENT TREATMENT PLANT (ETP PLANT)
LIST OF PLANT & MACHINERY
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)
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