Detailed Project Report on Fibre Cement Board

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FIBRE CEMENT BOARD

[EIRI/EDPR/4240] J.C.: 2415XL

INTRODUCTION

Fibre cement board (FCB) has been used since the 1900s when Ludwig Hatschek first combined 90% cement and 10% asbestos fibres with water. The mixture was run through a cardboard machine to produce asbestos cement board. This board was widely used for residential construction until the 1970s discovery that asbestos cement board causes mesothelioma (a rare form of lung cancer), at which time many countries strictly prohibited its use. FCB is not only the oldest type of cement board, but also the most widely used and produced. It is manufactured by 43 companies worldwide, 48% of cement board producers.

Fibre cement board consists of cement, water, silica, limestone flour and fibres, be they recycled, synthetic or cellulose pulp. Optional additives, including silica fume, metakaolin (Al2Si2O5), fly ash, calcium silicate, flocculants (chemicals that promote coagulation) and defoamer may also be used.

The strength of FCB is dependent upon the composite fibres in several ways. Synthetic fibres such as Kevlar or carbon produce the strongest board, which is both moisture resistant and very expensive. Cellulose fibres can contain high levels of sugars and other organics that increase cement setting time and reduce the board's water resistance, although the use of kraft pulps, which release only very low amounts of sugar, can help to combat this. They can also contribute to an increased saturated mass, poor wet-to-dry dimensional stability and lower saturated strength, which can lead to freeze/thaw damage. The latter can, however, be controlled by appropriate board formulation. Recycled cellulose fibres are both environmentally friendly and economical, but are shorter than virgin fibres and as such produce weaker boards.

Fibre cement board is fire, moisture, impact and decay resistant and also lightweight, rendering it easy to handle and transport. It is also possible to print wood or brick effects directly onto it with a texture imitating plate, rendering it highly decorative. FCB is suitable for both internal and external applications, including weatherboard and façade, roofing, cladding, external and partition walls, underlay, flooring and tile-backing. Prefabricated housing projects using FCB can be seen in New Zealand,1 Spain2 and much of Africa,3 while in 2007 James Hardie constructed the Denny Park Appartments in Seattle, USA.4 The complexes are owned by the Low Income Housing Institute and are made from a combination of metal, Hardieplank and HardiePanel, which are sustainable FCB products with a 50 year guarantee.

There are three processing methods employed for the production of fibre cement board, namely the Hatschek process, the Extrusion process and the Perlite process.

COST ESTIMATION

Plant Capacity 360 MT/Day

Land & Building (4850 sq.mt.) Rs. 4.39 Cr

Plant & Machinery Rs. 6.85 Cr

Working Capital for 3 Months Rs. 35.64 Cr

Total Capital Investment Rs. 47.47 Cr

Rate of Return 72%

Break Even Point 23%

CONTENTS

INTRODUCTION

HATSCHEK PROCESS PRODUCTION OF FCB

EXTRUSION PROCESS PRODUCTION OF FCB

PERLITE PROCESS OF FCB

WOOD WOOL CEMENT BOARD (WWCB)

CEMENT BONDED PARTICLE BOARD (CBPB)

BISON PLANT PRODUCTION OF CBPB

ELTOMATION PLANT PRODUCTION OF CBPB

WOOD STRAND CEMENT BOARD (WSCB)

USE/APPLICATION/ADVANTAGES

APPLICATION

LONG LIFE SPAN

VERSATILITY IN STYLE

THE BEST WAY TO EMULATE WOOD

INSTALLATION OPTIONS FOR AESTHETICS

MATERIAL IS FIRE (AND HEAT) RESISTANT

LARGELY WEATHER RESISTANT

RESISTANT TO WARPING AND ROTTING

IDEAL FOR TORNADO AND HURRICANE PRONE AREAS

MINIMAL MAINTENANCE REQUIRED

EASY INSTALLATION

FIBRE CEMENT CUTS A VARIETY OF WAYS

GREAT WARRANTY

EXPANDS AND CONTRACTS LESS THAN WOOD

USE OF FIBRE CEMENT BOARDS IN INDUSTRIALIZED HOUSE MAKING PROCESS

STEPS ARE FOLLOWS:

CUTTING MACHINES FOR LONGITUDINAL AND CROSS SECTIONS

THIS MACHINE ALLOWS ANGULAR CUTTING OF THE FRONT WALL ELEMENTS ON WHICH THE ROOF RACK PROFILES ARE MOUNTED

THE CONCRETE FLOOR SLAB IS PRODUCED EXACTLY ACCORDING TO PLAN

THE METAL DOOR AND WINDOW FRAMES ARE INSTALLED

FIBRE CEMENT BOARD/PANEL SPECIFICATIONS

ASTM TESTING METHODS

MARKET OVERVIEW

INDIAN FIBRE CEMENT MARKET SEGMENT ANALYSIS - BY TYPE

INDIAN FIBRE CEMENT MARKET SEGMENT ANALYSIS - BY PRODUCTION PROCESS

INDIAN FIBRE CEMENT MARKET SEGMENT ANALYSIS - BY APPLICATION

INDIAN FIBRE CEMENT MARKET SEGMENT ANALYSIS – GEOGRAPHY

INDIAN FIBER CEMENT MARKET DRIVERS

INDIAN FIBER CEMENT MARKET CHALLENGES

MARKET LANDSCAPE

GLOBAL MARKET

RAW MATERIALS

SPECIFIC PROPERTIES OF CEMENT

RAW MATERIAL COMPOSITION

PROCESS DESCRIPTION/PROCESS FLOW SCHEMATIC

THE TYPICAL PROCESS FLOW SCHEMATIC IS SHOWN BELOW:

PLANT & MACHINERY USED FOR THE PROCESS

PLANT & EQUIPMENT SUPPLIER

BOILER

GENERATOR SET (DG SET)

MANUFACTURERS/SUPPLIERS OF PLANT & MACHINERY

PRESSING MACHINE

COOLING TOWERS

BOILER

GENERATOR SET (DG SET)

BALL MILLS

CEMENT SILO

HYDRO PULPER

AUTO CLAVE SYSTEM

WATER JET SYSTEM

TURN KEY CONSULTANT

MANUFACTURERS/SUPPLIERS OF RAW MATERIALS

CELLULOSE FIBRE

GENERATION AND MANAGEMENT OF WASTES

SOLID WASTES

LIQUID WASTES

GASEOUS EMISSION

OTHERS

INDUSTRIAL WASTE MANAGEMENT

SEWERAGE SYSTEM

ANTICIPATED ENVIRONMENTAL IMPACTS

CONSTRUCTION PHASE

OPERATION PHASE

MITIGATION MEASURES (PROPOSED)

HEALTH SAFETY & ENVIRONMENT

SAFETY & OCCUPATIONAL MEASURE (STORAGE/HANDLING OF RAW MATERIAL & PRODUCT)

PROPOSED IMPLEMENTATION SCHEDULE

PROJECT FINANCIALS

BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)

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)

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