Industry Overview
Electroforged steel grating is manufactured through an electroforging process in which square twisted cross bars are fused to main load-bearing members using specialized welding equipment that combines high hydraulic pressure with heavy electric current. The process produces gratings with high load-bearing capacity, low dead weight, good transparency, visual appeal, and ease of installation, removal, repair, and maintenance. These characteristics make electroforged steel gratings suitable for locations requiring natural lighting and ventilation.
During manufacturing, pre-straightened bearing bars are cut and fed from coils, while cross bars are positioned under electrodes for simultaneous electroforging. The process provides a homogeneous combination of cross bars and bearing bars, supports mass production, reduces processing time and waste, and offers dimensional accuracy, consistent quality, and seamless welded joints. Electroforged gratings are available in smooth and serrated surface configurations and are used for walkways, steps, stairways, and industrial flooring.
The technology finds applications across pulp and paper mills, sugar mills, waste treatment plants, glass industries, poultry and cattlefeed industries, fertilizer industries, offshore platforms, coal mines, refineries and petrochemicals, cement plants, plastic industries, and other industrial facilities. Standard gratings are typically available in 6 meter X 1 meter configurations, with pitch sizes selected according to application requirements. PLC-controlled equipment combines hydraulic pressure of more than 100 tonnes with approximately 2200 AMPS of electric current to fuse the cross bars and bearing bars.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 24 MT/Day |
| Land & Building (4000 sq.mt.) | Rs. 3.44 Cr |
| Plant & Machinery | Rs. 2.43 Cr |
| Working Capital for 2 Months | Rs. 5.71 Cr |
| Total Capital Investment | Rs. 11.86 Cr |
| Rate of Return | 33% |
| Break Even Point | 54% |
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
- MANUFACTURING PROCESS OF ELECTROFORGED GRATING
- ELECTROFORGED PROCESS
- FABRICATION OF GRATINGS:
- SPOT RESSISTANCEWELDING
- 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
- VERIFICATION OF RAW MATERIAL BY
- (2) ELECTRLFORGE WELDING
- VERIFICATION OF WELDING PROCESS BY
- (3) CROPPING OF WELDED RODS
- VERIFICATION OF CROPPING PROCESS BY
- (4) CUTTING OF PANEL FOR REQUIRED SIZE
- VERIFICATION OF CUTTING PROCESS BY
- (5) LOOSE PART MANUFACTURING (OFFLOADED / BOUGHT OUT)
- VERIFICATION OF LOOSE IN INCOMING STAGE BY
- (6) FABRICATION (WELDING)
- VERIFICATION OF WELDING PROCESS BY
- (7) FINISHINGZ & GRINDING
- VERIFICATION OF FINISHING PROCESS BY
- (8) SURFACE TREATEMENT
- VERIFICATION OF FINISHING PROCESS BY
- (9) FINAL INSPECTION & DESPATCH
- MARKET OVERVIEW
- PLANT LAYOUT
- PRINCIPLES OF PLANT LAYOUT
- 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:
- 6. TRANSPORTATION:
- 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
- SUPPLIERS OF ELECTROFORGED GRATING
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF MILD STEEL ROD AND BAR
- SUPPLIERS OF PLANT AND MACHINERY
- SUPPLIERS FOR ELECTRO FORGED GRATING PLANT
- SUPPLIERS OF ELECTRO FORGED GRATING CUTTING MACHINE
- SUPPLIERS OF MULTI SPOT WELDING MACHINE
- SUPPLIERS OF EOT CRANES
- SUPPLIERS OF POWER TRANSFORMER
- 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 a steel grating manufactured by fusing square twisted cross bars to load-bearing bars using hydraulic pressure and heavy electric current. The process creates a strong and homogeneous connection between the members. Electroforged gratings are valued for their load-bearing capacity, low dead weight, transparency, rigidity, dimensional accuracy, and ease of installation and maintenance. They are commonly used for industrial walkways, steps, stairways, platforms, and flooring applications where strength, ventilation, and natural lighting are important.
Electroforged steel grating is manufactured by positioning cross bars and bearing bars under electrodes and joining them through a combination of hydraulic pressure and heavy electric current. Pre-straightened bearing bars are cut and fed from coils, while cross bars are positioned for simultaneous welding. Subsequent operations can include cropping, panel cutting, loose-part manufacturing, fabrication, finishing and grinding, surface treatment, final inspection, and dispatch. The report also covers electroforged welding, spot resistance welding, and galvanization processes.
The main types identified in the report are serrated grating and plain grating. These configurations differ primarily in the surface characteristics of the grating. Electroforged gratings can be selected according to application requirements, including load and span considerations. The report also discusses the surface of load-bearing bars and identifies smooth surface and serrated surface configurations as important categories for electroforged grating applications.
Electroforged steel gratings offer high load-bearing capacity with comparatively low dead weight, rigidity, dimensional accuracy, and a quality finished surface. The process provides a homogeneous combination of cross bars and bearing bars and is suitable for mass production. It can reduce processing time and waste while producing consistent welded joints. The gratings are also easy to install, remove, repair, and maintain, and their open structure can support natural lighting and ventilation in suitable industrial locations.
Electroforged steel gratings are used across a wide range of industrial facilities and infrastructure applications. The report identifies pulp and paper mills, sugar mills, waste treatment plants, glass industries, poultry and cattlefeed industries, fertilizer industries, offshore platforms, coal mines, refineries and petrochemicals, cement plants, and plastic industries among the application areas. They are particularly useful for walkways, steps, stairways, platforms, and open flooring where strength, rigidity, ventilation, and accessibility are required.
The report identifies a range of equipment and supporting systems associated with an electroforged grating plant. These include electro forged grating equipment, grating cutting machines, multi spot welding machines, EOT cranes, power transformers, electrical panels, air pollution control equipment, air conditioning equipment, air compressors, platform weighing machines, material handling equipment, fire fighting equipment, and shot blasting machines. The exact equipment configuration depends on the manufacturing process, product requirements, plant design, and operational needs.
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