Project Report on Cement Bricks Manufacturing
Project Report on Cement Bricks Manufacturing
Project Report on Cement Bricks Manufacturing has been prepared for the unit to be set up for manufacturing cement concrete products. A concrete block is primarily used as a building material in the construction of walls and floor concreting. It is sometimes called a concrete masonry unit (CMU).
A concrete block is one of several precast concrete products used in construction. The term precast refers to the fact that the blocks are formed and hardened before they are brought to the job site.
Most concrete blocks have one or more hollow cavities, and their sides may be cast smooth or with a design.
In use, concrete blocks are stacked one at a time and held together with fresh concrete mortar to form the desired length and height of the wall.
Concrete bricks Technology is based on the principle of densification of a lean concrete mix to make a regular shaped, uniform, high-performance masonry unit.
Concrete Block Technology can be easily adapted to suit the special needs of users by modifying design parameters such as mix proportion, water/cement ratio, and type of production system.
It is an effective means of utilizing wastes generated by stone crushers, quarrying, and stone processing units.
The technology has high potential in areas where raw materials are easily available. The Concrete Block Technology package is a highly profitable business for micro and small-scale building material producers and construction companies.
The market for concrete blocks is growing at a rapid rate, especially in areas where burnt bricks are not easily available or are of poor quality.
Concrete blocks will have a light grey concrete color, and on close inspection may show a granular texture depending on the type of aggregate used. Machine production provides an even finish that offers savings on further cement plaster etc.
Concrete blocks can be surface engineered by using pieces of stone or ceramic waste on their face. Another common type is hollow concrete blocks.
They are made with a richer mix but offer a number of advantages, such as lighter weight, easier handling, and a facility for conducting or reinforcement through the hollows.
The major advantage of concrete blocks is that their strength can be engineered as per requirement. Thus making them relatively stronger than masonry with brick walls by around 15-20%.
The specifications and the characteristics of a concrete block depend on the machine used to manufacture concrete blocks.
The basic raw material is cement, fine aggregate, and coarse aggregate. Very little water is used. This is possible only with mechanized compaction and vibration and gives the block high quality in spite of the lean mix, which uses very little cement.
These blocks are 4-5 times bigger than burnt bricks; the size of the block or brick used has a bearing on the strength of the masonry. As the bigger size accounts for a reduction in the number of mortar joints, thereby increasing wall strength.
High-quality machines provide optimum vibration in the mix so that the ratio of cement used can be reduced substantially without compromising on the strength of the blocks.
The machine also compacts and consolidates the mix so that the blocks are uniform in size and attain desired physical properties. The blocks are cured for a minimum period of 14 days before they are ready to use.
These are made from a mixture of cement, sand, and aggregate reinforcement materials.
Cement concrete hollow and dense bricks and blocks are very popular and are extensively used in building, dams, and other construction work throughout the country because of the many advantages such as durability, strength and structural ability, fire resistance, insulation, and sound absorption it possesses.
These have an attractive appearance and are readily adaptable to any style of architecture. It lends to a wide variety of surface finishes for both exterior and interior walls.
BASIS & PRESUMPTION-Project Report on Cement Bricks Manufacturing
- This report is detailed only Techno-Economic –Feasibility aspects.
- It has been presumed that the unit will run at least 300 days a year.
- The gestation period for the implementation of the project may be about 6 to 8 months. This period included making all arrangements, completion of all formalities, market surveys, and tie-ups, financial arrangements, purchase of machines, recruitment of staff, commissioning of plant and trial production, etc.
- The normal wages and salaries being paid in the industry to various grades of personnel have been considered and also the provision of minimum wages has been taken care of.
- The rate of interest both for fixed and working capital has been taken as 12.50% P.A.
- The payback period for finance to the financial institutions may be about 5/7 years in the case of a term loan. The working capital loan may however be in the shape of rolling/limit-based capital.
- It has been assumed that the unit will achieve its capacity of 70% 1st. one yr., 75% 2nd.yr & 80% 3rd.yr. and so on.
- The cost in respect of plant & machinery, raw materials, and finished products has been taken at the time of preparation of this project report and may vary depending upon various factors.
- All calculations have been based on assuming that the unit will produce 3,70,000 pcs. bricks and blocks.
- It has been presumed that the unit will run at least 300 days in a year.
- All calculations have based on single shift running.
LOCATION OF THE UNIT – Project Report on Cement Bricks Manufacturing
The proposed unit should be set up at a place that the site must justify to be suitable in view of the following basic considerations:-
- Availability of raw materials & consumables.
- Availability of Power, Fuel, Water.
- Banking facility.
- Marketing prospectus.
- Good communications.
- Labor facility.
RAW MATERIALS AND CONSUMABLES
- Mobil oil, grease, etc.
ITEMS TO BE PRODUCED
- Cement Concrete Bricks.
- Cement Concrete Blocks
- Cement Concrete paver.
- Cement Concrete Tiles.
3,70,000 Bricks and Blocks.
– 8 hours per day.
– 25 days per month.
– 300 days per annum.
Manufacturing Process-Project Report on Cement Bricks Manufacturing
The process of manufacture is simple and quite suitable to start. RCC mixture of raw materials such as cement, sand, and stone chips in the ratio of 1:3:6 and 1:5:6 or 1:2:4 depending upon the type of construction and strength required is prepared with the help of power operated cement concrete mixture.
For higher strength and a good finish, a mix ratio of 1:2:4 can b used. Then the mixture is collected in tipping barrows and fed into the mold of the hydraulic or mechanical emptying machine.
Then it is vibrated to ensure complete compactness. Now the products are placed on the floor for 24 hours for the initial setting. Soon after the initial setting, the products are stacked in layers.
It should have cared that stacking must be in 6 or 8 layue3rs and then subjected to curing with sprinkling water over the stacked blocks for 21 days. Then it is left to completely dry in the sunray. Now it is ready for sale.
Market Potential – Project Report on Cement Bricks Manufacturing
The cement concrete dense/hollow bricks and blocks gradually replace conventional red bricks due to inherent properties like strength, size accuracy, and insulation.
These are used for both laying load bearing and non-load bearing walls. The cost of blocks is very much compared t the cost of red bricks and quite low, especially, in hilly regions where building bricks cannot be made whereas red bricks have o be procured from distant places thus incurring extra heavy transportation costs.
Only in a few regions, the good quality clay is available and the red bricks industry has come up there. But the cement building blocks can be made anywhere. The main raw materials for production such as stone metals, sand girt, etc. are available in any state.
The blocks have some advantageous properties over the red bricks. It is easy to construct a wall that requires less mortar for inside and outside plaster and joining. It provides good insulation against heat and cold and resists vibration and absorbs sound.
So considering all the above-mentioned factors, one can foresee setting up such units.
PROJECT COST-Project Report on Cement Bricks Manufacturing
Manufacturing of cement concrete bricks, blocks, pavers, and tiles on small scale may be set up under the PMEGP scheme. After successful running of project and repayments on T/L made timely then after one crore loan under 2nd. PMEGP scheme may be taken for expansion of the unit.
I hope you have well-understood cement concrete bricks, blocks, paver, and tiles manufacturing process and marketing prospects.
Thanks for reading the post.