PROJECT REPORT ON CELLULAR LIGHT CONCRETE BLOCKS

Product : CLC Blocks

Annual Capacity = 4.50 Lakhs Blocks

Value : 2.70 Crs.

1. Introduction:

OBJECTIVE OF THE PROJECT:

‘Housing for All by 2022’ scheme, the Prime Minister Narendra Modi-led government at the Centre plans to build
affordable homes, which would provide residence to the country’s low-income groups (LIG) and economically weaker
sections (EWS). The vision to build affordable homes could revive the real estate sector, which has seen a slow growth
in past two years. The increasing demand for affordable urban homes can turn into an opportunity of over $10 billion
for real estate developers.

PROLINE Engineers LLP is a venture setup to facilitate the construction industry by supplying all the related materials
used for construction of different infrastructure facilities so as to accommodate the developmental change. The
objective of the company is not only to facilitate the industry but to facilitate the industry by introducing revolutionary
products which makes the quality of construction far better than using traditional products and also which helps in
saving time in construction period.

The company will enter into production of such revolutionary products along with a research and development centre
to make such revolutionary ideas turn into reality. Also the aim of the company is to provide one stop services
required for construction of any kind of infrastructure i.e. making available all the innovative precast concrete
products to the industry . This will save clients time, by not hindering places for requisite services, require for their
project. Also tie-ups with leading Builders, Architects and Interior Designer will enable the potential client to find all
such products under one roof for his potential project.

Constant endeavor of the company will be to introduce such method of development so as to facilitate the
construction industry by making a quality product of international specification and that too in most economical way.
There always will be scope of introducing new methods and technologies in this field as value for money is always
appreciated by the customer.

The very first revolutionary product which the company wants to start of with is Cellular Lightweight Concrete (CLC)
Blocks, Panels, etc.. this product has been successfully used all over the world and in India. Mumbai and Pune are the
major cities where use of these blocks is done in a large scale in Maharashtra. As government is implementing ban
on use of clay bricks in many areas soon it will be scraped from the construction industry. Conventional bricks
contribute to global warming and to soil erosion which damages the natural resources. There is an increase in the
pace of use of these blocks. The blocks are preferred for the large scale construction sites which results in substantial
saving in cost as well as time.

WHAT IS CLC ?

Cellular Lightweight Concrete (CLC) Blocks is a version of lightweight concrete that is produced like normal concrete
under ambient conditions. These blocks are environment friendly and manufactured from common natural raw
materials. The energy consumed in the production process is only a fraction compared to the production of other
materials like clay bricks etc. and emits no pollutants and creates no toxic products or by products. It is produced by
initially making slurry of cement + sand + fly ash + water, which is further mixed with the addition of pre-formed
stable foam in a concrete mixer

under ambient conditions. The foam imparts free flowing characteristics to this slurry due to ball bearing effect of
foam bubbles enabling it to easily flow into all corners and compact by itself in the moulds/forms without requiring
any kind of vibrations or compaction (20% volume of air).

CLC technology has been used in over 45 countries of the world over past 30 years to construct over a hundred
thousand houses, apartments, schools, hospitals, industrial, commercial buildings etc.. the new product brings quality
housing closer to the masses at a faster and at a lower cost.

Lightweight and free flowing, it is a material suitable for a wide range of purposes such as, but not limited to, panels
and block production, floor and roof screeds, wall casting (readymade walls), complete house casting (readymade
house), sound barrier walls, floating homes, void infills, outdoor furniture and many more applications.

Cellular Lightweight Concrete (CLC) is one of the recent emerging technology in making concrete. It has many
advantages when compared to the normal conventional concrete. Fly ash is considered as one of the waste industrial
product that cannot be easily disposed. It solves the problem of disposal of flyash and at the same time it reduces the
cost of the construction. Therefore, flyash based CLC is considered as environment friendly sustainable material
produced with least energy demand.

The density is considerably reduced by using fly ash based cellular lightweight concrete than normal concrete and at
the same time, the strength is not affected by appropriate design mix. When we use this type of concrete we achieve
large volume by less amount of concrete. The manufacturing process of this type of concrete does not involve any
high cost techniques. Manufacturing process of CLC is similar to normal concrete and in this additionally foam
generating machine is used.

Fly Ash Based Cellular Light Weight Concrete

• It is a version of lightweight concrete that is produced like normal concrete under ambient conditions. It is
produced by initially making a slurry of Cement +Sand + Fly Ash (constituting 26% – 34 % content) + water
• A cellular concrete is a lightweight product consisting of Portland cement, cement-silica, cement-pozzolan,
lime-pozzolan, lime-silica pastes or pastes containing blends of these gradients and having homogeneous void
or cell structure, attained with gas-forming chemicals of foaming agents.
• In cellular lightweight concrete, the density can be controlled by the introduction of gas or foam by foam
generator.
• CLC is an air-cured lightweight concrete with fly ash as a major ingredient that can be produced at large
project sites just like traditional concrete, utilising equipment and moulds normally used for traditional
concreting.
• It is especially suitable in India for low-rise load bearing constructions and for partitioning work in multistorey
blocks.
• Fly Ash as a new additional constituent in its manufacture. Fly ash can constitutes more than 25% (ranging
between 26% to 33%) of the solid material constituents of CLC mixes for different density outputs.
• Fly-ash- a nuisance waste product from thermal power plants – as an over 25 % constituent material. This
CLC can be produced in a density range of 400 kg/m3 to 1,800 kg/m3, with high insulation value and a 28-day
cube crushing strength of up-to 275 kg/cm2.
• It is not only found a productive use of a waste industrial product, but incorporation of fly ash also saves
nearly 40% on cement content, otherwise needed for the corresponding Cement and Sand only mixes,
thereby also leading to substantial reduction in the cost of manufacture.
• Normally the density of the cellular light weight concrete ranges from 400 kg/m3 to 1,800 kg/m3
• Cellular Light Weight Concrete based housing is fire proof, termite proof, thermally insulated, sound proof,
environment friendly.
Cellular light weight concrete – Density range:

This Cellular Lightweight Concrete (CLC) can be produced in a wide range of densities from 400 kg/m3 to 1,800
kg/m3 to suit different applications: –

The lower densities of 400 –600 kg/m3 are ideal for thermal insulation applications. CLC’s fire, termite, water-proof-
ness, termite-resistance, very low water absorption and environment friendliness. This range is also used in laying
sound insulating layer over structural slabs of intermediate floors in high-class hotels and institution buildings to
minimise transmission of noise between lower and upper floors. It can also be used as a filling in depressions in
bathrooms or other floors due to up-stand beams etc. It make a far superior alternative to the commonly used
Thermocole, glasswool, woodwool etc.

The medium density range 800-1000 kg/m3 is utilized for making pre- cast blocks for non-load-bearing walling
masonry in framed structures. The size of blocks for the party/external walls may be 500x250x200 mm and the
internal partition blocks may be 600x200x150 mm nominal size, although any desired size as per requirements, may
be produced.

The high density range from 1200kg/m3 (Crushing strength 65 kg/cm2) to 1800 kg/m3 (Crushing strength 250
kg/cm2) is structural grade material utilized for:-

(a) In-situ casting of structural (load-bearing) walls and roofs of low rise individual or group housing schemes.

(b) Manufacture of reinforced structural cladding or partitioning panels.

(c) Making pre-cast blocks (600x260x200/150 mm) for load- bearing walling masonry for low rise buildings.

Properties of cellular concrete:

It has the following properties:

1. It has low weight.

2. It has good fire resistance.
3. It has good thermal insulation property.
4. Thermal expansion is negligible.
5. Freezing and thawing problems are absent.
6. Sound absorption is good.
 7. It has less tendency to spall.

Uses of Cellular Concrete

1. It is used for the construction of partition walls.

2. It is used for partitions for heat insulation purposes.
3. It is used for the construction of hollow filled floors.

APPLICATIONS OF CLC:

1. Ideal for Multi storied buildings

2. Most suitable for where thermal comforts at home and saving in air- conditioning costs are reduced
3. Best for all fire rated applications
4. Ideal for ecological green buildings
5. Ideal for additional floors in existing building
6. Suitable for both load bearing and non load bearing walls

ADVANTAGES OF CLC:

1. LIGHT WEIGHT: Being light weight it reduces the load on foundation and structure resulting in substantial
saving in steel and cement. It weighs 1/3rd the density of clay bricks. This also improves the stability of the
structure.
2. LOWER WATER ABSORPTION: The closed cell structure of the blocks reduces water absorption, so no more
damp spots on the wall.
3. HIGH THERMAL INSULATION: Superior thermal insulation of the blocks makes it comfortable for the
occupant. It results in reduction of electricity cost due to reduction in air conditioning load. Low thermal
conductivity. Thermal performances 5 times better than clay bricks & 10 times better than RCC. Interiors
remain cool in summers and warm in winters.
4. LOWER LABOUR & MATERIAL COST: Decrease in number of joints and accurate dimensions of blocks results
in reduced cement mortar, plastering and labour. No need to plaster the walls, direct implementation of POP
can be done that too only 1mm layer of POP is sufficient. 1mm layer of cement plaster for outside walls is
required. This way there is a huge savings in cost of labour and cement. The quality also improves. Savings in
mortar.
 5. INCREASED CARPET AREA: Optimum width results in increased carpet area when compared to brick walls. An
engineered block, it can be offered in any thickness as per the construction design. For eg: by using 150mm
thick block instead of 9 inches brick, the customer gets an additional carpet area of 2% to 3%. The savings on
account of additional carpet area gained is more than the cost of blocks.

6. QUICK AND EASY ASSEMBLY AND HANDLING: Being larger in size the blocks speeds up the construction
process and makes it simpler. Apporx. 7 bricks are equal to 1 block, but it doesn’t weigh as much as that of 7
bricks, it offers superior reliability and chase cutting features as compared to hollow blocks and concrete
blocks (AAC).
7. SUPERIOR SOUND INSULATION: Acoustic properties of the blocks are superior compared to other walling
materials.
8. ECOLOGICAL STABILITY: The manufactured blocks are Green Blocks. No Green House Gases are emitted
during the manufacturing process. Valuable top soil is also not consumed, not resulting into soil erosion.
Carbon Credit are also available on the manufacturing of blocks which further evidences that it is a green
and eco friendly product. Also many institution which rates the building into different categories rates the
building using CLC blocks as Energy Saving Buildings.
9. SUPERIOR FIRE SAFETY: These blocks offer superior fire safety. Upto 400 degrees the block doesn’t emit any
toxic fumes.
10. AVAILABILITY THROUGH ALL SEASONS: CLC block is available all round the year, even during monsoons when
the availability of fire clay bricks is not consistent.

MARKET:

The construction industry boom can be seen in almost all the developing countries. As the development takes place
construction of new infrastructure is necessary to accommodate the change. The demand for supplies is high, supply
of raw material like bricks, cement, sand, iron and steel, builder hardware, paints, manpower and everything else
regarding construction.

The construction industry is also very vital because anybody who is concerned with the economic development these
days highlights the need for infrastructure development. The infrastructure is in the form of roads, ports, buildings,
factories and so on and all of them involve construction.

Bricks remain one of the most important building materials in the country. Brick making is a traditional industry in
India, generally confined to rural areas. Notably, the Indian Brick Industry, with more then 1 lakh production units
producing about 100 billion tons of bricks annually. It is the second largest brick producer in the world after that of
China. It is more importantly one of the largest employment generating industries, employing millions of workers.
However, brick making is an energy intensive process as fuel costs account for almost 30% of the production cost.

The country consumes about 180million tons of brick, exhausting apprx. 340million tons of clay every year and about
5000 acres of top soil is made infertile for long period.

Despite all initiatives to introduce alternative walling materials like CLC Blocks, Sand Lime Bricks, AAC blocks, Fly Ash
Bricks, it is envisaged that SLB and CLC would occupy the dominant position in the foreseeable decade.

FINANCIAL ASPECTS

TEKSYS ENTERPRISES PRIVATE LIMITED

CLC Block Manufacturing Plant
Plant & Machinery Required

Sl Motor
Machinery/Plant Name Unit Qty Rate Amount
No. HP
1 Foam Generator 1 No 1 57000 57000
2 Foam Concrete Mixure 10 No 1 250000 250000
3 Air Compressor 2 No 1 60000 60000
4 Control Panel No 1 60000 60000
5 Conveyor Belt with Hopper for Fly ash-6m 2 No 1 175000 175000
6 Screw Coveyor with Hopper for cement 2 No 1 175000 175000
7 Vibrating Motor with Hopper 2 No 1 40000 40000
8 MaterialTrolly No 1 10000 10000
9 Transport Trolly No 1 10000 10000
11 CLC Moulds 6X24X8 Inch Size-11 blocks-750 No 34 7500 255000
12 CLC Moulds 8X24X8 Inch size-9 blocks-750 No 42 7500 315000
13 Load cells with Indicator- 1Ton Nos 4 23000
Water Pump 1 No 1 5000 5000
Total Plant & Machinery 20 1435000
Land & Building Requirement( fixed cost excl rent)

Sl. Per
No. Details Month Annual
1 Open Land -7000 Sqft -on Rent @ Rs. 1.5/Sqft 10000 120000
2 Covered Shed- 3000 Sqft @ Rs.10/Sqft 30000 360000
3 Leveled PCC surface 2000 Sqft @ 50 100000
4 20 HP Power Connection 100000
Total 680000

Working Capital Requirement

Bas
11250
e 6" blocks=18750 450 60%
8" blocks=18750 11250 450 60%

1 6" Blocks= 18750 Nos

10125
Kg
Fly Ash @ 9 Kg/block 0 1.25 126563
Cement @ 3.25 Kg/block Kg 36563 6 219375
Foam 40 ML/block Kg 450 135 60750
Labour cost @ Rs. 5 56250
Transport Charges @ Rs. 1/- 11250
Loading and unloading chanrges @ 1.5 16875
491063 491063
Per block 44
2 8" Blocks =18750 Nos
13500
Kg
Fly Ash @ 12 Kg/block 0 1.25 168750
Cement @ 4 Kg/block Kg 45000 6 270000
Foam 50 ML/block Kg 562.5 135 75938
Labour cost @ Rs. 7 78750
Transport Charges @ Rs. 1.25/- 14063
Loading and unloading chanrges @ 2 22500
 Per block 56
112106
Total Direct cost on Production 3 1121063
3 Manager/Supervisor @15000/Pm 15000
4 Electricity Charges 20 HP -15KWH for 8 hrs KWH 3000 10 30000
5 Rent per Month 40000
Interest payment on WC of Rs. 40 L @ 12% @
6 50% 20000
5 Misc exp 27000 105000
125306
Total Working capital per month 3 1253063
Working capital required for 2 months 2506125

Project Cost
Plant & machinery 1435000
Land & Building ( fixed cost) 680000
Working Capital for 2 months 2506125
Total Project Cost 4621125

Source of Funds
Own Investment 1155281
Bank Finance 3465844
Total 4621125

Revenue (Annum)
15036750
Revenue Nos Rate Amount
13500
6" blocks 0 70 9450000
13500
8" blocks 0 50 6750000
 1620000
Total Revenue Total 0 16200000

Profit per Annum

Revenue per Annum 16200000
Cost Per Annum 15036750
Profit Before Tax 1163250