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Light Weight Block (CLC) Manufacturing Plant
- 1. Light Weight Block (CLC) Manufacturing Plant 1
- 2. 2 Company Overview GUBBI INTRODUCTION CLC Features Process Chart CLC Plant Link CLC Component Economics Plant Capacity COMPARISON Agenda WHAT IS CLC? CLC Advantages Comparison between CLC Block & AAC Block Comparison between CLC Block & Bricks Raw Material CLC Block
- 3. GUBBI INTRODUCTION Gubbi Paints Manufacturers & Suppliers of Paints & Coating. Gubbi Pavers & Tiles (I) Pvt Ltd Manufacture of paver block & tiles. Our Paver Blocks are manufacturer as per IS 1558:2006 GUBBI GROUP OF COMPANIES 3 Gubbi Civil Engineers Leading contractors in the field of Civil engineering. Gubbi Enterprises Manufacturer of ISI Cube Mould (IS :10086). All kind of construction Equipment., Chemicals, Testing Equipment
- 4. WHAT IS CLC? Raw Material Cement Fly Ash IESC Resource Pool Selecting Procedure IESC remote support and Performance tracing Deployment to requirement end OJT before deployment Resource requirement Requirement feedback 66.66% 22% 33.33 % 2% 1% 8% % of Volume GSM CDMA ADSL WIMAX LTE UMTS Final mixture results in many small air cells uniformly distributed through out the concrete. Foam air bubble CLC is called as Cellular Light Weight Concrete and it is also called as Foam Concrete. 4
- 5. CLC FEATURES CLC Quick returns Future product 10 HP Power require Easy to install Can earn more profit Less competi tion Green Product 6000 Sqft Area require Low Investm ent Foam concrete manufacturing consumes higher amounts of fly ash (which is a waste material from thermal power stations) hence it is considered as green building material. 5
- 6. CLC ADVANTAGES Two to Three times less weight then clay or fly ash bricks Light in Weight Eco friendly . Sound Insulation Thermal Insulation Lower Water Absorption Fire Protection Environment-friendly. The production process of CLC or its use does not release any harmful effluents to ground, water or air. excellent for Sound insulation which keeps the house cool in Summer and warm in Winter As a 100mm thick CLC wall, the equivalent thickness of dense concrete wall The low water absorption property of these blocks will help to reduce the cracks in the walls. CLC Blocks offers grate fire protection. Fire rating of cellular concrete is far superior to that of brickwork or dense concrete. 6
- 7. Water Hardener Tank Manual Plant Fly Ash/ Sand Foam Generator Foam Chemical Foam Mixer Foam Pumping Trolley Pre Fab Mould Stock Yard Curing Zone Cement Compressor PROCESS CHART 7
- 10. Foam Concrete Mixer 10 FOAM CONCRETE MIXER CLC MOULD
- 11. CLC components 11 AIR COMPRESSOR LOAD CELL & INDICATOR
- 12. CLC components 12 BELT CONVEYOR SCREW CONVEYOR
- 14. CLC Block Raw Material 14 Fly-Ash: This Raw material is freely available in Thermal Power plants. There are no taxes on this item whatsoever. Transportation charges are only to be attended by the entrepreneur. Cement: This Project aims to utilize OPC cement as main binder material. It will give faster strength to the bricks, besides giving improved consistent quality. It also ensures a better cost effectiveness for the same. Using OPC will be a standardized practice. The other prime advantages of using OPC (compared to other binders) is it’s easy availability locally through nationwide Retail Network of Cement Companies. Foaming Agent: Foaming agent is fully biodegradable protein-based foam concentrate that forms stable bubbles and provides necessary porosity to the foam concrete. The bubbles formed are strong enough to last until the concrete is set at required density. 40-50 gms per Ltr – Foam Density. Foaming agent is easily available in the market. Water. Water hardness maximum 100 PPM ·Need Industrial Softer for Hard Water
- 15. CLC Block Application CLC Block 15
- 16. The different sizes in CLC Blocks Size in MM Size in inches Weight in Kg 600 x 200 x 100mm 24 x 8 x 4” 10 600 x 200 x 150mm 24 x 8 x 6” 15 600 x 200 x 200mm 24 x 8 x 8” 20 600 x 200 x 225mm 24 x 8 x 9” 24 16
- 17. Cost of Product in per cubic meter Cement : 250kg x 6.5 Rs./kg = 1625.00 Rs. Fly Ash : 550kg x 0.8 Rs./kg = 440.00 Rs. Foaming Agent: 1.5kg x 80 Rs./kg = 120.00 Rs. Raw Material cost = 2185.00 Rs. * Production cost depend upon availability of Raw Material Economics 17
- 18. Standard Sizes & Weight * Production cost depends upon availability of Raw Material Size in MM No of Block in one m3 Weight in Kg Production Cost Selling Cost 600 x 200 x 100mm 83 10 24 40- 45 600 x 200 x 150mm 55 15 36 57- 60 600 x 200 x 200mm 41 20 50 76- 82 600 x 200 x 225mm 36 24 58 95- 105 Overall Economics 18
- 19. Plant Capacity 19 Mixer Capacity Plant Capacity Shaded area Open space Power (HP) 0.5 m3/ batch 6-8 m3/ day 3000 sqft 3000 sqft 15 HP 0.6 m3/ batch 8- 10m3/ day 4000 sqft 4000 sqft 15 HP 1.5 m3/ batch 25- 30m3/ day 5000 sqft 7000 sqft 25 HP
- 20. Parameters CLC Blocks AAC Blocks Basic raw materials Cement, fly ash, water and foam Cement, lime, specially grinded sand, aeration compound, high primary energy input Production process and set-up Using ribbon mixer and foam generator Produced only in well established plant, equipped with steam boiler and high pressure auto-claves Dry density kg/m³ 600/ 800 400/ 700 Compressive Strength kg/cm2 30- 40 20- 40 Usage Thermal insulation , partitions, non-load bearing blocks Non-load bearing panels and blocks Aging Gains strength with age (like conventional concrete) No aging Loses strength, if not protected against humidity Thermal conductivity (W/mK) 0.09 – 0.12 (depending on density) 0.09-0.15 (depending on density) Eco friendliness • Pollution free • No primary energy consumption • Consumes fly ash (an hazardous industrial waste material) * Pollution free * High energy consumption Comparison between CLC Blocks and AAC Blocks 20
- 21. Parameters CLC Blocks Burnt Clay Bricks Basic Raw Materials Cement, Fly Ash, water & foam Top agricultural soil, primary energy input Dry density kg/m³ 600/ 800 1900 Aging Gains strength with age (like conventional concrete) No Sound insulation Superior Normal Eco friendliness • Pollution free • No primary energy consumption • Consumes fly ash (an hazardous industrial waste material) • Creates smoke • high energy consumption • wastes agricultural land • Soil Erosion • Banned in more and more countries Thermal Insulation High Thermal Insulation Normal Thermal Insulation Compressive strength Compressive strength is more than other bricks Compressive strength is less Water absorption capacity CLC is a light weight block where water absorption is less as compared to red brick and fly-ash brick Red bricks and fly ash brick absorb more water than CLC blocks Comparison between CLC Blocks and Bricks 21
- 22. Parameters CLC Blocks Burnt Clay Bricks Concrete Blocks Basic Raw Materials Cement, Fly Ash, water & foam Top agricultural soil, primary energy input Cement, sand, aggregate Production process and set-up Using ribbon mixer and foam generator Processed in specially erected or central brick kilns Mobile or stationary Dry density kg/m³ 600/ 800 1900 1700 Compressive Strength kg/cm2 25 to 30 30-80 30-100 Aging Gains strength with age (like conventional concrete) No Yes Usage Thermal insulation , partitions, non- load bearing blocks Load bearing & non-load bearing walls Load bearing & non-load bearing walls Sound insulation Superior Normal Better Eco friendliness • Pollution free • No primary energy consumption • Consumes fly ash (an hazardous industrial waste material) • Creates smoke • high energy consumption • wastes agricultural land • Soil Erosion • Banned in more and more countries - low energy - no smoke Thermal conductivity (W/mK) 0.09 – 0.12 (depending on density) 0.4 2.1 Block / element size and shape Any size, shape given by mould/cut Typically shape and size Typically size Water absorption capacity CLC is a light weight block where water absorption is less as compared to red brick and fly-ash brick Red bricks and fly ash brick absorb more water than CLC blocks Concrete block absorb more water than CLC blocks 22 Comparison between CLC Blocks, Clay Bricks & Concrete Blocks
- 23. ASPECT BRICK WALL ECO BLOCKS (CLC WALL) REMARKS 1) Thickness •External •Partition 230 mm 115 mm 200/150 mm 100 mm Saving of 13 to 35 % Saving of 13 % 2) Mortar Masonry •External •Partition • Plastering 0.051 m3/m2 0.02 m3/m2 12 + 15 mm 0.011 m3/m2 0.005 m3/m2 8 + 10 mm Saving of 78 % Saving of 75 % Saving of 33 % 3) Dead Load •External •Partition 601 Kg / m2 319 Kg / m2 256 / 206 Kg/m2 148 Kg / m2 Reduction of 60 % Reduction of 48 % 4) Labour for work • Quality 100% Normal 60% Superior Reduction of 40 % Satisfied Client 5) Ease of Working • Chase cutting • Driving nail -Difficult -Easy -Easy Faster Laying service Happy client 6) Longevity May Detroit with time Gains strength with time as ordinary concrete Better Durability COMPARISON OF BRICKS AND CLC 23
- 24. GUBBI ENTERPRISES 18/26, Dev Prayag CHS Ltd, Bhakti Mandir Road, Nr. Hari Niwas Circle, Thane (W)-400 605 Tel No: 022- 25392279/ 25383839 Mob No. 7498532822/9224490588 Email: clcplant@gmail.com Web: www.clcblockmachine.in, www.clcplant.com