Investment Guidelines For CLC Block

Investment Guidelines for Establishing a
Cellular Lightweight Concrete (CLC)

Block Factory in Afghanistan
Contents
Table of Contents
FOREWORD .................................................................................................................................. 4
PREFACE ......................................................................................................................................4
Introduction .................................................................................................................................5
Overview .....................................................................................................................................6
What is it?.....................................................................................................................................6
Applications ..................................................................................................................................6
Benefits.........................................................................................................................................8
Alternatives/Substitutes............................................................................................................. 10
Market Overview ....................................................................................................................... 11
Market Entry Costs ..................................................................................................................... 13
Competitiveness......................................................................................................................... 21
CLC Manufacturing Process ......................................................................................................... 21
Quality Control........................................................................................................................... 23
Technical Specifications .............................................................................................................. 24
Materials.....................................................................................................................................24
Execution ....................................................................................................................................24
Quality Assurance ....................................................................................................................... 24
Weather Conditions ................................................................................................................... 25
Strength/density......................................................................................................................... 25
Table 3. CLC Strength/Density Table ........................................................................................... 25
Environmental ........................................................................................................................... 26
Frequently Asked Questions (FAQs): ........................................................................................... 27
Annex 1: Sample Floor Plan Drawing Used to Conduct Cost Comparisons ..................................... 30
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Annex 2: Cost Comparison Assumptions and Calculations............................................................ 31
Cost Estimates for Non-Structural Baked Brick ............................................................................ 32
Cost Estimates for Structural CMU .............................................................................................. 33
Cost Estimates for Structural Baked Brick .................................................................................... 34
Cost Estimates for Non-Structural CLC ......................................................................................... 35
Cost Estimates for Structural CLC ................................................................................................ 36
Annex 3. CLC Global Projects Photo Gallery ................................................................................. 37
This report was made possible through support provided by the United States Agency for
International Development (USAID). The opinions expressed herein are those of the
author(s) and do not necessarily reflect the views of USAID or the U.S. Government.
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FOREWORD
We have pleasure in presenting this investment guideline on setting up a Cellular Lightweight
Concrete (CLC) block manufacturing plant in Afghanistan. This is part of the Assistance in
Building Afghanistan by Developing Enterprises (ABADE) program, a USAID-funded effort
focused on strengthening the productivity of enterprises for sustained growth and job
creation.
ABADE’s objectives are to increase domestic and foreign investment, stimulate employment
and improve sales of Afghan products. It is designed to complement other USAID programs
focused on improving the business enabling environment, workforce development, and
access to finance. ABADE’s alliances with small and medium enterprises (SMEs) can accelerate
productivity and job creation by mitigating risk, and by leveraging small, catalytic capital with
much larger contributions from private companies. ABADE is a four-year project which began
in October 2012.
One of the high potential sectors ABADE works with is construction materials. As expressed
in several documents, the construction and construction materials sector is a primary driver
of Afghanistan’s economy contributing to employment, quality of life, economic efficiencies,
and innovation.
PREFACE
This is part of a series of carefully chosen and attractive business opportunities being prepared
by the ABADE Program and presented to companies wishing to invest in the establishment of
a Cellular Lightweight Concrete (CLC) block manufacturing plant in Afghanistan. Amongst
other advantages, CLC blocks are lighter than traditional CMU, have higher sound insulation
(quieter) and lower water absorption, are more eco-friendly than the alternatives, and can be
produced in various densities and strengths. CLC blocks are have much better thermal
insulation properties and fire ratings. CLC block manufacturing equipment and processes are
also mobile and thus can be easily and quickly set up on-site in remote locations. This typically
decreases manufacturing cost, transport cost, breakage during transit, and construction time
as well as provides opportunity for the utilization of local labor.
This investment guideline was prepared by ABADE based on information derived from the
field as well as from other information on stabilized compressed earth bricks and the economy
of Afghanistan including but not limited to the experience, information and data furnished by
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ABADE’s consultants and project partners. The objective of this document is to give to
prospective investors an indication of the potential and feasibility of such an investment,
considering the overall risk and opportunity factors. Note, this is not a feasibility study in itself
and potential investors are strongly urged to examine specific issues in greater detail as
needed. Also, given Afghanistan’s transitional economy, all figures represented herein must
be validated to ensure they are current and accurate.
Introduction
The following narrative will, hopefully, serve to inform readers of the advantages and
estimated costs of setting up, equipping and tooling a CLC block production plant as well as
the actual production costs in Afghanistan. We have also tried to comment on the profit
potential by looking into the cost of product alternatives and market demand. Note, all values
herein are estimates gathered by the ABADE team and need to be verified by anyone
contemplating an investment in this area. Further work is also needed to quantify and qualify
the market size, addressable market, availability of needed equipment, raw materials, and
labor, and ultimately the feasibility of the investment given Afghanistan’s socio-political
economy.
The objective of this document is to help potential investors determine if establishing a CLC
production facility is a good investment. The document is not comprehensive but will hope
to provide insight into the product, applications, technical specifications, costs, and other
critical information related to the installation, production, operation, and sales of Cellular
Lightweight Concrete (CLC) products.
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Overview
What is it?
Cellular Lightweight Concrete (CLC) is a mixture of Portland cement, sand, water and
preformed foam. The foam used in CLC is a non-chemical, biodegradable liquid emulsion agent
that when pressurized expands to produce a foam similar in appearance to shaving cream.
The small bubbles that comprise the foam are durable and have the stability to tolerate the
mixing process when cements and sands are added to the foam to produce a concrete. The
performed foam, weighing only 3.2 pounds per cubic foot, substitute for the large aggregate
in regular weight concrete significantly reducing the weight of
the concrete product. The small pre-formed bubbles
transform and dissipate during the curing process after the
concrete has achieved a solid state, leaving tiny dispersed air
voids in the concrete matrix. The proportion of foam in the
slurry can be increased to decrease the density of CLC and
increase thermal performance, but will decrease compressive
strength. Preformed foam
CLC in the plastic state is very low in viscosity and can be poured or pumped into forms or
molds. The evenly dispersed micro bubbles in the cement slurry act like tiny ball bearings
allowing the concrete to flow freely and gravity compact without vibrators for consolidation.
The low viscosity of the concrete slurry also allows the slurry to flow into the fine details of
any mold or void. CLC is produced with the same equipment traditional to regular weight
concrete although lightweight concrete requires a much smaller version of the equipment.
Pumping CLC is performed easily with less expensive peristaltic pumping equipment due to
the lubricating effect of the bubbles in the concrete mix and the lightweight properties of CLC.
Applications
CLC is a superior choice as a building material for instances where thermal conductivity
reduction, sound attenuation, lighter loading, longer building lifespan or protection against
seismic events are desired. These realities typify most of the developing world priorities and
physical environments. As such, a strong case can be made that CLC is a superior building
material selection for both single family/low rise as well as high rise residential structures for
Afghanistan. When CLC is used in structural (load bearing) situations, the lighter weight and
reduction in the spanning floor loads imposed by the partition walls ultimately reduces the
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overall dead load of the building. This is an excellent and highly desirable outcome as it
reduces risk and cost.
As we have been told, only one company in Afghanistan is currently producing CLC block. Their
focus is on producing lightweight blocks for infill and interior
partition walls (non-load bearing) in multiple story buildings.
There is a huge market for in-fill applications in Afghanistan
which certainly exceeds the capacity of one small company.
Note, the product being used in Afghanistan today is not of
high quality and cannot be safely using for load bearing
situations.
CLC is highly versatile due to the fact that it can be easily

made in varying densities, strengths, and insulation levels.
As described above, the initial application recommended for
Afghanistan is CLC block as a substitute for CMU and baked
brick. CLC blocks can be manufactured with in similar
shapes to baked bricks or solid CMU with smooth faces. In
this case, while they still have all of the benefits of CLC,
mortaring will be required for each block and each course. CLC
CLC block can also be manufactured in an interlocking
design such that it can be dry stacked and not require mortaring. A third possibility, and the
one recommended for Afghanistan is an interlocking block shape that also incorporates
cylindrical voids in the block design that can later be grouted with traditional mortar and steel
reinforcement. In this case, the grouted voids serve as small and integral load bearing columns
that result in continuous loading as opposed to point loading, found in traditional post and
beam or frame configurations. This also broadens the utility of CLC block by offering the
engineers greater flexibility when determining the buildings reinforcement schedule. It also
results in a stronger, safer, faster, and less expensive structure.
Another common use for CLC which goes beyond the focus of this document is using it to pre-
cast wall panels or other shapes in the factory before transporting to the construction site.
This is a natural derivative of CLC block making and is easily incorporated into any CLC
manufacturing factory.
A further derivative of pre-cast CLC is what is called “cast in place” or “cast in situ”. This is
when forms are put up on the construction site and the CLC is made in the field and pumped
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directly into the forms. This is certainly the fastest and best
use in many applications, especially when the project
requires the contractor to build the same design multiple
times (e.g. a large housing estate). In most cases the re-
useable forms are custom made to meet the architect’s
design, made out of steel, and sold or rented to the
construction company. In both pre-cast and cast in place,
steel reinforcement can be used to achieve the structural
Construction site using CLC
integrity required.
One other common use of CLC which is more geotechnical and also goes beyond the scope of
this document is to fill voids, typically in large civil infrastructure projects and in the mining
industry. Using CLC for slope stabilization when building roads through mountainous areas or
where there are frequent rock slides; bridge abutments where the road needs to be raised to
meet the bridge deck; filling the annulus of tunnels to add strength, stability and prevent
leakages; and filling mine shafts are but a few examples. In Afghanistan, rocks and concrete
seems to be the traditional material used in these situations. Some of the disadvantages of
using traditional concrete are the weight and difficulty in placement (e.g. when it has to be
pumped horizontally for long distances). As proven around the world, CLC works well in these
situations as it is lighter and less viscous allowing it be pumped longer distances. The air
bubbles act like ball bearings improving the flow characteristics. CLC is also used as a transport
medium for sand and other materials as the water requirement is minimal and evaporates
quickly.
Benefits
Lightweight: One of the most significant properties is reduced weight, and with a proper
reinforcement schedule, at no sacrifice in strength. The standard densities required vary
between one third to one half the weight of traditional concrete, depending on application.
For buildings, this significantly reduces the dead load. Weight reduction is a key advantage in
that it impacts cost, improves structural performance, reduces dimensions (or adds to interior
space), and results in a substantial savings of concrete and steel reinforcement in the
foundation. CLC density ranges from 300-1,800 kg/m3.
Lower Cost to Build: While the CLC block is sometimes comparable or even more expensive
than alternative block or brick products, the total cost to completion is measurably less.
Savings in mortar, reinforcement, time and labor as well as other factors typically reduce the
cost of a building by between 5 to 20 percent.
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Speed of Construction: Construction of CLC block buildings are typically 2-3x faster when
compared to traditional concrete block. Using pre-cast and cast-in-place applications, the
result is even faster.
Fire Resistance: The fire rating of CLC is far better than the rating of traditional concrete and
bricks. CLC has a fire rating of 1 hour per inch of thickness or 1 hour per 2.54 cm. A 100mm
wall using 1,000 kg/m3 density offers fire endurance by preventing heat transmission for
almost 4 hours without releasing any toxic fumes.
Thermal Insulation: CLC has a specific thermal conductivity that ranges from .097 to 0.56
W/mK compared to a 2.1 rating in specific thermal conductivity for regular weight concrete
(CMU included). A CMU wall or a regular weight concrete wall or roof would require over 5
times the thickness to equally compete with the thermal performance of CLC. The same ratio
applies to baked brick.
Sound Mitigation: As above, sound transmission is 5-7X less than traditional concrete and
bricks due to the air pockets inside the CLC.
Easy to Handle and Install: CLC can be cut with a handsaw, drilled and screwed into like wood
without causing any damage to the concrete substrate. This decreases construction cost by
dramatically increasing wall construction speed and reducing delays.
Finishing: Interlocking CLC block as is recommended herein quickly and easily stacks vertical,
plumb, even and tight. Thus, only a skim coat is required as opposed to the heavy plastering
usually required by CMU and baked bricks to finish a wall, especially interior. This saves a
significant amount of time and materials.
Lower Transport Costs: CLC can be easily produced at the project site, virtually eliminating
transport time and costs as well as improving control of the supply chain. When products are
made in a central factory, costs are still reduced due to the lower weight. For example,
comparable dimensions of CLC will weigh half that of traditional concrete block, reducing
transport cost in a fully loaded truck by half, and carrying twice as much volume of blocks.
Eco-friendly: The foam agent used in CLC is protein based and releases no harmful effluents
or VOCs to the environment.
Portability: A CLC production unit can easily be moved and set up on-site. This saves
significant cost, adds control, and reduces risk.
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Fly Ash Recycling: Although beyond the scope of this report, fly ash (depending on the quality)
is well known as a desirable and often used component of CLC. The main benefit here is
disposing a pollutant which has no other value. At the same time, it adds to the strength of
the product and reduces the cost as it replaces some of the cement. While most of
Afghanistan’s power comes from hydro and imported power from its neighbors, it is reported
to have coal reserves totaling 100-400 million tons. These mines are located from Badakhshan
and extend up to Herat Province. Afghanistan has more than 11 coal reserves and at least 9
provinces with coal fired power plants. Thus, CLC has the potential to recycle this waste
product as part of an energy saving building material.
Alternatives/Substitutes
Non-Structural: The main alternatives to CLC block in Afghanistan is concrete block, also called
concrete masonry units or “CMU” and baked brick. In Afghanistan, CMU is typically
manufactured locally in a wide variety of small, owner operated facilities. Quality can vary
greatly. Typically, builders survey the area around the job site and select a block manufacturer
to supply them with product of sufficient quality at a competitive price. Block sizes vary in
Afghanistan but in the main CMU comes in the following standard sizes:
Hollow CMU
20cm x 20cm x 40cm (8” x8” x 16”)
10cm x 20cm x 40cm (6” x 8” x 16”)
Solid CMU
20cm x 20cm x 30cm (8” x 8” x 12”)
The cost of CMU can vary greatly depending on quality and volume purchased. The average
cost of acceptable quality hollow CMU delivered on site for the above is estimated at 40
Afghanis ($0.62). The most common use of CMU is for infill in standard post and beam
buildings. In other words, wall assemblies that are not structural as the weight of the building
is carried by the pillars/columns and floor decks. The average weight of CLC for this application
is 1/3 the weight of standard concrete.
Another product commonly used in Afghanistan is baked brick. Baked bricks are also often
used for infill as above. The other most common use of bricks in vertical infrastructure is for
internal or partition walls. Bricks are manufactured in over 1,200 brick factories scattered
across the country. Most use the traditional BTK or FCK technologies which are known for
their high CO and dust (PM2.5) emissions. In many countries, these technologies are now
illegal due to their contribution to pollution. The standard size red brick in Afghanistan is 22
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x 11 x 7cm (8.7” x 4.35” x 2.75”). When using as external wall infill, the wall thickness is
typically 1.5 bricks or 33cm thick. For non-load bearing interior or partition walls, the wall is
usually 1 brick thick but laid along its length. Thus, the wall thickness is 22cm.
Brick prices, volume, and quality vary but on average the cost of a standard red brick is 2,900
Afghanis per 1,000 bricks or 2.9 Afghanis ($0.045) per brick. Like CMU, baked bricks are also
sometimes used for low-rise structural applications at a 1.5 brick or 33cm thickness.
Structural: Most building in Afghanistan, along with the rest of the world, uses what is called
a “post and beam” or frame structural system which is a skeletal framework of decking slabs,
beams, and posts (e.g. columns) supported on a foundation. In this configuration, steel
reinforced concrete columns are linked by lintels beams, and slabs/decks to carry the
building’s load. The remaining wall space, as described above, utilizes non-structural products
for what is called the “non-load bearing wall” or more commonly “in-fill”. In most situations
in Afghanistan, CMU blocks or baked bricks are used for infill purposes.
In Afghanistan the posts and beam frames are formed as steel reinforced concrete columns
and floor decks. These frame structures comprise a significant portion of the cost of the
building as these components require forms to be built and large amounts of concrete, steel
rebar, engineering, and labor. When cellular lightweight concrete is used for structural
applications, the need for steel reinforced columns (e.g. a frame structure) is eliminated.
Market Overview
Globally, the demand for cement based products is up because the natural resources required
to produce concrete are nearly universal in their presence and availability. Material scientists,
chemical engineers and others have entered this field (once the sole domain of civil engineers)
in an effort to improve material performance and expand the reach and usefulness of concrete
products. CLC is only one of many successes in broadening the field of use for concrete
products.
CLC has been on the global market for over 25 years. Reasons for optimism in Afghanistan
include but are not limited to its low cost of entry, simple manufacturing process, relatively
higher use of unskilled labor, application versatility, and proven track record. Some people
are more familiar with Autoclaved Aerated Concrete or AAC. AAC is also a very good product
but costs millions, as opposed to thousands, of dollars to construct and operate a production
facility. CLC is a very good substitute for AAC and can be produced with a small capital outlay
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by comparison because of the fact that the CLC is produced in the ambient atmosphere
without pressurized autoclaves and expensive sawing equipment.
Most recognize the peak of construction took place in 2012-2013 when the international
community, led by the US Army Corps of Engineers (USACE) was in full force. At this point,
there were hundreds of millions of dollars of projects being tendered to meet a variety of
military and civilian needs. During this period, the majority of the work was awarded to
foreign companies. Similarly, the majority of the materials used were imported from Pakistan,
Russia, Turkey, the UAE and other countries. However, some of the less sophisticated
requirements did trickle down to Afghan construction companies and construction materials
manufacturers. Most importantly, this served as a wake-up call for the public and private
sectors illustrating the unprecedented opportunity Afghanistan has in developing these
sectors and reducing imports.
Accurate and current data and information is extremely hard to obtain in Afghanistan but from
numerous focus groups, private interviews, and studies performed by the international
community, we purport that the construction sector has hit bottom and is poised to expand,
led by both internationally funded and Afghanistan initiated projects. For example, the US
Army Corps of Engineers (USACE) has announced $700M of infrastructure investment over
the coming 2 years. The Asian Development Bank has pledged $1.2 billion and the multi-donor
funded Afghanistan Reconstruction Trust Fund (ARTF), managed by the World Bank, is also
promising $300 million.
In this cycle, we anticipate a measurable increase in the use of Afghan construction companies
and Afghan manufactured building materials. The Ministry of Commerce and Industry’s
(MOCI) “Construction Materials Action Plan” (CMAP) articulated several critical
recommendations to make this a reality. A Working Group has been established to address
these recommendations, with one of the most urgent being the need to improve the quality
and portfolio of Afghan manufactured construction materials on the market.
In terms of CLC, we project the demand for urban and rural vertical construction to steadily
increase over the next 5 years. Projects like Kabul New City, the Ministry of Urban
Development’s efforts to build new cities in 10-15 provinces (with an emphasis on affordable
housing for police and other public servants), the new ring road, a couple of new airports, and
the eventual transition of Bagram Airfield into a new international airport all offer tremendous
opportunity to test and adopt better material solutions like cellular lightweight concrete.
In terms of void filling, we are seeing an increasing focus domestically and internationally on
building needed economic infrastructure in Afghanistan. Again, projects like Kabul New City,
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the Kabul ring road, planned airports, affordable housing for police and other public sector
workers, and USACE’s efforts to renovate military bases and water treatment plants all
provide further opportunity. However, most large infrastructure is funded by the government
and at this stage, the budget is not sufficient for building new infrastructure. The current
focus, where possible, is on rehabilitating existing infrastructure which could limit the use of
CLC for void fill. Finally, more research is required to determine precisely what technologies
and materials are currently in practice for void filling. One area of particular need and
potential is Afghanistan’s road network. Many roads in mountainous regions traverse rock
slide slopes where the large rocks used as road beds eventually compress and shift from the
weight of trucks and vehicles, thus destroying the road surface. CLC has been used
successfully to void fill the voids in the loose rock and preserve roads and extend their
longevity.
Market Entry Costs

Capital Expenditures: The investment required to establish a CLC block factory is low
compared to most other high tech alternatives. In the main, all that is needed is a foam
generator, an air compressor, a cement mixer, and moulds. The requirements in terms of
factory space, fuel, electricity, water and other utilities are similarly modest. This bodes well
not only for market entry but also for breaking even and obtaining an attractive return on
investment.
In this scenario, we are assuming the investor in Afghanistan starts with producing CLC block
with a plant capacity of only 2,000 blocks per day. It is highly recommended to produce
interlocking blocks as these cost no more but carry additional advantages in terms of overall
cost savings and reducing construction time. Below is a list of the primary and auxiliary pieces
of equipment required for different plant capacities.
CLC foam generator: Several companies worldwide make CLC foam generators. In almost all
cases, the companies who make the foam generator also make the foam agent (e.g. the raw
material used to make CLC foam). The foam formulation is customized to the machinery and
vice versa so clients almost always buy these as a pair. Herein it is of critical importance to
evaluate the quality of the foam as well as the foam generator. In some cases, one is much
better than the other. In other cases, both are highly suspect and of poor quality. Our
research has identified only a few companies which have documented quality, experience and
technical support for both their foam and foam generators.
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Foam generators come in various shapes, sizes, and production technologies, ranging from
small batch sizes to full size truck mounted continuous pouring. It is important to determine
the anticipated scale of the operation before determining the generator size. Fortunately, CLC
production is easily scalable by adding additional moulds, and if needed another machine.
CLC is mixed and pumped by various types and sizes of equipment depending on daily demand
for the material as follows:
1. Small plant production requirements for up to 50 cubic meters per 6 hour pouring day.
This equates to over 3,000 blocks per day at a size of 20cm x 20cm x 40cm. 3000 blocks
per day is 48 cubic meters.
a. Small concrete mixer – 0.5 to 1.0 m3 (0.65 to 1.3 cy) capacity
b. Small foam generator – 115 liter (30 gallon) tank style
c. Small peristaltic pump (squeeze pump) if pumping is required.
d. Small air compressor capable of 0.42 m3/min (15 cfm) at 80 psi.
2. Larger plant production requirements for 200+ cubic meters per day (over 12,500
blocks per day):
a. Larger unit mixer-foamer-pump machine or equivalent
b. Supporting gen-set or compressor if required
3. On-site transit ready mix truck method for large/continuous pours:
a. Foam generator mid-sized
b. Foam generator should be purchased from foam agent supplier for warranty
purposes and quality control.
c. Gen-set and compressors as required.
d. Note: In this method the transit, mixed mortar (sand, cement and water)
arrives on site and the foam generator hose end is placed manually in the
discharge end of the mixer truck. The foam is dispensed into the mortar while
the mixing drum is revolving. The foam is easily mixed into the pre-mixed
mortar to create CLC. Although this method sounds crude, it is actually very
effective – the foam bubbles are quickly ‘folded’ into the mixture to prevent
coalescence and rupture.
e. The CLC is dispensed by either a back chute straight into the forms or a
peristaltic pump with a small diameter discharge hose 5-8 cm (2” or 3”).
4. In line mixing devices require mitigating the effects of sharp sand ruptures
a. These devices are typically installed between the concrete pump and the
location designated for CLC placement. These devices are approximately 1
meter in length and look like a large truck muffler. Mixed cement, water and
sand are pumped through a hose into the in-line mixing device where foam is
injected and mixed into the mortar to produce CLC. This all takes place within
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the length of the mixing device. The mixture of CLC continues its migration to
the final discharge end of the hose under the originating pump pressure.
b. This method requires the following: a concrete mixing device (or a ready mix
truck), a traditional concrete pump, a foam generator, and an in-line mixing
device. The foam generator may require a gen-set.
c. While this method may sound less than sophisticated, it is effective. The one
meter distance traveled through the in-line mixer leaves little opportunity for
the foam bubbles to rupture when introduced to sharp sand. As mentioned
above, where possible, river sand, which has rounder edges so as to not
puncture the air bubbles in the foam, is preferred.
These methods are traditional using common tools and are not to be feared or viewed as
sophisticated by any measure. Laborers familiar with mixing and pumping concrete learn
these practices quickly and soon begin to appreciate the CLC material due to the smaller hoses
and easier handling of the concrete materials being produced.
For a 2,000 block per day plant, we recommend a 115 liter

(30 gallon) foam generator which will comfortably produce
8.4 m3/hour (300 ft3/hour) of foam. However, taking into
consideration the time it takes to re-fill the foam generator
with each batch being 2.2 m3 (78 ft3) and each batch
requiring 15 minutes to process, one can conservatively
estimate the average production rate to be closer to 5.38
m3/hour (190 ft3/hour). Assuming a block dimension of 20
Foam Generator
x 20 x 40 cm (8” x 8” x 16”), the total volume of material
needed to produce one block, accounting for the void space from the vertical cylinders, is
13,600 cm3 (0.48 ft3). Assuming a typical CLC density of 801 kg/m3 (50 lbs/ft3), which is one-
third the weight of traditional concrete, this results in a per block foam requirement of 0.0089
m3 (0.3170 ft3). At a rate of 5.38 m3/hour, including the time required to reload the foam
generator, we estimate the foam generator production capability to be approximately 600
CLC blocks per hour or 3,600 CLC blocks per 6-hour shift. This is clearly far more production
than is required for a 2,000 block per day pant. However, as the foam generator is not an
expensive piece of equipment, purchasing a 30-gallon unit is cost effective and still leaves
room for anticipated growth in the future.
The production capacity limits of this method are clearly related to the time it takes to empty
the mixer, fill the moulds, and recharge the mixer with the cement/sand slurry, rather than
the time it takes to recharge the foam generator. Thus, when great volumes are needed,
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additional mixers, a large mixer, and/or a more efficient pre-mix methodology (e.g. hopper
based conveyor belts to a larger mix station and a concrete pump) can be added.
Air Compressor: The air compressor is used to produce the air infiltrated CLC foam agent.
Using a 30-gallon foam generator, the minimum air pressure required is 80 psi. While a screw
type air compressor is preferred, any good quality tank compressor will do. In some
circumstance, especially if growth is anticipated, purchasing a 125 psi compressor is advised
as this will be sufficient to run up to a 200-gallon foam generator. Another consideration
when purchasing any equipment is the ability to obtain technical support and service; a
particularly challenging issue when purchasing foreign made equipment that is being shipped
to and for use in Afghanistan.
Cement Mixer: A good quality cement mixer is required to first mix

the cement, sand and water slurry and then later the foam as it is
added in. In this case, there are even more alternatives available.
Many companies around the world manufacture cement mixers,
which come in a wide variety of shapes, sizes, and mix technologies
(e.g. rotary, paddle wheel, pug mill, etc.). A rotary or drum type
mixer is recommended herein to account for the difference in
density between the foam and the cement/sand slurry. The vertical Cement mixer
drop will help fold in the foam and mix it without causing damage to
the air bubble matrix structure. A center paddle type mixer which creates a vortex is not
recommended. The size and shape of the mixer will depend on the plant’s capacity and
pouring methodology. For example, in the small plant scenario described above,
wheelbarrows and buckets can be used to move the CLC mix from the mixer into the moulds.
In larger volume operations, cement pumps and hoses are used. In cast in place and large civil
infrastructure projects, a continuous feed, as opposed to batch plant, operation is required.
In this case, it is common to have the entire plant, including foam generator, air compressor,
and mixer, built on to a truck body as a mobile turnkey operation.
For a 2,000 block per day plant, a 0.5 m3 (18 ft3) capacity mixer is recommended. See inset. It
is important to be sure the buckets used can easily and completely remove the mix from the
mixer to minimize waste. In cases where the CLC mix will be pumped from the mixer to the
block moulds (or any other forms which may be used), a larger capacity mixer with a valve or
coupling to install a cement pump will be required.
Moulds: As described above, moulds can be fabricated in a wide variety of sizes and shapes.
The most common CLC blocks are flat surfaced block ranging from 10cm to 80cm in length,
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width, and height. Given the most frequent use in the beginning is to replace CMU for in-fill
purposes, they are often made to match the sizes of the standard CMUs used in that particular
location.
Manufacturing options for flat faced (non-interlocking)

block include pouring each block individually; pouring
several at a time in what is called a comb mold (see inset),
or pouring a larger cube of CLC and then cutting it vertically
and horizontally with a hot wire machine or band saw into
the correct block sizes. Each option comes with different
cost implications with the most expensive being a large scale
CLC Moulds
continuous production block facility which automatically
takes the solid CLC block through a series of steps resulting in palletized blocks ready to ship.
The fastest growing sector of the CLC block market today is

interlocking blocks that can be dry-stacked with no mortar
required between courses. Herein the producer buys
individual mould sets and pours sets of blocks without the
need for any post pour cutting. These often come in mould
sets of between 6-10 blocks such that they are easily
movable by hand without machinery. The moulds comprise
“head forms” giving the top and bottom pattern to the blocks
Interlocking CLC Moulds
and “gang forms” which address the remaining three sides to
the block. The last surface is left open and is made smooth
by manually striking the block with a smooth surface prior to curing. The picture here shows
interlocking moulds which also have the cylindrical voids to be used for added strength and
reinforcement where necessary. In all cases, moulds have to always be kept clean,
maintained, and stored safely. In some cases, a mould release agent will be required to assist
in the de-moulding process.
There are a limited number of mould manufacturers specializing in CLC. Smooth surface block
moulds are certainly easier to find, or fabricate yourself. The interlocking block moulds, with
cylindrical voids for structural use, are only made by a few companies. One of those, LiteBuilt
from Australia, requires the purchaser to sign up and buy the complete package – agent,
moulds, training, etc. CLC Global (CLCG), from the United States, has the most advanced
design, greatest body of test results, and appears to be the leader in this subsector of the CLC
industry.
17
Raw Materials: Most of the raw material required to make CLC are readily available in
Afghanistan. In fact, the only material not available is the foam agent, which typically comes
in liquid form in either 19 liter (5 gallon) pails or 205 liter (55 gallon) drums. The 4 raw
materials required to make CLC are as follows:
Foam Agent: Foam agent in liquid form turns to a white foam (e.g. akin to shaving cream)
after being mixed with water and put through the foam
generator. There is a wide range in quality of foam agents on
the market so exercise caution in your selection. Always
obtain testing data from the manufacturer to be sure it will
adequately serve your requirements. When using for the first
time, the CLC and product to be produced should be tested in
situ to fully understand its performance properties and failure
limits. The standard for foam quality is under ASTM C869; White foam
ASTM C796 provides guidance in how to make CLC foam; and
ASTM C495 provides the protocols in how to test it. The key factor in terms of foam quality is
the size, strength, and uniform dispersion of the air bubbles. Another important characteristic
is the eco-friendliness of the foam. There are again a variety of both protein-based and
synthetic foams on the market and one must be sure they are selecting the right type(s) of
foam for their application(s). Finally, when selecting a foam agent, one must look at the costs
including shipping and clearing as well as yield and strength characteristics. For vertical
infrastructure, protein based foam agents are recommended. For specialty applications,
including void filling for mountain road stabilization of large underground infrastructure,
synthetic foams are more commonly used.
Cement: High quality Portland Type 1 cement should be used. This is typically available in all
markets. In some cases, type II or even III can be sued. For example, in colder conditions
where a faster cure time is required. The selection of cement should be determined in the
same manner as when making traditional concrete.
Sand: Clean and soft (e.g. river) sand should be used. Sharp, crushed or cut sand from
aggregates can damage the internal air bubble structure of the CLC. The sand should also be
clean of debris, organics, and other impurities. In some cases, this requires washing before
use. Follow ASTM C33 standard for guidelines for “fine aggregates”.
Water: The water should be as clean as possible. The risk here is in the reaction with the
cement, not the foam. Thus, the water should be as free from debris, metals, organics, salt,
and other impurities as possible. Potable water is the safest to use. It is suggested that the
18
water be tested before use to be sure it is compatible with the cement being used in
accordance with ASTM AC 531.
Other Additives: In certain applications, other elements such as fibers can be added to
improve the strength or other performance criteria of the CLC. At this juncture, we do not
envisage the need in the Afghanistan market.
The first purchase order of raw materials depends on the company’s pipeline of projects. If a
large contract is likely or has been awarded, they must buy a sufficient volume of materials to
complete the project. Hence, this is a decision that must be based on the market realities and
projections of the company’s leadership.
Below, we have assumed year 1 sales to comprise of 70% non-structural CLC blocks to be used
for infill and partition walls and 30% for the structural use in constructing single family
detached low rise houses. We have also assumed that sales will require ~13,440 m 2 of infill
and partition walls (168,000 CLC blocks) and 36 x 90 m2 houses, each requiring ~160 m2 or
2,000 CLC blocks. The 36 houses will therefore require approximately 72,000 CLC blocks. This
results in year 1 production requirement of 240,000 CLC blocks or approximately 1,000 per
day (less than 50% of the capacity of a 2,000 CLC block per day factory).
While not represented herein, it is logical to assume that additional applications will be
introduced in subsequent years. For example, the company might start supplying pre-cast
components in addition to blocks in year 2 and do a small road stabilization or void fill job for
a civil engineering project. Year 3 could include a few cast in place projects in addition to the
others and a large void fill supply contract. And so on.
Table 1. Estimated Raw Materials Required for Year 1
Raw Material Required Quantity Unit Cost ($) Cost (US$) Cost (Afs)
Foam Agent (gallons) 760 78* 59,280 3,823,500
Cement (50 kg bags) 23,000 5.3 121,900 7,862,500
Sand (m3) 945 8.5 8,032 518,000
Water (liters) 456,400 -0- -0- -0-
*Including $3/gallon for handling and shipping
Factory-related Items: Initially, there is very little required other than a factory space to stage
raw materials, produce CLC, and store the inventory. However, as the company begins to
trade and become profitable, there are other items that will be needed.
19
Factory Space: When first starting off, it is recommended to install the plant in a space of
between 250 - 500m2, depending on the raw material and finished good inventory
requirements. The main need is floor space to place the machinery, fill the moulds, de-mould
and cure the finished blocks, and then palletize, wrap, label and store the inventory. In
addition, there should be secure interior space to store and lock-up the raw materials, hand
tools and other sundry items, and have an office for the plant manager and plant engineer.
Other items that should be part of the company’s operating equipment include the following:
 Company 4x4 or pick-up truck

 Fork Lift
 Strapping machine to strap blocks to pallets for transport
 Tarps to cover freshly made blocks for curing
 Concrete blankets in cold weather to aid concrete curing
 Pallets
 Compression tester
 A digital scale
 A clean and stable source of electricity
 Access to clean, potable water
 Sundry items (hand tools, buckets, brooms, gloves, water hose, etc.)
Labor: To run the plant at a capacity of 2,000 blocks per day requires approximately 8 staff
excluding senior management and front office personnel (management, sales, marketing,
finance, etc.). More specifically, a small plant as described above would require the following:
Plant Manager/Supervisor: This person would be responsible for running the plant, including
but not limited to overseeing CLC production, mould filling and equipment maintenance,
inventory, ordering raw materials, and ultimately manufacturing and preparing the block for
sale.
Factory Labor: In addition, a compliment of 7 unskilled laborers are needed to complete such
tasks as loading, emptying, and cleaning the cement mixer, filling the block moulds, de-
moulding the blocks from the moulds once set, stacking, curing, and packaging the blocks for
sale, and so on.
20
Competitiveness
In many cases, depending on the size of the block, the cost of the raw materials and labor
locally, and other factors, the cost of CLC block can be less than or more expensive than CMU
or other alternatives. The key point to understand is it is NOT the price differential between
CLC block and CMU (or bricks) that makes CLC economical but rather the resultant decrease
in total building cost. As stated above, the many benefits of CLC combine to offer a less
expensive, faster build, better insulated, stronger and safer structure.
Using an example of a 90m2 house (see Annex 1 for the floor plan drawing), we have
conducted materials and labor comparative analyses between CLC blocks and CMU as well as
baked brick. Both non-structural (infill) and structural (replacing steel reinforced concrete
columns) comparisons were made. As shown below, the cost of using CLC in Afghanistan
works out to be between 5-20% less expensive than the commonly used alternatives. This
also excludes the non-financial benefits of SCEB such as stronger, more insulated, faster and
easier to build, more interior floor space, safer in seismic conditions, and environmentally
friendly to mention a few. For more information, see Annex 2 for comparative pricing.
Table 2: Comparisons of CLC with CMU and Baked Brick Walls for both non-structural (in-fill, partition) and structural wall applications
Total Cost CLC Ratio %
(Afs) with others difference Comments
Non-Structural Use for Walls (e.g. columns take the weight)
1 CLC infill with steel reinforced concrete columns 196,123 (including interior partition walls)
2 CMU infill with steel reinforced concrete columns 207,002 0.95 5.3 CLC is 5.3% less expensive than CMU
3 Baked Brick infill with steel reinforced concrete columns 210,346 0.93 6.8 CLC is 6.8% less expensive than Baked Brick
Structural Application for Walls
4 CLC without columns 156,041

5 CMU (filled and reinforced) without columns 188,802 0.83 17.4 CLC is 17.4% less expensive than CMU
6 Baked Brick without columns (1.5 brick thickness) 169,131 0.92 7.7 CLC is 7.7% less expensive than Baked Brick
21
CLC Manufacturing Process
High quality CLC can be produced easily if given good quality ingredients including foam agent,
sand, water, and cement. By design, CLC is intentionally made in differing densities depending
on the application. The lighter the density, the more insulating but lower the compressive
strength. The heavier the density, the more compressive strength but lower insulating
properties. For example, CLC at a 769 kg/m3 density will yield approximately 34 kg/cm2 (480
psi) in compressive strength while CLC at a 1,682 kg/m3 (105 lbs/ft3) density yields
approximately 105 kg/cm2 (1,500 psi) in compressive strength.
The dry ingredients of cement and sand, and sometimes fly ash if available, are fed into the
mixer first and thoroughly mixed to ensure even distribution of cement. The appropriate
amount of water is added and the mixing is continued to form a mortar slurry. The pre-formed
foam, produced by the foam generator and calibrated for a specific discharge rate, is then
added in a measured amount into the mortar slurry in the mixer. In just a few minutes, the
cellular lightweight concrete (CLC) product mix is complete and ready to be transferred to the
assembled block moulds. The dimensions of the blocks vary depending on market demand.
The moulds, whatever their size and shape, should be clean and dry. The CLC is not viscous
and flows freely and easily into all the corners and recesses due to the ball bearing effect from
the foam air bubbles. No additional compaction or vibration is required.
Note, properly made traditional concrete typically requires mechanical compaction and/or
vibration. This is a major expense and as such, is often skipped. Studies have proven this to
be a major contributor to failure, resulting in death and destruction in seismic events. Haiti is
a classic example. Improperly made CMUs with non-crushed, non-angular river sand and no
vibration (e.g. “roadside CMU”) is dangerous and will become a major contributor to death
and building collapse or destruction during earthquakes. Naturally occurring river sand is both
recommended for CLC and less expensive than crushed sand. As mentioned above, there is
no need for vibration or compaction. The CLC block-making processes is very robust. CLC
blocks will be uniform and in structural situations, server as insulated forms for the grout
column and rebar reinforcement.
Once poured, the blocks are then left to cure for approximately 10 to18 hours. During this
time, the pipes used to make the cylindrical voids are turned and removed at certain times.
After the blocks are de-moulded, typically the following day, they are stacked and cured for
another 7 days by simply watering them 1 to 2 times per day depending on the ambient
22
humidity level. This helps the cement cure properly. After this they are ready to be palletized,
wrapped, sold and used, although the cement will continue to cure for another 21 days,
gradually increasing the strength of the block.
Quality Control
Quality control is achieved by taking care in the foam production and mixing processes. For
example, the foam being recommended herein, purchased from CLC Global, needs to be 51.26
kg/m3 (3.2 lbs/ft3). This will produce the proper strength bubble structure. The other key step
is mixing the determined volume of foam with a consistent volume of mortar. If these two
steps are performed correctly, uniform and high quality CLC with be produced every time.
Some manufacturers offer varying levels of automation in the production of CLC. RBM in
Malaysia, with a small representative office in Afghanistan, for example, offers a complete
solid state unit with numerous self-regulating features. While convenient, it is also very
expensive given the fact that the actual process of making CLC is simple and straight forward.
Note, no manufacturer will ever guarantee the quality or consistency of materials mixed by
others. Ambient temperature and raw material temperature can affect the curing time and
to some extent quality of final CLC. Potential investors or purchasers of a CLC plant should
insist that training in preparing the mortar mix, operating the foam generator, and then
managing the final CLC mixing be provided by the equipment manufacturer or provider.
The most important variable in terms of performance is the quality of the foam agent. High
performance CLC requires clean water, smooth sand properly graded, quality cement and
quality foam agent. The foam bubble must exhibit stability, uniform size and the toughness
to tolerate the abuses of the mixing process. In addition, the bubbles must disperse uniformly
throughout the mortar mix, and with proper high-quality foam agent, the bubble size will
remain uniform and bubbles will not coalesce. As of today, most CLC foam agent and foam
produced worldwide is intended for non-structural void fill purposes, so will be inadequate
for quality vertical construction. Thus, the purchaser must ensure the foam agent and
resultant mix densities, as per the recommendations herein, will satisfy all structural
requirements.
23
Technical Specifications
Materials
Foam agent concentrate should comply with the standard specifications of ASTM C 869 when
tested in accordance with ASTM C 796.
Portland cement should comply with ASTM C 150, Type I, II, or III.
Sand needs to be saturated surface-dry (SSD), and needs to be washed and clean.
Mixing water should be free from deleterious amounts of acids, alkali, salts, oils, and organic
materials that would adversely affect. Potable water would be ideal but if not available, water
testing, including pH, should be conducted and the product tested before sale.
Execution
The mix design and all other works including batching, mixing, and placing of CLC of the
appropriate type should be as indicated on the plans or as directed by the engineer.
Examine the areas and conditions under which work will be performed. Correct conditions
that may be detrimental to timely and proper completion of the work. Do not proceed until
satisfactory conditions are established.
Quality Assurance
Use skilled labor that is thoroughly trained, experienced, and familiar with the specified
requirements and the methods for proper performance of this work.
Use only the approved job site proportioning, mixing, and placing equipment that is in good
working order.
Mix the materials according to the mix design and promptly convey to the location of final
placement before the CLC begins to dry and cure.
Avoid excess handling of the CLC.
The location area should not have any standing water in it prior to placement of CLC.
24
Weather Conditions
Avoid freezing temperatures before the initial set of CLC.
Do not place CLC at temperatures lower than 0 degrees centigrade (32 degrees Fahrenheit) or
when freezing conditions are expected in less than 24 hours.
Strength/density
CLASSIFICATION OF CLC BLOCKS:

GRADE-A: These are used as load bearing units and have a block density in the range of
1200kg/m3 to 1800kg/m3.
GRADE-B: These are used as non-load bearing units and have a block density in the range of
800kg/m3 to 1000kg/m3.
GRADE-C: These are used for providing thermal insulation and have block density in the range
of 400kg/m3 to 600kg/ m3.
Therefore, CLC can be produced in a density range of 400kg/m3 to 1800kg/m3. As discussed

earlier, with CLC, the density/strength attribute is controlled by simple calculation of the ratio
of CLC foam to the mortar slurry. See Table 3 below for more detail.
Table 3. CLC Strength/Density Table (Sand/Cement Grout Mixes)

Avg. Compressive
Cast Density Strength (28 days) Cement Sand Water Foam Volume
lbs/ft3 kg/m3 psi Mpa lbs/yd3 kg/m3 lbs/yd3 kg/m3 gallons liters ft3/yd3 m3/m3
90 1441 400 2.76 512 304 1640 973 32.8 151.9 10.1 0.37
95 1521 750 5.17 542 322 1730 1026 34.6 160.8 9.1 0.34
100 1601 1000 6.19 570 338 1815 1077 36.5 169.1 8.2 0.30
105 1681 1500 10.34 600 356 1915 1136 38.3 178.0 7.3 0.27
110 1761 2000 13.79 630 374 2010 1192 40.2 186.9 6.4 0.24
115 1841 2500 17.24 658 390 2100 1246 42.0 195.2 5.4 0.20
120 1921 3000 20.69 688 408 2190 1299 43.8 204.1 4.5 0.17
125 2002 3500 24.14 714 424 2280 1352 45.7 211.8 3.5 0.13
25
*Reference: National Bureau of Standards Data from “Insulating Concretes”- ACI Journal
The above chart illustrates the various typical properties of weight/density and compressive
strength values attainable with various volumes of pre-formed foam additions to
sand/cement mixes. The material weights and measures used above are for one cubic yard or
one cubic meter of cellular concrete. Multiply these amounts by the number of cubic yards
or cubic meters you wish to batch for your project.
The compressive strengths shown above are approximate. As with traditional concrete, the
strength at any given density and mix proportion will also vary with the type of cement and
the final water content of the mix. Substantial increases in strength will result by reduction of
the w/c ratio, such as is possible with efficient mixing equipment and by curing in low-pressure
steam. Other admixtures such as foam compatible dispersing agents and water reducing
agents may also contribute to strength increases. Actual properties will depend on cement
used, curing conditions and other variables as dictated by job site conditions.
Environmental
Cellular Lightweight Concrete (CLC) blocks can be used as an alternative to the CMU and baked
bricks, to reduce environmental pollution and global warming. CLC blocks are environmentally
friendly. The energy consumed in the production of CLC blocks is only a fraction compared to
the production of baked bricks and emits no pollutants and creates no toxic products or by
products. In scenarios where waste fly ash is also added to the CLC cement slurry, further
recycling and environmental advantages can be realized.
Bricks remain one of the most important and traditional building materials in Afghanistan.
Usually confined to the rural areas, over 1,000 brick kiln factories exist across the country. In
recent years, with expanding urbanization and increasing demand for construction materials,
brick kilns have grown to meet the demand. In so doing, it has directly and indirectly caused
a series of environmental and health problems.
The baked brick production industry is a well-recognized and documented source of

deforestation and air pollution in developing countries. The process of manufacturing clay
bricks requires high energy to heat and burn, resulting in significant greenhouse (CO 2)
emissions. At a local level (in the vicinity of a brick kiln), environmental pollution from brick-
making operations is injurious to human health, animals and plant life. At a global level,
26
environmental pollution from brick-making operations contributes to the phenomena of
global warming and climate change. Also, extreme weather may cause degradation of the
brick surface due to frost damage.
Frequently Asked Questions (FAQs):

Can cellular lightweight concrete be under mixed?
The cement and water slurry should be mixed until there are no dry clumps or balls of cement.
The pre-formed foam mixture is then added into the mixture. The foam mixes quite rapidly
into the slurry and only requires modest mixing times depending upon the mixing equipment.
Can cellular lightweight concrete be over mixed?
Mixing until there is a reduction of volume of product is not recommended. Air cell stability is
a mark of all high quality engineered liquid foam concentrates and foam generators. With
typical mixing procedures, CLC formulated with high quality pre-formed foam is very stable,
even with modestly extended mixing times.
How far can cellular lightweight concrete be pumped?
CLC is a highly fluid and non-viscous mixture that can be easily pumped. The bulk of CLC
produced in the world is placed by pumping. CLC will typically move easily through the pump
lines requiring less pressure than typical heavier grout mixes. Documentation of CLC being
pumped up to and exceeding 150 m (500 ft.) vertically and 3,000 m (10,000 ft.) horizontally is
available.
How do you finish cellular lightweight concrete?
For vertical construction, plaster is typically used but due to the smoother surface of CLC, the
plaster or finishing coating materials requirement is greatly reduced. Interlocking CLC block
as is recommended herein naturally stacks vertical, plumb, even and tight. Thus, only a skim
coat is required as opposed to the heavy plastering usually required by CMU and baked bricks
to finish a wall, especially interior. This saves a significant amount of time and materials.
How is cellular lightweight concrete tested?
Cellular lightweight concrete follows ASTM test methods that apply to lightweight insulating
concrete. ASTM C 495 is the standard method for testing compressive strength, and ASTM C
796 is the standard testing method for foaming agents used in the production of CLC using
27
pre-formed foam. In many cases, the final product (e.g. the CLC blocks) are tested locally to
ensure they meet the local building codes.
How does cellular lightweight concrete compare in price to traditional concrete?
A typical cellular lightweight concrete project will be less expensive than traditional concrete
or brick applications when considering the total cost to complete the project. This is due to
labor savings, less time required to build, much less mortar, and less material cost considering
interlocking CLC blocks and/or CLC structural blocks replace the traditional post and beam
point loading scenario. In addition to two 5 cm cylindrical voids per block for further
reinforcement in load bearing applications, CLC Global’s “FastBlocks” have a fillable cylindrical
void in the block’s vertical head joints where they butt up against the adjacent blocks. This
provides a way to further stop air infiltration and adds to the fire rating of the wall assembly.
Operational costs, as opposed to construction cost, are also reduced due to improved thermal
efficiency. In other words, inhabitants of CLC constructed buildings pay less for cooling and
heating as well as live in a more comfortable, healthy, and environmentally efficient
environment with more stable temperatures and humidity.
- Summary: Why Invest in Cellular Lightweight Concrete?
For CLC block manufacturers, there are numerous cost and performance benefits to be
obtained from using CLC blocks instead of traditional CMU and/or baked brick. Some are listed
below:
 Low initial capital investment.
 Huge opportunity due to market demand and product competitiveness.
 Easily scalable.
 Quick returns and highly profitable.
 First mover advantage in Afghanistan. Limited competition; opportunity to become
the market leader in a transitioning economy.
 Portable equipment for on-site production in remote locations.
 Eco-friendly green product.
 Easy manufacturing process with minimal manpower; low requirement for costly and
hard to find skilled labor.
 Small area required to start up a pilot plant to prove viability.
 Low utility (electrical power) requirement to run a plant.
For the builder/developer, advantages include:
 Lighter weight results in reduced transport costs, faster construction, and less fatigue
for workers.
28
 Reduced masonry time as the blocks are interlocking and the plastering process uses
significant less mortar.
 Faster completion times from reduction in delays.
 CLC can cut like wood so finishing and fixing mistakes is faster, easier, and less
expensive.
 Faster completion times allow a builder/developer to complete more projects in a
given period of time and spread fixed costs across more revenue.
 Faster completion times reduce construction finance costs.
In addition to the above, the end-user/consumer also benefits from the following:
 Improved comfort, health, and less climate control related costs due to much better
insulation.
 Better safety and a more comfortable indoor environment.
 Less maintenance cost due improved durability.
 Better fire, water, mold, and insect resistance.
In summary, unlike many other building products, CLC block manufacturing is a very resilient,
low CAPX, mobile or on-site, and scalable process, creating consistent high-quality and
uniform products using unskilled labor.
Reader’s Note: This document reflects our best assessment of prevailing conditions and
practices in Afghanistan. Professional judgment was employed based on the explanations and
information made available through a limited amount of time and interactions with industry
stakeholders. No warranties for either quantitative or qualitative accuracy are provided,
intended or implied hereto.
29
Annex 1: Sample Floor Plan Drawing Used to
Conduct Cost Comparisons
30
Annex 2: Cost Comparison Assumptions and
Calculations
Cost Estimates for Non-Structural CMU
CMU with Columns: Breadown Cost Estimation from FFL* of 9.9x9.05M Building With 2.75M Height
No. Description Work Unit QTY U/Price (Afs) Amount (Afs)
I Columns (labour included)
1 Concrete of Columns (35x35cm), (9 columns) M3 3.03 7,000.00 21,223.1
2
2 Form work of columns M 34.65 180.00 6,237.0
3 Rebar for Columns Kg 260.00 60 15,600.0
4 Stirrups Kg 86.70 60 5,201.8
Sub-total for Columns 48,261.9
II Exterior Walls CMU (20cm width)
1 CMU+5% Waste Nos 775.97 40 31,039.0
2 Workforce
Mason Head 5.17 800 4,138.5
Labour Head 10.35 350 3,621.2
3 Mortar M3 2.40 3,500 8,400.0
4 Plastering both side of walls M2 186.40 130 24,232.0
5 Painting both side of walls M2 186.40 100 18,640.0
Sub-total for Exterior Walls 90,070.7
III Interior Walls CMU (20cm width)
1 CMU+5% Waste Nos 627.46 40 25,098.4
2 Workforce
Mason Head 4.18 800 3,346.5
Labour Head 8.37 350 2,928.2
3 Mortar M3 2.00 3,500 7,000.0
2
4 Plastering both side of walls M 131.73 130 17,124.3
Sub-total for Interior Walls 68,669.8
Grand Total 207,002.5
*Finished Floor Level (excluding earth work and foundation work)
31
Cost Estimates for Non-Structural Baked Brick
Baked Brick with Columns: Breadown Cost Estimation from FFL* of 9.9x9.05M Building With 2.75M Height
I Columns (labour included)
1 Concrete of Columns (35x35cm), (9 columns) M3 3.03 7,000 21,223.1
2
2 Form work of columns M 34.65 180 6,237.0
4 Stirrups Kg 86.70 60 5,201.8
II Exterior Walls Baked Brick (35cm width)
1 Baked Brick+5% Waste Nos 11,817.00 3 35,451.0
2 Workforce
Mason Head 9.09 800 7,272.0
Labour Head 18.18 350 6,363.0
3 Mortar M3 2.40 3,500 8,400.0
2
III Interior Walls Baked Brick (22cm width)
2 Workforce
Mason 4.52 800 3,619.2
Labour 9.05 350 3,166.8
3 Mortar M3 2.00 3,500 7,000.0
2
32
Cost Estimates for Structural CMU
CMU without Columns: Breadown Cost Estimation from FFL* of 9.9x9.05M Building With 2.75M Height
I Exterior Walls CMU (20cm width)
1 CMU+5% Waste Nos 820.81 40 32,832.3
2 Rebar in every other cell Kg 190.00 60 11,400.0
3
3 Grouting in rebar cells M 1.80 4,000 7,200.0
4 Workforce
* Mason Head 5.47 800 4,377.6
* Labour Head 10.94 350 3,830.4
3
5 Mortar M 2.40 3,500 8,400.0
II Interior Walls CMU (20cm width)
1 CMU+5% Waste Nos 627.46 40 25,098.4
3 Grouting in rebar cells M3 0.88 4,000 3,520.0
4 Workforce
* Mason 4.18 800 3,346.5
* Labour 8.37 350 2,928.2
5 Mortar M3 2.00 3,500 7,000.0
33
Cost Estimates for Structural Baked Brick
Baked Brick without Columns : Breadown Cost Estimation from FFL* of 9.9x9.05M Building With 2.75M Height
I Exterior Walls Baked Brick (35cm width)
2 Workforce
* Mason Head 10.40 800 8,316.0
* Labour Head 20.79 350 7,276.5
3 Mortar M3 2.40 3,500 8,400.0
II Interior Walls Baked Brick (35cm width)
2 Workforce
* Mason 4.52 800 3,619.2
* Labour 9.05 350 3,166.8
3 Mortar M3 2.00 3,500 7,000.0
34
Cost Estimates for Non-Structural CMU
CLC with Columns: Breadown Cost Estimation from FFL* of 9.9x9.05M Building With 2.75M Height
I Columns (including labor)
3
1 Concrete of Columns (35x35cm), (C9) M 3.03 7,000 21,223.1
2 Form work of columns M2 34.65 180 6,237.0
4 Stirrups Kg 86.70 60 5,201.8
II Exterior Walls CLC (20cm width)
1 CLC+2% Waste Nos 772.66 48 37,087.7
2 Rebar (12mm dia) in every 3rd cells Kg 115.22 60 6,913.1
3 Grouting for rebar cells M3 0.23 4,000 924.0
4 Workforce
Mason Head 1.55 800 1,236.3
Labour Head 1.55 350 540.9
III Interior Walls CLC (20cm width)
1 CLC+2% Waste Nos 624.76 48 29,988.5
2 Rebar 12mm dia for grouted cells Kg 90.58 60 5,434.6
3 Mortar for grouting M3 0.19 3,500 673.8
4 Workforce
Mason Head 1.25 800 999.6
Labour Head 1.25 350 437.3
35
Cost Estimates for Structural CLC
CLC without Columns: Breadown Cost Estimation from FFL* of 9.9x9.05M Building With 2.75M Height
I Exterior Walls CLC (20cm width)
1 CLC+2% Waste Nos 817.27 48 39,229.0
2 Rebar in every other cell 12mm dia Kg 161.62 60 9,697.0
3
3 Grouting in rebar cells M 0.35 4,000 1,386.0
4 Workforce
Mason Head 1.63 800 1,307.6
Labour Head 1.63 350 572.1
3
5 Mortar M 0.00 0 0.0
II Interior Walls CLC (20cm width)
1 CLC+2% Waste Nos 624.76 48 29,988.5
3 Grouting in rebar cells M3 0.28 4,000 1,100.0
4 Workforce
Mason Head 1.25 800 999.6
Labour Head 1.25 350 437.3
5 Mortar M3 0.00 0 0.0
36
Annex 3. CLC Global Projects Photo Gallery
Interlocking Block Walls

panels
Agricultural school in Iraq in Tunis Pre-cast wall panels

3,000 units in Tunis
Interlocking Block Walls CLC housing estate

panels
37
USAID/Afghanistan ABADE International Development
U.S. Embassy Compound Q Kabul Hotel
Great Masood Road Old Taimany Square, 40M Road
Kabul, Afghanistan Kabul Afghanistan
Tel: 202.216.6288 Phone: +93 (0) 797 957 209
Web: www.usaid.gov/afghanistan www.abade.org
38

Investment Guidelines For CLC Block

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Investment Guidelines For CLC Block

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Investment Guidelines for Establishing a

Cellular Lightweight Concrete (CLC)

Market Overview ....................................................................................................................... 11

Market Entry Costs ..................................................................................................................... 13

CLC Manufacturing Process ......................................................................................................... 21

Technical Specifications .............................................................................................................. 24

Quality Assurance ....................................................................................................................... 24

Weather Conditions ................................................................................................................... 25

Table 3. CLC Strength/Density Table ........................................................................................... 25

Frequently Asked Questions (FAQs): ........................................................................................... 27

Cost Estimates for Non-Structural Baked Brick ............................................................................ 32

Cost Estimates for Structural CMU .............................................................................................. 33

Cost Estimates for Structural Baked Brick .................................................................................... 34

Cost Estimates for Non-Structural CLC ......................................................................................... 35

Cost Estimates for Structural CLC ................................................................................................ 36

Annex 3. CLC Global Projects Photo Gallery ................................................................................. 37

CLC is highly versatile due to the fact that it can be easily

Market Entry Costs

For a 2,000 block per day plant, we recommend a 115 liter

Cement Mixer: A good quality cement mixer is required to first mix

Manufacturing options for flat faced (non-interlocking)

The fastest growing sector of the CLC block market today is

Table 1. Estimated Raw Materials Required for Year 1

 Company 4x4 or pick-up truck

Structural Application for Walls

4 CLC without columns 156,041

Avoid excess handling of the CLC.

CLASSIFICATION OF CLC BLOCKS:

Therefore, CLC can be produced in a density range of 400kg/m3 to 1800kg/m3. As discussed

Table 3. CLC Strength/Density Table (Sand/Cement Grout Mixes)

The baked brick production industry is a well-recognized and documented source of

Frequently Asked Questions (FAQs):

Can cellular lightweight concrete be over mixed?

How far can cellular lightweight concrete be pumped?

How do you finish cellular lightweight concrete?

How is cellular lightweight concrete tested?

How does cellular lightweight concrete compare in price to traditional concrete?

- Summary: Why Invest in Cellular Lightweight Concrete?

Interlocking Block Walls

Agricultural school in Iraq in Tunis Pre-cast wall panels

Interlocking Block Walls CLC housing estate

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