The document provides details about a 4-week industrial training completed at Speedcrafts Ltd in Patna, India. It includes: 1) An overview of Speedcrafts Ltd, which manufactures road construction equipment, including their product range and international partnerships. 2) Descriptions of the manufacturing process for road rollers, from sourcing materials to assembly of components like the chassis, engine, transmission and wheels. 3) Explanations of key roller components such as the clutch, gearbox and braking system.

1. Four Weeks Industrial Training
at
SPEEDCRAFTS LTD, Patna
Submitted in Partial Fulfillment for award of Degree of
Bachelor Of technology in Mechanical Engineering
Department Of Mechanical Engineering,
Maharishi Markandeshwar University, Sadopur,
Session 2013-14
Submitted By:
PARAG PRIYANK
Roll No. 75114037
B.Tech (M.E, 4Th SEM)
Batch:- 2011-2015

2. ABOUT THE COMPANY
The foundation stone of SPEEDCRAFTS Ltd now an ISO 9001 company
(manufacturer of Road Building Component) was laid down in the year 1971
at Patna, by Mr R.K.Agarwala now handled by Mr. S. K. Agarwala in the
capital of Bihar being the first one in the state with commitment to deliver
quality and excellence, the company has ranked top on the industrial map of
India. From a modest beginning, the Company is having manufacturing unit
spread over 25 acres of land, with approximately 20,000 sq. metres. (200,000
sq.ft) of covered area, in-house machine shops, fabrication shop, press shop,
mechanical, hydraulic and electrical assembly facilities and paint shop as
well as handling and packing facilities and quality control division.
Company’s plant shares its one of boundaries with JAI PRAKASH
INTERNATIONAL AIRPORT, PATNA as it is in the very close vicinity of
one end of the runway. Their production is always of high quality which
provides it acceptable and acclaimed by Indian Railways, Defence, State
Government Road Departments, Contractors and Various Construction
Industries because the products are raised on Stringent International and
Indian Standards. Now company has opened another unit in HARIDWAR for
detailed manufacturing and governing.

3. PRODUCTS AT A GLANCE
Asphalt Batch Mix Plant Asphalt Drum Mix Plant
Asphalt Plant (American Specs) Mobile Asphalt Plant
Wet Mix Macadam Plant Concrete Batching Plant

4. INTERNATIONAL TIE-UPS
1. As emerging on the globe the Company decided to work for the Railway Track
Maintenance Equipment and for the same it has collaborated with HARSCO
RAIL (North America) to produce some of the quality and excellence and
service and sparing too. This is the company’s first tie-up in field of railway
track maintenance and working for Indian Railways.
2. Secondly, the Company has tied up with M/s BERNARDI IMPIANTI, Italy,
World Leaders in Asphalt Mixing Technology for manufacture of Batch type
Asphalt Plants in India. These plants are available from 80 to 260 tph capacity.
It produces some of the following products under collaboration in the
Haridwar plant
3. The company has recently entered an amicable tie-up with Dmix S.R.L. to
start the production of Self Loading Concrete Mixers in the modern
manufacturing facilities in Haridwar. This again enables company to stretch its
arm over the market where there are customers for self-loading concrete mixer
anywhere in the world.

5. Containerised Concrete plant Mobile Concrete Plant
Bitumen Pressure Distributor Pothole Repairing Machine
Diesel Road Roller Paver Finisher

6. Mobile Hot Mix Plant Concrete Conveyor
Road Sweeper Chip Spreader

7. Products Raised Within Tie-Ups
In collaboration with DMIX SRL :-
DS 1000 DS 2500
DS 4000

8. OHE tower Wagon Railway Utility Vehicle
Over Head motorcar Over Head Track Maintenance Car
And other components like Rail threader, Gang Bus, Flash Butt welding
machine, Ballast Hooper Car, Inspection Car and other.
In Collaboration with RAIL HARSCO:-

9. In Collaboration With Bernardi Impianti:-
Asphalt plants
Other products raised under this collaboration are Dryer Drum, Burner,
Batching Tower, Bag House Filter, Control Unit.

10. Market Involvement
The company has totally stretched its arm over the globe . Not only in India
but in the other countries too the company has managed to grasp the center
and keen of the customers . As the products are robustly there is no
alternative in terms of performance, design and quality so it is a bane for the
company. In over 60 countries of Europe, Asia, USA, Africa and some
parts of NewZealand the company is exporting almost all its components.
With annual turnover of Rs. 250 Crore the company is commemorating
on the map. Some of its Indian Customer of this company are follows:-
1) L&T
2) Nagarjuna Constructions
3) Bihar State Road Development Authority
4) Ministry of Defence, India
5) KMK Construction, Indore
6) Gammon Construction
7) Jaypee Construction
8) Geet Constructions, Faridabad
9) And many other construction companies and contractors

11. International Clientele
As mentioned earlier that company is international exporting on each
corner of globe following are some of the major international
customers:-
1) M/s Kays Consultancy & Marketing Service, Bhutan
2) Quasi Engineering Works, Bhutan
3) Annapurna Construction Company, Nepal
4) Panjore Construction, Bhutan
5) Rirab Construction, Bhutan
6) Passwing Construction, Bhutan
7) M/s Innovetech Pti (Ltd), Singapore
8) M/s Mr. S & S Sons Constructions, Tanzania
9) M/s Sarzameen Aftab Construction Company, Afghanistan
10) Acciona Construction ltd, Spain
11) Obrascón Huarte Lain, Spain
12) Julius Berger Construction, Nigeria
13) Rocad Constructions, Nigeria
14) And many other anonymous companies

12. Management Chart
SRI S.K. AGARWALA
Chairman-cum-Managing Director
SRI R.K. AGARWALA
Executive Director
SRI S. AGARWALA
Director International
Export
SRI S. KHADERIA
Director Work
SRI R. AGARWALA
Director Imports
SRI GOPALAGARWALA
Director Finance
SRI H.K. SHARMA
Director Operations
(Haridwar Unit)

13. SRI S AGARWALA
Director International
Export
Mr. M.J. JAFERI
DGM, Marketing
Mr. A. KUMAR
Manager Export
Mr. SAMEER KUMAR
Asst. Manager Export
Mr. ASHUTOSH JEET
Asst. Manager
SRI V.P. NAYAK
Asst. Manager
Mr. ANUBHAV
Senior Executive
Marketing
Miss. SMRITI SINGH
Executive Marketing
Mr. MUKESH
Marketing Head
Miss APARNA
Marketing
Executive

14. SRI GOPALAGARWALA
Director Finance
Mr. LALIT MOUR
GM Finance
Mr. KAJORI DAS
Manager Finance
SRI NAND JHA
Senior Accountant
Mr. ABINDYO GHOSH
Account Officer
SRI SHYAM KHADERIA
Director Work
MR. MANOJ
DGM, Work
SRI RAKESH SINHA
Senior Manager Production
Mr. ABHAY KUMAR
Manager Production
Mr.
CHANDAN
JHA
HEAD HR

15. ROAD ROLLER
Q. WHAT IS A ROAD ROLLER?
A road roller (sometimes called a roller-compactor, or just roller) is a
compactor type engineering vehicle used to compact soil, gravel,
concrete, or asphalt in the construction of roads and foundations, similar
rollers are used also at landfills or in agriculture. Today there are simply
taking Static Roller, Pneumatic Roller, Vibratory Roller and others.
Static Road Roller

16. HISTORY OF ROAD ROLLER:-
The first road rollers were Horse Driven Rollers aroun 18th century
Since the effectiveness depends upon the power of Road Roller, In 19th
Century Steam Road-Roller were Introduced.
Horse Driven Rollers
Steam Road Rollers

17. Q. What is the use of Road Roller ?
Road rollers use the weight of the vehicle to compress the surface being rolled
(static) or use mechanical advantage (vibrating).
These rollers feature two rows (front and back) of mild steel heavy rolls that
overlap, and the flexibility of the rolls provides a kneading action that seals the
surface and with some vertical movement of the wheels, enables the roller to
operate effectively on uneven ground.
Q. How is Road Roller manufactured ?
The Company handles every part of the manufacturing of Diesel Road Roller in
such a way that each and every component to be fitted or assembled anyhow must
cope the roller to pass any kind of stringent condition in future if it faces any time
in its lifetime.
The construction of Road Rollers is not easy although the company has employed
many a new techniques so that they are able to manufacture 25-30 road rollers and
almost 360 per year.

18. Plant Layout Road Roller
Chasis Fabrication
Shop

19. (Line 1) (Line 3)
(Line 2)
Mild Steel From store to Fabrication Shop
CHASIS FABRICATION CENTRE Wheel Fabrication CentreFront Roll Yoke
Shop
Gas Cutting
Shop Floor
Wheel Rolling machines and
Lathe Machines for grooving
Fabrication & Final Drive ring
on rear roll and internal
bushing of both rolls
Assembly Line
Pressure
Balancing weight
installed
Gear Box Fabrication
shop
Production Process Chart – Road Roller

20. (Line 4)

21. 1. Mild Steel Fabrication
In the Mild Steel fabrication center the sheet arrives after being cut from
PLASMA ARC CUTTING MACHINE and then taken to Chasis Fabrication
Shop And Front Roll Yoke Shop and Awning Shop.
Plasma Arc Cutting Machine

22. 2. Chasis Fabrication:-
The manufacturing and fabrication of the chasis takes place under the
Chasis Fabrication Shop.
In the chasis manufacturing Mild Steel sheets are used. The chasis of a
road roller is basically very un-identical that of used in automobiles
normally. The chasis is big as compared and is made by joining of five
different parts by welding and drilling on the end corners of plates to fix it
with help of bolts
Chasis of Road Roller

23. 3. Engine
The engine or prime mover is basically exported from SIMPSON INDIA Ltd. The
engine is of 4 cylinder inline diesel engine. It delivers a power of 41.5 bhp @ 1500 rpm.
The engine provides the much power required to operate whole system. The flywheel of
the engine is really huge.
4. Front Roll Yoke And Carriage
Front roll (wheel) Yoke is made by using MILD STEEL and is fabricated whole in the
Front Roll Fabrication Shop adjacent to Chasis Fabrication Shop under same roof.The
yoke is pivoted in the head of roller to withstand sudden jerks and loads. The carriage is
bolted tightly on both sides of yoke to provide a good support for movement of front
roll.On both the ends there is a big center hole so that the carriage is easily fixed into this
with joints and clamps.Carriage is another component which is provided with yoke
which basically governs holds the Front Roll with help of axle and bush pipe on both
sides.

24. 5. Transmission
(a) Gearbox:-
The gear box is totally made and fabricated out of MILD STEEL. Bevel gears, large
and heavy spur gears and pinions which are made of some special alloy are housed in
the gearbox. The gearbox contains 17 bearings and all are dependent on each other, if
one gets tamed then it will affect the operation of others and the transmission will be
deprived.
The whole of operation takes place under GEARBOX FABRICATION SHOP.
The gear box is having the bevel gears which messes with helical gears of driving
shaft or main shaft.
There are total of 10 gear wheels comprising haringborne (double helical), spur and
bevel gears. There are in total 12 holes on the gearbox, 5 on both sides and 1 on front
face and rear face. The diameter of holes on front and rear side is 260 mm and
150mm respectively. While on the side faces there are two holes of equal diameter
that is 110mm and other three are of 230mm, 160mm, 175mm. The dimensions of
gear box is 800x380x450mm.
The fabrication of gearbox is done on lathe machine. The basic fabrication process
done here is boring which is carried out to achieve greater accuracy of the diameter of
a hole. The cutting tool used here was the carbide tip P01.

25. Gear Box Fabrication
After all the fabriction operation is employed to make the gearbox ready, it is taken
to gearbox test centre where it is tested for three hours so that it is confirmed that it
is ready to perform in any stringent condition. The testing happens in GEARBOX
TESTING SHOP just in rear side of Gear box fabrication shop.

26. (b) Clutch:-
The Clutch is really a matter of wonder here. The clutch is heavy automotive and
double action type. The clutch consist of two clutch plates one for forward motion &
another for reverse motion but is controlled with single lever separately provided for
both kind of motions.
Clutch For Roller
The clutch box is casted and then machined. The diameter of clutch plate is
330mm. After the fabrication of clutch it is assembled to the gear box under the
GEARBOX & CLUTCH ASSEMBLY.

27. 6.GEARBOX & CLUTCH ASSEMBLY:-
Here the assembling of clutch and gearbox is done. The gear box arrives after successfully
passing the test in Gear Box Testing Shop. The assembly is done and precisely checked and
after this the whole transmission setup is taken to the roller assembly to be fitted with engine
stored already in the roller.
Gearbox is first engaged to clutch by help of shafts coming out from gearbox. Now the clutch
is coupled to flywheel of engine. Hence the clutch rests in between the transmission system and
whole of this system is in single line.
7. PROCESS OF TRANSMISSION:-
When the engine is started and the gear is employed by the help of lever present in upper cabin,
and the motion is selected by another lever which governs the motion and clutch (let it be
forward or reverse motion and clutch) present in left side of driver seat then it happens that the
desired direction of motion is achieved by clutch lever and the speed is taken by gear lever the
accurate gear starts meshing with the main or driver gear on main shaft.
This tends to give motion to the driven shaft. Now there are two Final Drive Pinion coming out
of the gear box which are connected to driven shafts.
The Left Hand Final Drive pinion is connected to Clutch & driven shafts by help of Bevel
Gears in gearbox and it has the power of accelerator and all while, the Right Hand Final Drive
Pinion is free and just rotates on power of LHFDP.
The wheels are fitted here in such a way that the rear axle goes under center hole and teeth of
Final drive pinion meshes with the Drive ring present in both rear rolls.

28. Final Drive Point & Rear Axle
Total arrangement of engine-clutch-gear

29. 8. WHEELS (ROLLS):-
The wheels or rolls are made from heavy Mild Steel. The sheet is of
depth 36mm. It is rolled on rolling machine to get a circular shape.
This all happens in Wheel Fabrication Section.
Mild Steel Sheet Being RolledGrooving Process of Rear Roll on
Lathe

30. (a)Rear Roll:-
This roll is much more engineered as compared to front roll. It contains Final
Drive Ring which meshes with final drive pinion and provides motion and center
bush in which the rear axle is fixed. The diameter of rear roll is 1370mm and
width of 535 mm. The unballasted weight is 302 kg and ballasted weight is 406 kg
for 10 ton
The rear roll has one more fabrication process as compared to front roll. In this the
grooving is done so that the final drive ring having 72 teeth is attached by use of
bolts and side welding. The diameter of this ring is 536mm and is 100mm thick
Final roll after total fabrication

31. (b) Front Roll:-
It is fabricated and machined in such a way that it is hold good on Front
Roll Yoke and Carriage. All the processes are same like rear roll except
grooving which is not done in this roll. The diameter of this roll is
1030mm and width is 470 mm. The unballasted weight of front roll is 200
kg and ballasted weight is 280 kg for 10 ton.
Front roll on Lathe, bush is being developed
9 Heads:-
The heads are again made of Mild Steel. They are very amazingly
designed. It has two wholes one for the steering and another for
pivoting the yoke (front roll).

32. 10. Brakes:-
The brakes are fully self-wrapping and contracting type.
The brake is fixed over the final drive ring in rear roll and covers the
circumference of drive ring. The brake shoes are riveted to the brake ring. When
brake lever is acted upon then brakes contracts and meshes with outer ring of final
drive ring on rear roll and hence the vehicle is stopped. Basically the brakes are
provided for locking of wheels and for parking of the road roller.
But the rollers are not fully dependent on these brakes. The clutch lever is also
employed during this operation.
11. Steering:-
Easily operated mechanical steering comprising of worm shaft and gear. It is
designed to give jerk free movement to front rolls. The steering wheel is casted
and its shaft comes out from the roller head.
The worm used here is single start.

33. 12. Pressure Balancing Device:-
Two weights are provided on the base of chasis with sliding floor. These are
governed by the arm coming out from the body near the rear roll. It provides
variation of pressure on rolls and also helps the Road roller to roll on inclined
and sloppy surface. The weights are of 500 kg and 250 kg.
13. Scrappers:-
Adjustable and reversible scrapers are fitted to cover the entire width of all
rolls.They are again made up of mild steels and used to take out mud and other
negative things that sticks to the rolls like concrete and muds.
Front roll scrappers Rear roll Scrappers

34. 14.Ballast:-
Arrangement for ballasting the roller with either sand or water is
provided in all the rolls. Opening this on all the four wheels can make
easy loading of ballasting of water and sand. It is done to increase the
weight so that pressure can be incresed.
Ballast arrangement on rear roll

35. 15. Other Parts:-
Road roller have some more parts like Awning, fuel tank, water tank and water
sprinklers. TECHNICAL SPECIFICATION
Model
DRR/10 (4 speed) & DRR-3/10
(3 speed)
Unballasted Weight 8,000 Kg.
Water Ballasted Weight 9,000 Kg.
Sand Ballasted Weight 10,000 Kg.
Engine S-4(I)/RB-33 41.5/37.5 BHP. at 1500 RPM.
Overall Length 4880 mm.
Rolling Width 1810 mm.
Overall Height 2860 mm.
Dia. of Rear Rolls 1370 mm.
Width of Rear Rolls 535 mm.
Dia. of Front Rolls 1030 mm.
Width of Front Rolls 940 mm.
Line Pressure
Minimum
Maximum
Front Rolls Rear Rolls
27.6 Kg./cm. 47.5Kg./cm.
41.1 Kg./cm. 61.7Kg./cm.
Overlap of Rolls 100 mm.
Wheel Base 2800 mm.
Turning Radius 3935 mm.
No. of Speeds
Model DRR/10
Model DRR-3/10
4 forward and 4 reverse
3 forward and 3 reverse
Speed
Model DRR/10
Model DRR-3/10
1.95 to 9.00 Km./hr.
1.74 to 7.47 Km./hr.
Gradient 1 in 5.
Fuel Tank Capacity 150 ltrs. (including spare tank)
Water Tank Capacity 225 ltrs. (including spare tank)
Permissible Variation ± 5%

36. 16. Paint Shop:-
After the roller is ready in assembly shop it is taken to the paint shop where it
is painted manually in such a way that there is none kind of imperfection.
First the primer is coated on the surface with help of spray jet and then after
some hours the paint is coated on the surface of road roller with the help of
another spray jet.
Roller being painted in Paint shop

37. 17. Road Roller:-
When all above task completes for one then it is taken to the test center,
where all of its dynamism and other operations are checked in condition
which is really very hostile and asks the product give its 100%. The test
drivers are very experienced and do not compromise if there is a slight
complaint with performance.
The test ride completes under 45 minutes of drive in stringent conditions.

38. 18. Quality Control Division:-
All products manufactured are thoroughly inspected and tested for quality and
reliability. The inhouse testing laboratory well equipped with advance and
sensitive testing equipment controlled by experienced Engineers, faithfully
uncompromising on the subject of quality. If any fault is found, then the
component is sent back to that particular section to rework. The checks begin
with the incoming material and components and ends only when the finished
product is tested and taken over to store.
One of the laboratory of Quality Control Division

39. 19. Lubrication Chart:-
It is a kind of chart which is pasted on the body of road roller after test driving and
passing out all the checks from Quality Control Division and after the servicing.
The chart provides all the necessary information for lubricating like where the oil has
to be given where the grease has to be given and what time interval.
With the help of this chart the owner or the operator can easily keep lubricating the
roller and hence as a result it will provide with the desired eminent performance.
Lubrication Chart

40. Machine Shop
Number Of Lathe Machines
Radial Drilling Machine
Rolling Machine Plasma Arc Cutting Machine

41. Bending Machine Shearing Machine

42. LESSON LEARNT
The most important lesson what I have learnt here is that how to keep in
cohesion with each other and work for the best output in the time when your
competitors are just not following but trying to pull you down. The discipline
and the keen and magnanimous “love with the work” and cohesion and team
spirit have been a lesson that inspired me more in my whole training period.
Well apart from this the lesson what has been in-housed in me was from the
section in what I was training. The manufacture of Road Roller is totally
captured in me.
The journey from tiny mild steel to huge and hunk Road Roller has been totally
understood. Each and every operations have been considered very carefully.
The machining operation like boring, grooving and gas cutting and welding
processes has been learnt. The process of wheel rolling fabrication, chasis
fabrication, gearbox fabrication, clutch-gear assembling and the assembling of
the total of road roller has been carefully learnt.
Thus, I can say that I have in-housed all those things which is required to make a
huge Road roller using tiny mild steel sheets.