Cement Pipe Manufacturing Process
Introduction of Cement Pipe Manufacturing process
Cement Pipe manufacturing process industry can be set up upto Rs.25.00 lakhs under PMEGP scheme on small scale. This scheme provides upto 95% loan amount and govt. provides upto 35% subsidy. System of Bank loan and subsidy has been divided in the following catogery:-
For general catogery loan 90% and subsidy for rural area @25% and for urban area 15% subsidy is allowed.
For all other catogery than general bank loan 95% and subsidy for rural are 35% and for urban area 25% is allowed.
The proposed unit for manufacturing of Hume Pipes, are made from the mixture of cement, sand, and collected with reinforcement materials of steel rods and wires. Only SSI units can manufacture the RCC pipes up to 1000 mm diameter. For the purpose of average, drainage, irrigation, and culvert only these pipes are widely used. Such pipes are classified into two groups as pressurized and non-pressurized. These types of pipes are used for different purposes. NPI, NP2, NP3, P1, P2, P3 for use under specific conditions. Cement, coarse and fine aggregate, sand, and mild and HT steel rods are used for the manufacture of such pipes. These pipes are mostly manufactured in two lengths such as 1.8 meters and 2.8 meters with varying diameters from 10 cm to 100 cm. The RCC pipes are used for irrigation, culverts construction, sewerage, and drainage purposes for smooth transportation of effluents and to avoid seepage.
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The RCC pipe is used for agriculture purposes, urban and rural development in the construction drainage, sewerage by the various department and private agencies like agriculture and irrigation department, public health and engineering department, and rivers and valley projects. In the coming time due to the increase of construction work the demand for RCC pipes will naturally go up.
Department of Public Health Engineering, Department of Public Works, Department of Agriculture and Forests, National Highway, Department of Environmental Engineering, Panchayat Municipal Corporation are the bulk consumers of RCC spun pipes. Most of the customers are approved civil contractors carrying out the functions of government departments and public sector undertakings. Presently the government is emphasizing rural irrigation and improving the methods of water supply schemes, hence the demand for pipes is increasing.
BISIS & PRESUMPTION
- The unit will produce 46,000 running meters of pipes and other products.
- This report detailed only in Techno-Economic –Feasibility aspects.
- It has been presumed that the unit will run at least 300 days in a year.
- All calculations have based on single shift running for Hume pipe, cement tiles & other products.
- The gestation period in the implementation of the project may be about 8 to 12 months. In this period the promoter completes all the legal formalities side by side market survey and tie up, procurement of plant and recruitment of skilled workers commissioning of plant and trial production, etc.
- The normal wages and salaries being paid in the industry to various grades of personnel have been considered and also the provision of minimum wages has been taken care of.
- The rate of interest both for fixed and working capital has been taken as 14% P.A.
- The payback period for finance to the financial institutions may be about 5/7 years in case of term loan. The working capital loan is sanctioned limit based capital.
- It has been assumed that the unit will achieve its capacity as 70% 1st.yr., 75% 2nd.yr & 80% 3rd.yr. and so on.
- Tax, Freight, Installation, and electrification cost is taken @ 15% of the cost of machinery and equipment.
- Non-refundable deposits, project report cost, trial production, security deposits with Electricity Board are taken under pre-operative expenses.
- Depreciation has been considered:
(a) On Building @ 5%
(b) On plant and machinery @ 10%
(c) On office furniture and fixtures @ 10%
(d) On other fixed assets @ 10%.
LOCATION OF THE UNIT
The proposed unit will be set up at a site that will justify the following basic considerations:-
- Availability of raw materials & consumables.
- Availability of Power, Fuel, Water.
- Banking facility.
- Marketing prospectus.
- Good communications.
- Labor facility.
RAW MATERIALS AND CONSUMABLES FOR CEMENT PIPE MANUFACTURING PROCESS
- M.S. reinforcement rod and wire.
- Mound oil, grease, etc.
ITEMS TO BE PRODUCED
- Hume pipes of different diameters,
- Cement Tiles & other products.
Quality Control and Standards:
The Bureau of Indian Standards has formulated IS 458:1971, for maintaining the quality of the product.
The project does not create any noise or water pollution. The air pollution in the mixing area needs to be contained by providing a cyclonic dust collector. Workers may use a dust mask.
General precautions for saving electricity are required to be followed by the unit by adopting energy conservation techniques.
Motive Power required – 20 kW.
INSTALLED CAPACITY OF CEMENT PIPE MANUFACTURING PROCESS
46,000 running meters of Hume pipes & other products.
- 8 hours per day.
25 days per month.
300 days per annum.
Manufacturing Process of cement pipes
RCC mixture with raw materials such as cement, sand, and stone chips in 1:2.5:2.5 ratios are prepared with the help of power operated cement concrete mixture. Steel rod with reinforcement case is made in accordance with the dimensions of the pipe in a reinforcement making/winding machine. This case is then placed inside the pipe mold. The mold is mounted horizontally on the runners of the pipe molding machine. The mold is then rotated at a slow speed.
The concrete mixture is fed into the rotating molds through its open ends at both sides. When the mold is filled with required quantity of the mixture to obtain requisite thickness, the speed of the rotation of the mold is increased and kept at a fixed speed for few minutes depending upon the pipe diameter, length, etc. the inside diameter of the green pipe in the rotating mold is then finished for smoothness with the help of wooden reaper and to remove excess water. Thereafter neat cement is sprinkled inside the pipe to obtain a well-polished surface and to reduce friction coefficient at the time of its setting. The mold is taken out from the machine by the system and left in curing bay for the initial setting. On the following day, the molds are removed and the pipe is passed on to the curing tank and allowed to remain in the water for 15 days and then taken out for inspection and quality test. The finished product is then stocked in the yard for disposal.