Detailed Project Report (DPR) on steel fabrication (peb, solar panel mounting structure fabrication, transmission tower, steel poles for street light fabrication, pipe fabrication etc)

STEEL FABRICATION (PEB, SOLAR PANEL MOUNTING STRUCTURE FABRICATION, TRANSMISSION TOWER, STEEL POLES FOR STREET LIGHT FABRICATION, PIPE FABRICATION ETC.)
[CODE NO.3100]  


(A) PEB

"Pre-engineered steel buildings" are those which are fully fabricated in the factory after designing, shipped to site in CKD(completely knocked down) condition; and all components are assembled and erected at site with nut-bolts, thereby reducing the time of completion.

Pre–engineered means, generally speaking, is any part of a structure that is manufactured prior to its arrival on the building site. The concept of the pre-engineered building (PEB) is one where the fabrication is completed in a controlled environment with the latest technology, and then subsequent erection is carried out.

Technological improvement over the year has contributed immensely to the enhancement of quality of life through various new products and services. One such revolution was the pre engineered buildings. Through its origin can be traced back to 1960’s its potential has been felt only during the recent years. This was mainly due to the development in technology, which helped in computerizing the design and design.

Though initially only off the shelf products were available in these configurations aided by the technological development tailor made solutions are also made using this technology in very short durations. A recent survey by the Metal Building Associations (MBMA) shows that about 60% of the non residential low rises building in USA are pre engineered buildings.

Although PEB systems are extensively used in industrial and many other non residential constructions world wide, it is relatively a new concept in India. These concepts were introduced to the Indian markets lately in the late 1990’s with the opening up of the economy and a number of multi nationals setting up their projects. The market potential of PEB’s is 1.2 million tones per annum. The current pre engineered steel building manufacturing capacity is 0.35 million tones per annum. The industry is growing at the compound rate of 25 to 30 %.

With respect to design of the structure and aesthetic appearance India is way behind. Indian manufacturers are trying to catch up; comparatively PEB’s is a new concept in India. Beside, in fabrication and other areas of PEB India is very good. As compared to other countries Indian codes for building design are stringent but safer. IS standards are upgraded continuously. In India, American codes are also followed.


COST ESTIMATION

Plant  Capacity                                :       STEEL FABRICATION (PEB, SOLAR PANEL
Land & Building (6500 Sq.MT)    :    Rs. 4.88 Cr
Plant & Machinery                          :    Rs. 3.69 Cr
Working Capital for 2 Months      :    Rs.15.99 Cr
Total Capital Investment              :    Rs.24.95 Cr
Rate of Return                               :    34%
Break Even Point                          :    42%


INTRODUCTION    
ADVANTAGES OF PRE ENGINEERED BUILDINGS    
PRE ENGINEERED BUILDINGS VS CONVENTIONAL STEEL BUILDINGS    
USES AND APPLICATIONS    
ROOF MOUNTING SYSTEM    
GROUND MOUNTING SYSTEM    
TYPES OF TOWER    
B.I.S. SPECIFICATION    
MARKET OF PEB STRUCTURE    
MARKET OF SOLAR MOUNTING STRUCTURE    
CHALLENGES AND CONSTRAINTS    
MARKET OF TELECOM TOWER IN INDIA    
MARKET PROSPECTS OF POWER TRANSMISSION TOWER    
NEW INDUSTRY BENCHMARK IN TRANSMISSION LINE TOWER
BUSINESS IN INDIA    
MARKET FOR STREET LIGHT POLES    
SUPPLIERS OF PEB STRUCTURE    
SUPPLIERS OF SOLAR PANEL MOUNTING STRUCTURE    
SUPPLIERS OF TRANMISSION TOWER    
SUPPLIERS OF STREET LIGHT POLES    
PROCESS FLOW CHART FOR PEB    
FABRICATION PROCESS OF PEB    
FABRICATION PROCESS OF PRIMARY MEMBER OR MAIN FRAME SUCH
AS COLUMN AND TAPERED RAFTER    
FABRICATION PROCESS OF SECONDARY MEMBER SUCH AS PURLIN
AND GIRTS, C-SECTIONS, EAVE STRUTS, OPEN WEB TRUSES,
CABLE BRACING ETC.    
FABRICATION PROCESS OF WALL PANEL AND ROOF PANEL
BY ROLLING PROCESS    
QUALITY CONTROL FOR FABRICATION PROCESS    
PROCESS FLOW CHART FOR SOLAR PANEL MOUNTING STRUCTURE    
FABRICATION PROCESS FOR TRANSMISSION TOWER    
PROCESS FLOW CHART FOR STREET LIGHT POLES     
FABRICATION PROCESS OF STREET LIGHT POLES    
HOT DIP GALVANIZED BENEFITS    
COATING DEFECT    
QUALITY CONTROL    
METHODS OF ANODODIZING    
PLANT LAY OUT
SUPPLIERS OF PLANT AND MACHINERY    
SUPPLIERS OF RAW MATERIALS    


APPENDIX – A:

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET