CHAPTER 3

INDUSTRY PROFILE

PROFILE OF THE STEEL INDUSTRY

STEEL INDUSTRY IN INDIA
Operating performance is the main drive of competitive of any company.
Based on the parameter Indian steel industry is much below global standards. Although
significant improvement has been observed in materials, energy and man power
productivity, it is not in a position to complete with steel majors like PSCO, CS or NUCOR.
India is placed in eighth position overall among the steel producing countries in the world.

Steel industry is becoming more and more competitive with every passing day.
During the period 1960s to late 1980s the steel market used to be dominated by OECD
organization for economic co-operation and development countries].
Steel industry in India is on an upswing because of the strong global and
domestic demand. Indias rapid economic growth and soaring demand by sectors like
infrastructure, real estate and automobile, at home and abroad, has put Indian steel
industry on the global map. According to the latest report by International Iron and Steel
Institute [IISI], India is the seventh largest steel producer in the world.
The origin of the modern Indian steel industry can be traced back to 1953
when a contract for the construction of an integrated steel works in Rourkela, Orissa was
signed between the Indian government and the German companies Fried Kruppund
Demag AG. The initial plan was an annual capacity of 500,000 tones, but this was
subsequently raised to 1million tones. The capacity of Rourkela Steel Plant [RSP], which
belongs to the SAIL [Steel Authority of India Ltd] group, is presently about 2million tones.
At a very early stage the former USSR and a British consortium also showed an interest in
establishing a modern steel industry in India. This resulted in the Soviet-aided building of a

steel mill with a capacity of 1 million tones in Bhilai and the British-backed construction in
Durgapur of a foundry which also has a million tones capacity.

The Indian steel industry is organized in the 3 categories. i.e., main

producers, other major producers and the secondary producers. The main producers and
other major producers have integrated steel making facility with plant capacities over 0.5
mt and utilize Iron ore and coal/gas for production of steel. The main producers are Tata
steel, SAIL, and RINL, while the other major producers are ESSAR, ISPAT, and JVSL.
The secondary sector is dispersed and consists of
1] Backward linkage from about 120 sponge iron producers that use iron ore and noncooking coal, providing feedstock for steel producers;
2] Approximately 650 mini blast furnaces, electric are furnaces, induction furnaces and
energy optimizing furnaces that use iron ore, sponge iron and melting scrap to produce
steel;
3] Forward linkage with about 1,200 re-rollers that roll out semis into finished steel
products for consumer use.

STRUCTURAL WEAKNESS OF INDIAN STEEL INDUSTRY

Although India has modernized its steel making

considerably, however nearly

6% of its crude steel is still produced using the out dated open heart process.
Labor productivity in India is still very low according to an estimate crude steel
output at the biggest Indian steelmaker is roughly 144 tones for worker per year,

where as in western Europe the figure is around 600 tones.

India has to do a lot of catching in the production of stainless steel, which is
primarily required by the plant and equipment, pharmaceutical and chemical

industries.
Steel production in India is also hampered by power shortages.
India is deficient in raw materials required by the steel industry. Iron ore deposits or
finite and there are problems in mining sufficient amounts of it. Indias hard coal

deposits are of low quality.

Insufficient freight capacity and transport infrastructure impediments too hamper
the growth of Indian steel industry.

STRENGTHS OF INDIAN STEEL INDUSTRY

Low labor wage rates

Abundance of quality man power
Mature production base
Positive stimuli for construction industry
Booming automobile industry

Economic stability of a nation depends on the strong industrial base it enjoys. The
Indian economy is on a new growth plan with burocracy in capital marketing positive
growth in GDP, strong forex reserves and a remarkable growth by 8.2% in 2005-06
compared to 7.0% growth in 2004-05.manufacturing industry has growth at 10%[till April

05] as against 8.8% growth in april-2004, with brisk demand for steel, textiles, gem
jewellery.

GLOBAL SCENARIO
Present China is the worlds largest crude steel producer followed by JAPAN and
U.S.A is the largest importer of semi finished and finished steel products, Japan is largest
export of the same. However, the world at large is grappling gone through the most difficult
years between 1998-2002.
India is the tenth largest producer of steel in the world. Recent development have
amply demonstrative the mettle of the Indian Steel Industry to rise further and became a
major player in the world.
The iron and steel industries in India has 56 large scale and 80 mediums and small
scale industries. These produce a wide range of iron and steel products which make
absolutely self-confident. Over the past years not only the industry has been able to
substantially match demand, it has also become largely self-confident in design engineering
and to develop the new technology and implement the project indigenously.
India has produced nearly 1200million tones in 2002-03. The total man power
directly employed in iron distribution is about 1million making it. It is one of largest
industries in India, and still the growth rating is increasing.
In India steel is produced in primary and secondary sectors. Primary sector units
are companies like TISCO in private sector and SAIL in public sector. SAIL has taken a
massive modernization as its Durgapur, Rourkela and Bokaro plants of further improve
quality and reduce costs. Primary sector units produce average, 14% of the total supplies
accounted by the secondary sector.

MAJOR STEEL PRODUCTION STATES IN INDIA

1.
2.
3.
4.
5.
6.
7.
8.

GUJARAT
ANDHRA PRADESH
KARNATAKA
BIHAR
ORISSA
TAMILNADU
WEST BENGAL
CHATISGARH

MAJOR INDUSTRIES IN ANDHRA PRADESH

Visakhapatnam Steel Plant

----------------Vizag

Ram Dev Steel Plant

----------------Hyd

Adithya Steels

----------------Hyd

Dhana Lakshmi Steels

----------------Hyd

Balaji Steels

----------------Nellore

CLASSIFICATION OF STEELS
Steel Industry can be classified into Integrated Steel Plants, and Induction furnace
plants.

Integrated

Steel

Plants

are

also

called

as

primary

steel

producers.

VIZAG,TISCO,SAIL etc, have a size of 1MTPA and produce steel from iron ore and coal

using blast furnace and basic oxygen or open-heart process, these plants are highly capital
intensive.
Mini Steel plants that are typically of size of around 1-2.5 lakhs tones produce
steel by melting scrap in an Electric are furnace. These plants have low capital cost but
have higher variable cost, as they are power intensive. The induction furnace units are of
lower capacities between 30,000-50,000 TPA unused in small scale sector cater to domestic
requirements of low value added steel product. They are also highly power intensive. About
50% of the total demands are met mini steel plants. In our country there are many rerolling units carrying the activities of producing finished steel products such as fro steel
and structural section using the out-put of Electric are furnace and induction furnace units.
Many mini steel plants are integrated , i.e., they combine the activity of both melting metal
scrap and forming carbon steels together with the re-rolling of such steel into various
finished products.

Steel is mainly used in:

1.
2.
3.
4.

Machine and Plant Building

Automotive, Railway and Ship Building
Construction
Other Alloy Products

Following are the various factors affecting iron consumption

Technological advancements
Affordability of the ore freely
Rules and regulations of the government
International changes ,demand and supply
Lifetime of the products and corrosion

Availability of the required grade of iron

Availability of the transport facility
Credit availability
Moisture and climate conditions
Industry related problems
The utilization of iron products in the construction activity was very

less when compared to other countries we can conclude India is consuming less
quantity of iron and steel where the construction activity is more , the second major
consumer is infrastructure projects followed by various industries. Although the
consumption rate is high, the Indian industry is having surplus production capacity
through which it is targeting export markets.

Legal mechanism and Governing Body

The department of iron and steel came into existence as a separate
Department.
It has become a par of the ministry of iron and steel. The main objective of
the department include sectoral planning , promotion and regulation of the industry and
monitoring the production , imports /exports/distribution of iron and steel products so that
the economy did not phase the problem.

IRON AND STEEL FEDERATION OF INDIA

Popularly known as FAI is an autonomous body established by Central Government
and its office located at Delhi .The main objective of FAI is to bring all the iron and steel

manufacturers under a common platform for exchange of ideas, transfer of technology and
other matters pertaining to exercise duty and customs duty. The association takes all such
sensitive & important problems that are commonly faced by manufacturers.
Today the iron and steel industry is totally de-controlled by the central government
and it has given entire right to the industrys to fix the selling price and marketing the
products produced. The government controls the price of the products by making the
necessary. India has become a part in the global economy, changes in the international
markets will be reflecting in the Indian markets.
Imports
Every form has certain problems in the same way there is no shortage for the iron
ore which is the basic raw material but the other key material needed for the production of
the iron ore which is the basic raw material but the other key material needed for the
production of the iron and steel is coal. Though India has huge reserves of coal the ash
content is more so India has to import coal from other countries. So Indian companies has
entered into some long-term contracts with coal producing countries. Some factories use oil
products, which have to

Ex: Rainotino (Australia)

To reduce the dependence the Indian companies are implementing the technologies to
reduce the ash content in the Indian Coal and thus the economy is saved.

IRON & ITS ADVANTAGES

In Agriculture:
Iron & steel Used in crop production equipments promotes

Agriculture promotion

Increase food growth

Income in living standards of rural areas
Productivity development

IN INDUSTRY
Iron and steel industry promotes

Foreign Exchange Earning

Employment
Manpower utilization
Technological Transfer and Development
Industry Development
Economic Growth
Development of supplement industries

IN SERVICE
The marketing and distribution of iron and steel promotes

Domestic and world trade

Research and development
Bank service development
Credit Facilities
Transport and Storage services

CHAPTER 4
COMPANY PROFILE

COMPANY PROFILE
Established in 1987 G S Alloy Castings developed into one of Indias prominent
jobbing foundry dedicated to producing superior steel castings ranging from 50 to
27000kgs. The Companys steady growth is a reflection of its commitment to customer
needs and quality. We offer Cost effective solutions for the success of our customers.
Team:
Designation

Name

Managing Director

G.Prasada Rao

Executive Director

G.Srinivasa Rao

Director

G.Sarala

General Manager

K.K.Rao

Works Manager

S.S.Pillai (Unit II)

Production Manager

Krishnam Kutti (Unit II)

K.Radhakrishna (Unit II)

Methoding Manager

M.Hanumantha Rao (Unit II)

Qualitational Manager

Ch.R.K.Ramu (Unit II)

Qualitational Dept Manager

Mr.Ramana

Maintenance Manager

Mr. Ramesh

Administration Manager

K.G.R.Sundaram

Accounts Manager

Mr. Venkateswara Rao

Marketing Research

M.Hanuman Prasad

Civil Works Manager

Mr. Raghavayya

Fertiling Dispatch

Mr.Rajendra

Methods Engineer

Mr.Shyam

Accouintant

Ms. Lakshmi

Office Incharge

Mr. Rama Rao

VISION
The bottom line is to meet the requirements of the customers and they at G.S.Alloy
develop products and solutions which suits the modern day demands of the customers.

Their vision is to provide quality and contemporary information to the customers which
can help them in furthering their business. Of course, they also keep in mind that the
solutions at G.S.Alloy offer can optimize and improve the business process of the
customers, which would surely take wise decisions for enhancing their horizons.
Providing quality and technology products / services that surpass the expectations of
the customers in their functionality, usability, reliability, performance, adaptability and
supportability which help becoming market leaders with upward improvement of business
performance is part of their vision.

QUALITY POLICY:
G.S Alloy Ltd., shall provide quality products services that exceed customer
expectations in their functionality, usability, reliability, performance, adaptability and
supporting to achieve market leadership and continual improvement of business
performance, for this, the organization shall establish and review quality objectives to focus
on

Technology Management for building Competence

Quality Improvement
Customer education
Human Resource Development
Customer Support
Design and implementation

QUALITY OBJECTIVES

Establishment of HRD Process to train and nurture employees to realize

their intrinsic talent.

100% increase in turnover every year
Improve response time to customer requests
Education of customers in regard to product / technology application

R&D
G.S.Alloy Casting is a knowledge driven company. Their continuous investment in
R&D activities enabled them to develop innovative processes, products and technologies, by
pioneering new ways of collecting and managing information and knowledge, they have
strengthened and extended their R&D activities to diverse areas. The company has vast
knowledge in comprehensive design, development assembly for diverse interfaces and
applications from the concept.

KEY FEATURES
G.S.Alloy Casting manufacture quality steel castings up to
6,000 kgs. Single piece in unit I
34,000kgs. Single piece in unit II

In G.S.Alloy Casting Ltd they believe that the most valuable resource they possess is
their people. People in the company are very much proud to be foundry men in serving
Indian Engineering Industry since 1987. G.S.Alloy Casting is not just a gathering of highly
skilled individuals, but a team.
The company follows the policy of:
Work with team
Think with team
Live with team
Prosper with team &
Build Team work

It is built not only on someones exceptional skills, but rather on collaboration and
team work. Throughout years of growth, owing to investments into training, scrupulous
selection procedures, competitive benefits and appealing career possibilities, they managed
to assemble a mosaic of motivated, loyal and highly skilled professionals.

G.S.ALLOYS MANUFACTURERS

Cast Steel
Alloy Steel
Mn Steel
Stainless steel
Heat Resistant steel
Nihard and Cast Iron Casting

G.S ALLOY PRODUCTS

PROCESS OF MAKING OF A CASTING

1. ESTIMATION

2. PATTERN MAKING
3. MOULDING AND CORE MAAKING
4. MELTING AND POURING
5. KNOCK OUT
6. HEAT TREATMENT
7. FETTLING
8. INSPECTION
9. MACHINING
10. DISPATCH

1. ESTIMATION AND SUBMISSION OF QUOTATION

Received receipt to be studied and estimate according to their requirements
and then prepare the quotation. This quotation will send to the customer with all
details. After negotiations made by the customer, if the conditions are acceptable by
the customer, deliver the order for manufacturing of the product.
Receipt of customer purchase order & Contract Review:
After receiving the purchase order and formal agreement, we should prepare
the method card for manufacturing the produce: and also gai8ning of the
production of the product in correct duration.

2. VENDOR FOR PATTERN MAKING

According to the customer supplied drawing the pattern shop in charge or pattern maker
himself has to carefully go through and understand the written instructions, drawing views
and then prepare the pattern.
Production Planning:
Production Planning is the routing of the Raw-Materials i.e. scrap to convert
into the finished goods i.e., Castings. According to the availability of the raw
materials, detailed equipments, production runs per tonnage of metal, order
priority, finance, manpower, and the production may be planned.

Introduction:
Pattern: A pattern is the replica or modal of the desired casting
It carries an additional allowance to compensate for metal shrinkage
It Carries the necessary draft to enable its easy removal from the
mould
It carries additional protection, called core points, where cores are to
be used
Types of Patterns:
a.
b.
c.
d.
e.

Solid or single piece pattern

Two piece or split pattern
Multi piece pattern
Match plate Pattern
Sweep Pattern etc.,

Pattern Materials
All patterns are subjected to wear due to the ramming and rapping that are
necessary and the subsequent abrasive action of the sand.
Pattern material should settle to with stand this wear and tear depending upon
the no. of
1. Wood
2. Aluminum
3. Thermocoal

Pattern Making Process

Layout of pattern
The complete construction of a pattern consists of two stages. The first stage
is preparing a layout and the next is to shape the different parts. The layout
preparation consists of measuring, making, and setting out the dimensions on a
layout board including the allowances. The layout is as follows:

SEQUENCE IN PATTERN MAKING

1.
2.
3.
4.
5.

The layout is studied and the location of the parting line is decided.
From the pattern layout the shape of the pattern layout is visual lord.
The construction of the pattern is started from the main part of the body.
The different parts are shaped by cutting, providing adequate draft on them.
All the prepared parts are checked finally by placing the over the prepared
layout.

COLOUR CODES OF PATTERNS

Patterns are located with certain colors and shades in order to
1.
2.
3.
4.
5.

Identify quickly the main body of the pattern and the different parts of pattern
Indicate the type of the metal to be cast
Identify core prints, loose pieces etc.,
Visualize the surfaces to be machined etc.,
Indian Standards
o Red
Un machined area & Mn Steel also
o Yellow Machined Area
o Black
Core prints

As per British standard

Blue is for carbon steel on steel casting

Loose pieces : Red strips on yellow base

Stop off or Supports black strips on yellow background
Parting Line : Red

Moulding
The prepared sand is packed rigidly around the pattern and when the
pattern is with drawn a cavity corresponding to the shape of the pattern remains in
the sand and is also known as mould cavity is filled with molten metal it produces a
casting of the shape of the mould. The process of making mould is moulding.
In Moulding process they use different types of sands:
Types of Sands:

1. Quarters Sand
2. Silica Sand
3. Chromate Sand
4. Zircon Sand
5. Olivine Sand

Types of Mould
1. Green Sand Mould
2. Dry Sand Mould
3. CO2 Mould

IN G.S.ALLOYS USING ONLY CO2 PROCESS ONLY

1. Green Sand Mould:
Green sand moulds are prepared with retrial mould sands or with mixtures
of silica sands bonding clay and water. In order to give the casting a green and
bright surface and to prevent the sand from burning on the face of the mould, a
layer of facing sand is given surrounding the pattern.

2. Carbon-Di-oxide Mould:
This process is basically a hardening process for moulds and cores. The Sand
mixture used in the process consists of pure dry silica sand and sodium silica binder. This
mixture is rammer around the pattern in the mould or in the core box for core making
either manually or by machines. As per packing the sand carbon-di-oxide gas is forced in to

the mould or the core at a pressure of about 1.5 kgs / Cm2. The process of forcing the gas
into the sand mass is called goosing. The passage of carbon-di-oxide through the sand
containing sodium silicate produces carbonic acid in the aquas solution which causes rise
the SIOP2 Na2O ration and the formation of colloidal silica gel. This hardness and forms
bond between the sand gradients and provides strength to the mould or core.
Immediately after gassing the moulds are ready for pouring so the cores for being
placed in the moulds the gassing process usually taken 15 to 50 seconds.

APPLICATIONS
1. This process has been widely used for making larger cores and in foundries for
heavy ferrous castings.
2. This Process is particularly suitable for heavy or thick walled steel castings.
3. Beside steel, carbon-di-oxide process is also employed for producing ores for iron,
aluminum and copper base ally casting.

CORE
Core: Cores are sand shapes, which form the contour of a casting that is not molded with
patterns.

Cores must have sufficient hardness as well as strength in both dry and green states.
Otherwise the core will not able to support its own weight and withstand the force of
molten metal.
Core Sands: In G S Alloy Castings, the following sands are for making cores
Silica sand, Zircon, Olivine, Quartz sand, Chromate sand
Core Sand Properties:
Hot strength, Green strength, collapsibility, core density, Refractoriness,
Response to core making: Core Hardness, Permeability
Core Binders
Core binders serve to hold the sand grains together and impart strength, resistance
to erosion and to breakage and degree of collapsibility.

Core Making
The following steps are involved in core making:
1. First some amount of facing sound sprayed in the entire area of core pattern. It
gives good surface finish to core.
2. Core sand is placed in the loose to the required level and sufficient ramming is
given.
3. Wires and rods are placed in the boy, to give handling strength, the molding sand
placed again ands proper ramming is given.

Types of cores

The cores used in the foundries are typed according to their shape and their position
in the mould. The types horizontal core, vertical core, stock cores, Balanced cores, Cover
cores, Hanging cores, Wing cores and Ram-up cores.

Core Coatings
Core coatings may be applied as liquids by spraying, dipping or brushing and as
solids by dusting. Core coatings for steels casting work are largely based on silica flour,
magnate or chrome ore as the refractory materials; core coatings for cast iron castings
make the use of refractoriness of graphite.

Melting
They are using inductotherm Dual track system, and rated capacities of 12 MT + 15
MT, 5 MT, 2.5 MT, 1 MT, 0.5 MT. The total amount of liquid metal per heat is 34 MT and
single piece casting poured so far as 16.5 MT. Both top pouring ladles of 5 ton, 2Y2 and 1
Ton and bottom pouring ladles of 15 MT, 12 MT, 20 MT, 35 MT. Immersion pyrometer,
and radiation pyrometers are used for measuring the temperature of molten metal. Oil
fired ladle, Pre-heated to maintain the ladle temperature at 600 Deg.C.

HEAT TREATMENT CYCLE OR PROCESS

Casting will be heat treated as per the customers specification if customer

specification insists for a particular heat treatment cycle, which shall be

followed.
If customers specification does not insist for a specific heat treatment cycle,
the heat treatment cycle will be selected keeping in view of mechanical

properties to be achieved and desired microstructure.

Heat treatment temperature, Cooling medium will be selected depending
upon material type, grade, mechanical properties to be achieved, material
specification and required grain.

Soaking time will be selected depending upon the casting material and
section thickness. Usually soaking time will be one hour for every 25 mm
thickness of casting from exposed surface to heat. For calculating soaking
time maximum section thickness of the casting will be taken into
consideration.

Heat-Treatment
Sl.No.
1
2
3
4
5

Process
Homogenizing
Normalizing
Annealing
Tempering
Annealing

Temp C
900-950
900-950
900-950
900-950
900-950

Soaking time
3 Hours upto
5 Hours
3 Hours
FLOW HT Los shut
FLOW HT Los shut

Cooling Media
35 * CF/L cool

CLEANING OPERATION AND EQUIPMENT

The series of operations in the cleaning department may be classified as follows:
1. Surface cleaning, interior and exterior casting
2. Trimming, the removal of fins, wires and protuberances at gate and riser locations.
3. Finishing, final structure cleaning, giving the casting its outward appearance.

Surface Cleaning
Cleaning Operations ordinarily follow the removal of gates and risers. However,
surface cleaning may facilitate gate removal. For instance, the elimination of sand from the
casting favors sawing and torch cutting so that surface cleaning may be done before the
gate removal in the case of non-ferrous alloys and sometimes steel. When flogging is used

in steel or C. It is easier to perform the surface cleaning after gate removal. One of the
surface cleaning methods is shot blasting.

Trimming
Either after, before or during the initial surface cleaning, the casting sare trimmed
to remove fins, gate and riser pads protruding beyond the casting surface, chaplets, wires,
parting line flash, or other appeared damages to the casting which are not a part of its final
dimensions.

Chipping
Pneumatic chipping hammers may be used to remove fins, gate and riser pads, wires
and to remove corers. A variety of hammer and chisel sizes are used for various casting
alloys.
Grinding
Grinding or Snagging of castings is practices to remove excess metal. Two
principal types of grinders are employed for these purposes: portable grinders, and swing
frame grinders. In addition, Specialized machines such as disk grinders, Betts and cutoffs
may be used.

Visual Inspection
Certain types of casting defects are immediately oblivious upon visual examination
of casting cracked castings, tears, dirt, blow holes, scabs, metal penetration, severe shifts,

run outs, poured short, swells or strains, cracked mould or cores and numerous other
defects can be identified by the inspector. Casting defects of this type are usually associated
with defective moulds, cores, their materials of construction. Flask equipment, the
operations of molding and core making and the rest of the factors in making and pouring
the mould.

Dimensional Inspection:
Dimensional inspection of castings involves the principles of gauging as it is applied
to my machine elements. Surface plates, height and depth gauges, layout tables, dividing
heads, non-gauges, snap and plug gauges, templates, dies contour gauges etc., as used in
slandered layout and inspection procedures may be applied to castings.
Careers:
They believe that their main strength is their people. They are their assets and they
are the ones who make them realize their vision.
The Present business scenario is highly competitive and technological advances are
making this environment more and more competitive thus making each individual to
motivate himself to a higher level of performance. For this, they provide an able and
positive environment that motivates their employees and thus ensuring their success.
They believe in continuous education to their employees and they strive to provide
best training facilities to enable them to develop not only in their professional lives but in
their individual lives as well.
G.S.Casting firmly believes that the success of the company is the sum total of the
efforts and capabilities to their team members. They constantly strive to align people to
their core value proposition and core values, promote career development, and seek twoway feedback through informal and formal means.
A Career at G.S.Castings Means

Opportunity to learn & Grow continuously

Opportunity to become a domain expert
Opportunity to work on latest technologies
Challenging assignments
A world class working environment
Work with professional management
Along with excellent rewards