Cement Concrete Tiles and Paving Blocks - DCMSME

1 INTRODUCTIONC ement Concrete Tiles and pavingblocks are precast solid products madeout of Cement Concrete . The product ismade in various sizes and shapes , square and round blocksof different dimensions with designs forinterlocking of adjacent Tiles Blocks . Theraw materials required for manufactureof the product are portland Cement andaggregates which are available locally inevery part of the POTENTIALC ement Concrete Tiles and pavingblocks find applications in pavements,footpaths, gardens, passenger waitingsheds, bus-stops, industry and otherpublic places. The product is commonlyused in urban areas for the aboveCement Concrete Tilesand Paving BlocksPRODUCT CODE: 94459 QUALITY AND STANDARDS: CAPACITY: Quantity: 1200 Tonnes (per annum)Value : , 00, 000 MONTH AND YEAR: February, 2003OF PREPARATIONPREPARED BY: Small Industries Service Institute,Rajajinagar Industrial Estate,Bangalore - 560 044 Phone Nos.

2 : 080 - 3351581, 3351582 Fax No.: 080 - 3351583E - mail: Hence, the unit may be setup in urban and semi-urban areas, nearthe lot of face-lift is being given toroads, footpaths along the Paving Blocks are idealmaterials on the footpaths for easylaying, better look and finish. Whereasthe Tiles find extensive use outside thelarge building and houses, lots of thesematerials are also used in flooring in theopen areas of public offices andcommercial buildings and AND PRESUMPTIONSE fficiency: It is envisaged that the unitwill run on one shift a day for 25 days ina month or 300 days in a year.

3 75percent efficiency of machinery andmanpower is Period: Full capacity utilizationis expected to be achieved within 12months of commencement ofcommercial Wages: Minimum applicablewages are Rate: An interest rate of 14%per annum on the total capitalinvestment has been Money: Promoter is expectedto bring in 25% of the total Back Period: The project will havea payback period of about 3-4 and Construction Cost: Landcost is considered at Rs. 500 per squaremeter, and Construction cost for officeand stores at Rs. 2000 per square meter,and work shed at Rs. 1500 per SCHEDULE Sl.

4 Of the project 2 monthsreport, selection of site,provisional registrationfrom DIC, availabilityof of building, 3 monthsprocurement ofmachinery andequipment, availabilityof electrical and1 monthcommissioning,recruitment ofmanpower, trial runsand commencement ofcommercial productionTotal implementation period 6 ASPECTSP rocess of ManufactureCement Concrete is a mixture ofportland Cement , aggregates (sand andstone chips) and water. Aggregatespassing through mm IS sieve areknown as fine aggregates and theaggregates retained on this sieve arecoarse process of manufacture ofcement Concrete Paving Blocks involvesthe following steps:a) Proportioningb) Mixingc) Compactingd) Curinge) DryingA Concrete mix of 1:2:4 ( Cement :sand: stone chips) by volume may beused for Cement Concrete Paving blockswith water to Cement ratio of Theconcrete mix should not be richer than1:6 by volume of Cement to combinedaggregates before mixing.

5 Finenessmodules of combined aggregates shouldbe in the range of to the raw materials are placed in aconcrete mixer and the mixer is rotatedfor 15 minutes. The prepared mix isdischarged from the mixer andconsumed in the next 30 table may be used forcompacting the Concrete mix in themoulds of desired sizes and compacting the Blocks aredemoulded and kept for 24 hours in ashelter away from direct sun and Blocks thus hardened are curedwith water to permit completeCEMENT Concrete Tiles AND Paving BLOCKS29moisturisation for 14 to 21 days. Water inthe curing tanks is changed every 3 to4 days.

6 After curing, the Blocks are driedin natural atmosphere and sent for Concrete Paving Blocks gain goodstrength during the first 3 days of curingand maximum gains in strengths aresecured in the first 10 to 15 days ofcuring. After curing, Blocks are allowedto dry in shade so that the initialshrinkage of the Blocks is completedbefore they are used in the work. Adrying period of 7 to 15 days wouldnormally complete the drying shrinkageafter which they can be used. Theconcrete Tiles are similarly produced withthe help of semi-dry pressing of themixture and allowed to set for 24-36hours.

7 It is cured in the tanks for 15days. If need be water can also besprinkled to gain maximum physicalstrength in 15-21 Control and Standardsa) Indian Standard SpecificationThere is no Indian StandardSpecification specifically on cementconcrete Paving Blocks . However, thespecifications laid down in IS 2185 (Part1) Specification for Concrete masonryunits: Part 1 for Hollow and Solidconcrete Blocks , may be used as generalguidelines for meeting the qualityparameters, since the Paving Blocks arealso essentially solid Cement ) Quality RequirementsProportioning of raw materials,mixing, compacting, curing and dryingare the important stages of parameters like actual proportionof the individual raw materials, ratio ofcoarse aggregates to fine aggregates,water to Cement ratio, good finish, accuracyin size and shape and compressionstrength after curing are the some of theimportant parameters that should bechecked periodically to ensure goodquality of the Capacity (per annum)Quantity: 800 tonnesValue: Rs.

8 22, 00, 000 Motive ControlDust collecting unit is required to beinstalled at the mixing and raw materialhandling section. The workers may usedust ConservationGeneral maintenance of the machineand drive system can be employed forsaving ASPECTSA. Fixed Capital(i) Land and (Rs.) (Rs.)Land4005002,00,000 Built up AreaOffice and Stores502,000 1,00,000 Working Shed1501,500 2,25,000 Total5,25,000 Cement Concrete Tiles AND Paving BLOCKS30(ii) Machinery and (Nos.) (Rs.) (Rs.)Production UnitConcrete mixer: capacity 10cft/7cft with 3 hp motor, speed of ,00075,000mixer drum 20 rpm, and other accessoriesHydraulically operated Concrete block making ,25,000 1,25,000capacity 1500 Blocks per shift, with pressure vibrationtechnique for compaction, 3 HP motor, and other accessoriesMechanical tile melting press with 7HP motor145,00045,000 Construction of curing ,50025,000 Mould tools, ,000 Water pump ,00025,000 Cost of erection, installation and electrification, at 10% of the above32,000 Cost of office equipment, furniture ,500 Total3,95,000(iii) Pre-Operative Expenses (per month)(Rs.)

9 Project report cost, non-refundable25,000deposits, etc.(iv) Total Fixed Capital (i+ii+iii)9,45,000B. Working Capital (Per Month)(i) Personnel (per month) (Rs.) (Rs.)Administration andSupervisory personnelSupervisor15,0005,000 Clerk13,0003,000 Watchman12,0002,000 Technical: Skilled and Semior Unskilled personnelSkilled Workers22,5005,000 Unskilled workers81,800 14,400 Perquisites @15% of the above4,410 Total cost of Salaries and wages33,810(ii) Raw Materials (per month)ParticularsImp/Qty. UnitRate ValueInd. (Rs.) (Rs.)Portland cementInd. 15 Tonnes3,200 48,000 SandInd. 35 Tonnes 2508,750 Cement Concrete Tiles AND Paving BLOCKSP articularsImp/Qty.

10 UnitRate ValueInd. (Rs.) (Rs.)Stone chipsInd. 70 Tonnes 30021,000 Total77,750(iii) Utilities (per month) (Rs.) (Rs.)(Rs.)Electrical Power500kWH42,000 Water100 Kiloliters202,000 Total4,000(iv) Other Contingent Expenses (per month)ParticularsValue (Rs.)Postage and Stationery500 Telephone500 Consumable stores2,000 Repairs and maintenance1,500 Transport Charges1,500 Advertisement and Publicity1,000 Insurance500 Taxes500 Sales Expenses1,500 Miscellaneous Expenses500 Total10,00031(5) Rate of Return (percent)=Net Profit per year x 100 Total Capital investment=4,48,900 x 10013,21,680= (6) Break Even PointFixed CostValue (Rs.)