REPORT ON MICRO SCALE CLC BLOCKS INDUSTRY

REPORT ON MICRO SCALE CLC BLOCKS INDUSTRY

Contact: rajivbabuchintala@gmail.com

INTRODUCTION

This world is changing day by day. Technologies are also changed with time.Technological advancement leads business process in all new different dimensions.

Country like India is growing rapidly. Infrastructure Development is in big bane. Development forms and methods are also changed due to change in technology.

In case of a conventional construction of a building or any structure, the main source of raw material is Sand bricks or Stones or wooden sheets as a wall. The new concept for making wall has been developed that is Cellular Lightweight Concrete (CLC) Bricks. It is a light weight, water resistant, fire- proof, sound proof and environment friendly. The main feature of this bricks is light in weight. Cellular Lightweight Concrete bricks are made of fly ash, cement, and foaming agent. These can be extensively used in all building constructional activities similar to that of common burnt clay bricks. The CLC bricks are comparatively lighter in weight and stronger than common clay bricks. Since fly ash is being accumulated as waste material in large quantity near thermal power plants and creating serious environmental pollution problems, its utilization as main raw material in the manufacture of bricks will not only create ample opportunities for its proper and useful disposal but also help in environmental pollution control to a greater extent in the surrounding areas of power plants. In view of superior quality and eco-friendly nature, and government support the demand for CLC Bricks has picked up.

ABOUT PROJECT

Cellular Lightweight Concrete Bricks (CLC) is produced by adding millions of Micro-Sized air bubbles into a cement based mixture. The addition of millions of air bubbles is achieved by using a Proprietary Foam Generator to produce highly stable and injecting the Foam directly into a concrete mixer containing a sand/ cement/ fly ash/ water slurry.The amount of cement, sand (if included), water. Fly-Ash and foam included in the Light weight Cellular concrete mix design depends on the required properties (i.e. strength, thermal conductivity or durability).Also, depending on the required CLC density and variance, an appropriate mixer is selected. The hardened material consists of small-enclosed air bubbles thereby resulting in a light weight stable cellular material with densities ranging from as low 300kg/m3 to 1800Kg/m3. Good Curing gives strength and dimensional stability to Bricks. Bricks are cured either by air curing or high-pressure steam curing procedure. Because of great-Engineered properties, CLC Bricks have become popular in wide range of applications in construction sector.

Advantages of CLC Bricks

- Low thermal conductivity.

- Thermal Performances 5 times better than clay bricks & 10 times better than RCC

- Interiors remain cool in summer and warm in cold wintry days.

- Savings in recurring energy costs in air-conditioning.

- Ideal material for applications in cold storage rooms.

Good Sound Insulation

- Up to 37-42db sound reduction based on thickness.

- It is possible to achieve even higher values depending upon the thickness and the plaster.

- Savings in recurring energy costs in air-conditioning.

- Can fulfill required STC (Sound Transmission Class) rating.

Reduction of Dead Load

- 1/3rd the density of clay bricks.

- Economic design: savings in cement and steel.

- Enables faster construction.

- Suitable for low-soil bearing capacity & seismic zones.

- Facilitates construction of unplanned walls any where anytime.

Fire Protection

CLC Bricks offer great fire protection. With a just 100mm. thickness of wall 1000 kg/m3,

CLC block offers fire endurance for heat transmission for 4 hours without releasing any

toxic fumes during.

Enhances Carpet Area

An engineered block, it can be offered in any thickness as per the construction design. By using 150 mm thick Bricks in place of 9 inch brick, the customer gets an additional 2% to 3% carpet area. The savings on account of additional carpet area gained is more than the cost of Bricks

Other Advantages of CLC Bricks:

- CLC offers economical POP or putty finish in internal partition walls.

- Accurate size and shapes help in reducing plastering costs.

- Better finishing of walls offers good amount of reduction in paints.

- Eco-friendly.

- Speedier Constructions.

- Ease of Work ability.

- Universal Acceptability.

- Low Water Absorption.

Size, Weight and No of bricks per cubic meter:

Size (in Inches)	Size (in mm)	No. of Bricks in cubic meter	Weight in kgs
24 X 8 X 4	600 X 200 X 100	82	10 - 10.5
24 X 8 X 6	600 X 200 X 150	55	15 – 15.5
24 X 8 X 8	600 X 200 X 200	41	20 – 20.5
24 X 8 X 9	600 X 200 X 225	37	25.5 - 26

Production Capacity Per Year:

Project having production capacity of 15 cubic mtr per day.

So, it is assume that plant will run 300 days in year.

Total Capacity:

15 cubic mtr x 300 days = 4500 cubic mtr

Market price per cubic mtr will run Rs.3500 to Rs.3800.

FINANCIAL ASPECTS

A. Fixed Capital

Land and Building: 1500 to 2000 Sq.mt approximately

Plant & Machinery: 1400000 amount approximately

Item

Integrated CLC Unit

which Includes Mixer (1.2m3),

Foam Generator,

Compressor

Control Panel

Conveyor belt

Moulds

Raw-material and Transport trolley

B. Working Capital Requirement for 1 month

Average daily production capacity of 15 cubic mtrs

Cost of Production for per cubic mtr. (Approx)

Particulars	Kgs	Rate	Total(Rs)
Cement	200	6	1200
Water	200	0.05	10
Fly-ash	450	0.05	225
Foam Generator	1.50	140	210
Power fuel			10
Labor			200
Mis. Expenses			50
Total			1905

Calculation of working capital requirement per day:

15m3 x 1905 per m3 = 28,575/-

Calculation of working capital requirement per month:

28,575 x 26 days = 7,42,950/-

Selling Price (Approx)

3500 m3 - 1905 = 1595 / m3 profit

1595 X 15m3 =23,925 day profit

23,925 X 26 = 6,22,050 profit of 26 day working

Per year profit is 6,22,050 X 12 = 74,64,600.