DETAILED PROJECT REPORT

OF

PURVI ENTERPRISES
(Manufacturing of CLC Bricks and Interlocking cementing blocks)

508 D, Nu life Navya Appartments, Sheelanagar,

Visakhapatnam - 530013
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 above applications. 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 one shift a day for 25 days in a month or
300 days in a year. 75 percent efficiency of machinery and manpower is considered.

RAW MATERIALS
Concrete is a mixture of ordinary Portland cement, mineral aggregate (sand and stone chips)
and water. The water used in preparing the concrete serves two purposes:

• It combines with the cement to form a hardened paste

• It lubricates the aggregates to form a plastic and workable mass

The water that combines with the cement varies from about 22 to 28% of the total amount of
mixing water in concrete.
Mineral aggregates (sand and stone chips) are normally divided into two fractions based on
their particle size. Aggregate particles passing through the No.4 or 4.7 mm Indian Standard
sieve are known as fine aggregate. The particles retained on this sieve are designated as
coarse aggregate. Natural sand is often used as fine aggregate in cement concrete mixture.
Coarse aggregate are crushed stone chips. Crushed stone chips broken into particle sizes
passing through the 4.7 mm sieve may also be used as fine aggregate. The maximum size of
the coarse aggregate that may be used in cement concrete hollow blocks is 12.5 mm.
However, the particle size of the coarse aggregate should not exceed one third thickness of
the thinnest web of the hollow blocks.
Ordinary Portland cement is the cementing material used in cement concrete hollow blocks.
Cement is the highest priced material per unit weight of the concrete. Hence, the fine and
coarse aggregates are combined in such proportions that the resulting concrete is workable
and has minimum cement content for the desired quality.

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.

MANUFACTURING PROCESS

The process of manufacture of cement concrete hollow blocks involves the following 5
stages;

(1) Proportioning
(2) Mixing
(3) Compacting
(4) Curing
(5) Drying

(1) Proportioning:

The determination of suitable amounts of raw materials needed to produce concrete of

desired quality under given conditions of mixing, placing and curing is known as
proportioning. As per Indian Standard specifications, the combined aggregate content in the
concrete mix used for making hollow blocks should not be more than 6 parts to 1 part by
volume of Portland cement. If this ratio is taken in terms of weight basis this may average
approximately at 1:7 (cement : aggregate). However, there have been instances of employing
a lean mix of as high as 1:9 by manufacturers where hollow blocks are compacted by power
operated vibrating machines. The water cement ratio of 0.62 by weight basis can be used for
concrete hollow blocks.

(2) Mixing :

The objective of thorough mixing of aggregates, cement and water is to ensure that the
cement-water paste completely covers the surface of the aggregates. All the raw materials
including water are collected in a concrete mixer, which is rotated for about 1 ½ minutes. The
prepared mix is discharged from the mixer and consumed within 30 minutes.
(3) Compacting :

The purpose of compacting is to fill all air pockets with concrete as a whole without
movement of free water through the concrete. Excessive compaction would result in
formation of water pockets or layers with higher water content and poor quality of the
product. Semi-automatic vibrating table type machines are widely used for making cement
concrete hollow blocks. The machine consists of an automatic vibrating unit, a lever operated
up and down metallic mould box and a stripper head contained in a frame work. 5 Wooden
pallet is kept on the vibrating platform of the machine. The mould box is lowered on to the
pallet. Concrete mix is poured into the mould and evenly levelled. The motorised vibrating
causes the concrete to settle down the mould by approximately 1 ½ to 1 ¾ inches. More of
concrete is then raked across the mould level. The stripper head is placed over the mould to
bear on the levelled material. Vibration causes the concrete come down to its limit position.
Then the mould box is lifted by the lever. The moulded hollow blocks resting on the pallet is
removed and a new pallet is placed and the process repeated. The machine can accommodate
interchangeable mould for producing blocks of different sizes of hollow or solid blocks.

(4) Curing :

Hollow blocks removed from the mould are protected until they are sufficiently hardened to
permit handling without damage. This may take about 24 hours in a shelter away from sun
and winds. The hollow blocks thus hardened are cured in a curing yard to permit complete
moisturisation for atleast 21 days. When the hollow blocks are cured by immersing them in a
water tank, water should be changed atleast every four days. The greatest strength benefits
occur during the first three days and valuable effects are secured up to 10 or 14 days. The
longer the curing time permitted the better the product.

(5) Drying :

Concrete shrinks slightly with loss of moisture. It is therefore essential that after curing is
over, the blocks should be allowed to dry out gradually in shade so that the initial drying
shrinkage of the blocks is completed before they are used in the construction work. Hollow
blocks are stacked with their cavities horizontal to facilitate thorough passage of air.
Generally a period of 7 to 15 days of drying will bring the blocks to the desired degree of
dryness to complete their initial shrinkage. After this the blocks are ready for use in
construction work.

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

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.

CLC BRICKS

CLC Cellular light weight concrete

Foam Concrete is also Known as " Cellular light weight concrete", "CLC", "Foamed
cement", "Light Weight Concrete" across the world with its greater advantages from 5
years.

The basic foam concrete is made from mixing aqueeous foam which is produced from
generators (IFG) into Slurry of Cement, fly ash OR sand, water and other additives in a
precise mixing in foam concrete mixer(IFM) for accurate mixing without disturbing its
original chemical and physical properties.

Advantages
• Light in Weight

• High Thermal Insulation

• High Fire Protection
• High Sound Insulation
• Lower Water Absorption
• Eco Friendly
• Economical
Applications

 Blocks
 Panels
 Ceiling Panels
 Pre-cast Exterior Walls
 Void Filling
 Roof Insulation
 Thermal Insulations
 Sound Insulation
 Floors

 Cast Insuit Applications

 Tank Infill
 Road Construction
 Subway Infill
 Tunnel Infill
 Mine Infill
 Water Proof Material
 Floors
 Low Cast Housing

Advantages in detail:
• Savings in Raw Material:

The tremendous savings described when using CLC are manifold, continuing with
substantial savings in raw material (no gravel required), in dead load of high-rise
reducing by almost half. Considering that a substantial amount of steel is necessary
only to carry the weight of the structure, steel requirement might reduce by hundreds
of ton in high rise.

• Considerably Lower Weight:

Weight reduction is obvious in transport, where almost double of volume of building

material can be produced, it has an impact on craning, where either larger panels can
be taken, or the full capacity in span. Alternatively less re-location of the crane is
necessary.

• Thermal Insulation:

Thermal Insulation increasingly turns to be the most important issue in the

planning and construction of buildings. There are many costly ways of insulation
on sandwich structure of a wall, adding the one or another rigid insulation
material, with a satisfactory result by computation but not always a sound solution
in safety, health or environment. The best solution is, to incorporate thermal
insulation in the mix of a concrete, such offered in air-cured CLC.
• Fire Protection:

The air-embedded in the CLC is also instrumental for the high fire-rating. In 1200
kg/m³ density a 13-14 cm thick wall has a fire endurance of 5 hours. The same delay
occurs with a 400 kg/m³ layer of CLC in only 10 cm thickness. CLC is otherwise
non-combustible.

• Sound Insulation:

Over the efforts to keep on increasing the thermal capacity of building members,
other aspects have been neglected, such as sound insulation. Sound is experienced as
air-borne or foot-fall sound (impact ). Air-borne it is a rule of density and therefore
CLC offers superior protection than very light concrete (ACC). In impact sound it is
superior to conventional concrete. Hitting a wall with a hammer, will let you feel the
full force on the other side, whilst the air embedded in CLC will not allow the blow to
pass through. At the most it will suffer a small dent and thereby prevent any greater
damage.

• Insulated Flooring:

As the impact force will not transmit, slabs produced of CLC or topped with a layer
of CLC floor screen will prevent any sound being noticed in the room below. Walls
of CLC will also serve as sound retaining walls on roads or railway tracks therefore,
absorbing the sound and preventing it from bouncing to the other side.

• Customisable Physical Properties:

Adding fibers to CLC is a further important benefit, increasing bending stress

substantially and most of it impact strength. The three dimensional acting fiber (e.g.
polypropylene) will further reduce shrinkage, therefore reducing water absorption
and increasing strength (up to 25 %. This is appreciated most when producing
slender building components.

• Economical Production:

Using only flyash, cement, water and foam, the cost for one m³ of CLC in most cases
is less even than for the equivalent volume of conventional concrete. Adding all the
described highly appreciated benefits (comprising CLC) to regular concrete, if at all
possible, the cost for such regular concrete would probably double but still not reach
the overall quality of CLC.
Technical Specifications

Walls of CLC have excellent sound insulation

CLC Bricks are available in 3 grade strengths:

• Grade A: These are used as load bearing units & have a brick density in the
range of 1,200 kg/Cum – 1,800 kg/Cum
• Grade B: These are used as non-Load bearing units & have a brick density in the
range of 700 – 1,000 kg/Cum.
• Grade C: These are used for providing thermal insulation & have a brick density in
the range of 400 – 600 kg/Cum.

Technical Specifications of CLC Bricks:

Brick Size (mm) Approximate Weight/Brick (Kg) No. of Brick/Truck No. of
Bricks/Cu.Mtr.
600 x 200 x 200 20.500 305 41

600 x 200 x 150 15.500 416 55

600 x 200 x 100 10.250 610 83

Recommended usage of CLC based on density:

• Density 300-600 kg/m³: This density is primarily applied for thermal insulation or
fire protection. It uses only cement (or little flyash), water and foam and can easily be
pumped. Foam generators allow the production of stiff foam for slopes to be applied
on roof-tops.
• Density 700-800 kg/m³: Is also used for void-filling, such as an landscaping (above
underground construction), to fill voids behind archways and refurbishing of
damaged sewerage systems. It is also been used to produce building blocks.
• Density 900-1100 kg/m³: Serves to foremostly produce blocks and other non-
load bearing building elements such as balcony railings, partitions, parapets
and fence walls etc.
• Density 1200-1400 kg/m³: Are the most commenly densities for prefab and cast
in situ walls, load-bearing and non-load-bearing. It is also successfully used for
floorscreeds (sound and insulation plus weight reduction).
• Density 1600-1800 kg/m³: would be recommended for slabs and other load-
bearing building elements where higher strength is obligatory.
CLC Manufacturing

CLC manufacturing setup is cheap & profitable and highly customisable.

Required Equipment
• MFG / MFG-A Foam Generator
• Conventional Mixers, pan-mixer, truck-mixer
• Conventional conveying system (buckets, Concrete pumps etc)

• Conventional moulds, horizontal/vertical

Raw Material
• flyash or sand (2, 4, 6, 8 mm, depending on density and availability)

Preference
• Flyash
• min. 20% fines
• Cement, Preference Portland
• Water for Foam production: Potable
• Foaming Agent

Optional
• Fibre: Polypropylene
• Fly-ash up to 40% on total mix
• Lightweight Aggregate (e.g. expanded clay etc.)

Production Procedure
Flyash: Optimum properties are achieved when selecting the most suitable raw material
(flyash, Cement). Preference : power -plant flyash, sieved and with minimum 20% fines.
Impurities in flyash increases the demand for water and cement, without adding to the
properties. It also increases shrinkage. A certain, small amount (20%) of fines contributes
towards strength. As in conventional concrete (CC), the flyash should be free of organic
material or other impurities. Crushed sand, due to sharp edges may destroy the foam
mechanically hence not recommended.
Cement: Portland cement is preferred over other cements, such as pozzolan. For Early
stripping and optimum mechanical properties, high- grade (early strength) cement is
recommended. Thick walls and when using battery-moulds, excess heat is developing within
and might therefore ask for a lesser grade of cement. Remember : The slower the hardening,
the better the final quality of concrete. Where economical, fly-ash may be added to the mix
to substitute some of the cement. Fly-ash normally will retard hardening though.

Water: When used to produce foam, has to be potable and for best performance should not
exceed 25°C. Under no circumstances must the foaming agent be brought in contact with any
oil, fat, chemical or other material that might harm its function (Oil has an influence on the
surface-tension of water). The oil/wax used in moulds will not harm, since the foam by then
will be embedded in mortar. Water to prepare the mix has to conform with general
requirements for concrete

Foaming Agent: The containers holding foaming agent must be kept air-tight and under
temperatures not exceeding 25°C. This way the shelf-life is guaranteed for 24 months from
date of Invoice. Once diluted in 4o parts of potable water, the emulsion must be used as
soon as possible.

Correct density of foam: The weight of the foam should be minimum 80 g/l. Use a
containers of as close as possible to 10 liters in volume, to check the weight (density) of the
foam. Smaller containers may not allow to pour foam into, without possible large voids. A
fast check on the correct weight is also possible by turning the bucket with foam up-side
down. If the weight of the foam is minimum 80 g/l and does not drop out of the bucket, the
consistency of the foam is correct. After several weeks of experience the person in charge of
producing foam will know the correct quality of the foam by sight. Once set correctly, the
foam generator will keep the consistency stable, as long as air-and water-supply remains
constant as well. We still recommend to check the weight of the foam once in a week or if the
density/consistency of the mix varies.

Preparation of moulds: For smooth surfaces clean moulds completely of remaining

concrete, the steel/or wood surface must be oiled/waxed. Preference : Organic or vegetable
oil/wax. Trials with different materials will have to show best results. Oil or wax will not
destroy the mix, once the foam has been mixed in the mortar.

Steel reinforcement will be placed in the moulds as usual. No coating of the steel is
necessary – as in AAC (Syporex etc.) In panels of more than 12-15 cm thickness, we
recommend the use of a double mesh (100 x 100 or 150 x 150 mm). The steel connected to
the lifting anchors should reach more then half of the width of the panel and should possibly
not be connected to the mesh. Ordinary steel is used as in CC when casting densities of 1200
or higher. The high ratio of cement to material in CLC ensures proper protection of the steel
against corrosion.

The steel embedded has to be covered by minimum 25 mm of concrete The use of spacers is
recommended. To prevent cracking when lifting/tilting, steel rods may be placed across the
anchors. A triangular strip of plastic or wood might be inserted along the bottom edge of the
mould – better also along the top, to prevent sharp edges, that might break of when handling
and give the panels a poor appearance.
Charging, Mixing and Pouring:

Before charging the mixer with material, it must be rinsed, in particular if the concrete
produced before, used any additive, which might have adverse reaction on the foam. Where
possible, start the mixer before charging it with material. If the flyash contains excessive
amount of water, the weight has to be adjusted, adding that much more flyash as it contains
water by weight, reducing at the same time the amount of water to be added to the mix. To
obtain optimum performance, flyash is first fed into the mixer, first absorbing water left after
rinsing or from the previous (CLC-) mix.

This way, the cement to follow will not clod, allowing best possible distribution in the
flyash. Keep on mixing, until a homogenous colour of the mix is achieved. If using fibre,
this is the moment it has to be added, mixing approx. 1 min. for each kg added, to allow
the fibrillated polypropylene fibre to “open-up”.

Check “Recommended Mix Design” for the recommended configuration of material to be

used in different densities. The densities referred there-under are oven dry, achieved when
drying the mix for 24h at 105°C. Before adding foam, the water/ cement (w/c) ratio of the
mortar must be minimum 0.35. Lower ratios may cause the cement to draw water from the
foam, causing it to partly or totally collapse, increasing the density and decreasing the yield.
This is one of the most likely mistakes when learning how to produce CLC. Therefore, if
one is in doubt, one should always add more, rather than less water. To a certain extend this
might even increase initial strength. Doing the same with CC would definitely reduce
strength, as excessive water causes voids when evaporating . CLC on the other hand consists
of voids only. The weight of the foam should be minimum 80 g/l. Use a container of as
close as possible to 10 liters in volume, to check the weight (density) regularly.

Gravity mixers (e.g. Ready Mix) take the foam under almost instantly and distribute it
homogeneously in the mix. It takes more time to achieve a proper distribution when using
pan-mixers or similar. In between pours, the mixer should be kept in motion until it is
completely discharged.

CLC always should be poured in the shortest possible time. If buckets are used to fill
moulds, they should hold as much CLC as possible, possibly even pouring one complete
panel in onestep. Extended time between pours of one building member might result in
the creation of dry-joints as happening in the case with regular concrete as well.

Although CLC does not require vibration – at least not to densify the mix – which is liquid
anyhow, vibration of horizontally produced panels will show an even better surface, drawing
cement slurry to the mould side. Preference is given to High- Frequency vibrators. Length of
vibration 15-20 sec. or until bubbles on the surface appear in large numbers. Use aluminium
or other straight and sharp-edged screedslats immediately after pouring the concrete. Delayed
screeding might “smear” the surface. If moulds have to be moved after screeding, this might
have to be repeated. Any disturbance of the freshly poured CLC during the setting process,
might be harmful and cause part of it to collapse, in particular when the concrete is not hard
enough yet to carry the weight and the foam has been weakened by loss of water, drawn by
the cement already for setting.
The poured building member should be covered, if possible, with a canvass or plastic sheet to
keep the evaporating water on the surface. As with CC, hardening may be accelerated either
by heating the moulds, steam or chemical (ask for details). Using most standard types of
cement, panels may be lifted the day after casting. Due to the reduced strength in CLC,
moulds should be tilted before lifting the panels. For the same reason panels of CLC should
be handled with utmost care to avoid damage.

Curing / Transport / Assembly: Panels should be positioned upwards on the curing yard,
resting on a soft underground – best on a rake or wooden beams. All possible efforts should
be taken, in particular in dry and hot climate or more even when windy, to keep the panels
damp for at least three, bettor for more days. A sprinkler will be helpful or canvas that is kept
wet. Curing compound would be the costly alternative. Standards call for a 24 day curing
period for cement-based building members.

Remember: Cement/Concrete only hardens with water or in a humid environment.

Due to reduced weight, more volume of CLC building elements can be transported at the
same (increased pay-load) then of CC. Panels should be kept upright during transport and
also on a soft/wooden underground. Unload only in tilted position.

Assembly: Assembly of panels in CLC happens usually the same way as with CC. Special
care has to be taken not to apply any mechanical force to avoid damage. If necessary, panels
of CLC may be sawn (no gravel), definitely nailed (without the use of dowels as in AAC),
drilled or profiled. In densities of 1200 kg/m³ and higher, where reinforcement is used, CLC
requires no special coating/plaster on the outside. Water-repellent paint (dispersion-paint)
will be suitable.

Vertical casting: The high fluidity of CLC allows full height walls or complete houses (floor
by floor) to be cast in one pour, inclusive the slab. Frames for voids for windows, doors and
other opening, or penings therefore are cast in place, together with empty tubes and pipes for
power and sanitary. No voids, no sagging (beneath frames). Walls/ partitions may be as
slender as 50 thick only as no vibration is necessary. With a coarse sand-paper stuck to a
piece of board, rub the walls immediately after stripping, in circular motion, to eliminate
possibly honey-web or “noses” caused by possible irregularities in the mould or by joints.
Perhaps a day after stripping it is recommended to saw imitation joints from both sides of the
walls on neuralgic positions to allow possible shrinkage to “accumulate” in the joints and not
show on the walls, as also done in CC when casting in situ.
As with all lightweight concretes (lesser with CC) hair-cracks might appear but have no
adverse effect on the reintorcement, and usually disappear when painted. This way one
complete house is cast each day with every set of vertical mould. Where applicable even the
gable can be cast at the same time with appropriate modification to the mould.

UTILITIES

Electrical Power requirement: 25 HP power for industrial purpose is required.

Water: water used in making concrete should be free from acids, alkalis, oil, dissolved
carbon dioxide and decayed vegetable matter. Generally, water suitable for human
consumption is considered adequate for concrete mixing.
(1) LAND & BUILDING

Sl Description Quantity Units Amount

(Rs)
1 Land 2024 Sq. meters 23,23,552.00
2 Building & Plant Area 500 Sq. meters 25,00,000.00
3 Concrete platform 1524 Sq. meters 1,00,000.00
4 Borewell with pump 25,000.00
TOTAL 49,48,552.00

MACHINERY & EQUIPMENT

Sl Description Quantity Units Amount

(Rs)
Hydraulically operated concrete block
1 making machine with quadruple 1 No. 3,50,000.00
(4) vibrators:
hydraulic system – 5 HP
Mould vibrators – 5 HP
Ram vibrators – 3 HP
(1.5 HP – 2 Nos.)
Travel motor – 1 HP
2 Concrete mixer: 10/7 cft 1 No. 56,448.00
with 5 HP motor,
hydraulic hopper and road
wheels
3 Platform electronic 1 No. 12,000.00
weighing scale 500 kgs
capacity
4 Water dosing pump 1 No. 8,000.00
5 Erection and commission-
ing charges @ 10% 3,00,000.00
6 Ram and mould for 5,00,000.00
hollow blocks & Pavement Blocks
7 Wheel borrows with 2 Nos. 25,000.00
pneumatic wheels
8 Office equipment LS 7,00,000.00
9 Vehicles 30,00,000.00
10 Wooden palettes LS 1,00,000.00
TOTAL 50,51,000.00
EMPLYOMENT DETAILS

Unskilled 20

Skilled 5

Supervisory 3

Managerial 2

Total 30

Gender Details

Male 20

Female 5

Indirect Employment 5

Maximum No. Of Workers Proposed to be employed in the factory 30

INTERLOCKING CEMENTING PAVEMENTS
MACHINERY
INTERLOCKING CEMENTING BLOCK
FLOW CHART
CLC BRICK MACHINERY
CLC BRICK FLOW CHART
PLANT LAYOUT