TORKARI PLANT (PRODUCTION CAPACITY: 36,000 TPA)
[EIRI/EDPR/4511] J.C.: 2727XL
INTRODUCTION
TOR-KARI steel reinforcement bars are made by a process of cold rolling from mild steel coils and consequently come out in small diameters from 4.5 mm to 9 mm. This range of sizes will not only cause structurally superior components in addition to savings in steel consumption, in comparison to the 40 Grade bars which come in a minimum dia of 8 mm.
Conventional high strength deformed bars of Fe 415 grade of dia 8 mm and 10 mm can be conveniently replaced by High Strength TOR-KARI reinforcement bars (TOR 55 Grade) of dia 7mm and 9mm. TOR-KARI of dia 5mm can also economically replace mild steel bars of dia 6/6.8 mm often used as secondary reinforcement.
Due to the smaller diameters and High Strength, TOR-KARI steel reinforcement gets more closely placed and thus leads to smaller and more evenly distributed bending as well as shrinkage cracks in structural components.
Due to the smaller diameters available, there is unlimited possibility for use of High Strength TOR-KARI steel reinforcement bars in precast components.
Since TOR-KARI is available in smaller diameters and has far superior strength and bond properties compared to even Fe 415 grade steel (Tor 40 for example), it can be efficiently and effectively used to achieve maximum economy. The savings in cost is in the order of 8 to 10% when TOR-KARI is used in place of Fe415 grade steel and as much as 35% when used in place of plain MS.
It is intended to prepare a Feasibility Report to install a TOR KARI Plant with production capacity of 3000 Tons/Month as a Green Field Project.
COST ESTIMATION
Plant Capacity 120 MT/Day
Land & Building (4575 sq.mt.) Rs. 3.66 Cr
Plant & Machinery Rs. 4.98 Cr
Working Capital for 0.5 Months Rs. 7.06 Cr
Total Capital Investment Rs. 16.30 Cr
Rate of Return 52%
Break Even Point 48%
CONTENTS
INTRODUCTION
PROPERTIES/SPECIFICATIONS
SPECIFICATION
MECHANICAL PROPERTIES
CHEMICAL PROPERTIES
BENEFITS/ADVANTAGES
ADVANTAGES OF USING TORKARI
HIGH BOND PROPERTIES
ROLLING TOLERANCE
SIZE ADVANTAGE
SAVINGS IN STEEL CONSUMPTION
TECHNOLOGY
RAW MATERIAL
MANUFACTURING PROCESS
RAW MATERIAL SUPPLIERS
SUPPLIERS OF PLANT AND EQUIPMENTS
WIRE STRAIGHTENING MACHINE
BULK BLOCK TYPE HEAVY DUTY WIRE DRAWING MACHINE
EOT CRANES
DG SETS
POWER TRANSFORMERS
ETP PLANTS
AIR CONDITIONING EQUIPMENTS
AIR POLLUTION CONTROL EQUIPMENTS
WEIGHING MACHINE
MATERIAL HANDLING EQUIPMENTS
ELECTRICAL MEASURING INSTRUMENTS
WIRE POINTING MACHINE
ETP FACILITY
ETP FLOW DIAGRAM (TYPICAL)
SEWAGE AND WASTE WATER EFFLUENT
STP FLOW DIAGRAM (TYPICAL)
PRINCIPLES OF PLANT LAYOUT
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
RAW-MATERIAL SUPPLY:
MARKETS:
POWER AND FUEL SUPPLY:
WATER SUPPLY:
CLIMATE:
TRANSPORTATION:
WASTE DISPOSAL:
LABOR:
REGULATORY LAWS:
TAXES:
SITE CHARACTERISTICS:
COMMUNITY FACTORS:
FLOOD AND FIRE CONTROL:
ANTICIPATED ENVIRONMENTAL IMPACTS
CONSTRUCTION PHASE
OPERATION PHASE
MITIGATION MEASURES (PROPOSED)
HEALTH SAFETY & ENVIRONMENT
PROPOSED IMPLEMENTATION SCHEDULE
PROJECT FINANCIALS
BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)
PRELIMINARY LAYOUT
CONCLUSIONS
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)
