Detailed Project Report (DPR) on vibrated casted/vertical casting r.c.c. pipe making plant

VIBRATED CASTED/VERTICAL CASTING R.C.C PIPE MAKING PLANT
[CODE NO.3320]


Concrete is a building material made by thoroughly mixing cement; sand; aggregate, such as gravel or crushed stone; and water in desired proportions. The cementitious material usually is hydraulic cement that sets and hardens in water. Initially, the concrete mix is a plastic material that assumes the shape of the mold into which it is cast. The mixture is poured into a cavity, an excavation in the ground, or a form designed for a specific purpose. After hardening, concrete has the appearance and structure of stone. In fact, it may be thought of as "moldable stone." When the mixture is deposited in its final position, it is known as cast-in-place concrete. When a concrete product or element is cast elsewhere (whether in a plant or on a field site) and then brought to its final position, it is termed precast concrete.

Precasting is a manufacturing procedure, whereas casting-in-place is a construction procedure. Being a manufacturing operation, precasting can have certain advantages: o Work can be performed at a fixed site with accelerated curing facilities. o A single location for batching and mixing concrete can be provided, o A convenient source of water and other raw materials can be used, o A location convenient to transportation facilities can be selected, o Mass production techniques can be employed. o Opportunities for storing product and working under shelter reduce the impacts of cyclical demand and weather conditions.

RCC pipes are classified as pressure and non pressure pipes viz. NPI, NP2, NP3, P1, P2, P3 for use in specific conditions. These pipes are made from cement, coarse and fine aggregate, sand, mild steel and HT rods and bars

In IS 458, RCC pipes are classified in two major categories i.e. Non Pressure Pipes and Pressure Pipes. Pressure Pipes are further divided according their capacity to withstand hydrostatic pressure.



COST ESTIMATION

Plant  Capacity                                              :       650.00 Nos./day
land & Building (20000 Sq.Mtrs)               :       Rs.  10.17  Cr
Plant & Machinery                                        :       Rs.  7.42   Cr
Working Capital for 2 Months                    :       Rs.  12.22  Cr
Total Capital Investment                            :        Rs.  30.21  Cr
Rate of Return                                             :         61%
Break Even Point                                        :        30%

INTRODUCTION    
USES AND APPLICATION    
APPLICATIONS    
B.I.S. SPECIFICATION    
MARKET SURVEY    
1. INDUSTRY STRUCTURE & DEVELOPMENT:    
2. OPPORTUNITIES AND THREATS:    
3. SEGMENT-WISE ACTIVITY:    
(A) WATER SUPPLY AND SEWERAGE PROJECTS:    
(B) BAR WRAPPED STEEL CYLINDER (BWSC) PIPES/PRESTRESSED
    CONCRETE CYLINDER PIPES (PCCP):    
(C) RAILWAY SLEEPERS:    
(D) NATIONAL RIFLE DIVISION:    
3. OUTLOOK:    
4. RISKS & CONCERNS:    
5. INTERNAL CONTROL SYSTEMS:    
6. FINANCIAL PERFORMANCE WITH RESPECT TO OPERATIONAL
   PERFORMANCE:    
7. HUMAN RESOURCES AND INDUSTRIAL RELATIONS:    
8. CAUTIONARY STATEMENT:    
EXPORT DATA OF RCC HUME PIPE    
TOTAL VALUE & VOLUME OF EXPORTS IN INDIA    
TOP SUPPLIERS    
TOP PORTS OF DISCHARGE    
IMPORT DATA OF RCC PIPE    
TOTAL VALUE & VOLUME OF IMPORTS IN INDIA    
TOP SUPPLIERS    
TOP PORTS OF DISCHARGE    
PRESENT MANUFACTURERS/SUPPLIERS OF R.C.C PIPE    
MANUFACTURING PROCESS FOR R.C.C PIPE    
THERE ARE BASICALLY 2 PROCESSES OF MANUFACTURING THESE PIPES:    
VERTICAL VIBRATED DRY CAST METHOD:    
ADVANTAGES OF VIBRATED CASTING PROCESS    
SAVINGS IN CEMENT.    
MATERIALS:    
CEMENT:    
AGGREGATES:    
REINFORCEMENT:    
WATER:    
CONCRETE:    
1. STORAGE OF RAW MATERIAL    
2. MATERIAL HANDLING    
3. CONCRETE BATCHING    
4. REINFORCEMENT FABRICATION    
5. VERTICAL VIBRATION CASTING PROCESS    
6. OFF BEARING AND CURING    
7. TESTING    
8. MARKING    
PROCESS FLOW CHART    
PLANT LAYOUT    
SUPPLIERS OF RAW MATERIALS    
PORTLAND CEMENT    
SUPPLIERS OF AGGREGATES    
SUPPLIERS OF CONCRETE SAND    
SUPPLIERS OF HARD DRAWN STEEL WIRE    
SUPPLIERS OF PLANT AND MACHINERY    


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