greatweld engineering pvt.ltd. grating introduction.pdf · greatweld engineering pvt. ltd. grating...

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GREATWELD ENGINEERING PVT.LTD.

Company Profile

Products / Services : Metal Products - Electroforged Steel Grating - Flat bar Grating, Serrated bar Grating, Structural Steel,Fabrication, Stainless Steel Grating. Stair tread Grating. Drainage covering Grating-trench cover. Hot dip Galvanizing Grating. Hand rail, Stair Tread & Clamp.

Factory Address : Plot No. A 18, 5 Star MIDC, Indapur, Lonideokar Village, Pune-Solapur Highway, NH 9, Post : Indapur, Dist. Pune- 413 132. Maharashtra, INDIA.

: Gat No. 213-214, 230-233, Markal Udyog Nagar, Plot No. C & D, Post : Markal, Tal.- Khed. Dist. Pune-412 105.

Office Address : Office 3 & 5, IInd Floor, Kunal Puram, ‘G’ Bldg., Opp. Atlas Copco Ltd.,Pune-Mumbai Road, Dapodi, Pune - 411 012.

Business Nature : Manufacturer

Year of Establishment : 2005

Plant Capacity : 30,000 MT / Annum

No. of Total Staff : 350 Nos.

Current Export Markets : Well Established in Middle East Countries

Shipment : Sea, Air, Road

Delivery Schedule : Min. 600 MT / Week

Currency : INR. / USD

Company Area : 6296 Sq. Mtrs. Markal, Pune Plant. 48,000 Sq. Mtrs. Indapur, Pune Plant.

GOVERNMENT REGISTRATION INFORMATION :-

R. O. C. No. : CIN U 27109 PN 2005 PTC 021883

Factory Registration No. : 3914/SIA/IMO/2006 (Ministry of Commerce & Industry)

Shop Act No. : Pimpri / II / 11023

PAN No.

TAN No.

VAT No.

CST No.

Excise Reg. No.

MPCB Consent No.

: AACCG5316J

: PNEG06179F

: 27770528514 V

: 27770528514 C

: AACCG5316JXM001/AACCG5316JXM002

: ROP/E-25/CC/UB/PUNE/2830/6342/06

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GREATWELD ENGINEERING PVT. LTD.

We are committed to enhance the satisfaction of all interested parties by manufacturing cost effective GRATING through continually improving the effectiveness of Quality Management System in every Process function.

We will achieve it through .......

Improvement in all interested parties satisfaction

On time delivery performance to Customer

Overall Cost Reduction

Strengthening communication process (internal &exernal)

Creating Healthy and Safety environment

Motivating all the employees


Managing Director

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Quality Policy


WHY ELECTROFORGE GRATING IS SUPERIOR ?

CONVENTIONAL PROCESS ELECTROFORGE PROCESS

Process cost is comparatively high Economy with compare to manual

Productivity is very Low Productivity is extremely high

Construction is notching the slot & welding Construction is machine based with advancethe cross bar which is primitive & conventional technology of High Current & High Pressure.

Quality generates by Man hence unreliable Quality is reliable due to Machine process.

Notches punch in bearing bar is weakens Homogenous forge weld gives Highthe strengths strength, Improve load bearing capacity,

Excellent stability

Large air gap in process lead to poor weld Every intersection weld is homogeneous &which reduces load bearing capacity by 25% hence there are no air gaps, which improvecompare to Electroforge the load bearing capacity.

Cutouts not as strong and stable as Cutouts have a high degree of strongest andElectroforged gratings stability

Handmade/fabricated gratings are Accuracy of dimensions is far superior.not very precise in shapes & dimensions This speeds up laying and fixing operations

of gratings. This means more cost effective.

Because of arc welding, flux, which causes Galvanizing appearance is very good. imperfect galvanizing leaves behind black spots. & no black spot is remaining.

LIMITATIONS OF ELECTRO FORGE PROCESS GRATINGS.

1 Very few resources are available for manufacturing by ELECTRO FORGE Technology.

2 The Grating design for cross member as a flats cannot be made by ELECTRO FORGE.

3 Specially Square Twisted bar require to be use as a cross member for better strength

BENEFITS OF GALVANISING ?

1 Lowest Long Term Cost : Even in cases where the initial cost of galvanising is higher than a comparable alternative coating systems, galvanising is invariably cheaper in the long run.

2 Long Life : The standard 600 gms / m2 galvanised coating has a typical life without maintenance of more than 50 yrs. in rural environment and 20-25 years in urban& coastal conditions.

3 Reliability : The galvanised coating bonded metallurgic ally to the base steel so that it becomes part of steel surface, it protects coating life and performance are therefore reliable and predictable.

4 Coating Toughness : A galvanised coating has unique metallurgic structure, which gives outstanding resistance to mechanical damage in transport, erection and service.

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GRATING MANUFACTURE UNDER ONE ROOF

Rolling Mill

Raw Material

Electro Forge

Black Grating

Galvanising

Galvanising Storage

Testing

Packing

Dispatch

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GRATING SPECIFICATIONS

M.S. Bearing Bar (available in different size)

25 x 3mm 25 x 5 mm 25 x 6 mm30 x 3 mm 30 x 5 mm 30 x 6 mm32 x 5 mm 32 x 6 mm40 x 5 mm 50 x 5 mmMaterial Standard - IS 2062, Grade ‘A’

Sq. Twist Bar (available in)

5.4 x 5.4 mm = 6 mm Sq. twisted6.6 x 6.6 mm = 8 mm Sq. twsited

Material Standard - IS 1786

Electroforge gratingspecify as per standard BS 4592

Quality Testing of Grating

Deflection TestDeflection can be measured by uniform distributed (UDL) or concentrated load method.Deflection test strength of panel should be on 500 kg. of UDL or 25 kg. CL on one flat with minimum deflection of span / 200 or 6 mm which ever is less.

GREATWELD STRENGTHELECTRO FUSION... MOST HOMOGENEOUS & MORE THAN 10 KN

Bearing Bar SizeCross Bar SizeB/B - PitchCross Bar PitchFrame Bar SizeWorking load on the grating in UDL or CL.

How to specify Grating ?Cross Bar Pitch

Sq. Twisted Bar

Bearing Bar PitchBearing Bar

Pull Load TestStrength of the electroforge joints of bearing and cross bar is tested by applying max. pull load to get the fracture.

What is Electroforge ?

Electroforge grating is a processof high current and high pressureresistant, welded steel bar panel,which are rugged in nature andhave one piece constructed panel.Our product has the most economicalstandard Electrofusion welded grating.

?Load carrying member is the bearing bar and dimension along with bearing bar is known as Span.Electrofusion binding member of bearing bar is knownas cross bar and dimension along with cross bar is known as Width.

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Span

Width

Frame Bar

Cross Bar

Supporting ‘I’ BeamBearing Bar Pitch

Deflection Test


GRATING MANUFACTURING PROCEDURE

QUALITY CHECKS

VERIFICATION OF RAW MATERIAL BY

i) RAW MATERIAL QUALITY PLANSUPPORTED BY IS STANDARD

ii) SUPPLIER RMTC VERIFICATION AS PER RMQPiii) R.M. DIMENSIONAL CHECKINGiv) OUTSIDE LAB VERIFICATION AS PER RMQPv) ACCEPTANCE OF MATERIAL

VERIFICATION OF WELDING PROCESS BY

i) INTERNAL WORK ORDER OR CUSTOMERDRAWINGS / MANUFACTURING RELEASE NOTE(MRS)

ii) MACHINE PROCESS QUALIFICATIONiii) PROCESS PARAMETER SETTINGiv) DIMENSIONS CHECKINGv) WELDING STRENGTHvi) BB / CB / CB HEIGHT./ CONSTRUCTION DETAILS /

MRS/ NUMBERING / CROSS BAR / BEARING BAR

VERIFICATION OF CROPPING PROCESS BY

i) EQUAL CROPING OF RODSii) NO ROUGH EDGE OR LOOSE OF CROSS BAR

VERIFICATION OF CUTTING PROCESS BY

i) INTERNAL WORK ORDERii) DIMENSIONS CHECKINGiii) DIAGONALiv) NUMBERING(WHITE PAINT)

REMOVE BURR OCCURES FROM PREVIOUS OPERATIONS

VERIFICATION OF LOOSE IN INCOMING STAGE BY

i) BO / OL QUALITY PLANii) DIMENSIONS CHECKINGiii) VISUAL INSPECTION.iv) GRN CLEARANCE

VERIFICATION OF WELDING PROCESS BY

i) MRS / ANNUXTURE / DRAWINGS BY HARD PUNCHii) MACHINE QUALIFICATIONiii) OPERATOR QUALIFICATIONiv) PROCESS PARAMETER SETTINGv) DIMENSIONS CHECKING( DIAGONAL/SPAN/

WIDTH/NOTCH/LAYOUT)vi) VISUAL CHECK (WELDING SPECN/ SPATTER/ JOINT

WELD/ WELD CRACK/ UNFUSED CROSS BAR

VERIFICATION OF FINISHING PROCESS BY

i) QUALITY ASSURANCE PLAN (QAP)i) DIMENSIONS CHECKINGii) VISUAL INSPECTION.+ ALL PARAMETERS IN OP. 60

VERIFICATION OF FINISHING PROCESS BY

i. QUALITY ASSURANCE PLAN (QAP)ii. THICKNESS (DFT) CHECKINGiii. VISUAL INSPECTION.iv. WITNESS GALVZ. TESTING

i) QUALITY ASSURANCE PLAN (QAP)ii) FINAL INSPECTIONiii) PACKING LISTiv) DESPATCH TO CUSTOMER

OPERATIONS

RAW MATERIAL RECEIPT

ELECTRLFORGE WELDING

CROPPING OF WELDED RODS

CUTTING OF PANEL FOR REQUIRED SIZE

GRINDING (OPCTIONAL)

LOOSE PART MANUFACTURING(OFFLOADED / BOUGHT OUT)

FABRICATION ( WELDING )

FINISHINGz & GRINDING

SURFACE TREATEMENT

FINAL INSPECTION & DESPATCH

OPEN. SEQUENCE

10

20

30

40

50

60

60

70

80

90

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30 MM Centre to Centre (Type : GG 30/100, GG 30/50

U 11000 4880 2740 1760 1230 900 680

25 X 3 D 0.6 1.4 2.6 3.9 5.9 7.9 10

C 1660 1100 820 660 550 470 410

D 0.5 1.1 2 3.1 4.3 6.1 8

U 18300 8100 4560 2920 2020 1490 1150 850

25 X 5 D 0.6 1.4 2.5 3.9 5.6 7.5 10 12.7

C 2740 1820 1370 1100 910 780 690 570

D 0.5 1.1 2 3.1 4.3 6.1 8 10.5

U 15800 7100 3950 2520 1750 1290 690 780 680 600

30 X 3 D 0.5 1.1 2.1 3.2 4.3 5.4 6.5 7.2 8.3 12.9

C 2370 1580 1180 950 790 670 590 520 410 400

D 0.4 0.9 1.6 2.6 3.7 5 6.6 8.3 9.4 10.3

U 22800 11700 6580 4210 2920 2150 1610 1300 1050 860

30 X 5 D 0.5 1.1 2.1 3.2 4.3 5.4 6.5 7.2 10.8 12.9

C 3950 2630 1970 1580 1310 1130 980 870 780 710

D 0.4 0.9 1.6 2.6 3.7 5.0 6.6 8.3 9.4 13.3

U 28100 12500 7100 4490 3100 2280 1740 1380 1120 920 770 660

40 X 3 D 0.3 0.8 1.5 2.4 3.5 4.8 6.2 7.9 9.7 11.8 13.8 16.4

C 4200 2800 2110 1690 1400 1200 1050 930 840 760 700 640

D 0.3 0.7 1.2 2.1 2.8 3.9 4.9 6.3 7.7 9.4 11.2 13.0

U 47200 20800 11700 7500 5200 3820 2920 2310 1860 1650 1230 1100 950 830

40 X 5 D 0.3 0.8 1.5 2.4 3.5 4.8 6.2 7.9 9.7 11.8 13.8 16.4 19.5 20.6

C 7000 4680 3510 2800 2330 2010 1750 1560 1400 1270 1170 1080 1000 930

D 0.3 0.7 1.2 2.1 2.8 3.9 4.9 6.3 7.7 9.4 11.2 13.0 15.1 17.3

U 73100 32500 18300 11700 8100 5900 4570 3610 2920 2410 2030 1730 1490 1300 1140

50 X 3 D 0.3 0.7 1.2 2.0 2.8 3.8 5.0 6.3 7.8 9.4 11.2 13.2 15.2 17.5 19.9

C 10900 7500 5500 4380 3600 3130 2740 2430 2190 1990 1830 1690 1560 1460 13.7

D 0.2 0.6 1.0 1.5 2.2 3.1 4.0 5.0 6.2 7.5 9.0 10.5 12.1 14.0 15.9

MaterialIS 2062 - Gr. AU - Uniformly distributed load in kg/sq.mC - Concentrated load in kg. m width at mid-spanD - Deflection in milimeters

Spans to left of heavy line producea deflection of 6 mm or less undera uniform load of 500 kg/sq.m

This Deflection is recommendedas per BS : 4592 - 1970

OUR GRATING PRODUCT

Main member known as Bearing bar. (flat) Secondary member is known as Cross bar (Twisted Bar)

Grating can be made in std. Pitch of 30, 35 & 40 mm. for bearing bar & 50, 75 & 100 mm. pitch of cross bar.

Grating bearing bar sizes varies from Min. -25 x 3 mm. thick to Max. - 75 6 mm. in plain or serrated type of flats. Grating Surface finish can be available

A) Self Coloured

B) Painting - As per painting specification

C) Hold dip Galvanizing -As per Specification IS 2629 & 4759.

LOAD TABLE FOR M.S. GRATING

SPANLOADBEARINGFLAT 300 450 600 750 900 1050 1200 1350 1500 1650 1800 1950 2100 2250 2400SIZE IN MM

Standard Grating6 x 1 mm. panel

Rectangular GratingAs per drawing cutout

Circular GratingAs per drawing cutout

Stair TreadsAs per L x W

Grating Clip

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greatweld engineering pvt.ltd. grating introduction.pdf · greatweld engineering pvt. ltd. grating...

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