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Hot-Dip Galvanizing - Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study, Investment Opportunities, Cost and Revenue

Hot-dip galvanizing is usually a process of coating a steel surface with a layer of pure zinc or zinc coating along with a few alloying elements like tin, aluminum etc in molten condition by immersing the steel component in a bath of molten zinc. The coating of zinc so developed provides a catholic protection to underneath steel surface. Hot dip galvanizing occupies the place of highest application since galvanized steel surfaces offer better surface protection at lower cost particularly in humid atmosphere. The demand for different types of galvanized items is increasing year after year keeping the above in view the unit provides good scope for new entrepreneur in the field.
Plant capacity: 80.0 MT/DayPlant & machinery: Rs. 174.0 Lakhs
Working capital: Rs. 406.0 LakhsT.C.I: Rs. 632 Lakhs
Return: 42.82%Break even: 42.19%
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Hot Dip Galvanizing Plant - Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study, Investment Opportunities, Cost and Revenue

Hot dip galvanizing is a process in which an adherent, protective coating of zinc compounds is developed on the surface of iron and steel products by immersing them in a bath of molten zinc. The protective coatings usually consists of several layers. Those closest to the basic metal are composed of iron-zinc compounds; these in term are covered by an outer layer consisting almost entirely of zinc. The complex structure of layers that comprise a galvanized coating varies greatly in chemical properties, being affected by chemical activity, diffusion and subsequent cooling. Hot dip galvanized coatings are produced on a variety of steel mill products, using fully mechanized, mass production methods. This article, however, is concerned primarily with the hot dip galvanizing of fabricated articles in manual or semiautomatic batch operations. From a modest beginning, about a century ago, the engineering industry in India has come along way and today the industry produces a stupefying range of products like plant and machinery, machine tools, power generating transmission and distribution equipments, commercial vehicles and a variety of other industrial goods and consumer durables. The significance of the engineering industry in India industrial set up stems from its forward and backward linkages with virtually all sectors. There is bright scope for new investment. Any entrepreneur can enter in this field.
Plant capacity: 12 MT/DayPlant & machinery: RS. 176 Lakhs
Working capital: -T.C.I: Rs. 859 Lakhs
Return: 53.00%Break even: 48.00%
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GALVANIZED IRON WIRE - Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study, Investment Opportunities, Cost and Revenue

The production of G.I. Wire from H.B. wire is not complicated. In case of H.B. wire drawing from H.B. bars, certain mechanical process is used. An important difference between bar drawing and wire drawing is that the bars must remain straight. The length of the bars, which can be drawn, is limited by the maximum travel of the carriage, which may be from 50 to 100 feet. Wire and wire products, including flat strips are one of the largest consuming items. G.I. Steel wires of standard quality are used for the manufacture of ropes for various applications, barbed fencing and nails etc. Although the G.I. flat wires are manufactured from mild steel as starting material, range over a wide field. The project, however, is designed to turnout only wires, which have the largest demand, i.e. flat wires or strip in galvanized form. There is a good scope for new entrepreneurs to venture into this field.
Plant capacity: 8.00 MT./dayPlant & machinery: Rs. 70 lakhs
Working capital: -T.C.I: Rs. 419 lakhs
Return: 46.00%Break even: 32.00%
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Transmission Tower & Tele Communication Tower with Galvanizing Plant - Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study

The purpose of a transmission line tower is to support conductors carrying electrical power and one or two ground wires at suitable distances above the ground level and from each other. A transmission line tower is a space-frame and high order indeterminate structure. Its cost is influenced by its weight. Reliability of a transmission structure depends not only upon its design, but also on the development of structural arrangement, detailing of connections, uniformity of quality of structural sections, accurate fabrication, erection in the field and ultimately maintenance. Transmission lines are subjected to various loads during their lifetime. These loads are classified into climatic loads, failure containment loads and construction and maintenance loads. Proper fabrication while maintaining permissible tolerance, galvanizing and testing of towers are very essential. An economical foundation design and proper erection techniques are also very vital for the safety of the tower. The demand is growing for mobile telephony towers. There is an increasing demand for telecom towers in rural/semi-urban areas as the penetration is still very low. The demand for telecom towers is also a function of steadily growing subscriber base and higher usage time of subscribers. India would have an estimated 42.5 crore mobile subscribers by 2010, creating a demand for 4.5 lakh base transmission stations, with major demand coming from rural areas. There is a good scope for new entrants.
Plant capacity: 24,000 MT /YearPlant & machinery: 149 Lakhs
Working capital: -T.C.I: Cost of Project : 716 Lakhs
Return: 46.00%Break even: 53.00%
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Pre-painted Coloured Galvanized Roofing Steel Sheet (Plain & Corrugated) - Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study

There is significant increase in demand for pre-coated galvanized sheet-for industrial, storage and warehousing projects. In USA & Europe 55% Aluminium Zinc coated steel is used for roofing which gives increased life compared to ordinary coated sheets. The corrugated galvanized iron sheets are extensively used in various fields e.g. Industrial sheds, dairy farm sheds, poultry farm sheds and warehouses etc. for roofing purpose. It is observed that asbestos cemented roof sheet, plastic corrugated sheet, and red mud sheets are also used in the construction of industrial shed. However, the use of asbestos sheet is not preferred and there is a potential for growth of this product, in industrial projects, warehouses and storage establishments.
Plant capacity: 15 MT / DayPlant & machinery: 58 Lakhs
Working capital: -T.C.I: 793 Lakhs
Return: 50.00%Break even: 27.00%
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HOT DIP GALVANIZING PLANT - Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study, Investment Opportunities, Cost and Revenue

Galvanized coatings are applied to iron and steel primarily to provide protection against corrosion of the basis metal. Hot Dip Galvanizing is a process in which an adherent, protective coating of zinc and zinc compounds is developed on the surfaces of iron and steel products by immersing them in a bath of molten zinc. The protective coatings usually consist of several layers. Those closest to the basis metal are composed of iron-zinc compounds these in turn are covered by an outer layer consisting almost entirely of zinc. The complex structure of layers that comprise a galvanized coating varies greatly in chemical composition and physical and mechanical properties, being affected by chemical activity, diffusion, and subsequent cooling. Small differences in coating composition, bath temperature, time of immersion, and rate of cooling or subsequent reheating can result in significant changes in the appearance and properties of the coating. Hot dip galvanized coatings are produced on a variety of steel mill products, using fully mechanized and mass production methods. Hot dip galvanized zinc coatings have their longest life expectancy in rural areas where sulfur dioxide and other industrial pollutant concentrations are low. These coatings also give satisfactory service in most marine environments. Although the life expectancy of hot dip galvanized coatings in more severe industrial environments is not as long as for less aggressive environments, the coatings are still used extensively in those exposures, because in general, no more effective and economical method of protection is available. India's steel pipe industry is primarily engaged in manufacturing seamless or welded steel pipes or tubes or ferrous metal pipes or tube fittings. Steel pipes are primarily of two types, seamless and welded. Other specific types extend the basic classification to include: (a) cast iron pipes, (b) stainless steel tubes, (c) ERW (electric resistance welding) steel pipes, (d) galvanized pipes, (e) API pipes, (f) SAW (submerged arc welded) pipes, and (g) spun pipes. Welded steel pipes include a wide variety of pipes and tubes. Welded pipes are normally manufactured from HR and CR coils by ERW. Galvanized pipes are zinc-coated to prevent corrosion. ERW tubes are meant for high performance applications, such as trusses and columns in housing, industrial and construction sectors, chassis for two-wheelers and light commercial vehicles, propeller shafts and axles. According to observation of engineering goods statistics, we can conclude about the essentiality of the galvanizing process as companys work or on the job work base. It can be concluded that galvanization process is partially proportional to the increase of demand of the engineering goods or most or ancillary item production the steel base. It can be concluded that demand of galvanizing industries will be increased 10% per annum. On that base it can be predicted that there is good scope for galvanizing industries as job work base.
Plant capacity: 3600 MT/AnnumPlant & machinery: 102 Lakhs
Working capital: -T.C.I: Cost of Project : 378 Lakhs
Return: 44.00%Break even: 54.00%
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Transmission Towers & Tele Communication Towers With Galvanizing Plant - Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study

A transmission tower (colloquially termed an electricity pylon in the United Kingdom and parts of Europe, an ironman in Australia, and a hydro tower in English Canada) is a tall structure, usually a steel lattice tower, used to support an overhead power line. They are used in high voltage AC and DC systems, and come in a wide variety of shapes and sizes. Typical height ranges from 15 to 55 metres (49 to 180 ft), though the tallest are the 370 m (1,214 ft) towers of a 2700 metres long span of Zhoushan Island Overhead Powerline Tie. In addition to steel, other materials may be used, including concrete and wood. The products of the Proposed Fabrication units are covered by well designed and fabricated structures for a. state electricity boards for the purposes of electricity supply (i,e) a) power transmission Towers, TV and Radio Towers, Telecommunication Towers, b) Railway and Highway bridges etc. c. Industrial structures etc. Some transmission towers combine these basic functions. Transmission towers and their overhead power lines are often considered to be a form of visual pollution. Methods to reduce the visual impact include undergrounding. Tower structures can be classified by the way in which they support the line conductors. Suspension structures support the conductor vertically using suspension insulators. . Strain structures resist net tension in the conductors and the conductors attach to the structure through strain insulators. Dead end structures support the full weight of the conductor and also all the tension in it, and also use strain insulators. Where the conductors are straight, a tangent tower is used. Angle towers are used where a line must change direction. Structures are classified as tangent suspension, angle suspension, tangent strain, angle strain, tangent dead end and angle dead end.
Plant capacity: 144 MT /day Plant & machinery: 11576 Lakh
Working capital: -T.C.I: Cost of Project : 15505 lakh
Return: 22.45%Break even: 42.26%
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Transmission Towers & Tele Communication Towers With Galvanizing Plant - Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study

A transmission tower (colloquially termed an electricity pylon in the United Kingdom and parts of Europe, an ironman in Australia, and a hydro tower in English Canada) is a tall structure, usually a steel lattice tower, used to support an overhead power line. They are used in high-voltage AC and DC systems, and come in a wide variety of shapes and sizes. Typical height ranges from 15 to 55 metres (49 to 180 ft), though the tallest are the 370 m (1,214 ft) towers of a 2700 metres long span of Zhoushan Island Overhead Powerline Tie. In addition to steel, other materials may be used, including concrete and wood. Uses & Applications The products of the Proposed Fabrication units are covered by Well designed and fabricated structures for a. state electricity boards for the purposes of electricity supply (i,e) a) power transmission Towers, TV and Radio Towers, Telecommunication Towers, b) Railway and Highway bridges etc. c. Industrial structures etc. Four major functions of transmission towers are in use: Suspension Towers, Terminal Tower, Tension Towers & Transposition Tower. Market Survey The Indian market has also the potential to generate 150,000 MW of hydro power. The Vadodara facility received fresh investments of about USD 30 mn with a scalable manufacturing capacity that currently stands at 1500 MW per annum. The Vadodara facility is one of the three largest hydro equipments facilities in the world. With the fast development of cellular telephones, a completely new segment of tower industry has emerged. The demand has increased precipitately in sympathy with the galloping expansion of cellular telephones.
Plant capacity: 24000 Mt/ Annum Plant & machinery: 163 Lakhs
Working capital: -T.C.I: Cost of Project : 833 Lakhs
Return: 45.00%Break even: 43.00%
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Corrugated Galvanized Sheet - Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study, Investment Opportunities, Cost and Revenue

Galvanized Corrugated Sheets are manufactured using best grade steel and is widely applied in construction industry. Galvanized Corrugated Sheets have excellent corrosion resistance, these Sheets have become the most preferred material for various construction purposes, particularly roofing and walling. The demand for corrugated iron sheet depends mainly on the performance of its end-user (i.e. the construction sector or more specifically the building construction sector). Therefore, the demand for the products under consideration is a derived demand, which depends directly on themperformance of its major end – user. The construction sector of the country has undergone tremendous changes and development in recent years. The contribution of the construction sector to the GDP during the period 2001 – 2010 have been growing at annual average growth rate of 13 percent which is above the average annual growth rate of real GDP during the period under consideration (11.4 %), indicating a rise in the share of the construction sector within the overall economy. Moreover, during the GTP period (2010 – 2015), the construction sector is expected to grow at annual average growth rate of 20%. Uses and Applications The corrugated galvanized iron sheets are extensively used in various fields e.g. industries sheds, dairy farm sheds, poultry farm sheds etc. for roofing purpose. In recent years, a lot of multi scale projects have taken up the Indian industry by a storm and these levels have given a larger scope for steel companies. The galvanised plain coils / sheets and corrugated sheets (GP/GC) are value - added steel products which are tough, sturdy, light weight, bright and corrosion resistant. In India these are produced in the thickness range of 0.15 mm to 2.0 mm and width range of 800 mm to 1560 mm. The function of the zinc layer is mainly three fold: To retain the steel intact with its full initial strength; to provide the surface a more pleasing appearance and to increase the life of any suitable organic finishing system applied over it. Market Survey There is always a need for galvanized sheets, rollers, and other varieties of pressed sheets that make up the steel industry. The construction process needless to say remains the same but has new implementations that are adapted from the western counterparts. Steel manufacturers are now in demand for infrastructure and automobile sectors as well, thus widening their scope of development. The recent growth of these newly developed industries has given a new lease of hope to steel developers. This sudden splurge of industrial growth has honed the success of the leading steel companies in India. Roofing industry in India is preparing for the next generation of ambitious projects. That roofing is an important component of the construction industry is evident from the fact that it accounts for over 25 per cent of the total building construction cost. There are many roofing options in the Indian roofing sector, such as asbestos cement fibre sheets, corrugated galvanised iron sheets. Growth in the infrastructure and industrial segment has been a major demand driver for roof and wall cladding industry. It has registered a double digit growth over past three years and the future of this industry is also looking bright considering the low steel penetration and high demand in construction industry. Major shift is observed from clay tiles and conventional roofing system to metal cladding solution. Customers are looking for architectural solution which provides innovative shapes such as convex, concave in addition to new attractive colors. The future of roof and wall cladding industry is bright considering the low steel penetration and high demand in construction industry. Few Major Players are as under:- Bharat Berg Ltd. National Steel & Agro Inds. Ltd. Ram Krishan Kulwant Rai Enterprises Ltd. Sipta Coated Steels Ltd. [Erstwhile]
Plant capacity: 500 Nos./ dayPlant & machinery: Rs.12 Lakhs
Working capital: -T.C.I: Cost Of Project : Rs.165 Lakhs
Return: 39.00%Break even: 59.00%
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E.R.W. Galvanized Steel Pipes - Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study, Investment Opportunities, Cost and Revenue

GI Pipes/ Galvanized pipes are steel pipes covered with a protective coating of zinc that greatly reduces its tendency to corrode and extends its life expectant galvanized steel tubes are covered by a layer of zinc & are used for varied applications. These are available in various size and shapes based on the customer’s requirements. These tubes are natural corrosion resistant and hold functional durability, even in outdoor environments. Apart from preventing water corrosion, it is equally effective in dry, indoor environments. Electric Resistance Welded Pipe uses the high frequency induction heating (HFI) process to manufacture pipes ranging in nominal diameter from 219 mm (8,58 inch) to 610 mm (24 inch), and in wall thickness. In order to ensure completely smooth pipes, welds are scarfed both internally and externally. Immediate confirmations of welds are assured as pipes pass through a multi-probe ultrasonic inspection system located after the welding and scarfing stations. Following ultrasonic assessment, weld joints are induction heated to normalize the metallic structure of the weld. Normalizing also improves toughness of the steel in the region and significantly decreases the weld line corrosion effect. Prior to hydrostatic testing, pipes are sized to required tolerances before being cut to length and the ends bevelled. Weld seams is again ultrasonically tested. Pipes are inspected, weighed and can be varnished and marked prior to final inspection and dispatch, or transferred to the coating and lining plants for corrosion protection treatment. Uses & Applications These are pipes suitable for irrigation and water supply, plumbing, cold storage applications, scaffolding, antenna and telecom towers, water wells etc. GI pipes for various purposes depending upon the requirements of our customers. These pipes and tubes find diverse applications in the following sectors: Air and Water Line - Main water supply, Plumbing / Pumping, Chilled Water Line, Sewerage, Firefighting equipment, Waste water conveying, Cooling tower, Air duct, Chimney, Compressed Air line, Refrigerated line, in cold storage, Gas piping LPG cylinder supporting ring, Chemical transportation. It may be used in residential water supply lines, but not gas lines because natural gas causes the zinc to flake off and clog the system. It's not frequently used for water supply lines because the minerals in the water react with the galvanizing material and form scale, which builds up over time and will eventually clog the pipe. For industrial purpose it could be used in Industrial water lines/plant piping, Waste waterlines, Scaffoldings, Electrical Cable conduits, Gas/Natural gas pipe lines, Oil pipe lines, Cooling towers, LPG & other non-toxic gas pipelines, Cold storages, Vehicular chassis and frames, Idlers & belt conveyors Market Survey Steel pipes are primarily of two types, seamless and welded. Seamless pipes and tubes are used in both oil and non-oil sectors in a wide range of applications as line pipes, casing pipes, production tubings, drill pipes and the like. In the oil sector, API (American Petroleum Institute) standard pipes are preferred for line pipes and casing pipes. Oil sector absorbs nearly 60% of seamless pipes, while some 30% are consumed by bearings and boiler manufacturers. According to the London-based Iron and Steel Statistics Bureau (ISSB), steel tubes industry is poised for a 30% growth in the wake of a growing demand in the infrastructure construction sector, mainly in scaffolding in buildings. The sector has grown dramatically in the recent past at a record 20% growth owing to several infrastructure projects lined up by the government and the private sector. The use of steel rods and bars in stadia, railway stations, multiplexes and gas pipeline has been replaced with steel tubes, fuelling further growth potential for the tube industry. Salem plant (of Steel Authority of India) created awareness of stainless steel also in areas other than utensils. As a result, it found its way increasingly into processing industry, construction, railways and engineering industry. From 85%, the consumption of stainless steel by the utensil manufacturing sector dropped down to nearly 75%. As against the high level of stainless steel used for utensils in India, only 35% is used in the developed countries. India utilizes only about 12% of stainless steel in industrial applications as against 19% in developed countries. Out of total stainless steel produced, more than 70% of production is of SS 200 grade series, while SS 300 grade series constitutes just 15 to 20%. India also has good facilities for stainless steel long products like bars, wire rods and wires which have good prospects in Europe, USA and South East Asian region. Few Indian Major Players are as under: A N S Steel Tubes Ltd. Aravali (India) Ltd. Asrani Tubes Ltd. Bhawani Industries Ltd. Binjrajka Steel Tubes Ltd. Gemini Steel Tubes Ltd. J T L Infra Ltd. Maharashtra Seamless Ltd. Nav Bharat Tubes Ltd. Samana Steels Ltd. Surya Global Steel Tubes Ltd. Thapar Concast Ltd. Tube Investments Of India Ltd. Vallabh Steels Ltd.
Plant capacity: 60 MT/Day.Plant & machinery: Rs.701 Lakhs.
Working capital: -T.C.I: Cost of Project:Rs.2462 Lakhs.
Return: 28.00%Break even: 40.00%
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