MANUFACTURING ZINCALUME TANKS
[EIRI/EDPR/4565] J.C.: 2782XL
Zincalume Water Storage Tanks are manufactured from steel sheet which has been continuously coated with zinc and aluminium to produce the excellent corrosion resistance that is commonly experienced by tanks that are exposed to the harshest of atmospheric conditions.
These tanks are fabricated using the highest grade of “Zincalume Steel” as MOC; which lasts up to four times longer than galvanized steel.
Aluminum in the coating provides barrier protection to the steel while the zinc element provides sacrificial cut edge protection. It is this double protection mechanism which accounts for Zincalume Steel’s superior corrosion performance.
This material provides customers with one in every of the foremost price effective, project specific choices for the storage of any water between the pH ranges of three to 12 and includes Potable Water, Irrigation Water, Fire Water with Water Reclamation.
Zincalume steel is manufactured by an eternal hot dipped metallic coating process. The alloy coating of Zincalume steel provides glorious corrosion resistance and has been found to possess greater resistance to cracking and peeling.
Zincalume steel has an alloy coating of 55p.c Aluminium, 43.5% Zinc and 1.5% Silicon. The 150g/m2 (with choice of 200g/m2) coating weight is distributed equally on each surfaces of the coated strip. Metallic surface is coated with separate layers of special passivation resolution and resin.
Advantages of bolted steel Zincalume tanks:
• Eliminates the necessity for expensive labour, intensive site welding and at the same time dispenses with the need of elaborate and expensive re-enforced concrete base structures.
• Removes the chance of fire and explosion throughout erection, a explicit advantage on sites that store flammable products and liquids notably within the Oil & Gas Sector.
• Construction methods permit tanks to be erected at intervals days by a supervisor and team of semi-skilled labourers.
• Zincalume Bolted Cylindrical tank kits are reduced to one tenth of their total volume allowing a 100m? Tank to be packed onto pallets making a 10m? Cubic capability load that vastly reduces shipping costs.
• Standard panels are readily available ensuring speedy response to orders and delivery
• Zincalume pre-installed liner sealed tanks are easily re-located and can also have storage capacities increased by extending the height with minimal expense and disruption.
• Cost effective
• Easy and cheap to transport
• Fast Installations
• Relocating is easy
• Maintenance Free
• Flexibility in size
• Stronger structure
• Lighter Weight
Zincalume water storage tanks Accessories
Panel of tank:
Panels include, bottom panel, Roof panel, Side panel
Stays and Cleats:
The stays and cleats are made of steel angle bar and steel plate
Bolts, Nuts and Washers:
Hot Dipped Galvanised steel bolts, nuts and washers for internal and external
Jointing Materials:
Non toxic PVC foam to be used for all jointing between tank panel flanges
Water Level Indicator:
Mechanical Ball Float Type
Ladder:
Galvanised ladder for internal and external
Finish:
(a) Hot Dip Galvanised conform to ISO equivalent
Internal Liner:
A PVC Reinforced Liner that separates the water from the Tank Wall. Our liner is AS/NZS 4020 approved for use in contact with Drinking Water. Also they are perfect for hard water (bore water, chlorinated water or river water) applications.
COST ESTIMATION
Plant Capacity 4 Tanks/Day
Land & Building (6500 sq.mt.) Rs. 7.36 Cr
Plant & Machinery Rs. 80 Lac
Working Capital for 2 Months Rs. 2.82 Cr
Total Capital Investment Rs. 11.30 Cr
Rate of Return 34%
Break Even Point 48%
CONTENTS
INTRODUCTION
ADVANTAGES OF BOLTED STEEL ZINCALUME TANKS:
ZINCALUME WATER STORAGE TANKS ACCESSORIES
PANEL OF TANK:
STAYS AND CLEATS:
BOLTS, NUTS AND WASHERS:
JOINTING MATERIALS:
WATER LEVEL INDICATOR:
LADDER:
FINISH:
INTERNAL LINER:
USES AND APPLICATION
THESE TANKS ARE USED FOR VARIOUS APPLICATIONS LIKE
B.I.S. OF ZINC ALUMINIUM TANK
PROCESS FLOW CHART
PRODUCTION PROCESS
1. PROCUREMENT OF RAW MATERIAL
2. DECOILING
3. SHEET STRAIGHTENING (LEVELLER)
4. SHEARING
5. ROLL FORMING
6. PUNCHING
7. DIMENSIONAL CHECKING
8. FINAL CHECKING
9. DISPATCH TO SITE
10. QUALITY CONTROL
(A) DOCUMENT CONTROL
(B) PROCUREMENT AND MATERIAL CONTROL
(C) INSPECTION, TESTING AND VERIFICATION
(D) PROCESS CONTROL
(E) NON CONFORMATION CONTROL AND CORRECTIVE ACTION
MARKET POSITION
PRINCIPLES OF PLANT LAYOUT
STORAGE LAYOUT:
EQUIPMENT LAYOUT:
SAFETY:
PLANT EXPANSION:
FLOOR SPACE:
UTILITIES SERVICING:
BUILDING:
MATERIAL-HANDLING EQUIPMENT:
RAILROADS AND ROADS:
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:
SPECIFIC FACTORS
6. TRANSPORTATION:
A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES
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
PLANT LAYOUT
SUPPLIERS OF ZINCALUME TANK
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF ZINC ALUME SHEET
SUPPLIERS OF GI NUT, BOLT AND FASTNERS
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF FABRICATION MACHINERY
SUPPLIERS OF DG SETS
SUPPLIERS OF EOT CRANES
SUPPLIERS OF POWER TRANSFORMERS
SUPPLIERS OF ELECTRICAL PANEL
SUPPLIERS OF ELECTRIC MOTOR
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 JIGS AND FIXTURE
SUPPLIERS OF SUBMERSIBLE WATER PUMP
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)
