About Rcc Spun pipes

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


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


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.


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.


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


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.


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.


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.


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


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.


STRUCTURE OF THE INDUSTRY

Purchasing of Raw Materials

Production Process

Human resource

Finance

Marketing


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.


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


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


Winding process


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.


Mixture Drum


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.


ROLLING MACHINE


Other equipments used in the production process are:


Shovels

Runners


Motors used in Rolling


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


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.


CURING POOL

In Kanakadurga Pipe Industry, they produce two types of RCC Spun Pipes they are:


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


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


Water Pressure Testing Machine


Load Testing Machine

HUMAN RESOURCE


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

FINANCE


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


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


SWOT ANALYSIS

Strengths


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.


WEAKNESS

They have lack of technology.

They don’t have a godown or storage place to store the

Manufactured RCC 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.


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


FINDINGS

SUGGESTIONS

CONCLUSION

FINDINGS


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


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


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.

About Rcc Spun pipes

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