Download pdf - Preoject Report CLC Plant - 3.imimg.com3.imimg.com/data3/GS/KC/MY-4452558/clc-block-making-machine.pdf · •CLC Blocks being light weight the handling and transportation is easy

1. Introduction2. About New Project3. Advantages of CLC Bricks4. Application of CLC Bricks5. Market Potential6. Basis and Presumption7. Technical Aspect8. About Relative Comparisons of Alternative Walling Material9. Financial Aspects.

Index

G/1505 GIDC, Opp. Tlephone Exchange, At. Metoda. Dist. Rajkot. Gujrat (India).Email: [email protected] www.greenstone-clc.com

Phone: +91 9426996888, +91 9426201058

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 itsproper 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 NEW 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 foamincluded 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. The Hardened Material Consists Of Small-Enclosed Air Bubbles Thereby Resulting In ALightweight Stable Cellular Material With Densities Ranging From As Low 300kg/M3 To 1800 Kg/M3. Good Curing gives strength and dimensional stability to Bricks. Bricksare 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.


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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.


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TECHNICAL ASPECTS

Manufacturing Process:

1. Pour water into the mixer according to mix design2. Add Fly-ash & Cement afterwards3 Mix this slurry as per proper mixed desire ratio.4. Add network former and stabilizer (Optional)5. After final mixture is poured into material trolley. 6. From Material trolley mixture is poured into mould. 7. After 6 - 8 hours moulds is released then put blocks in to stake. 8. 6-7 day the stake are water cured.9. After 6-7 day atmospheric curing material can be transported for dispatch.

Size, Weight and No of bricks per cubic meter:

Size (in inches) Size (in mm) No of bricks per 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.3100 to Rs.3800

About Relative Comparisons of Alternative Walling Material


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FINANCIAL ASPECTS

A. Fixed Capital

Land and Building

Plant & Machinery:

B. Working Capital Requirement for 1 month

Average daily production capacity of 15 cubic mtrs

Calculation of working capital requirement per day:

15m3 x 1960 per m3 = 29,400/-

Calculation of working capital requirement per month:

29,400 x 26 days = 7,64,400/-

Selling Price (Approx)

3100 m3 - 1960 = 1140 / m3 profit

1140 X 15m3 =17,100.00 day profit

17,100 X 26 = 4,44,600 profit of 26 day working

Per year profit is 4,44,600 X 12 = 53,35,200.00

Item

Integrated CLC Unit

which Includes Mixer (1.2m3),

Foam Generator,

Compressor

Control Panel

Conveyor belt

Moulds

Raw-material and Transport trolley

14,00,000 approx Amount

1500 to 2000 Sq.mt. Approx Land require.

Cost of Production for per cubic mtr. (Approx)

Particulars Kgs Rate

Cement 250.00 5.00 1250.00Water 200.00 0.05 10.00Fly Ash 450.00 0.50 225.00Foam Generator 1.50 140.00 210.00Power Fuel 10.00Labour 200.00Mis. Exp. 5.00

All Exp. Like Intrest, Office, Fuel,etc 50.00

Total Cost 1960.00


Phone: +91 9426996888, +91 9426201058


Phone: +91 9426996888, +91 9426201058

Power consumption is required for running CLC brick machinery plant?

1.2 cubic meter mixer 7.5 hp

Foam generator 1hp

Compressor 2 hp

Water motor 2hp

Conveyor 2 hp

Total 15 hp needed(approx)

Labor force is required in running a CLC light weight brick machinery plant.

A minimum of ten 10 unskilled workers are essential in the production of CLC bricks.

Raw material is required to manufacture CLC bricks

The raw material required to manufacture 1000 blocks of size 24x8x9 are:

·Foaming agent: 50 kg.

·Cement: 100 bags

·Fly ash: 16 tons

·Water: to prepare a slurry mix similar to general requirement in concrete production.

Foaming agent used in CLC bricks production.

Protein foaming agent (non-veg) 85gm to 95gm per liter (density) can use for CLC bricks.

Protein foaming agent (veg) can be used for roof insulations.

Cement grade use in CLC light weight bricks manufacturing.

53 grade ordinary Portland cement (OPC) is used for manufacturing CLC bricks.

Fly ash can be used for CLC bricks production.

We should use fine fly ash(may be use pond ash), which is available in thermal power plants.

(It is also available in certain industries free of cost. You got make to make your own transport arrangement).

This raw material is one hundred percent (100%) suitable for CLC bricks production.

P.S. we can use pond fine fly ash.

Conveyor used in CLC bricks machinery plants.

There are two types of conveyors that can be used:

1.Belt conveyor for fly ash

2.Screw conveyor for cement However, our suggestion would be to use only belt conveyor for both, which is sufficient.

It is better to avoid screw conveyor for cement.

Molds for 1 cubic meter CLC bricks manufacturing.

There are four molds needed if it is 8 feet ms (mild steel) sheet.

There are five moulds needed if it is 6 feet ms (mild steel) sheet.


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Main Features Of CLC Blocks, Prefab Elements & In-Situ Moulded Housing:-

·CLC Blocks are very light in weight Density ranging from 400 to 1800 Kg/m3 can be produced

as required.

·CLC Blocks are excellent for Earthquake Resistant Housing due to light weight reducing dead

weight by more than 50% of the normal concrete. Multi-Storey high rise towers constructed has

saved cement and steel to large extent, which can be verified on STAAD-III Computer Programme.

·CLC Blocks are excellent for Thermal and Sound insulation which keeps the house cool in

Summer and warm in Winter saving energy/electricity for cooling and heating.

·CLC Blocks are “Environment-friendly” using more than 30% of “Fly Ash” from Thermal Power

Stations and converting directly into valuable Building Materials. CLC Blocks will also replace

“Clay Bricks” which is destroying Agricultural top soil. Our Technology will save Environment

and Ecology from the hazardous & polluting material Fly Ash and prevent destruction of

Valuable Agricultural Land.

·CLC Blocks Production Plant can be Stationary or Mobile Unit to be mounted on truck to

manufacture CLC Blocks, Prefab reinforced Building Elements, and In-Situ Moulded Housing at

site, will save breakage, transport charges and delay, etc.

·Cellular Lightweight Concrete is a self flowing concrete with ball bearing action to avoid

Honeycomb and Voids in the Blocks, Prefab Building Elements and In-Situ Moulded Housed walls.

·CLC Blocks being light weight the handling and transportation is easy. The construction

speed is 2 ½ times more than the Clay Bricks construction.

· In-Situ Moulded Housing is excellent technology to Produce 5 to 20 houses per day by using

simple machinery and moulds. The fast construction speed is a first necessity for quick

Rehabilitation of Earthquake affected villages and towns or for the Rehabilitation of the villages

displaced due to the major “Dam Projects” besides the Rehabilitation programme for the Slums

in the Metro Politan Cities.

·In-Situ Moulded Houses have no joints and hence it will not damage by high intensity Earthquake

or Cyclone. The doors, windows, sanitary and water pipes are inserted in the Moulds before pouring

CLC in the Moulds resulting into a compact house without any maintenance cost for a long period.

· In-Situ Moulded Housing, Prefab reinforced Building Elements and CLC Blocks are used regularly

in more than 40 countries and more particularly by the Developing Countries.

·Micro Air Cells of CLC are intact, not interconnected as it is produced by Stable Foaming Agent.

Therefore our product has very low Water Absorption avoiding any leakage, seepage or dampness

in the walls and ceiling.

· House built with CLC Blocks or Prefab Building Elements or In-Situ Moulds do not require inside

or outside plaster but if insisted only 6 mm thick plaster is sufficient for internal and external surface.

·Steel reinforcement is not required for the Ground Floor Housing with Sheet Roofing or

CLC Panel Roofing. Any shrinkage can be avoided by using Synthetic Fibers, which adds to the

strength of the concrete.

·CLC has basic raw material of Cement for the appropriate strength and hence the strength is

increasing every year on Aging of the Concrete.


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·CLC Blocks Production Plant, Machinery and Equipment besides critical raw-material-Foaming

Agent is manufactured in India and hence no imports are involved.

·CLC do not require stone aggregates and the Slurry of Cement, Sand, Fly Ash, Foam and

Water can be pumped easily in length and height.

·CLC is excellent for Snow bound Cold Regions/Zones and also for Hot climate Desert Zones

for the comfortable living. CLC Blocks can be produced in the remote Snow bound areas by

our Mobile Production Unit. CLC Blocks can be transported by Mules to difficult terrains since

the material is light weight.

·CLC is excellent Fire Retardant and can be used for fire fighting operations in Coal Mines,

Forests, etc.

·CLC is excellent for Roofing Thermal Insulation and sound Insulation for Floor Slabs.

·CLC is best for Trench Reinstatement, Void filling, Bridge Abutment, Tunnel work and

Floor Construction.

· CLC is also suitable for Soil Stabilization, Road Foundation, Land Reclamation and

Harbour Fills.

· CLC is excellent for Fire Breaks in the Buildings.

·CLC is most suitable to construct Sound Barriers at the Air Port to prevent Noise Pollution

while landing and Take-off.