ELECTROFORGED GRATING MANUFACTURING PLANT
[CODE NO. 3265]
Grating is open grid assembly of metal bars, in which the bearing bars, running in one direction, are spaced by rigid attachment to cross bars running perpendicular to them or by bent connecting bars extending between them.
Grating is a structural element that has a high load-bearing capacity with a low dead weight and a high level of transparency. The positive-fitting connection of the bearing bars and cross bars with the surround make the grating not only a very stable, but also visually attractive product. The applications are very diverse, as grating is used everywhere in industry and architecture. As an extremely robust, safe yet light platform flooring, the grating is indispensable in all areas of heavy industry.
Grating is installed in refineries, power stations, steel mills, mines and on oil platforms. Grating is being used increasingly more in the logistics industry as platform flooring and shelves. Architects and building owners appreciate the grating as a product which is both aesthetically pleasing and functional, be it used as a decorative facade cladding, a suspended ceiling or sun shield.
Steel grating is a kind of open steel member with its bearing bars & cross bars jointing at their intersections either by welding or by locking.
Electroforged Steel Gratings are made using the electroforging process. In this process, the sqaure twisted rods (Cross Members) are fused into the main load bearing members at using a special welding machine at very high current and tonnage. The Cross Members are properly set-in the Load Members such that it projects out of the grating top member by only a little more than 1 mm. This improves the slip resistance during walking. Electroforged Grating Panels are generally manufactured to 6000 mm lengths.
Grating is composed of following member.
BEARING BARS
Load carrying bars made from steel strip or slit sheet or from rolled or extruded aluminum and extending in the direction of the grating span.
Bearing bar types Steel grating is made up of bearing bar and cross bar as certain distance by welding or pressure locked. Bearing bar have the types: flat type (also called plain type), serrated type, I bar type (I plain type and I serrated type). According to the bearing bar materials, there are carbon steel bars, mild carbon steel bars, stainless steel bars and so on.
Flat type bearing bars are made from steel strip or slit sheet or from rolled steel. These are produced using high quality steel materials which exhibit good hardness, ductility and tensile strength. Our bearing bars provide extremely good level support for floor joists. They have excellent finishing and based on clients’ need we provide them with untreated, galvanized or painted bearing bars. Surface of Load Bearing Bar is Plain
Commonly used size------25 x 3 mm
Commonly used pitch-----23 mm
Applications: flat type bearing bar gratings are the most widely used gratings, available for flooring sidewalk, all kinds of ditch cover, stair tread, etc.
Serrated type-bearing bars delivers excellent performance in application areas, which are slippery, oily, moisture filled. They form a sort of anti-slip grating with their non-slip notches offering them a very good grip. They are made using mild carbon steel or stainless steel materials. We offer variety of serrated products in this category such as, normal serrated, serrated interrupted, serrated trapezoid, serrated carrier bar and serrated carrier bar with cross bar. For inclined gangways with a pitch of 10-25 degrees, we also provide grating with tread strips. notches are made on tip of the Load Bearing Bar to improve skid resistance.
COST ESTIMATION
Plant Capacity : 9.00 MT/day
land & Building : Nil
Plant & Machinery : Rs. 1.37 Cr
Working Capital for 1 Month : Rs. 1.29 Cr
Total Capital Investment : Rs. 2.94 Cr
Rate of Return : 71%
Break Even Point : 50%
BEARING BARS
CROSS BARS
TYPES OF ELECTROFORGED GRATING
LIMITATIONS OF ELECTRO FORGE PROCESS GRATINGS.
USES AND APPLICATION
B.I.S SPECIFICATION
MARKET SURVEY
GRATING IMPORT DATA IN USA
MANUFACTURERS/SUPPLIERS
OF ELECTROFORGED GRATING
MANUFACTURING PROCESS
OF ELECTROFORGED GRATING
SPOT RESSISTANCEWELDING
QUALITY CONTROL
INSPECTION & TESTING
FABRICATION OF GRATING
GALVANIZATION OF GRATINGS
PROCESS FLOW CHART
PLANT LAYOUT
PRINCIPLES OF PLANT LAYOUT
EXPLANATION OF TERMS USED
IN THE PROJECT REPORT
PROJECT IMPLEMENTATION SCHEDULES
SUPPLIERS OF PLANT AND MACHINERIES
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
