2018

CLC BRICKS PROJECT

REPORT

MR. Atul Satpute

Shohan Enterpizes
4/11/2018
 CLC BRICKS PROJECT REPORT

CLC BRICKS PROJECT

REPORT

MR. Atul Satpute

4/10/2018

Sohan Enterprizes , Wardha Maharashtra , Mo No: +91916819721 Page 2

 CLC BRICKS PROJECT REPORT

Index
1. Introduction
2. About New Project
3. Advantages of CLC Bricks
4. Application of CLC Bricks
5. Market Potential
6. Basis and Presumption
7. Technical Aspect
8. About Relative Comparisons of Alternative Walling Material
9. Financial Aspects.

Sohan Enterprizes , Wardha Maharashtra , Mo No: +91916819721 Page 3

 CLC BRICKS PROJECT REPORT

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.

ABOUT NEW PROJECT

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.

Sohan Enterprizes , Wardha Maharashtra , Mo No: +91916819721 Page 4

 CLC BRICKS PROJECT REPORT

Advantages of CLC Bricks

- Low thermal conductivity.

- Thermal Performances 5 times better than clay bricks & 10 times better than RCC
- Interiors remain cool in summer and warm in cold wintry days.
- Savings in recurring energy costs in air-conditioning.
- Ideal material for applications in cold storage rooms.
- It is possible to achieve even higher values depending upon the thickness and the plaster.
Good Sound Insulation
- Up to 37-42db sound reduction based on thickness.
- Savings in recurring energy costs in air-conditioning.
- Can fulfill required STC (Sound Transmission Class) rating.

Reduction of Dead Load

- 1/3rd the density of clay bricks.

- Economic design: savings in cement and steel.
- Enables faster construction.
- Suitable for low-soil bearing capacity & seismic zones.
- Facilitates construction of unplanned walls any where anytime.

Fire Protection

CLC Bricks offer great fire protection. With a just 100mm. thickness of wall 1000 kg/m3,
CLC block offers fire endurance for heat transmission for 4 hours without releasing any
toxic fumes during.

Enhances Carpet Area

An engineered block, it can be offered in any thickness as per the construction design.
By using 150 mm thick Bricks in place of 9 inch brick, the customer gets an additional
2% to 3% carpet area. The savings on account of additional carpet area gained is more
than the cost of Bricks

Other Advantages of CLC Bricks:

- CLC offers economical POP or putty finish in internal partition walls.
- Accurate size and shapes help in reducing plastering costs.
- Better finishing of walls offers good amount of reduction in paints.
- Eco-friendly.
- Speedier Constructions.
- Ease of Work ability.
- Universal Acceptability.
- Low Water Absorption.

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 CLC BRICKS PROJECT REPORT

TECHNICAL ASPECTS
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.

Size, Weight and No of bricks per cubic meter:

Size (in inches) Size (in mm) No of bricks per cubic meter Weight (in kgs)

24 x 8 x 4 600 x 200 x 100 82 10 - 10.5

24 x 8 x 6 600 x 200 x 150 55 15 - 15.5
24 x 8 x 8 600 x 200 x 200 41 20 - 20.5
24 x 8 x 9 600 x 200 x 225 37 25.5 - 26

Production Capacity Per Year:

Project having production capacity of 15 cubic mtr per day.

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

Total Capacity:
15 cubic mtr x 300 days = 4500 cubic mtr
Market price per cubic mtr will run Rs.3100 to Rs.3800

About Relative Comparisons of Alternative Walling Material

Sohan Enterprizes , Wardha Maharashtra , Mo No: +91916819721 Page 6

 CLC BRICKS PROJECT REPORT

FINANCIAL ASPECTS
A. Fixed Capital
Land and Building 1500 to 2000 Sq.mt. Approx Land require.

Plant & Machinery: 14,00,000 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

Cement 250.00 5.00 1250.00

Water 200.00 0.05 10.00
Fly Ash 450.00 0.50 225.00
Foam Generator 1.50 140.00 210.00
Power Fuel 10.00
Labour 200.00
Mis. Exp. 5.00
All Exp. Like Intrest, Office, Fuel,etc 50.00
Total Cost 1960.00

Calculation of working capital requirement per day:

15m3 x 1960 per m3 = 29,400/-
Calculation of working capital requirement per month:
29,400 x 26 days = 7,64,400/-

Selling Price (Approx)

3100 m3 - 1960 = 1140 / m3 profit
1140 X 15m3 =17,100.00 day profit
17,100 X 26 = 4,44,600 profit of 26 day working
Per year profit is 4,44,600 X 12 = 53,35,200.00

Sohan Enterprizes , Wardha Maharashtra , Mo No: +91916819721 Page 7

Power consumption is required for running CLC brick machinery plant?
1.2 cubic meter mixer 7.5 hp
Foam generator 1hp
Compressor 2 hp
Water motor 2hp
Conveyor 2 hp
Total 15 hp needed(approx)

Labor force is required in running a CLC light weight brick machinery plant.
A minimum of ten 10 unskilled workers are essential in the production of CLC bricks.

Raw material is required to manufacture CLC bricks

The raw material required to manufacture 1000 blocks of size 24x8x9 are:
Foaming agent: 50 kg.
Cement: 100 bags
Fly ash: 16 tons
Water: to prepare a slurry mix similar to general requirement in concrete production.

Foaming agent used in CLC bricks production.

Protein foaming agent (non-veg) 85gm to 95gm per liter (density) can use for CLC bricks.
Protein foaming agent (veg) can be used for roof insulations.

Cement grade use in CLC light weight bricks manufacturing.

53 grade ordinary Portland cement (OPC) is used for manufacturing CLC bricks.

Fly ash can be used for CLC bricks production.

We should use fine fly ash(may be use pond ash), which is available in thermal power plants.
(It is also available in certain industries free of cost. You got make to make your own transport arrangement).
This raw material is one hundred percent (100%) suitable for CLC bricks production.
P.S. we can use pond fine fly ash.

Conveyor used in CLC bricks machinery plants.

There are two types of conveyors that can be used:
1.Belt conveyor for fly ash
2.Screw conveyor for cement However, our suggestion would be to use only belt conveyor for both, which is sufficient.
It is better to avoid screw conveyor for cement.

Molds for 1 cubic meter CLC bricks manufacturing.

There are four molds needed if it is 8 feet ms (mild steel) sheet.
There are five moulds needed if it is 6 feet ms (mild steel) sheet.
Main Features Of CLC Blocks, Prefab Elements & In-Situ Moulded Housing:-

CLC Blocks are very light in weight Density ranging from 400 to 1800 Kg/m3 can be produced
as required.
CLC Blocks are excellent for Earthquake Resistant Housing due to light weight reducing dead
weight by more than 50% of the normal concrete. Multi-Storey high rise towers constructed has
saved cement and steel to large extent, which can be verified on STAAD-III Computer
Programme. CLC Blocks are excellent for Thermal and Sound insulation which keeps the house
cool in Summer and warm in Winter saving energy/electricity for cooling and heating.
CLC Blocks are “Environment-friendly” using more than 30% of “Fly Ash” from Thermal
Power Stations and converting directly into valuable Building Materials. CLC Blocks will also
replace “Clay Bricks” which is destroying Agricultural top soil. Our Technology will save
Environment and Ecology from the hazardous & polluting material Fly Ash and prevent
destruction of Valuable Agricultural Land.
CLC Blocks Production Plant can be Stationary or Mobile Unit to be mounted on truck to
manufacture CLC Blocks, Prefab reinforced Building Elements, and In-Situ Moulded Housing at
site, will save breakage, transport charges and delay, etc.
Cellular Lightweight Concrete is a self flowing concrete with ball bearing action to avoid
Honeycomb and Voids in the Blocks, Prefab Building Elements and In-Situ Moulded Housed
walls. CLC Blocks being light weight the handling and transportation is easy. The construction
speed is 2 ½ times more than the Clay Bricks construction.
· In-Situ Moulded Housing is excellent technology to Produce 5 to 20 houses per day by using
simple machinery and moulds. The fast construction speed is a first necessity for quick
Rehabilitation of Earthquake affected villages and towns or for the Rehabilitation of the villages
displaced due to the major “Dam Projects” besides the Rehabilitation programme for the
Slums in the Metro Politan Cities.
In-Situ Moulded Houses have no joints and hence it will not damage by high intensity Earthquake or
Cyclone. The doors, windows, sanitary and water pipes are inserted in the Moulds before pouring CLC in
the Moulds resulting into a compact house without any maintenance cost for a long period.
· In-Situ Moulded Housing, Prefab reinforced Building Elements and CLC Blocks are used regularly
in more than 40 countries and more particularly by the Developing Countries.
Micro Air Cells of CLC are intact, not interconnected as it is produced by Stable Foaming Agent.
Therefore our product has very low Water Absorption avoiding any leakage, seepage or
dampness in the walls and ceiling.
· House built with CLC Blocks or Prefab Building Elements or In-Situ Moulds do not require inside
or outside plaster but if insisted only 6 mm thick plaster is sufficient for internal and external surface.
Steel reinforcement is not required for the Ground Floor Housing with Sheet Roofing or
CLC Panel Roofing. Any shrinkage can be avoided by using Synthetic Fibers, which adds to
the strength of the concrete.
CLC has basic raw material of Cement for the appropriate strength and hence the strength
is increasing every year on Aging of the Concrete.
CLC Blocks Production Plant, Machinery and Equipment besides critical raw-material-
Foaming Agent is manufactured in India and hence no imports are involved.
CLC do not require stone aggregates and the Slurry of Cement, Sand, Fly Ash, Foam
and Water can be pumped easily in length and height.
CLC is excellent for Snow bound Cold Regions/Zones and also for Hot climate Desert Zones
for the comfortable living. CLC Blocks can be produced in the remote Snow bound areas by
our Mobile Production Unit. CLC Blocks can be transported by Mules to difficult terrains since
the material is light weight.
CLC is excellent Fire Retardant and can be used for fire fighting operations in Coal
Mines, Forests, etc.
CLC is excellent for Roofing Thermal Insulation and sound Insulation for Floor Slabs.
CLC is best for Trench Reinstatement, Void filling, Bridge Abutment, Tunnel work
and Floor Construction.
· CLC is also suitable for Soil Stabilization, Road Foundation, Land Reclamation
and Harbour Fills.
· CLC is excellent for Fire Breaks in the Buildings.
CLC is most suitable to construct Sound Barriers at the Air Port to prevent Noise
Pollution while landing and Take-off.