Industrial Visit Report

To Jejuri, Pune
On
5th May 6th May 2017

Indiana Gratings Pvt Ltd

Indiana Conveyors Pvt Ltd
Indiana Cable Trays Corporation
Indiana International

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 INTRODUCTION

Established in the year 1968, Indiana is a leading global

manufacturer and exporter of fabricated structural steel (I-
Beam, H-Beam, T-Beam, Plus Beam & Box Beam), floor
gratings, safety handrails, cable trays (perforated, ladder & wire
mesh type), cable support system, cable management system,
welded wire mesh, conveyors and bulk material handling
equipments.

Based in Mumbai, India, Indiana is an integrated steel

fabricator with an annual output of 75,000 tons.

Today, we are one of the largest manufacturer-exporter of

Electro-forged gratings in the world and have established an
impeccable reputation and carved a permanent niche with
clients.

Our strength is derived from ultra-modern manufacturing

facilities, a strong team of qualified and experienced engineers
and a highly motivated and skilled workforce.

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 REPORT

Factory Survey
Indiana Group has a huge set up for manufacturing of Gratings,
Structural Beams, Girders, Cable Trays, Wire-mesh, Handrails,
FRP Cable Trays, etc. The Plant consists of 5 Units namely D-
5, D-7, D-9, C-1, and F-5. It has more then 200+ people
working in it (inclusive of Staff +Workers). The Plant is situated
in Jejuri, Pune.
Firstly, we visited to the HR Department, wherein we were
given a briefing about what the company is about hoe is t
Running etc. Mr. Tambhode accompanied us. He took us to the
D-5 Unit where we meet Mr. Praveen. He told us about the
cable Trays manufacturing. Cable Trays are usually made up of
GI sheets which are placed in the Rolling machine which helps
to acquire the desired Dimensions. Accessories are usually
handmade. Bends, T joints too are manufactured. With help of
the proper alignment the rungs are welded with the C-Channels
for a ladder Type cable Tray. Perforated Trays are directly feed
into the machine. Its thickness ranges from 1.5-5mm,
depending upon the Requirement. The Width ranges from
50mm-600mm too. The company has a proper Lean
Manufacturing wherein the Materials are properly stacked in
their respective Places.

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 Wire-mesh
Wire-mesh generally made up of 16-20G wire. These
wires are feed in to the machine which actually prepares
the finish product in terms of Mesh.

Structural Steel
After finish up the D-5 Unit, we proceeded to the D-7 Unit.
We met Mr. Suresh, who was in Charge of the Structure
Steels. Here the Heavy Engineering works were Carried
Out. He gave briefing about how the Girders, beams are
manufactured.
After entering the D-7 Unit, we saw the manufacturing of
beams. The important Test for Weld Check is:
Visual Test
Penetration Check
Ultrasonic Test
Radiography Test
Magnetic Particle Test
There are two types of Structure which are manufactured
in this Unit:
Bolting Structure
Building Structure.

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 The Unit is spacious which has a good capacity to store the
Structure.
The best part of the plant is that it has a license from the
National Thermal Power Corporation (NTPC).

Machine such as Flux welding machine, Arc welding too

were observed. The beams were lifted by EOT Cranes which
has a capacity to hold 25MT of Weight

Hot Dip Galvanization(HDG) Unit (F-5)

Galvanizing coatings are applied to Iron and Steel
primarily to provide protection against corrosion. HDG is a
process in which an adherent, protective of Zinc and Zinc
Compound is developed on the surface of Iron and Steel
products by immersing them into the bath of molten Zinc.
Here we were accompanied by Mr. Pansare who gave us
the full working and setup of Galvanizing Unit. It
undergoes through various process.
1. De-Greasing: This is the initial process for Galvanization.
The material is hanged to the Jig with the Help of Wire.
Depending upon the weight the Wires are Place.
Weight of Material is directly proportional to the No.
Of Wires

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 After the material is hanged to the Wire, the EOT lifts up
and the material which is to be Galvanized and is
immersed into the Degreasing Tank.
Dimensions of the Bath is 8m X 1.2m X 2.5m deep
The degreasing Tank consists of Acid, Thinner which
actually helps to remove the oil, burrs and provide
smoothing surface. The Gangue is separated in this Tank.
Here the material lasts for 15-20mins for a proper
smoothness.
2. Pickling: After the oil, Burrs and Gangue is separated, the
material is then immersed into the Pickling Tank which
consists of Acid (HCL-15% Conc.). Pickling is done to
remove rust. This
process can be undergone at normal Room Temperature.
Here the material is kept for 10-15mins for a proper finish.

3. Rinsing: As soon as the material is removed from the

pickling tank, it is immersed into the Rinsing Tank, which
consists of 100% water. In this Process the material is
washed which helps to provide a clean Surface. Rinsing also
helps to maintain the Temperature because of cool water.
4. Flux: After Rinsing, the material is now immersed into the
Flux Tank. Flux Tank Consists mixture of Zinc Chloride and
Ammonium Chloride. The Ratio at which the solution is

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 present is for 1 litre=200mg/l. The solution in the tank has a
PH value of 4
5. Dryer: In this Process, the material is dried with help of the
air blower. The Temperature at which this process is carried
out is 88 degree Celsius. This process dries up the material
with no liquid on the surface of material.
6. Galvanizing: In this process, the material is immersed into
the Tank which consists of Zinc. The is quality is 99.98%
Pure Zinc. The material is coated with zinc on the surface.
Here, the Temperature of the solution which is present in the
Galvanizing tank is about 450-460 degree Celsius. According
to the IS grade the temperature ranges from 440-460 degree
Celsius. More the time the solution is immersed into the
solution, will help to increase the micron rate. Usually, 86
microns is used on the surface of the material.
7. Quenching: As the material is coated with Zinc, due to high
temperature of the material it cannot be used for further
process. To overcome the problem with handling, the
material undergoes cooling process. The material is
immersed in the water Tank. Quenching is a process of
cooling the material from its hot state. Cool Water is
continuously passed in the Tank to drop the hot material.

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8. Di-chromate: As quenching is done, the material is now
placed in the dichromate Tank. This tank is the most
Hazardous, because it contains Sodium dichromate in it.
Following Test undergone after the Galvanizing
Process
1. Hammer Test
2. Copper Sulphate Test(CuSO4)
3. Night Test
4. Randomly Check

Handmade Gratings are manufactured. Machine like Welding,

Cutting, EFG are place in this Unit. Workers prepare the
Gratings which do not match our standards. Toe Plate too are
Fixed. On the other Hand, Unit C-1 which is first the Plant
Established by Indiana. Here Gratings are made. Electric
Forged Grating machine is there which helps in manufacturing
it. Cross bars are forged with the Bearing Bars. Conveyors too
are manufactured here. Slotting machine, Lathe machine which
are operated by CNC are placed. Shaft are made and shaped
accordingly.
After Completing the C-1 Unit we were taken to D-7 Unit, where
the Grating as well as Handrails are manufactured on a Large
Scale. Handrails are made up of M S hollow pipe.

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Electro-forged Steel Gratings
We manufacture a wide range of Steel Gratings such as Plain,
Serrated, Heavy Duty Steel Grating, Gully Grating and Light
Duty Steel Grating, Cut-out Gratings for different open steel
floor requirements. In this process, square twisted cross bars
are welded or electro-forged to the rectangular shaped bearing
bars by a process that combines heavy hydraulic pressure with
a heavy electric current. Pre-straightened bearing bars are cut
and fed in whilst the cross bars are fed directly from coils. Two
crossbars are shot into the welder and placed under the
electrodes by pulling hooks for simultaneous welding.

Type of the Grating

Standard type of open steel floor Gratings
Heavy Duty Grating / Gully Grating
Cut-to-Size Gratings
Circular gratings

Stair Treads

We manufacture a wide range of stair treads in various

types and sizes. Stair treads are manufactured/fabricated
using gratings with checkered plate nosing options and
can be supplied with or without carrier plate. They can be
made to suit any stair or tread opening and are furnished

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 Complete with pre-punched and slotted End Plates ready
to bolt to the stringers.

Moulded Type FRP Gratings

Indianas FRP gratings are manufactured / fabricated by

inter-weaving continuous thoroughly wetted fibre-glass
strands with a thermosetting resin system.

Liquid resin and the glass Rovings are poured into the
standard mould manually. Moulded gratings are taken out
of the mould only after curing the resin. These gratings are
the perfect solution for working platforms, walkways,
ramps, stair treads, bridges, jetties and are also suitable
and widely used in chemical, petrochemical, and fertilizer
plants, refineries, oilfields, ports and sewage water
treatment plants.

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Conclusion:

The Visit to the Factory was productive, which help us to

know the product more closely. Mr Shantanu concluded us and
shared all the knowledge and various problems faced by unit
during manufacturing. He also added that Quality is an integral
part of any product. At last we met Mr Ganesh (Plant Head)
who asked about the How the visit was. After which we Left
from there to Mumbai.

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