ELECTROFORGED STEEL GRATING

[CODE NO.4056]

It needs to be well noted that Electroforged Steel Grating is made using the process of electroforging. The square twisted rods are fused well into the main load bearing members. For this to be done, a very special kind of a welding machine at high tonnage and current is used. There are various advantages associated with the use of electroforged steel gratings. These gratings have a high load-bearing capacity with low dead weight. These gratings are known to depict high levels of transparency. These gratings are known to be visually attractive. These gratings depict easy installation and removal of repair and maintenance. These gratings are suitable for sites and places that require natural lighting and ventilation.

In the manufacturing process of electroforged steel gratings, the square twisted cross bars are electroforged or welded to the rectangular shape bearing bars by a process that much combines the hydraulic pressure with heavy electric current. The pre-straightened bearing bars are cut and fed directly from the attaché coils. In the manufacturing process, two crossbars are shot into the welder and placed under the electrodes by pulling hooks for simultaneous welding.

It is important to note the types of electroforged grating: smooth surface grating as well as the serrated surface grating. The process of electroforged grating is much preferred as: it leads to homogenous combination of cross bars and bearing bars, mass production, less time consumption process, economically less cost, quality finished product, dimensional accuracy, no air gap between welded joints, less waste, and much more. It is much beneficial as compared to manual weld grating.

The electroforged grating process has many applications in various industries such as – 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 many more. The technical experts resorting to this process of electroforged steel grating refer to technical load charts for technical specifications and quality assurance.

It is worthwhile to note the features of electroforged gratings. These gratings are cross bars that are fused to different types of bearing bars to assure maximum strength and productivity. These electroforged gratings are used for walkways, steps and stairways. The steel electroforged gratings are durable and economical and are considered to be worthwhile and most versatile in nature.

It needs to be well noted that electroforged gratings provide much rigidity and strength. Most manufacturers who are competitive in this industry manufacture economical gratings that are based upon the load and span requirements of the clients. The manufacturers of the electroforged steel grating process have wide range of different open steel floor gratings. Based on the load and span requirements, the most economical gratings are manufactured by the customers. The in-house engineering departments have the best of AUTOCAD systems that offer the best of design, detail and offering facilities to convert the structural drawing to detailed grating drawing.

The standard electroforged gratings are typically available in 6 meter X 1 meter. These gratings can be produced with almost any combination of pitch size. The electroforged gratings are versatile depicting much strength and rigidity. The electroforged gratings are much manufactured by PLC controlled equipments which combine the high hydraulic pressure which is more than 100 tonnes and high electric current of approx 2200 AMPS to fuse the cross bearing bar into a joint which is absolutely seamless.

COST ESTIMATION

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%

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 – 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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