Detailed Project Report on aac block manufacturing plant

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AAC BLOCK MANUFACTURING PLANT [3533]

To begin with, it is important to know that AAC Blocks are Autoclaved Aerated Concrete building product which has specific characteristics. These blocks are lightweight, highly-insulating and load-bearing. These blocks are much lighter in weight than the red brick blocks (three times lighter).

The ACC material is known to be developed in Sweden in 1924. It is known to be widely used in Europe and its use is rapidly increasing in other countries across the globe. The production of ACC is done using raw materials such as lime, cement, sand, water and a small amount of rising agent. The unique properties of AAC are achieved after the mixing and molding and autoclave under high heat and pressure.

AAC blocks are known to have unique set of properties of thermal insulation as well as acoustic absorption. AAC blocks are also known to be pest and fire resistant. These blocks are known to be environmentally and economically superior to the other widely used building materials such as stone, brick and wood.

Due to certain specific characteristics of AAC Blocks such as lightweight, durability, flexibility and ultimate workability – they are known to be excellent building material blocks. The properties of AAC offers the best of opportunities to increase the quality of building and reduce the costs involved in construction. AAC is used for various construction projects such as industrial buildings, commercial properties, residential homes, schools, hotels, and other properties.

The advantages of using ACC blocks in building are listed below:

- Lightweight

- Easy workability and design flexibility

- Faster construction

- Minimum wastage

- Energy efficient and thermal insulation

- Eco friendly and sustainable

- Acoustic performance

- Fire-resistant

- Cost-saving

- Seismic resistant

- Termite pest-resistant

- Water saver

The disadvantages of using ACC blocks are listed herewith:

- Non-load-bearing material (hence, can be used only for partition walls)

- Brittle nature (thus, require more crack than clay brick while transporting and handling)

- Cost per unit of ACC block is high

- Can’t hammer AAC block for services such as chiseling as it may break.

- Get cracks as these have brittle nature, depict dry shrinkage and use cement mortar.

It needs to be noted well that AAC is manufactured by combining lime, cement, pulverized fly ask, gypsum and aluminium powder into a mould. The lime, fly ash and aluminium powder react to form millions of microscopic hydrogen bubbles. These bubbles cause the concrete to expand to doule the rimes of original volume by which the evaporation of hydrogen leaves the concrete. This concrete is then cut into blocks which are then pressurized and steamed for 8-12 hours.

AAC blocks are known to offer both material and performance aspects from the perspective of sustainability. These blocks are known to incorporate a large quantity of air that contain much of raw material than many other building products. These blocks are known to create an energy efficient envelope that protects against loss of unwanted air. AAC blocks are also known to contribute in the local materials credits in green buildings.

COST ESTIMATION

Plant Capacity                              200 Cubic Mtr/Day
Land & Building (3 Acre)         Rs. 7.37 Cr
Plant & Machinery                        Rs. 3.79 Cr
Working Capital for 2 Months Rs. 3.93 Cr
Total Capital Investment             Rs. 15.30 Cr
Rate of Return                              32%
Break Even Point                        50%

INTRODUCTION
AERATED CONCRETE BLOCKS
AUTOCLAVED AERATED CONCRETE
STACKED BLOCKS OF AAC (WRAPPED IN FOIL)
RAW MATERIALS
FLY ASH SAND LIME AERATED BLOCKS
AUTOCLAVED AERATED CONCRETE BLOCKS
ADVANTAGES OF AUTOCLAVED AERATED CONCRETE BLOCKS:
PROPOSAL:
USES AND APPLICATIONS
AERATED CONCRETE BLOCKS
PROPERTIES
COMPOSITION OF PORTLAND CEMENT
ORDINARY PORTLAND CEMENT MAY HAVE THE COMPOSITION AS BELOW
B.I.S. SPECIFICATION
MARKET SURVEY
STRUCTURE AND DEVELOPMENT
AAC BLOCK: AN EMERGING GREEN BUILDING MATERIAL IN INDIA
SALIENT FEATURES OF AAC BLOCK: LEADING TO INCREASING
ACCEPTANCE OF THE PRODUCT
A QUICK COMPARISON BETWEEN AAC BLOCK AND CLAY BRICK
FLY ASH: CHANGING STATUS FROM HAZARDOUS INDUSTRIAL WASTE
TO USEFUL AND SALEABLE COMMODITY
DEMAND-SUPPLY SCENARIO OF AAC BLOCKS
INCREASING COMPETITION RESULTING INTO PRESSURE ON REALIZATIONS
FINANCIAL PERFORMANCE OF AAC BLOCK MANUFACTURERS
THE WAY FORWARD
1. SUSTAINABLE BRICKS
AAC BLOCKS HAVE A POTENTIAL MARKET WORTH $5.5 BILLION
   (RS. 330 BILLION) BY 2030
AAC VS. CLAY-FIRED BRICKS
BRICK INDUSTRY IN INDIA
INVESTMENT BOOST IN INFRASTRUCTURE THROUGH HIGHER
PUBLIC FUNDING POSITIVE
FUTURE OF CONSTRUCTION MARKET IN INDIA
LATEST MARKET RESEARCH REPORT (2014) BY PWC HIGHLIGHTS:
GROWTH DRIVERS
INVESTMENT OPPORTUNITIES IN INDIA
FDI POLICIES
FDI POLICY FOR INDUSTRIAL PARKS
ADVANTAGE INDIA
8 TOP REASONS TO INVEST IN INDIA
1. SIZE OF INDIA
2. ECONOMIC GROWTH
3. DIVERSITY
4. DEMOGRAPHICS
5. HIGH SAVINGS
6. DOMESTIC ECONOMY
7. A ROBUST FINANCIAL SECTOR
8. QUALITY OF INVESTMENT MARKETS
DETAILED EXPORT DATA OF AUTOCLAVED BLOCK
INDIA BRICKS AND BLOCKS MARKET TO 2021 – FOCUS ON AAC BLOCK
SCENARIO OF AAC BLOCK MARKET
OVERVIEW OF CONSTRUCTION INDUSTRY
MARKET SHARE OF DIFFERENT WALLING MATERIALS
COMPOSITION AND CHEMISTRY OF AAC
THE FINAL HYDRATION PRODUCTS ARE THEN PRINCIPALLY:
CALCIUM SILICATE HYDRATE COMPOSITIONS IN AAC
OTHER HYDROTHERMALLY-FORMED MINERALS:
ENVIRONMENTAL BENEFITS OF AUTOCLAVED AERATED CONCRETE
ADVANTAGE AND DISADVANTAGE OF AAC BLOCK
ADVANTAGES
DISADVANTAGES
BRICKS AND AAC BLOCKS
TECHNICAL SPECIFICATION OF AAC BLOCK
TECHNICAL SPECIFICATIONS & COMPARISON BETWEEN BRICK
   AND AAC BLOCK
COMPARISION BETWEEN BRICK AND AAC BLOCK
FORMULATION OF AAC BLOCKS
MANUFACTURING PROCESS OF AAC BLOCKS
DETAILS OF DOSING AND MIXING
PROCESS FLOW DIAGRAM
DETAILED MANUFACTURING PROCESS OF AAC BLOCKS
BRIEF PRODUCTION PROCESS:
COAL FLY ASH:
QUICK LIME:
GYPSUM:
CEMENT:
ALUMINUM POWDER PAST:
SCRAPE AND WASTE SLURRY:
BATCHING, MIXING, AND CASTING:
CUTTING AND GROUPING:
AUTOCLAVED AND FINISHED PRODUCT:
THE BOTTOM PLATE RETURNING, COMBINING WITH MOULD AND OILING:
AERATED CONCRETE BLOCK MACHINE
PRODUCT DESCRIPTION
1. INTRODUCE
2. AERATED CONCRETE COMMON CONCEPTION
3. ADVANTAGES LIGHT WEIGHT
KEEPING TEMPERATURE
HAVE MANY KINDS MATERIAL, HAVE LOWEST WASTE
AVAILABLE ABOVE MACHINE AT:
PLANT LAYOUT
PRESENT MANUFACTURERS/SUPPLIERS OF AAC BLOCKS
SUPPLIERS OF PLANT AND MACHINERY
COMPLETE PLANT AND EQUIPMENTS SUPPLIERS FOR AERATED
CONCRETE BLOCKS (FOREIGN)
SUPPLIERS OF RAW MATERIALS
FLYASH
CEMENT
GYPSUM
LIME POWDER
ALUMINUM POWDER
COMPLETE PLANT AND MACHINERY SUPPLIERS AND TECHNICAL
   ADVISORS FOR AAC BLOCKS

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)

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