1.
A Brief Introduction
CHELSEA BLOCKS AND PIPES PRIVATE LIMITED
Plot No 11, Sector – 5, Industrial Estate, Phase II, G.C. Bawal (Haryana)
Tele No: 0124 4556500 FAX No: 0124 4103537
Email: rishabhjain@chelseamills.com

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INDEX
Topic Page No.
1. Introduction 3
2. Production and Location of Plant 3
3. Raw material 3
3.1. Cement Consumption 4
3.2. Fly Ash Consumption 5
4. Products 5
4.1. Solid Concrete Block 6
4.1.1. Advantages of Solid Concrete Blocks 6
4.2. Hollow Concrete Block 7
4.2.1. Advantages of Hollow Concrete Blocks 7
4.2.2. Structural Advantage 8
4.2.3. Constructional Advantages 8
4.3. Pavers 9
4.3.1. Grassy Pavers 10
4.3.2. Advantages of Pavers 10
4.3.2.1. Versatility 10
4.3.2.2. Durability 11
4.3.2.3. Economical 11
4.3.2.4. Environmentally Friendly 11
4.3.2.5. Weather Resistant 11
5. Great investment for Developers, Individual homes and Farm Houses. 12
6. What are the advantages of using concrete blocks over conventional Clay bricks? 12

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1. Introduction
We are a Garment export company based in Gurgaon. We have been supplying garments to the
leading names in global retail like GAP, banana republic, Old Navy, Armani exchange etc. for over
30 years. In our endeavor to diversify, we have selected the production and Supply of Green
Building in the NCR. The line of products we will be introducing first, are Concrete‐Fly ash Blocks
and High‐end Pavers. We will be manufacturing these products using state‐of‐the‐art, German
plant and machinery.
2. Production and Location of Plant
We are using state of the Art German machinery from Hess Group , Germany with Capacity to
produce 30,000 concrete Blocks and over 5000 M2
of Pavers every 8 Hours. We have established
our plant in Bawal, Haryana.
3. Raw Materials Required

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3.1. Cement Consumption
Concrete is a mixture of ordinary cement, mineral aggregate (sand and stone chips) and water.
The water used in preparing the concrete serves two
Purposes:
(1) It combines with the cement to form a hardened paste
(2) 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... Natural sand is often used as fine aggregate in cement
concrete mixture. Coarse aggregate are crushed stone chips. 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.
Approximate of Cement Consumption in our Plant
Cement Consumption Per Day – 2 Shift 100 Tons

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3.2. Fly Ash Consumption
Fly ash improves block manufacturing in two basic ways. It gives producers the strength required
and, at the same time, the added plasticity that fly ash contributes to the relatively harsh block
mixes assures improved finish and texture; better mold life, and better, sharper corners. Additional
benefits of fly ash in block include reduced permeability and shrinkage, increased durability and
virtual elimination of efflorescence. It is used as replacement of cement and to that extant the
volume of the product will reduce as the fly ash will have lower weight on compaction.
Approximate of Fly Ash Consumption in our Plant
Fly Ash Consumption Per Day – 2 Shift 80 Tons
4. Products
In present construction scenario, concrete blocks are well accepted masonry unit to build
foundations, walls, arches, and corbels etc. A typical concrete block, proposed by the company, is
equivalent to 9 bricks thus construction is faster than with other masonry units. The mortar used
is also less which results in cost saving. Concrete blocks have been extensively used is also less
which conventional roofing systems like fired bricks, dressed stone and compressed earth blocks
for composite wall construction.
Acceptability of concrete blocks is very high in urban areas for all types of buildings. It is a popular
walling material for major qualities like low maintenance, insulation and strength for institutional
and industrial buildings. The durability of a cement based product is making concrete blocks a
preferred choice in rural areas as well. The increase in construction activities as well as the huge
demand of concrete products in India mainly in North India is a major decisive factor to setup a
factory in the region. This facility will mainly be to produce concrete blocks using Fly Ash and its
Blocks, interlocking pavers, and other landscaping products.

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4.1. Solid Concrete Block
Strength and durability are special characteristics of solid concrete blocks. As a core building
material, it has stood the test of time and is now meeting the needs of modern designers. Solid
blocks are ideal for structural application like foundations, load bearing walls and structures. These
can also be used for protection against fire and for sound insulation.
Products Dimension
(mm)
Strength
(N/mm)
U‐Value
(w/m²k)
Weight
(kgs)
Density
(kg/cu.m)
Fire
Resistance
(hrs)
Sound
Insulation
(db)
Solid
Block
400 X 200
X 200
15 ‐ 20 1.5 32‐34 2000 6 48
4.1.1. Advantages of Solid Concrete Blocks
∙ Light weight
∙ High load bearing capacity
∙ Faster construction
∙ Thermal insulation
∙ Resistant to earthquake
∙ Eco‐Friendly
∙ Saving in steel reinforcement
∙ Less cement consumption

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4.2. Hollow Concrete Block
Hollow concrete blocks are precast masonry units made out of Op Cement, aggregate, fly ash and
concrete mix with 4 hollow cavities and are intended for use in the construction of both load
bearing and non‐load bearing wall structures. One can use dry concreting method for
manufacturing these hollow blocks using variotronic compaction which is a patented system
involving state of the art vibration coupled with compression. These hollow blocks never
disintegrate during their lifetime and deliver trouble free performance. It is very easy and fast to
conceal electrical and sanitary service lines within these hollow blocks. The tool required for
conducting is double blade wall chaser.
Products offered by the company ‐ Main Variant
Product Size
Hollow Block 200*400*200
Solid Blocks 200*400*200
Paver 100*200*60
4.2.1.Advantages of Hollow Concrete Blocks
1. Highly Durable: The good concrete compacted by high pressure and vibration gives substantial
strength to the block. Proper curing increase compressive strength of the blocks. Far exceeding
ISO codes
2. Low Maintenance, Color and brilliance of masonry withstands outdoor elements.
3. Load Bearing, strength can be specified as per the requirement.

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4. Fire Resistant
5. Provide thermal and sound insulation: The air in hollow of the block, does not allow outside
heat or cold in the house. So it keeps house cool in summer and warm in winter.
6. Environment Friendly, fly ash used as one of the raw materials.
7. Lower insurance rates.
4.2.2.Structural Advantages
1. In this construction system, structurally, each wall and slab behaves as a shear wall and a
diaphragm respectively, reducing the vulnerability of disastrous damage to the
structure/building, during the natural hazards.
2. Due to the uniform distribution, this construction system can safely resist lateral or cyclic
loading, when compared to other conventional masonry construction systems. This
construction system has also been proved to offer better resistance under dynamic loading,
when compared to other conventional systems of construction.
4.2.3. Constructional Advantages
1. No additional formwork or any special construction machinery is required for reinforcing the
hollow block masonry.
2. Only semi‐skilled labor is required for this type of construction.
3. It is a faster and easier construction system, when compared to the other conventional
construction systems.
4. It is also found to be a cost‐effective disaster resistant construction system, as explained in the
report.

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4.3. Pavers
The fast moving product in the construction segment now is Paver
Pavers are made from a very dry mix of gravel, sand, cement and color. Pavers are said to have
zero slump. The more the slump, the weaker the concrete. Therefore the Pavers manufactured
will be high on strength and this is ensured through slump tests. A slump test is done in a
laboratory to test the strength of concrete. A surface is tested for strength by placing a point load
onto it and exerting a direct force until it fails. The pressure is calculated, and that is the failing
point. The pavers will have 60mm thickness have a compressive strength of a range M40 to M50
which can essentially be used for a very heavy duty traffic as per IS codes recommendations

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4.3.1.Grassy Pavers ( Other Pavers )
Grassy Pavers are environmentally friendly. They allow the drainage of storm water back into
the underground soil rather than into storm drains. This helps keep place / property hydrated
and reduces runoff into local sewer systems. They provide the strength of pavement with the
natural beauty of grass while simultaneously eliminating soil compaction, reducing reflective
heat and allowing for all weather accessibility at a very cost effective price. In addition to the
environmental benefits, Grassy Pavers can carry weight of fire tenders.
4.3.2.Advantages of Pavers
4.3.2.1. Versatility
Concrete pavers are an ideal choice for both residential and commercial applications, including
surface covering for driveways, parking lots, promenades, sidewalks. Interlocking concrete pavers
are sensible and aesthetically attractive choice for all outdoor surfaces. They have non‐skid surface
and are safe to walk even when they are wet.

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4.3.2.2. Durability
Pavers' combination of strength, resilient abrasion resistance, and flexibility deliver highly durable,
crack‐proof pavement able to handle all types of wheeled traffic and pedestrians with very low
maintenance requirements. Areas surfaced with concrete pavers are immediately useable,
guaranteeing a quick process of any application and contract jobs, which is especially important
when resurfacing highly populated areas. Whether for new construction or resurfacing of old
unsightly or damaged surfaces, consider the valuable benefits of interlocking pavers.
Manufactured to tight dimensional tolerances, pavers are stronger than regular poured concrete
surfaces and more durable than black asphalt. They can take more abuse and last for generations.
A segmental paving system allows for expansion and contraction without producing surface
cracks, unlike monolithic concrete surfaces and stamped concrete.
4.3.2.3. Economical
When considering maintenance and replacement costs, pavers offer an economical long‐term
alternative to other types of pavement. They can be laid in almost any weather condition and
require no grouted joints, mortar (other than perimeter reinforcement), and concrete sub‐base
or curing time. We will consider the initial installation costs and the long term maintenance costs
involved, so as to get an estimate of the overall costs of the project at hand.
4.3.2.4. Environmentally friendly
Pavers are made of natural aggregates without petroleum‐based products. Water percolates
through joints, preventing less run off. This makes pavers an environmentally safe product and
enables us to all pitch in and be green.
4.3.2.5. Weather Resistant
Pavers can be used in all climates and can be walked on immediately upon completion. Cracking,
which is common with traditional asphalt and concrete pavements, is not an issue with these
interlocking concrete pavers due to the joints between the pavers. Interlocking concrete pavers
are a flexible system and allow for movement. They are almost indestructible. This pavement
system moves in unison with the earth's usual tendency to swell and contract over the long term,
thus avoiding any serious damage. In colder climates where snow is a common element, concrete
pavers are the ideal choice. Concrete pavers resist deterioration of freezing and thawing cycles
and de‐icing salts better than asphalt and ordinary poured in place concrete. Snow can be plowed,
blown, or shoveled just like asphalt or concrete pavements. The beveled or chamfered edges of

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pavers prevent plows or shovels from catching on the edge. Other methods of snow removal can
also be applied to these pavers. De‐icing products such as calcium, chloride, or salt will not harm
the pavers. Electric or liquid snow melting systems work well under concrete pavers, eliminating
snow removal while reducing slip hazards. Darker colored pavers can also aid in accelerating the
melting process.
5. Great investment for Developers, Individuals homes
and Farm Houses.
Interlocking concrete pavers will enhance the aesthetics and value of place / property. Offering a
wide selection of colors, shapes and finishes, these products enhance any architectural style from
Craftsman to Contemporary and Mission to Mediterranean. All of these will add immediate value
to any place /property for several key factors. One, they are guaranteed for life and the
manufacturer backed warranty can be transferred from one owner to the next. Second, they are
beautiful pieces of functional art that will add curb appeal to any style home. In turn, they help
sell the house quicker. Third, they are environmentally friendly and anything that each of us can
do to help our environment is a great investment for all of us.
6. What are the advantages of using concrete blocks over
conventional clay bricks?
Concrete blocks have a proven track record and are used extensively in developed countries.
Uniformity of blocks and bigger size blocks ease up the speed of construction and saves mortars
in the masonry. The density of the blocks can be varied to make it a load bearing or non‐load
bearing block as per structural designs and this allows the architects and structural engineers to
experiment with more designs to meet different compressive strengths of the material. Concrete
blocks offer better sound insulation and excellent fire protection, Hollow blocks offer better heat
insulation, and it can be further enhanced by adding polystyrene insert in between them for
reducing the air conditioning load.
The manufacturing of red clay kiln bricks involves use of scarce fertile agricultural land and these
clays bricks are again burned in the kiln causing air pollution. These production sites are also found
wanting in terms of human safety as a major chunk of brick kiln manufacturing in India is in
unorganized sector. So I would state that environmentally also concrete block scores over very
positively over red clay bricks. HESS always looks into a turnkey project as per the clients need
from time to time.