Industry Overview
Fibre cement board (FCB) has been used since the 1900s, when Ludwig Hatschek developed a process combining 90% cement and 10% asbestos fibres with water to produce asbestos cement board. The material became widely used in residential construction until the discovery in the 1970s that asbestos cement could cause mesothelioma, a rare form of lung cancer. Consequently, many countries strictly prohibited its use.
Modern fibre cement board is manufactured from cement, water, silica, limestone flour and fibres, which may be recycled, synthetic or cellulose-based. Optional additives such as silica fume, metakaolin, fly ash, calcium silicate, flocculants and defoamers may be incorporated to modify processing and product properties. Board strength, moisture resistance, dimensional stability and cost depend significantly on fibre type and formulation.
FCB is fire, moisture, impact and decay resistant, while its relatively low weight facilitates handling and transportation. Decorative finishes can reproduce wood or brick effects. The material is suitable for internal and external applications including façades, roofing, cladding, walls, flooring, underlay and tile backing. Three principal production methods are identified in the report: the Hatschek process, Extrusion process and Perlite process.
Cost Estimation
| Cost / Financial Parameter | Value |
|---|---|
| Plant Capacity | 360 MT/Day |
| Land & Building (4850 sq.mt.) | Rs. 4.39 Cr |
| Plant & Machinery | Rs. 6.85 Cr |
| Working Capital for 3 Months | Rs. 35.64 Cr |
| Total Capital Investment | Rs. 47.47 Cr |
| Rate of Return | 72% |
| Break Even Point | 23% |
Content Index
- INTRODUCTION
- HATSCHEK PROCESS PRODUCTION OF FCB
- EXTRUSION PROCESS PRODUCTION OF FCB
- PERLITE PROCESS OF FCB
- WOOD WOOL CEMENT BOARD (WWCB)
- CEMENT BONDED PARTICLE BOARD (CBPB)
- BISON PLANT PRODUCTION OF CBPB
- ELTOMATION PLANT PRODUCTION OF CBPB
- WOOD STRAND CEMENT BOARD (WSCB)
- USE/APPLICATION/ADVANTAGES
- APPLICATION
- LONG LIFE SPAN
- VERSATILITY IN STYLE
- THE BEST WAY TO EMULATE WOOD
- INSTALLATION OPTIONS FOR AESTHETICS
- MATERIAL IS FIRE (AND HEAT) RESISTANT
- LARGELY WEATHER RESISTANT
- RESISTANT TO WARPING AND ROTTING
- IDEAL FOR TORNADO AND HURRICANE PRONE AREAS
- MINIMAL MAINTENANCE REQUIRED
- EASY INSTALLATION
- FIBRE CEMENT CUTS A VARIETY OF WAYS
- GREAT WARRANTY
- EXPANDS AND CONTRACTS LESS THAN WOOD
- USE OF FIBRE CEMENT BOARDS IN INDUSTRIALIZED HOUSE MAKING PROCESS
- STEPS ARE FOLLOWS:
- CUTTING MACHINES FOR LONGITUDINAL AND CROSS SECTIONS
- THIS MACHINE ALLOWS ANGULAR CUTTING OF THE FRONT WALL ELEMENTS ON WHICH THE ROOF RACK PROFILES ARE MOUNTED
- THE CONCRETE FLOOR SLAB IS PRODUCED EXACTLY ACCORDING TO PLAN
- THE METAL DOOR AND WINDOW FRAMES ARE INSTALLED
- FIBRE CEMENT BOARD/PANEL SPECIFICATIONS
- ASTM TESTING METHODS
- MARKET OVERVIEW
- INDIAN FIBRE CEMENT MARKET SEGMENT ANALYSIS - BY TYPE
- INDIAN FIBRE CEMENT MARKET SEGMENT ANALYSIS - BY PRODUCTION PROCESS
- INDIAN FIBRE CEMENT MARKET SEGMENT ANALYSIS - BY APPLICATION
- INDIAN FIBRE CEMENT MARKET SEGMENT ANALYSIS – GEOGRAPHY
- INDIAN FIBER CEMENT MARKET DRIVERS
- INDIAN FIBER CEMENT MARKET CHALLENGES
- MARKET LANDSCAPE
- GLOBAL MARKET
- RAW MATERIALS
- SPECIFIC PROPERTIES OF CEMENT
- RAW MATERIAL COMPOSITION
- PROCESS DESCRIPTION/PROCESS FLOW SCHEMATIC
- THE TYPICAL PROCESS FLOW SCHEMATIC IS SHOWN BELOW:
- PLANT & MACHINERY USED FOR THE PROCESS
- PLANT & EQUIPMENT SUPPLIER
- BOILER
- GENERATOR SET (DG SET)
- MANUFACTURERS/SUPPLIERS OF PLANT & MACHINERY
- PRESSING MACHINE
- COOLING TOWERS
- BOILER
- GENERATOR SET (DG SET)
- BALL MILLS
- CEMENT SILO
- HYDRO PULPER
- AUTO CLAVE SYSTEM
- WATER JET SYSTEM
- TURN KEY CONSULTANT
- MANUFACTURERS/SUPPLIERS OF RAW MATERIALS
- CELLULOSE FIBRE
- GENERATION AND MANAGEMENT OF WASTES
- SOLID WASTES
- LIQUID WASTES
- GASEOUS EMISSION
- OTHERS
- INDUSTRIAL WASTE MANAGEMENT
- SEWERAGE SYSTEM
- ANTICIPATED ENVIRONMENTAL IMPACTS
- CONSTRUCTION PHASE
- OPERATION PHASE
- MITIGATION MEASURES (PROPOSED)
- HEALTH SAFETY & ENVIRONMENT
- SAFETY & OCCUPATIONAL MEASURE (STORAGE/HANDLING OF RAW MATERIAL & PRODUCT)
- PROPOSED IMPLEMENTATION SCHEDULE
- PROJECT FINANCIALS
- BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)
Appendix
- APPENDIX – A:
- 01. PLANT ECONOMICS
- 02. LAND & BUILDING
- 03. PLANT AND MACHINERY
- 04. OTHER FIXED ASSESTS
- 05. FIXED CAPITAL
- 06. RAW MATERIAL
- 07. SALARY AND WAGES
- 08. UTILITIES AND OVERHEADS
- 09. TOTAL WORKING CAPITAL
- 10. TOTAL CAPITAL INVESTMENT
- 11. COST OF PRODUCTION
- 12. TURN OVER/ANNUM
- 13. BREAK EVEN POINT
- 14. RESOURCES FOR FINANCE
- 15. INSTALMENT PAYABLE IN 5 YEARS
- 16. DEPRECIATION CHART FOR 5 YEARS
- 17. PROFIT ANALYSIS FOR 5 YEARS
- 18. PROJECTED BALANCE SHEET FOR (5 YEARS)
Frequently Asked Questions
Fibre cement board is a composite construction material made primarily from cement, water, mineral components and reinforcing fibres. Depending on the formulation, the fibres may be cellulose, synthetic or recycled. Optional additives can be used to modify processing and product characteristics. FCB is valued for its fire, moisture, impact and decay resistance, relatively low weight and versatility. It can be manufactured in decorative finishes and used for applications such as façades, roofing, cladding, walls, flooring, underlay and tile backing in both internal and external construction.
The main raw materials for fibre cement board are cement, water, silica, limestone flour and reinforcing fibres. Fibre selection can include virgin cellulose, recycled cellulose or synthetic fibres, depending on the desired product properties and economics. The report also identifies optional materials such as silica fume, metakaolin, fly ash and calcium silicate, together with processing aids including flocculants and defoamers. The precise formulation is important because it influences strength, water resistance, dimensional stability, durability and manufacturing performance.
The three principal fibre cement board production processes identified in the report are the Hatschek process, Extrusion process and Perlite process. Each method uses a different approach to forming and processing the cement-fibre mixture into boards. Process selection depends on factors such as product design, raw-material formulation, required properties, equipment configuration and production requirements. A project evaluation should therefore consider the intended product range, process technology, machinery requirements, quality specifications and associated operating conditions before selecting a manufacturing route.
Fibre cement board is commonly used for both internal and external building applications. The report identifies weatherboard and façade systems, roofing, cladding, external and partition walls, underlay, flooring and tile backing among its applications. Its combination of durability, resistance to fire, moisture, impact and decay, and relatively easy handling makes it suitable for a wide range of construction requirements. Decorative surface treatments can also reproduce wood or brick appearances, allowing FCB products to combine functional performance with architectural and aesthetic requirements.
Fibre type significantly influences the strength, moisture behaviour, dimensional stability and cost of fibre cement board. Synthetic fibres such as Kevlar or carbon can produce very strong, moisture-resistant boards but are comparatively expensive. Cellulose fibres are economical and widely used, although their characteristics can affect cement setting and water resistance. Recycled cellulose fibres offer environmental and economic advantages but are generally shorter than virgin fibres and may produce weaker boards. Appropriate formulation and processing can help control these performance differences.
Fibre cement board offers a combination of durability, fire resistance, moisture resistance and relatively low weight that makes it useful in construction. The report also highlights resistance to impact, decay, warping and rotting, together with minimal maintenance requirements and easy installation. FCB can be cut in different ways and manufactured with finishes that emulate wood or brick. Its relatively stable dimensions compared with wood can also be beneficial in building applications. These characteristics support its use in façades, roofing, walls, flooring and other construction systems.
A fibre cement board manufacturing plant can require a range of process and utility equipment depending on the selected production technology. The report identifies equipment and systems including pressing machines, cooling towers, boilers, generator sets, ball mills, cement silos, hydro pulpers, autoclave systems and water jet systems. Equipment selection should be aligned with the chosen production process, product specifications, required capacity and plant layout. Supporting systems for raw-material handling, utilities, environmental management and occupational safety are also important components of an industrial project.
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