APPENDIX I

TABLES

Table 1
Typical Properties of Steels at Room Temperature (25°C)

Properties Carbon Alloy Stainless Tool

Steels Steels Steels Steels

Density (1000 kg/m3) 7.85 7.85 7.75 – 8.1 7.72 – 8.0

Elastic Modulus (GPa) 190 – 210 190 – 210 190 – 210 190 – 210

Poisson’s Ratio 0.27 – 0.3 0.27 – 0.3 0.27 – 0.3 0.27 – 0.3

Thermal Expansion (10-6/K) 11 – 16.6 9.0 – 15 9.0 – 20.7 9.4 – 15.1

Melting Point (ºC) 1371 – 1454

Thermal Cond. (W/m- K) 24.3 – 65.2 26 – 48.6 11.2 – 36.7 19.9 – 48.3

Specific Heat (J/kg-K) 450 – 2081 452 – 1499 420 – 500

Elect. Resistivity (10-9 W-m) 130 – 1250 210 – 1251 75.7 – 1020

Tensile Strength (MPa) 276 – 1882 758 – 1882 515 – 827 640 – 2000

Yield Strength (MPa) 186 – 758 366 – 1793 207 – 552 380 – 440

Percent Elongation (%) 10 – 32 4 – 31 12 – 40 5 – 25

Hardness (Brinell 3000 kg) 86 – 388 149 – 627 137 – 595 210 – 620

(Source: The Balance Dotdash Publication, 2019)

 Table 2
Galvanized Steel Product Properties

Coating Layer Characteristics Appearance

Product
Structure
Hot-rolled steel plate is used
as base metal for this
product. While molten zinc
GI (H) solidifies on the surface of
the steel sheet, normal zinc
crystallization is suppressed
creating fine crystals.
Cold-rolled steel plate is used
as base metal for this
product. While molten zinc
solidifies on the surface of
GI the steel sheet, normal zinc
crystallization is suppressed
creating fine crystals. The
surface is flat and has a fine
appearance after painting.
Through a thermal diffusion
process, steel sheet and zinc
react to produce an alloy
GA layer. The weldability and the
paintability are superior to
traditional galvanized steel
sheets.

(Source: Posco Steel, 2019)

 Table 3

Summary Statistics for Steel and Steel‐Related Establishments in the Philippines with Average
Total Employment of 20 and Over, By Industry Group
Employment Total
Industry Group No. of Revenues Cost
(Ave, for the Year) Compensations
Establishments (Million Pesos) (Million Pesos)
Total Average Paid Workers (Million Pesos)
Upstream Steel Sector 246 28.9 28.8 3,311.5 72,710.6 60,315.9
Downstream Steel Sector
(Intermediate)
403 31.6 31.3 3,497.9 29,400.3 22,939.9
Downstream Steel Sector
(Other Heavy)
Users of Steel in the
1,246 309.5 307.9 41,131.6 738,043.5 609,628.8
Manufacturing Industry
Downstream Steel Sector 1,649 341.1 339.2 44,629.5 767,443.8 632,568.8
TOTAL
(Steel Industry: Other
649 60.5 60.2 6,809.4 102,110.9 83,255.8
Heavy Users of Steel in the
Mfg Industry)
TOTAL
1,895 370.0 368.1 47,941.0 840,154.4 692,884.7
(Steel Industry)
TOTAL
6,397 942.2 937.4 116,222.4 1,807,531.1 1,420,204.4
(Manufacturing Industry)
(Source: DLSU Concluded Projects Volume 1, 2005
 FIGURES

Figure 1.Steel Consumption per Capita

(Source: Steel Asia, 2019)
 Figure 2. Steel Asia

(Source: Steel Asia, 2019)

Figure 3. Union Galvasteel Products
(Source: UGC, 2019)

Figure 4. Calamba Steel Center, Inc.

(Source: CSCI, 2019)
Figure 5.Puyat Steel Corporation
(Source: Puyat Steel, 2019)

Figure 6.BLUESTEEL Industries Inc.

(Source: BLUESTEEL Industries Inc., 2019)
 Figure 7.Sanyo Seiki Products
(Source: Sanyo Seiki, 2019)

Figure 8.Rubicon Steel Products

(Source: Rubicon Steel, 2018)
 Figre 9. AcerSteel Products
(Source: AcerSteel Industrial Sale, 2019)

Figure 10. Pag-asa Steel Works Products

(Source: Pag-asa Steel Works, 2018)
 Figure 11. Plant Location
(Source: Google Maps, 2019)
 FIGURES

Figure 12. Coiler and Uncoiler Machine

(Source: alibaba.com, 2019)
Figure 13. Longitudinal Seam Welding Machine
(Source: alibaba.com, 2019)
Figure 14. SPM & Chemical Treatment Machine
(Source: bharattech.com, 2019)

Figure 15. Annealing Furnace

(Source: bharattech.com, 2019)

 Figure 16. Galvanizing Furnace
(Source: Bonantechnology.com, 2019)

Figure 17. Rapid Quenching Unit

(Source: Weir Furnaces Industry)

 Figure 18. Air Knives
(Source: Google Images, 2019)

Figure 19. Side Trimmer and Inspection Table

(Source: ingenieria.com, 2019)
 Figure 20. Automatic Spray-Painting Line
(Source: anyuancoating.en.made-in-china.com, 2019)

Figure 21. Sheet Cold Roll Forming Machine

(Source: BotouShitong Cold Roll Forming Machinery Manufacturing Co., Ltd)
 Figure 22. Shearing Machine
(Source: globalspec.com, 2019)
 Figure 23. Forklift
(Source: Toyota Forklifts, 2019)

Figure 24. Paint Bath

(Source: BMW Manufacturing Co.)
 Figure 25. Overhead Crane
(Source: IndiaMART.com, 2019)
Figure 26. Quantitative Flow Diagram
Figure 27. Qualitative Flow Diagram
Figure 28. Combined Detailed Flow Diagram
Figure 29. Material Balance Diagram
Figure 30. General Plant Layout (Isometric View)

Figure 30.1 General Plant Layout (Top View)

Figure 31. Production House

Figure 32. Admin Building

Figure 33. Civil and Maintenance House

Figure 34. Storage Warehouse

 Figure 35. Delivery Trucks

Figure 36. Fire Protection Unit

 Figure 37. Transmission Yard

Figure 38. Water Treatment Facility and Water Tower

Figure 39. Recreational Facility

Figure 40. Guard House

Figure 41. Main Gate
 TABLES
Table 4

Quantitative Process Flow

PROCESS EQUIPMENT MATERIAL QUANTITY

DESCRIPTION

Process Line 1

Uncoiling Uncoiling Equipment No. of Coils: 10 coils/day

Length: 453 m/coil
Width: 1.2 m
Thickness: 0.7 mm
Longitudinal Seam No. of Coils: 10 coils/day
Stitching
Welding Machine Width: 1.2 m
Thickness: 0.7 mm

Pre- Treatment SPM & Chemical Capacity: 1875 ft/hr

Treatment Width: 1.2 m
Thickness: 0.7 mm
Annealing Annealing Furnace Capacity: 1875 ft/hr
Width: 1.2 m
Thickness: 0.7 mm
Zinc Pot Capacity: 1875 ft/hr
Hot Dip Galvanizing
Duration: 3 mins.
Width: 1.2 m
Thickness: 1.01 mm
Water Bath and Capacity: 1875 ft/hr
Quenching Accumulator Width: 1.2 m
Thickness: 1.01 mm
Blower Driven Air Knives Capacity: 1875 ft/hr
Drying Width: 1.2 m
Thickness: 1.01 mm
Side Trimmer and Capacity: 1875 ft/hr
Inspection Table Width: 1.2 m
Inspection
Thickness: 1.01 mm
Automatic Capacity: 1875 ft/hr
Spray-Painting Line Width: 1.2 m
Final Coating and Drying
Thickness: 1.21 mm
Cutting and Coiling No. of Coils: 10 coils/day
Equipment Width: 1.2 m
Cutting and Coiling
 Thickness: 1.21 mm

Process Line 2

Uncoiling Uncoiling Equipment No. of Coils: 10 coils/day

Length: 453 m/coil
Width: 1.2 m
Thickness: 1.21 mm
Roll Forming Machine 1500 sheets/ day
Forming and Cutting
Length: 8ft, 10ft, 12ft
Width: 3 ft.
Thickness: 1.21 mm

Table 5

Qualitative Process Flow

PROCESS DESCRIPTION

Process Line 1
Uncoiling
Cold rolled metal sheets are uncoiled.

For continuous feeding of the cold rolled metal

Stitching
sheets, a longitudinal seam welding machine is
used.
Thickness of material: 0.7 mm
Pre- Treatment In order to achieve a flat surface and elegant
finish, the steel sheet is processed with a skin pass
mill. In order to prevent the white rust, which often
forms on the surface of activated zinc, and to
improve corrosion resistance, the surface is coated
with a Cr-free resin.
Annealing The material properties of pre-treated steel sheet
can be altered and improved through
recrystallization during the annealing process.
Hot Dip Galvanizing After passing through the annealing furnace, steel
sheet is dipped into a zinc pot where molten Zn is
coated onto the surface. The desired coating
weight is achieved by removing excess zinc before
solidification with high pressure air from an air
knife.
Quenching The galvanized sheet metal will travel through the
quenching unit that contains water bath to create
passivation layer and to remove free iron so that
 corrosion will be less likely to occur.
The blower driven air knives control the thickness
of the metallic coating through a closed loop
process between coating thickness measuring

Drying instrument, a process computer and air knives. It

is also used for high speed drying of surfaces and
cooling.
Located at the line’s exit section are a side
trimmer, inspection table and oil coating
equipment. At this station all products are
inspected and judged relative to material
Inspection specifications required by the client.
An acrylic coating will be adhered directly to the
cleaned galvanized steel using an Automatic
Spray-Painting Line which is also equipped with
dust cleaner machine and drying machine.
Final Coating and Drying Working spray gun: 6
Air Pressure: 0.6 MPa
Paint dosage: 268 g/m2
Air Flow: 2400 L/min

After the production of galvanized steel sheets, it

will then be cut and coiled for the next process line.

Cutting and Coiling

Process Line 2
Uncoiling
The galvanized steel sheets are uncoiled.

Forming and Cutting A roll forming machine will be used to produce two
types of roofing profiles which are Duracorr and
Durarib.
Rolling Speed: 10 – 15 m/min
Rolling Stations: 23
Way of Drive: By Chain
Cutting System Tolerance: ± 1.5 mm

Dimensions: 3ft x 8ft, 3ft x 10ft, 3ft x 12ft

Thickness: 0.7 mm

Table 6
Process Equipment Selection and Specification
 Equipment Model Specifications
Brand Name: GEIT
Type: Hot Rolling Mill
Voltage: 380V/220
Maximum Coil Weight:
2,000 lbs
Uncoiler Machine GEI – uncoiler Maximum Coil Outside
Diameter: 48”
Maximum Coil Width: 12”
Coil Inside Diameter
Range: 12” – 16”
Approximate Weight:
1,500 lbs
Brand Name: HUAFEI
Pulse Frequency:
standard
Voltage: 380 V
Welding Diameter: 250 –
800 mm
Welding thickness: 0.4 – 8
Longitudinal Seam TIG – MIG – MAG – SAW mm
Welding Machine Work piece length: 200 –
2000 mm
Welding speed: 0.2 – 2.2
m/min
Rotating driving: AC
motor, frequency control
Cylinder Length: 2000 mm
Electric Motor Power:
3KW

Brand Name: WANXIN

Type: Coating Production
Line
Coating: Galvanizing
Substrate: steel
Zinc Pot Hot Dip Galvanizing Inter-blowing form: steam /
Production Line guide rod
Production mode:
double/single work line
Voltage: customize
Dimension: customize
Brand Name: Manvac
 Pressure: 5 kg/cm2
Wind speed: 400 m/s
Temperaure: 250 °C
Rated Voltage: 220/380 V
Blower Driven Air Knives JM-AT-300 Air knife length: 0.2 – 3m
Size: 60 cm
Shape: Stainless steel
type
Weight: 0.3 – 3mm
Outlet: 0.1 – 0.3 mm
Working Length: min. 300
mm
Working Width: 2- 1300
mm
Working Thickness: 5 – 80
mm
Feeding Speed: 5 – 25
Automatic Spray – Wharton m/min
Painting Line Feeding Power: 1.1 KW
Fan Power: 1.5 KW
Water Pump Power: 0.5
KW
Working Spray gun: 6
Spray gun caliber: 1.3 mm
Air pressure: 0.6 MPa
Paint dosage: 60 – 300
g/m2
Air flow: 2400 L/min
Type of paint: UV, NC and
Automatic Spray – Wharton water paint
Painting Line Power Supply: 380 V
Frequency: 60 Hz
Brand Name: DIXIN
Material: Color Steel
Material Width: 1250 mm
or as per required
Material Thickness: 0.3 –
0.8 mm or as per required
Rolling Speed: 10 – 15
m/min
Roller Stations: 23 stations
Roller Material: 45#steel,
 quenched and chrome
coated 0.05 mm
Shaft Material: 45# steel,
Double Layer Color Steel quenched
Roll Forming Machine Trapezoidal/Corrugated Shaft diameter: D70 mm
Roof Panel Forming Main motor Power: 5.5
Machine KW
Side Plate: Wall plate
Way of Drive: By Chain
Hydraulic Cutting Power: 3
KW
Blade Material: Cr12 Mov
Tolerance: ± 1.5 mm
Electric Source: 380 V, 50
Hz, 3-phase
Control System: PLC

Brand Name: Foxing

Annealing Furnace
Annealing Furnace
Type: Resistance Furnace
WC67K Usage: Heat Treatment
Furnace
Application: Bright
annealing, hardening,
quenching
Temperature uniformity: ±
5 °C
Thermocouple type: S
WC67K type
Surface temperature: ≤
1000 °C
Voltage: 380 V
Fuel: electric, gas

Supply Ability: 10000

m3/m3 per month
Thickness: 2 – 6 mm
Material: Carbon steel
Water Bath and Shandong HL – HDG Application: Water
Accumulator Zhejiang XINGLI Treatment
 Panel Size: 1.22 m x 1.1m
x 0.50 m
Type: 76 mm steel roller
Bearing: standard

Table 7

Material Handling Equipment Selection and Specification

Equipment Model Specification

Maximum lifting capacity:
8,000 lbs
Width over load tires: 69”
Back tilt: 8°C
Pressure load tires: 100
Forklift Yale psi
Pressure steer tires: 100
psi
Load center: 24”
Maximum fork height: 132”
Fork length: 48”
Fork width: 6”
Overall dimensions: 13’ 4”
x 69” x 91” high
Truck weight: 14,100 lbs
Overhead Crane AG Cranes Capacity: 5 tonnes
Wheel centers: 10.6 m
Chain 5 meters drop:
10,100
Rope hoist 6 mt: 11,225
Rope Drop 9.5 or 10
meters: 11,966
Line Shaft Roller Conveyor DRDSLC Overall width: 48.5”
Roller Diameter: 2.5”
Rollers set above frame
No accumulation zones
120’ runs available

APENDIX III
TABLES

Table 8

Equipment Cost

Equipment No. of Sets Price/Set Total Price

Sheet Metal Uncoiling Machine 2 1,750,000 3,500,000
Longitudinal Seam Welding
1 1,125,000 1,125,000
Machine
SPM & Chemical Treatment 1 2,040,000 2,040,000
Annealing Furnace 1 1,640,000 1,640,000
 Hot Dip Galvanizing Machine 1 1,650,000 1,650,000
Blower Driven Air Knives 1 1,143,750 1,143,750
Automatic Spray- Painting Line 1 1,380,000 1,380,000
Sheet Metal Coiling Machine 1 1,750,000 1,750,000
Roll Forming Machine 1 17,250,000 17,250,000
TOTAL 31,478,750

Table 9
Machineries Cost
Total
Equipment No. of Sets Price/Set Price

Gantry Cranes 3 125 000 375,000

Coil Lifter 3 225 000 675,000

Fork Lift 4 337 500 1,350,000

Electric Floor
Sweeper 2 97 500 195,000

Delivery Truck 4 400 000 1, 600,000

    TOTAL 4,195,000

Table 10
Labor Requirements
Annual
Position Quantity Monthly Salary Salary Total 
1,8 1,
President 1 150,000 00,000 800,000
Purchasing 9
Manager 1 83,000 96,000 996,000
Marketing 9
Manager 1 80,000 60,000 960,000
7
Chief Accoutant 1 60,000 20,000 720,000
1,2 1,
General Manager 1 100,000 00,000 200,000
1
Nurse 3 10,800 29,600 388,800
6
Plant Supervisor 1 50,000 00,000 600,000
Maintenance 5
Supervisor 1 45,000 40,000 540,000
2 2,
Operator 12 18,000 16,000 592,000
1
Mechanic 3 11,500 38,000 414,000
1
Warehouse Man 4 11,000 32,000 528,000
1 1,
Driver/Operator 10 10,000 20,000 200,000
1
Accounting Clerk 1 10,000 20,000 120,000
1
Secretary 1 13,500 62,000 162,000
1
Utility Man 3 9,000 08,000 324,000
1
Security Guard 4 10,000 20,000 480,000
1
Material Engineer 1 15,000 80,000 180,000

TOTAL ANNUAL SALARY 13,204,800

Table 11
Total Capital Investment
Fixed Cost Estimated Cost
Machineries and Equipment 35,673,750
Land Cost 171,990,000.00
Construction Cost 510,000,000
Fixed Cost Estimated Cost
Furnitures and Fixtures 500,000
Office Equipment 600,000
Utility Installation Cost 750,000
Total Fixed Cost 719,513,750.00

Table 12
Total Variable Cost
Variable Cost Estimated Cost (PHP)
Annual Salary and Wages 13,204,800
Utility Expenses 10,000,000
Miscellaneous Expense 7,000,000
Maintenance Cost 5,000,000
Benefits 3,000,000
Raw Materials 545,442,624.90
Taxes 172,800,000
Annual Expenses 756,447,425