Detailed Project Report on epoxy coated tmt bars (sariya)

EPOXY COATED TMT BARS (SARIYA)
[CODE NO.3385]  

TMT BAR

TMT bars or Thermo-Mechanically Treated bars are high-strength reinforcement bars having a tough outer core and a soft inner core. The very first step of the manufacturing process involves passing the steel wires through a rolling mill stand. Thereafter, these rolled steel wires are again passed through the Tempcore water cooling system. While passing the wires through the water cooling system, the water pressure is optimised. The sudden quenching and drastic change in temperature toughen the outer layer of the steel bar, thus making it super tough and durable. Once this process is over, the TMT bars are subject to atmospheric cooling. This is done in order to equalise the temperature difference between the soft inner core and the tough exterior. Once the TMT bar cools down, it slowly turns into a ferrite-pearlite mass. The inner core remains soft giving the TMT bar great tensile strength and elongation point. This design is unique to the TMT bars and gives superior ductility to the bars. Also, this unique manufacturing technique and the absence of Cold stress make this bar corrosion-resistant and boost its weldability.

This same manufacturing process is used to manufacture high-quality SRMB TMT bars. This delivers greater tensile strength to the TMT bars. The most important features of SRMB TMT bar include higher elongation. This improves the bend/re-bend properties or the TMT bars, thus making it safe from natural calamities such as an earthquake. The Thermal stability of SRMB TMT bars is high which makes them safe from any fire accidents. The special ribbed design of the SRMB TMT bars form a stronger bond with the concrete or cement, thus, provides additional support and strength to the building structure and improves their longevity and durability. The high tensile strength and flexibility make SRMB TMT bars the ultimate choice for earthquake-prone zones. SRMB TMT bars have greater shock-absorbing capacity when compared to other TMT bars. This prevents the collapse of a building during an earthquake and ensures the longevity of the structure. Compared to ordinary steel bars, the same quantity of TMT bars can provide 20% additional strength to the structure. Other SRMB products include AZAR Bars (Zinga coated TMT bars), De-formed TMT bars, and De-formed corrosion resistant TMT bars.


COST ESTIMATION

Plant  Capacity                                                     :     100.00 MT/day
land & Building (12000 Sq.Mtr)                         :    Rs. 8.29  Cr
Plant & Machinery                                                :    Rs. 20.43 Cr
Working Capital for 2 Months                            :    Rs. 14.00 Cr
Total Capital Investment                                     :    Rs. 44.98 Cr
Rate of Return                                                       :    38%
Break Even Point                                                   :    53%


INTRODUCTION    
PROPERTIES OF THE TMT BARS    
PROPERTIES OF TMT BARS    
PHYSCIAL PROPERTY    
CHEMICAL PROPERTY    
ADVANTAGES OF TMT BAR    
EPOXY COATING    
CHEMISTRY OF FBE COATING    
ADVANTAGES OF FBE COATING    
EPOXY-COATED REINFORCEMENT BAR EXTENDS LIFESPAN    
CLIMATIC CONDITIONS:    
CORROSION PROTECTION    
CORROSION CONTROL CAN BE SEEN IN TWO BASIC WAYS
DISADVANTAGES OF FBE COATING    
USES AND APPLICATION    
APPLICATIONS FOR EPOXY-COATED STEEL REINFORCING BARS    
BRIDGES    23
MARINE STRUCTURES    
PAVEMENTS    
PARKING STRUCTURES    
REPAIR    
B.I.S. SPECIFICATION    
MARKET SURVEY    
MARKET SIZE    
HISTORICAL BACKGROUND    
COMMODITIZING REBAR MARKETS    
FRAGMENTED MARKETS    
BRANDING IN THE REBAR INDUSTRY    
FRP IN THE FRAY,    
OUTLOOK    
MARKET POSITION OF RE-BARS    
THE DEMAND TREND FOR VARIOUS LONG STEEL PRODUCTS  
IS DEPICTED BELOW:    
THE DEMAND BREAK-UP OF BARS AND RODS (NON-ALLOY)
FOR 2012-13 IS DEPICTED BELOW:    
THE CEO’S PERSPECTIVE OF THE COMPLEX BUSINESS UNIVERSE    
TECHNOLOGY IMPACT    
MARKET OPPORTUNITIES/DEMAND DRIVERS    
CHALLENGES AND RESTRAINTS    
EXPORT DATA OF TMT BARS    
TOTAL VALUE & VOLUME OF EXPORTS IN INDIA    
TOP SUPPLIERS    
TOP PORTS OF DISCHARGE    
IMPORT DATA OF TMT BARS    
TOTAL VALUE & VOLUME OF IMPORTS IN INDIA    
TOP SUPPLIERS    
TOP PORTS OF DISCHARGE    
MANUFACTURERS/SUPPLIERS OF EPOXY COATED TMT BAR    
PROCESS FLOW CHART FOR STEEL BILLET    
PROCESS FLOW CHART FOR EPOXY COATED TMT BAR    
MANUFACTURING PROCESS    
(A) MANUFACTURING PROCESS M.S. BILLET    
1. PROCUREMENT OF RAW MATERIAL:-    
2. RAW MATERIAL PROCESSING:-    
3. MELTING PROCESS:-    
4. LADLE PURGING PROCESS:-    
5. CONTINUOUS CASTING PROCESS:-    
(B) MANUFACTURING PROCESS OF TMT BAR    
1. ROLLING PROCESS:    
ROUGHING MILL:    
CUTTERS:    
INTERMEDIATE MILL:    
FINISHING MILL:    
3. TMT PROCESS:    
4. CUTTING PROCESS:    
5. FINISHING:    
6. INSPECTION AND TESTING OF TMT BAR    
STAGE WISE INSPECTION DETAILS    
7. EPOXY COATING PROCESS    
8. DISPATCH:    
PLANT LAYOUT    
SUPPLIERS OF RAW MATERIALS    
PIG IRON    
SPONGE IRON    
STEEL SCRAP    
FERRO SILICON    
COKE    
LIME    
FERRO SILICON    
DEGREASING CHEMICAL    
PICKLING CHEMICALS    
EPOXY COATING POWDER    
SUPPLIERS OF PLANT AND EQUIPMENTS    
SCRAP BAILING MACHINE    
INDUCTION FURNACE    
ANNEALING FURNACE    
HEATREATMENT FURNACE    
CONTINIOUS BILLET CASTING COMPELETE PLANT    
TMT BAR ROLLING COMPELETE PLANT    
COOLING BED    
EPOXY COATING PLANT    
DRILLING MACHINE    
MILLING MACHINE    
CNC LATHE MACHINE    
BOARING MACHINE    
POWER HACKSAW    
GRINDING MACHINE    
POWER PRESS    
WELDING MACHINE    
EOT CRANE    
POWER TRANSFORMERS    
ELECTRICAL PANEL    
COOLING TOWER    
EFFULENT TREATMENT PLANT    
AIR POLLUTION CONTROL EQUIPMENTS    
AIR CONDITIONING EQUIPMENTS    
AIR COMPRESSORS    
PLATFORM WEIGHING MACHINE    
MATERIAL HANDLING EQUIPMENTS    
FIRE FIGHTING EQUIPMENTS    
SHOT BLASTING MACHINE    
JIGS AND FIXTURE    
SUBMERSIBLE WATER PUMP    

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