Kanakadurga RCC Spun Pipes

CONTENTS

Sl.No 1. 2. 3. 4. 5.

PARTICULARS Industry Profile Company Profile Organizational Structure SWOT Analysis Findings, Suggestions and Conclusion

PAGE NO 2-8 9 - 11 12 - 33 34 - 38 39 - 42

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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.

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
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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 companys 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.

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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.
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Winding of H.T. steel wire with accurate pitch and at controlled tension is an important feature of the process.

IHPs 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
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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.

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CONCRETE ADVANTAGES
HIGH DURABILITY AND LOW COST The prime objectives governing design and construction practices are durability and low cost. Water cement ratios of IHPs 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.
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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.
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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

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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.

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STRUCTURE OF THE INDUSTRY

Purchasing of Raw Materials Production Process Human resource Finance Marketing

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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.

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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

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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

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Winding process

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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.

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Mixture Drum

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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.

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ROLLING MACHINE

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Other equipments used in the production process are:

Shovels
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Runners

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Motors used in Rolling

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Raw materials used for manufacturing various sizes of pipes

Size of pipes

Steel(in kgs)

Cement (in pkts) 1 3 5 8 10 12

12in or 1ft 18in or 1.5ft 24in or 2ft 36in or 3ft 42in or 3.5ft 48in or 4ft

5 12 15 20 30 40

Stone pieces (jalli) (in baandlis) 6 18 25 38 45 60

Sand (in baandlis) 7 20 30 42 55 68

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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.

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CURING POOL

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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 hours.

These pipes are used in making pipe line for water tanks and in pumphouses

Selling price of 1 ft NP2 pipe Selling price of 4 ft NP2 pipe

= =

1800 Rs 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
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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

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Water Pressure Testing Machine

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Load Testing Machine

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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 villages people. There are 20 workers working in this industry in different section of manufacturing process.

Labourers

20 nos

Wages per day

400 Rs

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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

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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

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SWOT ANALYSIS

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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.

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WEAKNESS

They have lack of technology. They dont have a godown or storage place to store the Manufactured RCC pipes.

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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.

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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

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FINDINGS SUGGESTIONS CONCLUSION

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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

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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.

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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.

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