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Technology |
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Cement Concrete Tiles and Paving Blocks
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Product Code
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94459 |
| Quality and Standards |
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N.A. |
| Production
Capacity: |
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Quantity:
2400 Tonnes (per annum) |
| Value |
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Rs.1,45,03, 000 |
| Uploaded on |
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January 2007 |
Introduction
Cement concrete tiles and paving
blocks are precast solid products made out of cement
concrete. The product is made in various sizes and shapes
viz. rectangular, square and round blocks of different
dimensions with designs for interlocking of adjacent
tiles blocks. The raw materials required for manufacture
of the product are portland cement and aggregates which
are available locally in every part of the country.
Market Potential
Cement concrete tiles and paving
blocks find applications in pavements, footpaths, gardens,
passenger waiting sheds, bus-stops, industry and other
public places. The product is commonly used in urban
areas for the aboveapplications. Hence, the unit may
be set up in urban and semi-urban areas, near the market.
A lot of face-lift is being given to roads, footpaths
along the roadside. Concrete paving blocks are ideal
materials on the footpaths for easy laying, better look
and finish. Whereas the tiles find extensive use outside
the large building and houses, lots of these materials
are also used in flooring in the open areas of public
offices and commercial buildings and residential apartments.
Basis and Presumptions
Efficiency: It is envisaged that
the unit will run on two shift a day for 25 days in
a month or 300 days in a year. 75 percent efficiency
of machinery and manpower is considered.
Time Period:
Full capacity utilization is expected to be achieved
within 12 months of commencement of commercial production.
Labour Wages: Minimum applicable
wages are considered.
Interest
Rate: An interest rate of 12% per annum on the
total capital investment has been considered.
Margin Money: Promoter
is expected to bring in 25% of the total capital investment.
Pay Back
Period: The project will have a payback period
of about 3-4 years.
Land and Construction Cost: Land cost is considered
at Rs. 4000 per square meter, and Construction cost
for office and stores at Rs. 9000.00 per square meter,
and work shed at Rs. 6000 per square meter.
Implementation Schedule
| Sl. No. |
Activity |
Period |
| 1. |
Preparation of
the project report, selection of site, provisional
registration from DIC, availability of finance |
2 months |
| 2. |
Construction of
building, procurement of
machinery and equipment, availability of electrical
power |
3 months |
| 3. |
Erection and commissioning,
recruitment of manpower, trial runs and commencement
of commercial production |
1 month |
| Total implementation
period |
6 months. |
Technical Aspects
Process of Manufacture
Cement concrete is a mixture of
portland cement, aggregates (sand and stone chips) and
water. Aggregates passing through 4.7 mm IS sieve are
known as fine aggregates and the aggregates retained
on this sieve are coarse aggregates.
The process of manufacture of cement
concrete paving blocks involves the following steps:
a) Proportioning
b) Mixing
c) Compacting
d) Curing
e) Drying
A concrete mix of 1:2:4 (cement:
sand: stone chips) by volume may be used for cement
concrete paving blocks with water to cement ratio of
0.62. The concrete mix should not be richer than 1:6
by volume of cement to combined aggregates before mixing.
Fineness modules of combined aggregates should be in
the range of 3.6 to 4.0.
All the raw materials are placed
in a concrete mixer and the mixer is rotated for 15
minutes. The prepared mix is discharged from the mixer
and consumed in the next 30 minutes. Vibrating table
may be used for compacting the concrete mix in the moulds
of desired sizes and shapes. After compacting the blocks
are demoulded and kept for 24 hours in a shelter away
from direct sun and winds.
The blocks thus hardened are cured
with water to permit complete moisturisation for 14
to 21 days. Water in the curing tanks is changed every
3 to 4 days. After curing, the blocks are dried in natural
atmosphere and sent for use.
The concrete paving blocks gain
good strength during the first 3 days of curing and
maximum gains in strengths are secured in the first
10 to 15 days of curing. After curing, blocks are allowed
to dry in shade so that the initial shrinkage of the
blocks is completed before they are used in the work.
A drying period of 7 to 15 days would normally complete
the drying shrinkage after which they can be used. The
concrete tiles are similarly produced with the help
of semi-dry pressing of the mixture and allowed to set
for 24-36 hours. It is cured in the tanks for 15 days.
If need be water can also be sprinkled to gain maximum
physical strength in 15-21 days.
Quality Control and Standards
a) Indian Standard Specification
There is no Indian Standard Specification
specifically on cement concrete paving blocks. However,
the specifications laid down in IS 2185 (Part 1) Specification
for concrete masonry units: Part 1 for Hollow and Solid
concrete blocks, may be used as general guidelines for
meeting the quality parameters, since the paving blocks
are also essentially solid cement concrete blocks.
b) Quality Requirements
Proportioning of raw materials,
mixing, compacting, curing and drying are the important
stages of manufacture.
Quality parameters like actual
proportion of the individual raw materials, ratio of
coarse aggregates to fine aggregates, water to cement
ratio, good finish, accuracy in size and shape and compression
strength after curing are the some of the important
parameters that should be checked periodically to ensure
good quality of the product.
Production Capacity (per annum)
| Quantity: |
800 tonnes |
| Value: |
Rs. 22, 00, 000 |
| |
|
| Motive Power |
80HP. |
Pollution Control
Dust collecting unit is required
to be installed at the mixing and raw material handling
section. The workers may use dust masks.
Energy Conservation
General maintenance of the machine
and drive system can be employed for saving energy.
Financial Aspects
A. Fixed Capital
(i) Land and Building
| Particulars |
Sq. Meters |
Rate (Rs.) |
Value (Rs.) |
| Land |
2000 |
4000 |
80,00,000
|
| Built up area |
| Office, raw material and finished
product stores, D.G. set room, water bore well,
boundary wall gates, security room and workers room
etc. |
500 |
|
40,00,000
|
| Working Shed |
500 |
6,000 |
30,00,000
|
|
Total
|
1,50,00,000
|
(ii) Machinery and Equipments
| Description |
Imp/
Ind.
|
Qty. (Nos.)
|
Rate (Rs.)
|
Value (Rs.)
|
| Production Unit |
| Concrete mixer:
capacity 10cft/7cft with 3 hp motor, speed of the
mixer drum 20 rpm, and other accessories |
Ind. |
1 |
4,00,000 |
4,00,000
|
| Hydraulically operated
Concrete block making machine: capacity 1500 blocks
per shift, with pressure vibration technique for
compaction, 3 HP motor, and other accessories |
Ind. |
1 |
6,00,000 |
6,00,000
|
| Mechanical tile
melting press with 7HP motor |
|
1 |
4,00,000 |
4,00,000
|
| Construction of
curing tanks |
Ind. |
4 |
2,50,000 |
10,00,000
|
| Mould tools, weighing
scale etc., electrical generator and electrical
system, and pollution control system and laboratory |
Ind. |
LS |
|
23.00,000
|
| Water pump set
with tube well, water storage tank, |
Ind. |
1 |
2,00,000 |
12,00,000
|
| Cost of erection,
installation lump sum |
5,00,000
|
| Cost of office
equipment, furniture etc. |
300,000
|
| Total |
57,00,000
|
| (iii) Pre-Operative Expenses
(per month) |
(Rs.) |
| Project report
cost, non-refundable deposits, etc. |
3,00,000 |
| (iv) Total Fixed Capital
(i+ii+iii) |
2,10,00,000 |
B. Working Capital (Per Month)
(i) Personnel (per month)
| Designation |
No. |
Salary (Rs.) |
Total (Rs.) |
| Administration
and Supervisory personnel |
| General Manager |
1 |
25,000 |
25,000
|
| Administrative plus accounting
sales and finance staff |
8 |
9,000 |
72,000
|
| Watchman |
4 |
4,000 |
16,000
|
| Technical: Skilled
and Semi or Unskilled personnel |
| Skilled Workers |
4 |
5,000 |
20,000
|
| Unskilled workers |
20 |
3,500 |
70,000
|
| Perquisites @22%
of the above |
45,000
|
| Total cost of Salaries
and wages |
2,48,000
|
(ii) Raw Materials (per month)
| Particulars |
Imp/Ind. |
Qty. |
Unit |
Rate (Rs.) |
Value (Rs.) |
| Portland cement |
Ind. |
30 |
Tonnes |
4,000 |
1,20,000
|
| Sand |
Ind. |
70 |
Tonnes |
500 |
35,000
|
| Stone chips |
Ind. |
70 |
Tonnes |
600 |
42,000
|
| Total |
1,97,000
|
(iii) Utilities (per month)
| Particulars |
Qty. (Rs.) |
Unit |
Rate (Rs.) |
Value (Rs.) |
| Electrical Power |
24000 |
kWH |
4 |
96,000
|
| Water |
500 |
Kiloliters |
45 |
23,000
|
|
Total
|
1,19,000
|
(iv) Other Contingent Expenses
(per month)
| Particulars |
Value (Rs.)
|
| Postage and Stationery |
3,000
|
| Telephone |
5,000
|
| Consumable stores |
10,000
|
| Repairs and maintenance |
10,000
|
| Transport Charges |
15,000
|
| Sales, marketing and misc.
charges lump sum |
25,000
|
| Insurance |
13,000
|
|
Total
|
81,000
|
| Total Recurring Expenditure
(per month) (i +ii + iii + iv) |
6,45,000
|
| Total Working capital (on 3
months basis) |
19,35,000
|
C. Total Capital Investment
| (i) Total Fixed Capital |
Rs. 2,10,00,000
|
| (ii) Total working Capital |
Rs. 19,35,000
|
|
Total
|
Rs. 2,29,35,000
|
Machinery Utilisation
Machinery utilisation of 75% has
been considered in the project.
Financial Analysis
(1) Cost of Production (per
year)
| Description |
Value (Rs.) |
| Total recurring cost |
77,40,000 |
| Depreciation on building @
5% |
3,50,000 |
| Depreciation on Machinery and
Equipment @ 10% |
2,40,000 |
| Depreciation on office equipment,
mould etc. @ 20% |
5,20,000 |
| Interest on capital investment
@ 12% |
27,52,000 |
|
Total
|
1,16,02,000 |
(2) Sales Turnover (per year)
| Item |
Qty |
Unit |
Rate (Rs.) |
Value (Rs.) |
| Cement
concrete paving blocks |
1,600 |
Tonnes |
5,891 |
94,27,000
|
| Cement Concrete
Tiles |
800 |
Tonnes |
6345 |
50,76,000
|
|
Total
|
1,45,03,000
|
(3) Net Profit (before tax)
(2 - 1)
| Rs. 1,45,03,000 - Rs. 1,16,02,000 |
= |
Rs. 29,01,000 |
(4) Net Profit Ratio
| |
= |
Net Profit per year x 100
---------------------------- |
| |
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Sales Turnover per year |
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= |
29,01,000 x 100
---------------------- |
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1,45,03,000 |
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= |
20% |
(5) Rate of Return (percent)
|
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Net
Profit per year x 100
------------------------------ |
| Total Capital investment |
|
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29,01,000 x 100
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| 2,29,35,000 |
| |
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12.65% |
(6) Break
Even Point
| Fixed Cost |
Value (Rs.) |
| Total depreciation |
11,10,000 |
| Interest on total capital investment |
27,52,000 |
| Insurance |
1,56,000 |
| 40% of Salaries and wages |
11,90,000 |
| 40% of other contingent expenses
|
3,89,000 |
|
Total
|
55,97,000 |
| B.E.P. |
= |
Fixed Cost x 100
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Fixed Cost + Net Profit |
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= |
55,97,000 x 100
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55,97,000 + 29,01,000 |
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= |
65.8% |
Addresses
of Machinery and Equipment Suppliers
1. M/s. Engineers Enterprises
189, Bharathiyar Road,
Ganapathy
Maniyakaranpalayam Road,
Near IEC Bus Stop, Ganapathy
Coimbatore - 641 006
(Tamil Nadu)
Phone: 91-0422-530639, 530788, and 532260,
Fax: 91-0422-532260, 531893
2. M/s. Victor Electrical and Machinery Manufactures
3616, Netaji Subash Marg,
Daryaganj,
New Delhi - 110 002
Phone: 23263118, 23265823
3. M/s. Buildtech Engineering Co.
Shree Ashadweep Complex,
16-Civil Lines,
Roorkee - 247 667,
(Uttar Pradesh)
Phone/Fax: 01332-73443
4. M/s. Karthik Industries
36, J.C. Road, Bangalore-560 002
Phone: 91-80-2224825, 2235218; 2233739
Fax: 91-80-2213703
E-mail: karthikengineering@vsnl.com
5. M/s. Susanji Udyog Pvt. Ltd.
C-47, Industrial Estate,
Sanathnagar,
Hyderabad - 500 018
Phone: 3704194, 3711464
E-mail: susanji@satyam.net.in
6. M/s. Apco Concrete Blocks and
Allied Products
7th Mile, Kanakpura Road,
Doddasandra Post
Bangalore - 560 062
7. M/s. Ashok Engineering Works
81, Ajit Industrial Estate Rakhial,
Ahmedabad - 380 023
8. M/s. Hydro Engineering Works
K1/116, CIDC, Mori, (Gujarat)
Raw Material Suppliers
Local suppliers and dealers available for cement and
aggregates like sand and stone chips.
Contact for more information:
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