ELECTROFORGED STEEL GRATING

[EIRI/EDPR/4056] J.C.: 2190XL

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.

www.eiriindia.org 1
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

www.eiriindia.org 2
 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
MANUFACTURING PROCESS OF ELECTROFORGED GRATING
ELECTROFORGED PROCESS
FABRICATION OF GRATINGS:
SPOT RESSISTANCEWELDING
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
VERIFICATION OF RAW MATERIAL BY
(2) ELECTRLFORGE WELDING
VERIFICATION OF WELDING PROCESS BY
(3) CROPPING OF WELDED RODS

www.eiriindia.org 3
VERIFICATION OF CROPPING PROCESS BY
(4) CUTTING OF PANEL FOR REQUIRED SIZE
VERIFICATION OF CUTTING PROCESS BY
(5) LOOSE PART MANUFACTURING (OFFLOADED / BOUGHT OUT)
VERIFICATION OF LOOSE IN INCOMING STAGE BY
(6) FABRICATION (WELDING)
VERIFICATION OF WELDING PROCESS BY
(7) FINISHINGZ & GRINDING
VERIFICATION OF FINISHING PROCESS BY
(8) SURFACE TREATEMENT
VERIFICATION OF FINISHING PROCESS BY
(9) FINAL INSPECTION & DESPATCH
MARKET OVERVIEW
PLANT LAYOUT
PRINCIPLES OF PLANT LAYOUT
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:
6. TRANSPORTATION:
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

www.eiriindia.org 4
PROJECT SCHEDULING
PROJECT CONSTRUCTION SCHEDULE
TIME SCHEDULE
SUPPLIERS OF ELECTROFORGED GRATING
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF MILD STEEL ROD AND BAR
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS FOR ELECTRO FORGED GRATING PLANT
SUPPLIERS OF ELECTRO FORGED GRATING CUTTING MACHINE
SUPPLIERS OF MULTI SPOT WELDING MACHINE
SUPPLIERS OF EOT CRANES
SUPPLIERS OF POWER TRANSFORMER
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

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)

www.eiriindia.org 5
 COST ESTIMATION

Plant Capacity 24 MT/Day

Land & Building (4000 sq.mt.) Rs. 3.44 Cr
Plant & Machinery Rs. 2.43 Cr
Working Capital for 2 Months Rs. 5.71 Cr
Total Capital Investment Rs. 11.86 Cr
Rate of Return 33%
Break Even Point 54%

www.eiriindia.org 6