R.C.C. Spun Pipe
| Product Code | 94432 |
| Quality and Standards | IS 458 |
| Uploaded on | July 2007 |
Introduction
Reinforced cement concrete spun pipes upto 1000 mm dia are exclusively reserved for manufacture in the SSI sector. These pipes are widely used for water drainage, sewerage, culverts and irrigation. RCC pipes are classified as pressure and non pressure pipes viz. NPI, NP2, NP3, P1, P2, P3 for use in specific conditions. These pipes are made from cement, coarse and fine aggregate, sand, mild steel and HT rods and bars.
Market Potential
Public Health Engineering Department, Public Works Departments, Agriculture and Forest Department, National Highways, Environment Engineering Department, Panchayats Municipal Corporations are the bulk consumers of RCC spun pipes. Most of the customers are approved civil contractors who are executing the works of the Government Department and Public Sector Undertakings. Presently government is giving stress on rural irrigation and improving methods of water supply scheme, so the demand for pipes is increasing.
Technical Aspects
Process of Manufacture
The reinforced cage is first prepared on the cage-winding machine by hand process. The cage is then placed inside the pipe mould which is then hoisted up and mounted horizontally on the turn unions. It is rotated by driving shaft with variable speed arrangement, the rotation is kept slow in the beginning and then the speed is increased. The concrete mixture for the RCC spun pipe is prepared in proportion of 1:2:5:2:5 of cement stone, metal and sand respectively. The cement concrete is fed into the moulds during rotation which spreads inside evenly. The time required for completion of this operation depends upon the diameter and class of the pipe. The pipes are kept in the mould for 24 hours. On the following day the pipes are removed from the moulds and submersed in water in the curing tank for about 15-20 days depending upon the class of the pipe. The specimen of the pipes are subject to the following tests viz: (1) Hydrostatic pressure test (2) Three edge bearing test (3) Absorption test.
Quality Control and Standards
The Bureau of Indian Standards has formulated IS 458:1971, for maintaining Quality of the product.
Production Capacity (per year)
| Quantity | : 20,000 Running meter | |
| Value | : Rs. 6460000 | |
| Motive Power | 20kW. | |
Pollution Control
The project does not create any noise or water pollution. The air pollution in mixing area need to be contained by providing cyclonic dust collector. Workers may use dust mask.
Energy Conservation
General precautions for saving electricity are required to be followed by the unit by adopting energy conservation techniques.
Financial Aspects
A Fixed Capital
Land and Building
Value (Rs.) |
|
| Land 2 acre Building @ 1200000 per acre | 2400000 |
| Office, Testing laborator y 35Sq. m. @ Rs4000 | 140000 |
| Production shed 100 Sq. m. @ Rs2000 | 200000 |
| Stores room 30 Sq. m. @ Rs3000 | 90000 |
| Curing tank 40 x 20mtrs. | 100000 |
| Well, pump set, overhead water tank etc. | 150000 |
| Total | 3080000 |
Machinery and Equipments
Description |
Qty. Nos. |
Value (Rs.) |
| Pipe moulding machine of 2 metre length complete set with 10HP motor | 1 | 300000 |
| Gauge winding machine | 2 | 60000 |
| Concrete mixer | 1 | 80000 |
| Collar winding drum with stand | 2 | 40000 |
| Gantry with pull-push trolley | 1 | 160000 |
| Testing equipments | L.S. | 100000 |
| Collar moulds complete with end rings, tie rods, riving ring for pipes 100mm to 600mm dia and 2 metre length pipes | 40 | 280000 |
| Pipe moulds 100mm to 600mm dia 2 metre with accessories | 40 | 440000 |
| Electrification and installation charges | L.S. | 80000 |
| Office equipment and furniture | L.S. | 75000 |
| Total | 1615000 | |
Total Fixed Investment
(Rs.) |
|
| Land and building | 3080000 |
| Machinery and Equipment | 1615000 |
| Pre-operative expenses | 80000 |
| Total | 4775000 |
Working Capital (Per Month)
Staff and Labour (per month)
Designation |
Salary |
Nos. |
(Rs.) |
| Manager | 15000 | 1 | 15000 |
| Supervisor | 8000 | 1 | 8000 |
| Skilled workers | 4500 | 6 | 27000 |
| Un-skilled workers | 3500 | 10 | 35000 |
| Perquisites @22% | 18700 | ||
| Total | 103700 | ||
Raw Materials (per month)
(Rs.) |
|||
| Cement | 20MT Rs. | 4000/MT | 80000 |
| Steel | 4MT Rs. | 28000/MT | 112000 |
| Coarse and fine aggregate | L.S. | 35000 | |
| Mould oil grease and misc. expenses | L.S. | L.S. | 40000 |
| Total | 267000 | ||
Utilities (per month)
(Rs.) |
||
| Electrical power | 20kW | 12000 |
| Water | L.S. | 3000 |
| Total | 15000 | |
Other Contingent Expenses (per month)
Particulars |
(Rs.) |
| Postage and Stationery | 2000 |
| Telephone | 3000 |
| Repair and Maintenance | 5000 |
| Travelling expenses | 3000 |
| Transport charges | 10000 |
| Miscellaneous expenses | 2000 |
| Insurance | 15000 |
| Total | 40000 |
Total Recurring Expenditure (per month)
(Rs.) |
|
| Staff and labour | 103700 |
| Raw Material | 267000 |
| Utilities | 15000 |
| Other contingent expenses | 40000 |
| Total | 425700 |
| Total Working Capital for 2 months | 851400 |
Total Capital Investment
| Fixed capital | 4695000 |
| Working capital | 851400 |
| Total | 5546400 |
Machinery Utilization
Sufficient and timely availability of Grey cement will ensure optimum utilization of the installed capacity. The pipes are kept immersed in water for curing purpose in such a way that one is not put on the other. Sufficient moulds are required to maintain regular production otherwise non-availability of required pipe moulds or collar moulds will be a bottleneck in the optimum capacity utilization.
Financial Analysis
Cost of Production (per year)
Description |
Value (Rs.) |
| Recurring Expenditure | 5108400 |
| Depreciation on Building at 5% | 42570 |
| Depreciation on Machinery and Equipment at 10% | 74000 |
| Depreciation on moulds @15% | 108000 |
| Depreciation on furniture @ 20% | 15000 |
| Interest on total investment @ 13% | 721032 |
| Total | 6069002 |
Turnover (per year)
Items |
Qty. |
Rate |
Value (Rs.) |
| RCC spun pipes 2 meter length | 20000 | 340/ per pipe | 6800000 |
| (– 5% rejection) | Nos. | 340000 | |
| Total | 6460000 | ||
Net Profit
| Rs. 6460000– 6069002 | |
| 390998 |
Net Profit Ratio Over Turnover
Net profit x 100 Turnover |
||
390998 x 100 6460000 |
||
| 6.05% |
Rate of Return on Total Investment
Net profit x 100 Total Investment |
||
390998 x 100 5546400 |
||
| 7.05% |
Break-even Point
Fixed Cost (per year)
Description |
(Rs) |
| Total Depreciations | 239570 |
| Interest on total investment | 721032 |
| 40% of salaries | 497760 |
| 40% of other Contingent expenses | 120000 |
| Insurance | 180000 |
| Total | 1758362 |
| B.E.P | Fixed cost x 100 Fixed cost + Profit
|
|
758362x 100 1758362+ 390998
|
||
81.81%
|
Addresses of Machinery and Equipment Suppliers
- M/s. Prakash Fabricators
1034 E, Rajaram Road,
Kolhapur (Maharashtra) - M/s. A. P. L. Industries
415, Dave Industrial Estate,
Bhakti Nagar Station Road,
Rajkot – 2 (Gujarat) - M/s. Buildtech Engineering Co.
Shree Ashadweep Complex,
16-Civil Lines,
Roorkee – 247 667,
(Uttar Pradesh) - M/s. Karthik Industries
36, J.C. Road,
Bangalore-560 002 - M/s. Susanji Udyog Pvt. Ltd.
C-47, Industrial Estate,
Sanathnagar,
Hyderabad – 500 018 - M/s. Apco Concrete Blocks and Allied Product
7th Mile, Kanakpura Road,
Doddasandra Post,
Bangalore – 560 062 - M/s. Ashok Engineering Works
81, Ajit Industrial Estate Rakhial,
Ahmedabad – 380 023 - M/s. Hydro Engineering Works
K1/116, CIDC,
Mori, (Gujarat)
For further information please contact
Information Manager
TIMEIS Project
E-mail: timeis@ficci.com
