PRODUCTION OF CONCRETE BASED PRODUCTS (PAVING BLOCKS AND TYPES, BRICKS AND TYPES, TILES AND TYPES, CHEQUERED TILES, PRECAST SLABS/WALLS, CURB STONES/FLAGSTONES TERRAZZO, CHIPS & PEBBLES, GRC & FRP PRODUCTS)
[EIRI/EDPR/4740] J.C. 2960XL
INTRODUCTION
Interlocking Concrete Block Pavement (ICBP) has been extensively used in a number of countries for quite some time as a specialized problem-solving technique for providing pavement in areas where conventional types of construction are less durable due to many operational and environmental constraints. ICBP technology has been introduced in India in construction, a decade ago, for specific requirement viz. footpaths, parking areas etc. but now being adopted extensively in different uses where the conventional construction of pavement using hot bituminous mix or cement concrete technology is not feasible or desirable. The paper dwells upon material, construction and laying of concrete block pavement as a new approach in construction of pavement using Interlocking Concrete Paver Blocks.
Concrete paver blocks were first introduced in Holland in the fifties as replacement of paver bricks which had become scarce due to the post-war building construction boom. These blocks were rectangular in shape and had more or less the same size as the bricks. During the past five decades, the block shape has steadily evolved from non-interlocking to partially interlocking to fully interlocking to multiply interlocking shapes. Consequently, the pavements in which non-interlocking blocks are used are designated as Concrete Block Pavement (CBP) or non-interlocking CBP, and those in which partially, fully or multiply interlocking blocks are used are designated as 'Interlocking Concrete Block Pavement (ICBP).
CBP/ICBP consists of a surface layer of small-element, solid un-reinforced pre-cast concrete paver blocks laid on a thin, compacted bedding material which is constructed over a properly profiled base course and is bounded by edge restraints/kerb stones. The block joints are filled using suitable fine material. A properly designed and constructed CBP/ICBP gives excellent performance when applied at locations where conventional systems have lower service life due to a number of geological, traffic, environmental and operational constraints. Many number of such applications for light, medium, heavy and very heavy traffic conditions are currently in practice around the world.
COST ESTIMATION
Plant Capacity 10 MT/Day
Land & Building (2 Acres) Rs. 1.50 Cr
Plant & Machinery Rs. 2.36 Cr
Working Capital for 2 Months Rs. 74.64 Lac
Total Capital Investment Rs. 4.78 Cr
Rate of Return 21%
Break Even Point 71%
CONTENTS
INTRODUCTION
ADVANTAGES AND LIMITATIONS
HOWEVER, IMPORTANT LIMITATIONS OF THE TECHNIQUE ARE THE FOLLOWING:
PHYSICAL REQUIREMENTS
APPLICATION OF ICBP TECHNOLOGY
SHAPES AND CLASSIFICATIONS
MATERIALS
PAVING BLOCKS
BEDDING AND JOINT FILLING SAND
BASE AND SUB BASE MATERIALS
CONSTRUCTION OF INTERLOCKING CONCRETE BLOCK PAVEMENT
SEQUENCING OF OPERATIONS
PAVEMENT TYPES
PAVER PROPERTIES
PAVER DIMENSIONS
PAVING STRENGTH
MINIMUM BREAKING LOAD
COMPRESSIVE STRENGTH OF PAVERS
DURABILITY
SLIP RESISTANCE
ABRASION RESISTANCE
MOISTURE EXPANSION
EFFLORESCENCE
PITTING DUE TO LIME
COLD WATER ABSORPTION
HISTORY OF PAVING:
APPLICATIONS OF PAVING BLOCK PA
VINGCK PAVING
ROADS
COMMERCIAL PROJECTS
INDUSTRIAL AREAS
DOMESTIC PAVING
SPECIALIZED APPLICATIONS
INDUSTRIAL AREAS
DOMESTIC PAVING
SPECIALIZED APPLICATIONS
INDUSTRIAL AREAS
DOMESTIC PAVING
SPECIALIZED APPLICATIONS
ROADS:
COMMERCIAL PROJECTS
INDUSTRIAL AREAS
DOMESTIC PAVING
SPECIALISED APPLICATIONS
PATTERNS IN CONCRETE PAVING BLOCKS –
SHAPES –
ARISTOCRAT
SATINPAVE
CONLEAF
CLASSIC COBBLE
CLOVER TIFFANY
HONEYSTYLE
COROLOCK, DOUBLE ZIG ZAG
COROLINK
COMPARISON OF CONCRETE PAVING BLOCKS WITH OTHER TYPE OF PAVEMENT
ADVANTAGES OF PAVING BLOCKS –
REQUIREMENTS FOR CONCRETE PAVING BLOCKS
PROPERTIES:
MAINTENANCE FREE
RECOMMENDED GRADES OF PAVER BLOCKS FOR DIFFERENT TRAFFIC CATEGORIES
RESOURCES
MAIN RESOURCES
RAW MATERIALS AND CONSUMABLES
RAW MATERIALS FOR CEMENT CONCRETE BLOCKS
RAW MATERIALS FOR CEMENT CONCRETE TILES AND MOSAIC FLOORING TILES
COMPARATIVE ANALYSIS OF SOURCES AND PRICES OF CRITICAL INPUTS & CONSUMABLES
THE PLANT
SELECTION OF TECHNOLOGY
PROCESS TECHNOLOGIES USED
FACTORS INFLUENCING THE CHOICE OF TECHNOLOGY
TECHNOLOGY RECOMMENDED
CEMENT CONCRETE TILES AND MOSAIC FLOORING TILES SECTION:
PARTICULAR OF MACHINE
PROCESS OF MANUFACTURE
CEMENT CONCRETE BLOCKS
MOBILE STACKING DEVICE
PALLET HOPPER
DRY MIX CONVEYOR
CEMENT SCALE:
ONE SET OF CEMENTS SCREWS
PNEUMATIC GROUPS
MIXING PLANT
AUTOMATIC FACE MIXING AND BATCHING
SEMI AUTOMATIC FACE MIXING AND BATCHING
WET MIX CONVEYOR
SPECIFICATION OF FORK LIFT
SPECIFICATION OF LOADER
PECIFICATION OF COOLING TOWER
LIST OF EQUIPMENT FOR LAB
SPECIFICATION OF COMPRESSIVE TESTING MACHINE
VIBRO-HYDRAULIC PRESS
PAVER BLOCKS
PROCESS FLOW CHART
CEMENT CONCRETE TILES AND MOSAIC FLOORING TILES
PROCESS FLOW CHART
FINISHED PRODUCT
PROCESS AND QUALITY CONTROL
PHYSICAL TESTS:
TESTING EQUIPMENT’S:
TECHNICAL KNOW-HOW
ENVIRONMENTAL IMPACT
ENVIRONMENTAL ASPECT OF MANUFACTURING PROCESS
WASTE GENERATED AND MITIGATION MEASURES
WASTE GENERATED DURING CONSTRUCTION PHASE AND MITIGATION MODES
WASTE GENERATED DURING PROJECT OPERATION PHASE AND MITIGATION MODES
ADVANTAGES/APPLICATIONS
APPLICATIONS OF PRESTRESSED CONCRETE POLES
B.I.S. SPECIFICATIONOF PRODUCTS
MARKET OVERVIEW
PRESTRESSED CONCRETE MARKET DEFINITION
PRECAST CONCRETE POLE MARKET SIZE
MARKET DYNAMICS
PRESTRESSED CONCRETE MARKET SHARE BY REGION 2022 (%)
PRESTRESSED CONCRETE MARKET MAJOR PLAYERS ARE:
INDIAN MANUFACTURING INDUSTRY
INTRODUCTION
MARKET SIZE
INVESTMENT
GOVERNMENT INITIATIVES
IN THE UNION BUDGET 2023-24:
IN THE UNION BUDGET 2022-23:
ROAD AHEAD
PROCESS FLOW DIAGRAM
PRE CAST CONCRETE COMPONENTS & EQUIPMENTS
PRE-STRESSED COMPONENTS
PRE-STRESSED CONCRETE POLES
EQUIPMENT FOR MANUFACTURING
FLY ASH BRICKS/ BLOCKS & CONCRETE BRICKS/BLOCK / PAVER MAKING MACHINE
MAJOR ADVANTAGES:
FOR BLOCK MACHINE
AUTOMATIC PALLET STACKING DEVICE
WOODEN PALLET
FOR BATCHING & MIXING PLANT)
DISCHARGE CONVEYOR FOR BASE MIX
SUPPLIERS OF PAVING BLOCK
SUPPLIERS OF PORTLAND CEMENT
SUPPLIERS OF STONE CHIPS
LABORATORTY EQUIPMENTS MANUFACTURERS
D.G. SET MANUFACTURERS & SUPPLIERS
FIREFIGHTING EQUIPMENTS MANUFACTURERS & SUPPLIERS
SUPPLIERS OF WATER PUMP
SUPPLIERS OF PALLETS
SUPPLIERS OF MOULDS
PLANT AND MACHINERY SUPPLIERS FOR PAVERS BLOCKS
CHINA SUPPLIER OF AUTOMATIC PAVING BLOCK MAKING MACHINE
SUPPLIERS OF OTHER PLANT & MACHINERY
MACHINERY
MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF RAW MATERIALS
CEMENT
STEEL WIRES
OTHER PLANT & MACHINERY MANUFACTURERS
SUPPLIERS OF INTENSIVE SAND MIXTURE AND MULLER
SUPPLIERS OF SAND SIEVING MACHINE
SUPPLIERS OF MOLDING BOXES
SUPPLIERS OF DRILLING, LATHE, TAPING MACHINES
SUPPLIERS OF EOT CRANE
SUPPLIERS OF POWER TRANSFORMERS
SUPPLIERS OF ELECTRICAL PANEL
SUPPLIERS OF ELECTRIC MOTOR
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
SUPPLIERS OF PLATFORM WEIGHING MACHINE
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
SUPPLIERS OF JIGS AND FIXTURE
FINAL PRODUCTS
PRINCIPLES OF PLANT LAYOUT
STORAGE LAYOUT:
EQUIPMENT LAYOUT:
SAFETY:
PLANT EXPANSION:
FLOOR SPACE:
UTILITIES SERVICING:
BUILDING:
MATERIAL-HANDLING EQUIPMENT:
RAILROADS AND ROADS:
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
SPECIFIC FACTORS
6. TRANSPORTATION:
A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES
7. WASTE DISPOSAL:
8. LABOR:
9. REGULATORY LAWS:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME ATTACK:
14. FLOOD AND FIRE CONTROL:
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
1. DEPRECIATION:
2. FIXED ASSETS:
3. WORKING CAPITAL:
4. BREAK-EVEN POINT:
5. OTHER FIXED EXPENSES:
6. MARGIN MONEY:
7. TOTAL LOAD:
8. LAND AREA/MAN POWER RATIO:
PROJECT IMPLEMENTATION SCHEDULES
INTRODUCTION
PROJECT HANDLING
PROJECT SCHEDULING
PROJECT CONSTRUCTION SCHEDULE
TIME SCHEDULE
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)
SAFETY DATA SHEETS
ENVIRONMENTAL/SAFETY LIABILITY
PRE-PROJECT ACTIVITIES
PROPOSED IMPLEMENTATION SCHEDULE
PROJECT FINANCIALS
BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)
CONCLUSIONS:
PLANT LAYOUT
STATUTORY APPROVALS FROM GOVERNMENT
DOCUMENTS REQUIRED FOR LICENSES
LIST OF DOCUMENTS:
SWOL ANALYSIS
STRENGTHS
ORGANIZATION CHART
IMPLEMENTATION SCHEDULE
ADDRESSES OF RELEVANT GOVERNMENT OFFICES
ADDRESSES OF FINANCIAL INSTITUTIONS
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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