Detailed Project Report (DPR) on Cellular Lightweight Concrete Bricks (CLC Bricks)

CELLULAR LIGHTWEIGHT CONCRETE BRICKS (CLC BRICKS)

[EIRI/EDPR/1450] J.C. 230

NTRODUCTION

CLC Bricks are environment-friendly and manufactured from common natural raw material. The energy consumed in the production process is only a fraction compared to the production of other materials and emits no pollutants and creates no toxic products or by-products. These bricks are highly strong and of customized shape thus requiring less amount of cement and plastering and giving an even shape to the construction.

Bricks remain one of the most important building materials in the country. Brick making is a traditional industry in India, generally confined to rural areas. In recent years, with expanding urbanization and increasing demand for construction materials, brick kilns have to grow to meet the demand. It has directly or indirectly caused a series of environmental and health problems. 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, 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. Global warming and Environmental pollution is now a global concern. Cellular Light Weight Technology blocks can be used as an alternative to the red bricks, to reduce Environmental pollution and Global warming. CLC blocks are environment friendly. The energy consumed in the production of CLC blocks is only a fraction compared to the production of red bricks and emits no pollutants and creates no toxic products or by products. It is produced by initially making a slurry of Cement + Fly Ash + Water, which is further mixed with the addition of pre-formed stable foam in an ordinary concrete mixer under ambient conditions. Based on the trial mixes, it is found that compressive strength of CLC blocks is more than the compressive strength of conventional clay bricks. The addition of foam to the concrete mixture creates millions of tiny voids or cells in the material, hence the name Cellular Concrete.

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.

Cellular Lightweight Concrete Bricks (CLC) is produced by adding millions of Micro-Sized air bubbles into a cement based mixture. The addition of millions of air bubbles is achieved by using a Proprietary Foam Generator to produce highly stable and injecting the Foam directly into a concrete mixer containing a sand/ cement/ fly ash/ water slurry. The amount of cement, sand (if included), water. Fly-Ash and foam included in the Light weight Cellular concrete mix design depends on the required properties (i.e. strength, thermal conductivity or durability).Also, depending on the required CLC density and variance, an appropriate mixer is selected. The hardened material consists of small-enclosed air bubbles thereby resulting in a light weight stable cellular material with densities ranging from as low 300kg/m3 to 1800Kg/m3. The Hardened Material Consists Of Small-Enclosed Air Bubbles Thereby Resulting In A Lightweight Stable Cellular Material With Densities Ranging From As Low 300kg/M3 To 1800 Kg/M3. Good Curing gives strength and dimensional stability to Bricks. Bricks are cured either by air curing or high-pressure steam curing procedure. Because of great-Engineered properties, CLC Bricks have become popular in wide range of applications in construction sector.

COST ESTIMATION

Plant Capacity                                              60.00 Cubic.MT./Day
Land & Building (10000 Sq.Mtr)                Rs. 10.11 Cr
Plant & Machinery                                       Rs. 85.28 Lacs.         
W.C. for 2 Months                                       Rs. 65.52 Lacs           
Total Capital Investment                             Rs. 12.20Cr..              
Rate of Return                                             22%   
Break Even Point                                        52%

CONTENTS

INTRODUCTION

PROPERTIES AND PARAMETERS OF CLC BRICKS

MATERIAL AND BLOCK DIMENSION OF CLC BLOCK

MARKET SURVEY

MANUFACTURERS/SUPPLIERS OF CLC BRICK

PLANT LAYOUT

MANUFACTURING PROCESS OF CLC BRICKS

TECHNOLOGY AND PROCESS

CLC BRICK MANUFACTURERS IN JHARKHAND

B.I.S. SPECIFICATION

APPARATUS FOR DIVIDING AERATED CONCRETE BLOCKS

LIGHTWEIGHT CONCRETE AND METHOD OF MAKING SAME

LOW SHRINKAGE, HIGH STRENGTH CELLULAR LIGHTWEIGHT CONCRETE

COMPLETE PLANT & MACHINERY SUPPLIERS FOR CLC BRICKS AND OTHER BRICKS

MANUFACTURERS/SUPLIERS OF PLANT AND MACHINERY FOR BRICKS FROM CLC

COMPARISION BETWEEN FLYASH AND CLC BRICKS

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)