Kanakadurga RCC Spun Pipes CONTENTS Sl.No PARTICULARS PAGE NO 1. Industry Profile 2 - 8 2. Company Profile 9 - 11 3. Organizational Structure 12 - 33 4. SWOT Analysis 34 - 38 5. Findings, Suggestions and Conclusion 39 - 42 Page 1
Oct 25, 2015
Kanakadurga RCC Spun Pipes
CONTENTS
Sl.No PARTICULARS PAGE NO
1. Industry Profile 2 - 8
2. Company Profile 9 - 11
3. Organizational Structure 12 - 33
4. SWOT Analysis 34 - 38
5. Findings, Suggestions and Conclusion 39 - 42
Page 1
Kanakadurga RCC Spun Pipes
INDUSTRY PROFILE
History of Concrete Pipes
recast concrete pipes, popularly known as “Hume Pipes” were introduced in this country by The India Hume Pipe Co. Ltd., as early as 1926.This pipe material, because of
its inherent qualities such as durability, strength, economy, etc. soon found acceptance and still enjoys the confidence of Public Health and Highway Engineers. For 50 years, the pipes supplied through over 50 branches of company have been used for water supply, Drainage, Irrigation, Road Culverts, etc., and are still giving trouble – free service.
P
These superior quality pipes are produced by the centrifugal spinning process, discovering by walter hume of Australia.
While the basic spinning spinning process is still used by the Company, many refinements have been made to meet specific needs. The company attaches considerable importance to Research and Development in order to improve the product and
Page 2
Kanakadurga RCC Spun Pipes
production technology. Plant and product design also play a leading role In maintaining the reliability of concrete pipes. Considerable attention is paid to the quality of raw material and finished products. The pipes produced today are of high density, which ensure long life, maximum strength, impermeability and good resistance in aggressive service conditions.
The company’s R & D Division is always engaged in the development of these products with the result that the pipes produced tomorrow are superior to the pipes made today. It has an Engineering Division, and the company is thus in a position to undertake the design and production of any special type of pipes required.
With the development of controlled spinning technique, together with mix design, use of welded cage and rigid quality control at every stage of production, the IHP method of manufacture gives many advantages unobtainable by other manufacturers.
Page 3
Kanakadurga RCC Spun Pipes
What factors are important in Concrete Pipe Manufacturing?
There are several methods of manufacturing concrete pipe. Depending on the process, slag cement proportioning may vary. Certain factors, however, are important to the manufacturers of all concrete pipe:
Strength at early stages Surface texture and density Permiability Sulfate resistance Consistency
The main features of pipe
The core of the pipe is made of high performance, dense concrete by the spinning process, being followed in many of the developed countries.
The process allows the use of concrete with very low water cement ratio resulting in high strength is 40 MPa.
Page 4
Kanakadurga RCC Spun Pipes
Winding of H.T. steel wire with accurate pitch and at controlled tension is an important feature of the process.
IHP’s mechanically impacted mortar coat is highly impermeable and provides maximum protection to the prestressing steel wire and prevents corrosion.
Design Concept
Prestressed concrete pressure pipes are designed to withstand all the stress that the design engineer expects during service. Pipes must safely resist the internal working pressures including water hammer effects and vacuum pressure.
When a pipeline is subjected to pressure, tensile stresses are created in the pipe wall. Compressive strength of concrete is remarkably high but the tensile strength is poor. To get the best advantage, the core concrete is kept in compression under normal working pressure.
The objective of helical prestressing is to produce uniform compressive stresses In pipe wall . Compressive strength of concrete is remarkably high but the tensile strength is poor. To
Page 5
Kanakadurga RCC Spun Pipes
get the best advantage, the core concrete is kept in compression under normal working pressure.
The objective of helical prestressing is to produce uniform compressive stresses in pipe wall to offset tensile stresses resulting from internal pressure, dead and live loads.
JOINT DESIGN
Water tightness between two pipes is ensured by a rubber ring conforming to Indian Standard specifications. At the time of jointing, the ring, placed in groove, is compressed between the joint surfaces of the spigot and socket. Internal pressure further increases the compression of the rubber ring and the water tightness of the joint remains perfectly efficient during the service. The jointing operation is a very simple one as it is sufficient to introduce the spigot fitted with the rubber ring, into the pipe socket and to pull it home by means of a lever/tackle or any other device.
The water tightness of the pipeline is closely examined when line tests are carried out at site.
Page 6
Kanakadurga RCC Spun Pipes
CONCRETE ADVANTAGESHIGH DURABILITY AND LOW COST
The prime objectives governing design and construction practices are durability and low cost. Water cement ratios of IHP’s concrete and mortar are optimum and concrete compaction methods for core and coating mortar are most efficient. Relevant standard specifications and codes cover selection and use of materials. These measures are supported by extensive research with a comprehensive quality control programme, for water tightness, structural and dimensional checks.
PSC pipes can be designed for any combination of working pressure and external loads depending upon the actual field conditions and this results in an economical pipeline.
FAST AND SIMPLE INSTALLATION
Installation of PSC Pipes is simple, rapid and easy with minimum efforts.
Page 7
Kanakadurga RCC Spun Pipes
The inherent rigidity and robustness of IHP pipes eliminates the need for special precautions necessary for pipes with flexible materials and delicate coatings.
BUILT IN ADVANTAGES
PSC pipes do not totally rely on compaction of backfill to provide lateral support as they are rigid pipes.
PSC pipes have high crushing and beam strengths and are suitable for installation in most locations, both below and above ground.
PSC pipes have good abrasion resistance and not normally require any special lining. Their interior surface remains smooth, guaranteeing sustained high carrying for the lifetime of the pipe
EXTERNAL LOAD CARRYING CAPACITY
In our country, for drainage and culverts, RCC Pipes of NP2, NP3 and NP4 classes as per I.S.458 are used and are giving excellent service.
PSC Pipes can also be designed for any load combinations because of unique combination of durability of spun concrete and hign tensile wire, which will result in an economical pipeline under heavy external loads.
Page 8
Kanakadurga RCC Spun Pipes
2.0 COMPANY PROFILE
COMPANY NAME : Shri Kanakadurga Spun Pipes
Bomakkanahalli
Molakalmuru, 577535.
NATURE OF
BUSINESS : Mfg / selling Industry.
OWNERS : Krishna
TYPE OF
OWNERSHIP : Sole Entrepreneurship.
TEL-NO : 9448190609, 9611500038.
RAW MATERIAL : Cement, Sand
Stone Pieces
TURN OVER : 7-8 lacs/month
FINISHED
PRODUCTS : Ready RCC Spun Pipes
OWNERS
INVESTMENT : 1 crore
Page 9
Kanakadurga RCC Spun Pipes
Page 10
Kanakadurga RCC Spun Pipes
KANAKADURGA RCC SPUN PIPES
This is a concrete pipe manufacturing industry established in 2011 as a branch of their main industry located in Bellary. They having their big industry named Kamadenu Spun Pipes, Siruguppa road, Bellary.
They have their own vision, mission and policy that is,
VISION
Their vision is the Kamadenu and Kanakadurga spun pipes should become a best and Famous industry in Bellary and surroundings and then the next vision is to construct the big factory.
MISSION
His mission is to introduce modern technology to manufacture the RCC Spun pipes.
POLICY:
Mr. Krishna gives 365 days guarantee for the customers. He also gives discount to the customers.
Page 11
Kanakadurga RCC Spun Pipes
STRUCTURE OF THE INDUSTRY
Purchasing of Raw Materials
Production Process
Human resource
Finance
Marketing
Page 12
Kanakadurga RCC Spun Pipes
Purchasing Of Raw Materials
The Raw material viz. Cement, Stone pieces and steel is purchased in Bellary as it is convenient because near to the work place. Sand is purchased in surrounding places of the Bommakkanahalli. Water is sufficient in the work place as they installed a bore for 24 hours water.
They purchase the moulds that is essential in making pipes are purchased from Koimattur, Vijayawada.
Page 13
Kanakadurga RCC Spun Pipes
PRODUCTION PROCESS
Production of RCC Spun Pipes involves the following steps:
Jali machine used for winding the steel for making the cage
Mixture Drum used for mixing the sand, cement and stone pieces
Rolling machine used for making the cement pipes
But there is also some necessary equipment that are used for the purpose of production i.e.
Moulds
Trailer
Chain pull
Runners
Shovels
Page 14
Kanakadurga RCC Spun Pipes
Jali(Winding) machine
This machine is used for winding the steel rod into the a machine called
jail machine for making the steel rod into a cage. This cage is used in
making the concrete pipe because if steel rod is used means the
stiffness and roughness will improved. This steel rod can be winded as
the size that they want.
Using this machine they can produce daily 10 to 12 cages for
manufacturing the concrete pipes
There must be 2 labourers required for preparing a single cage because
it is not simple as we see it, it is very hard to wind the steel thread as it
takes the correct shape
Page 15
Kanakadurga RCC Spun Pipes
Winding process
Page 16
Kanakadurga RCC Spun Pipes
Mixture Drum
As we all seen the mixture drum i.e. the manual oriented machine used
for mixing the cement, stone pieces(jalli) and sand for preparing the
concrete. Here also same that this machine is used for preparing the
concrete by mixing sand, cement and stone pieces.
This concrete will be processed in the rolling machine with the moulds
as usual as cage for preparing the finished RCC Spun Pipes. This
machine works as a mixer of the concrete by using water as a solvent.
Here only 2 labourers are there for making the mixture of concrete.
Page 17
Kanakadurga RCC Spun Pipes
Mixture Drum
Page 18
Kanakadurga RCC Spun Pipes
Rolling Machine
This is a machine where it makes the final product. In this process a the
moulds are kept on a wheels called runner which is attached to a motor
with belts that are rolling. After it the cage will be put in the mould after
the spinning process will starts and immediately the workers begins to
put the concrete mixture on it by using baandlis.
After it spins until the concrete mixture will tightly fitted in the meshed
cage and lastly after an hour, the process will complete and the pipe
with mould will kept aside for drying whole ay by using chain pulls and
trailers.
The process is purely based on the centrifugal force.
Page 19
Kanakadurga RCC Spun Pipes
ROLLING MACHINE
Page 20
Kanakadurga RCC Spun Pipes
Other equipments used in the production process are:
Page 21
Kanakadurga RCC Spun Pipes
Shovels
Runners
Page 22
Kanakadurga RCC Spun Pipes
Motors used in Rolling
Page 23
Kanakadurga RCC Spun Pipes
Raw materials used for manufacturing various sizes of pipes
Size of pipes Steel(in kgs) Cement (in pkts)
Stone pieces (jalli)
(in baandlis)
Sand (in baandlis)
12in or 1ft 5 1 6 7
18in or 1.5ft 12 3 18 20
24in or 2ft 15 5 25 30
36in or 3ft 20 8 38 42
42in or 3.5ft 30 10 45 55
48in or 4ft 40 12 60 68
CURING PROCESS
Page 24
Kanakadurga RCC Spun Pipes
The last process after the manufacturing of concrete pipe is curing
means keeping the pipes in water for some specified days.
In Kanakadurga industries they have their separate big pool for keeping
the manufactured pipes. They have their own specified period for
curing the pipes that is they keeps the manufactured concrete pipes till
21 to 24 days.
Page 25
Kanakadurga RCC Spun Pipes
CURING POOL
In Kanakadurga Pipe Industry, they produce two types of RCC Spun Pipes they are:
Page 26
Kanakadurga RCC Spun Pipes
NP2 Pipes
These pipes are low in thickness compared to the other type NP4. These pipes will take short time to manufacture i.e. 2 to 2 ½ hours.
These pipes are used in making pipe line for water tanks and in pumphouses
Selling price of 1 ft NP2 pipe = 1800 Rs
Selling price of 4 ft NP2 pipe = 8000 Rs
NP4 Pipes
These pipes have more thickness that means these pipes have heavy gauge. These pipes takes some more time to manufacture compared to the NP2 pipes i.e. 3 to 4 hours.
These pipes are used in construction of bridges.
Selling price of 4 ft NP4 Pipe = 12000 Rs
Quality Tests
Page 27
Kanakadurga RCC Spun Pipes
In Kanakadurga Industry there are 2 quality testing machines that is
used for testing the quality of pipes they manufactures. If Order has
been from government means the engineers will came to the work
place and test the pipes in the following two types of machines:
1. Water Testing Machine, and
2. Load Testing Machine
Page 28
Kanakadurga RCC Spun Pipes
Water Pressure Testing Machine
Page 29
Kanakadurga RCC Spun Pipes
Load Testing Machine
HUMAN RESOURCE
Page 30
Kanakadurga RCC Spun Pipes
Human resource in this industry means workers that are working in this
industry. Kanakadurga Pipe industries provided more employment
opportunities to the surrounded village’s people. There are 20 workers
working in this industry in different section of manufacturing process.
Labourers : 20 nos
Wages per day : 400 Rs
FINANCEPage 31
Kanakadurga RCC Spun Pipes
As seen in the Kanakadurga RCC Spun Pipe Industry, there is a huge capital that the industry have. That is they invested approximately 1 crore for establishing the industry. This industry have well financial system that meets all working capital requirements.
Investment : approx. 1 crore
Turn over : approx. 7 - 8 lacs
MARKETING
Page 32
Kanakadurga RCC Spun Pipes
Marketing is the last process that all the industries have. In Kanakadurga industry their marketing is well because they supplies their product to various places viz. Bangalore, Hassan, Bellary, Places in Andhra also.
They supplies their product with their own transportation facility.
Mode Of Transportation : Owned 5 lorries
Page 33
Kanakadurga RCC Spun Pipes
SWOT ANALYSIS
Strengths
Page 34
Kanakadurga RCC Spun Pipes
They have good brand and image in Bellary and in
Bommakkanahalli.
They provide fair wages to the labours.
They manufacture good concrete pipes.
They have their own mode of transportation to supply the
product.
They are using traditional technology.
They have well equipped machineries.
Page 35
Kanakadurga RCC Spun Pipes
WEAKNESS
They have lack of technology.
They don’t have a godown or storage place to store the
Manufactured RCC pipes.
Page 36
Kanakadurga RCC Spun Pipes
OPPORTUNITIES
They can use latest technology of manufacturing the RCC
Spun Pipe for making the production faster that leads to
meeting the demand.
There is no other manufacturer in surrounding hence this as an
strength as well as opportunity.
Page 37
Kanakadurga RCC Spun Pipes
THREATS
There are more manufacturers in Bellary that is near to the
work place, hence this will cause some decline in sales.
Plans of other industry to establish in the surroundings of
Bommakkanahalli
Page 38
Kanakadurga RCC Spun Pipes
FINDINGS
SUGGESTIONS
CONCLUSION
FINDINGS
Page 39
Kanakadurga RCC Spun Pipes
As all know that Kanakadurga industry having a good brand
and image
They provide good wages to the workers
They established the industry with well furnished resources
They have their own vast land
They have a good financial system
They have good production system
SUGGESTIONS
Page 40
Kanakadurga RCC Spun Pipes
They can make their production even faster by using the
modern technology.
They can build a godown for storing the manufactured
pipes.
They can transport the pipes to the delivery place with
discount.
CONSLUSION
Page 41
Kanakadurga RCC Spun Pipes
As we seen that this industry is very well furnished with the
finance and machineries and land with all resources. We
learnt lot of things by visiting this industry.
Page 42