Raw Material Receiving (Coil Yard)
Galvanized or Galvalume coils with thickness ranging from 0.8 mm to 1.6 mm and widths between 1220 mm to 1250 mm are received from approved suppliers such as JSW, TATA, and AMNS. The coils are used for manufacturing floor deck sheets with profiles like 51 mm. Each incoming coil is checked for physical damage, edge condition, and proper identification tags. Handling is done using EOT cranes with C-hooks to prevent surface damage. The coils are unloaded on designated coil saddles to maintain shape and safety. All receipts are logged in the material register, and identification numbers are assigned for traceability.

Coil Certificate Verification
Quality Assurance verifies the Mill Test Certificate (TC) for each coil before acceptance. The certificate is checked for coating type (AZ or Z), base metal grade, tensile and yield strength, and elongation properties. Random coating thickness checks are done using a digital coating gauge to ensure compliance with standards. The coil weight and width are cross-verified with the purchase order. Coils not meeting specifications are quarantined and tagged for return or re-inspection. The verification process ensures that only qualified raw materials are released for production.

Coil Storage on Timber Saddles
After verification, the coils are placed on timber saddles to prevent direct floor contact and avoid moisture absorption. Timber saddles ensure safe storage and maintain coil roundness. Coils are segregated by thickness, width, and supplier for easy retrieval. Sufficient spacing is maintained between coils for safe movement of the crane hook. Each coil is labelled with its identification details, and a proper storage log is maintained. The storage area is covered to prevent dust accumulation and corrosion. Regular housekeeping ensures safe and clean working conditions in the coil yard.

Coil Loading on Decoiler
For production, the selected coil is lifted using an EOT crane and mounted on the motorized decoiler. The mandrel of the decoiler is adjusted to fit the inner diameter of the coil securely. Side guides are aligned to maintain proper sheet centering during feeding. The coil tail is clamped into the pinch roll for initial feeding. All safety interlocks and mechanical guards are checked before operation. Once ready, the decoiler starts uncoiling at a synchronized speed with the roll forming line.

De-coiling → Pinch Rolls → Levelling
As the coil is de-coiled, the strip passes through the pinch rolls that straighten and guide it into the leveller unit. The leveller removes minor coil set or camber to achieve a flat, tension-free feed. This process ensures that the sheet enters the roll forming stations uniformly, preventing waviness and distortion. Proper synchronization between decoiler speed and leveller feed rate is maintained through an automatic control system. The operator continuously monitors the alignment and tension to avoid bending or scratching of the sheet surface.

Roll Forming (Deck Profile Forming)
The flat sheet passes through a series of precisely machined roll forming stations that gradually shape it into the desired deck sheet profile, such as 51 mm deep ribs. The roll forming machine operates at controlled line speeds to ensure dimensional consistency. Each roller station is aligned and hardened for long service life. The profile depth, rib pitch, and embossing patterns are checked periodically during operation. Proper lubrication is maintained at roller bearings to ensure smooth movement. The process produces a high-strength, precision-formed deck sheet suitable for composite floor construction.

Hydraulic Shearing / Cutting
Once the sheet is roll formed, it moves to the hydraulic shear unit for length cutting. The operator pre-sets the required length based on customer order using the PLC control panel. The hydraulic shear cuts the sheet with high precision within a tolerance of ±5 mm. The cutting blade is maintained sharp to achieve burr-free edges. The machine is synchronized with the line speed for continuous operation. The cut sheet drops smoothly onto the receiving table to prevent surface damage. The production length report is automatically logged for quality and dispatch tracking.

Dimensional & Visual Inspection
After cutting, the deck sheets undergo dimensional verification for width, depth, and rib spacing using calibrated gauges. Visual inspection ensures no dents, scratches, or coating damage on the surface. The crest height and profile uniformity are verified against the approved drawing. Samples are periodically taken for physical measurement and alignment check. Any deviation beyond tolerance is reported to maintenance and production teams for immediate rectification. The inspection records are maintained for every batch for traceability and quality audit.

Stacking & Bundle Formation
Inspected sheets are stacked neatly on timber battens to prevent direct floor contact. Bundles are made as per order length and quantity. Edge protectors are placed at the corners to safeguard against transit damage. A visual check is done to ensure no sheet misalignment within the stack. The stacking area is demarcated based on dispatch priority and storage duration. Care is taken to maintain uniform bundle height for safe crane handling and optimal truck loading.

Labelling & Storage
Each finished bundle is labelled with order details including customer name, project, sheet type, thickness, profile, length, and quantity. The labelled bundles are moved to the finished goods storage area and arranged systematically. The storage space is ventilated, dry, and clean to avoid condensation and corrosion. Proper FIFO (First-In-First-Out) inventory practice is followed to maintain material freshness. The area is monitored regularly to ensure no deformation occurs during extended storage.

EOT Crane Loading → Dispatch
According to the dispatch plan, the finished deck sheet bundles are loaded on vehicles using an EOT crane or Hydra. Wooden spacers are placed between bundles to prevent surface abrasion during transport. The bundles are covered with Tarpaulin sheets for weather protection. The loading supervisor verifies the order number, bundle count, and destination before dispatch. The dispatch register records vehicle details, loading time, and customer information. This ensures safe, traceable, and damage-free delivery to the project site.