ELECTROFORGED STEEL GRATING

MANUFACTURING PLANT
[EIRI/EDPR/3837] J.C.: 1946

INTRODUCTION

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.

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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 3mm

Commonly used pitch: 23mm

Applications: flat type bearing bar gratings are the most widely used gratings,
available for flooring sidewalk, all kinds of ditch cover, stair tread etc.

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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.

Commonly used size: 25 x 5mm, 30 x 3mm, 30 x 5mm, 32 x 5mm,

40 x 5mm, 50 x 5mm

Commonly used pitch: 23mm, 30mm, 34mm, 35mm, 40mm, 41mm,

45mm, 50mm.

Advantages: Serrated type bearing bar gratings are best non-skid property &
safety compared with plain grating.

I type bearing bar is one among the highly demanded product in our range.
Features such as high strength, cost-efficient production processes and ease of
installation are incorporated in all of our mild steel grating products. Because of
its high strength and durability, these bar gratings can withstand extreme loads,
quite comparable to solid floorings. Our products have wide range of applications
such as Walkways, Platforms, Safety barriers, Drainage covers and Ventilation
grates. Standard panels available for this product are in 6 × 1 meter at any size of
bearing bar/cross bar and at any center distance as per load design.

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 CONTENTS

INTRODUCTION
GRATING IS COMPOSED OF FOLLOWING MEMBER:
BEARING BARS
BEARING BAR TYPES
SURFACE OF LOAD BEARING BAR IS PLAIN.
CROSS BARS
TYPES OF ELECTROFORGED GRATING
(A) SERRATED GRATING
(B) PLAIN GRATING
ADVANTAGES OF USING ELECTROFORGED STEEL GRATINGS
LIMITATIONS OF ELECTRO FORGE PROCESS GRATINGS.
USES AND APPLICATION
B.I.S. SPECIFICATION
PROCESS FLOW CHART
PROCESS FLOW CHARTMANUFACTURING PROCESS
OF ELECTROFORGED GRATING
ELECTROFORGED PROCESS
FABRICATION OF GRATINGS:
SPOT RESSISTANCE WELDING
PRINCIPLE:
SPOT WELDING:
ADVANTAGES AND DISADVANTAGES
ADVANTAGES:
DISADVANTAGES:
THE HOT DIP GALVANIZING PROCESS
SURFACE PREPARATION
CAUSTIC CLEANING –
PICKLING –
FLUXING –
GALVANIZING –
INSPECTION –
QUALITY CONTROL
INSPECTION & TESTING
FABRICATION OF GRATING
GALVANIZATION OF GRATINGS
(1) RAW MATERIAL RECEIPT
(2) ELECTRLFORGE WELDING
(3) CROPPING OF WELDED RODS
(4) CUTTING OF PANEL FOR REQUIRED SIZE

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(5) LOOSE PART MANUFACTURING
(6) FABRICATION (WELDING)
(7) FINISHING & GRINDING
(8) SURFACE TREATEMENT
(9) FINAL INSPECTION & DESPATCH
MARKET POSITION
KEY TAKEAWAYS
BY TYPE - SEGMENT ANALYSIS
BY APPLICATION - SEGMENT ANALYSIS
GEOGRAPHY - SEGMENT ANALYSIS
DRIVERS – STEEL GRATING MARKET
ADVANCEMENTS IN TECHNOLOGY LIKE HIGH LOAD CAPACITY
CHALLENGES – STEEL GRATING MARKET
EMISSION OF CARBON DURING THE PRODUCTION OF STEEL GRATING
MARKET LANDSCAPE
ACQUISITION
STEEL GRATING INDUSTRY
PLANT LAYOUT
SUPPLIERS OF ELECTROFORGED STEEL GRATING
SUPPLIERS OF MILD STEEL ROD AND BAR
SUPPLIERS FOR PLANT AND MACHINERY
SUPPLIERS FOR ELECTROFORGED STEEL GRATING PLANT
SUPPLIERS OF ELECTRO FORGED GRATING CUTTING MACHINE
SUPPLIERS OF MULTI SPOT WELDING MACHINE
SUPPLIERS OF EOT CRANES
SUPPLIERS OF POWER TRANSFORMERS
SUPPLIERS OF ELECTRICAL PANEL
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 SHOT BLASTING MACHINE

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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)

COST ESTIMATION

Plant Capacity 16 MT/Day

Land & Building (2000 sq.mt.) Rs. 1.78 Cr
Plant & Machinery Rs. 2.43 Cr
Working Capital for 2 Months Rs. 3.48 Cr
Total Capital Investment Rs. 7.99 Cr
Rate of Return 22%
Break Even Point 67%

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