Cellular Lightweight Concrete bricks

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

MARKET
As the construction activity is growing day by day, there is a good demand for
CLC bricks. These bricks are widely being used in construction because It is a
light weight, water resistant, fire- proof, sound proof and environment friendly.
MANUFACTURING PROCESS
1. Pour water into the mixer according to mix design

2. Add Fly-ash & Cement afterwards

3 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.

PRODUCTION CAPACITY PER ANNUM

Project having production capacity of 15 cubic mtr per day.

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

Detail of CLC brick

Size (IN) Size (MM) No bricks per Weight(KG)

cubic meter
24x8x4 600x200x100 82 10-10.5
24x8x6 600x200x150 55 15-15.5
24x8x8 600x200x200 41 20-20.5

Total Capacity: 15 cubic mtr x 300 days = 4500 cubic mtr

Market price per cubic mtr will run at average Rs 3400/-

PROJECT COST
A. Fixed Capital
 Land own
 Building 1500 to 2000 Sq.mt. approx land required
 Plant & Machinery: 4,50,000.00 approx amount

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 Amount

Cement 250.00 6.50 1625.00

Water 300.00 1.00 30.00
Fly Ash 450.00 1.00 450.00
Foam Generator 1.50 100.00 150.00
Power Fuel 50.00
Labour 200.00
Mis. Exp. 10.00
All Exp. Like Intrest, Office, Fuel,etc 50.00

Total 2565.00

 Calculation of working capital requirement per day:

15m3 x 2565 per m3 = 38,475/-

 Calculation of working capital requirement per month:

 45,000 x 26 days = 1,000,350/-

Selling Price (Approx)

3400 m3 - 2565 = 835 / m profit

835 X 15m3 =12525.00 day profit

12525 X 26 = 3,25,650 profit of 26 day working

Per year profit is 3,25,650 X 12 = 39,07,800.00

A. FIXED CAPITAL

i. Land Own

ii. Work shed of 500 sq ft, water curing tanks, etc Rs. 100000

iii. Machinery and Equipment

S.no Description Qty Rate

1 FOAM GENERATOR 1
2 FOAM CONCRETE MIXER 1
3 CLC MOULD 1 194000.00
4 WEIGHT SCALE 1
5 AIR COMPRESSOR 3HP 1 40000.00
6 ACCESSORIES: TROLLEY 1
2NOS, FOAMING AGENT, 60000.00

TOTAL 2,94,000.00

B. WORKING CAPITAL

i. Salaries & Wages (per month)

S.no Description No.s Sal/mon Amount

1 Supervisor/Entrepreneur 1 15000 15000
2 Skilled labour 1 12000 12000
3 Semi-skilled 1 8000 8000
4 Unskilled worker 3 5000 15000
Total 50000

ii. Raw Material (per month)

S.no Description Unit Qty Rate Amount

1 Cement Bags 500