Detailed Project Report on sand cement based ready mix mortars

SAND-CEMENT BASED READY MIX MORTARS
 [CODE NO. 3124]

Dry Mortar Mix is gaining eminence in modern times owing to its versatile

superiority in regard to characteristics over the conventional in-situ mortars

viz. better performance easy to uses easy to set and the quality of leaving no

crakes and voiles. Besides it has preferably better and wider field of

application as patching & repairing materials for plasting purposes and other

construction works viz. internal/external plastering masonry work etc.  It is a

very good substitute for  conventional  in-situ mortars.

    Various  types  of  Ready mix  dry  mortar  comprise internal plaster  

mortar,  external plaster mortar masonry  mortar,  quick setting  mortar high

strength mortar repair mortar  self  leaving flooring mortar pre-mix RCC mortar

etc.

    One specific advantage regarding manufacture of these ready mix dry mortar

is that they can be manufactured in a single unit by variation in composition  

proportions  as  per   different formulations.

    Ready mix dry mortar is particularly useful on congested siles or in road

construction where little space for the  mixing plant and for extensive

aggregate stockpile is available but  the greatest single advantage of ready

mix dry mortar is that it may be made under better conditions of control than

are  normally possible on any large construction sites.

MORTARS

    These consist of finely ground refractory grain and plasticizers that can

be  thinly spread on brick during construction.

    For air - setting mortars sodium silicates or phosphates provide strength

at  room temperature. Heat setting mortars contain no additives and develop

strength only when a ceramic bond is formed at high temperatures.


AIR - SETTING MORTAR

A refractory composition containing chemical agents that sure hardening at

temperatures below that of ceramic bonding but above room temperature sometimes

called "air hardening".

HOT-SETTING BONDING MORTAR

A refractory mortar material which requires relatively high temperature fro the

development of a bond.

MASONRY CEMENTS

Masonry cements are cements fro use in mortars for masonry construction.  They

are formulated to yield easily workable mortars and contain special additives

that reduce the  loss  of water from the mortar to the prours masonry units.


COST ESTIMATION

Plant  Capacity                               :       1600.00 MT/day
Land & Building (35000 Sq.ft)    :    Rs. 13.30 Cr
Plant & Machinery                          :    Rs. 21.00 Cr
Working Capital for 2 Months     :    Rs. 35.25 Cr
Total Capital Investment              :    Rs. 70.00 Cr
Rate of Return                               :    26%
Break Even Point                           :    47%


INTRODUCTION                                    
USES AND APPLICATION                            
PROPERTIES AND CHARACTERISTICS                            
B.I.S. SPECIFICATION                                
RAW MATERIALS FOR DRY MIX MORTAR                        
PRODUCTION AND TYPES OF DRY MIX MORTAR                        
MARKET SURVEY (INDIAN)                                
MARKET POTENTIAL OF DRY MIX MORTORIN MAHARASHTRA            
PRESENT MANUFACTURERS/SUPPLIERS OF DRY MIX MORTAR                
RAW MATERIALS AND COMPOSITION     OF DRY MIX MORTAR                
TECHNICAL DETAILS OF MORTAR MIX                            
FORMULATIONS                                    
FORMULATION OF DRY MIX MORTAR (TILE ADHESIVE)                    
PROCESS OF MANUFACTURE OF READY DRY MIX MORTAR                
PROCESS IN DETAILS AND EXPERIMENTAL WORK FOR
PROPERTY SPECIFICATION                                
PROCESS FLOW DIAGRAM                                
DRY MIX MORTOR TECHNOLOGY AND ITS ADVANTAGES                
MANUFACTURING OF VARIOUS TYPES OF READY MIX DRY
MORTARS IN THE SAME PLANT                            
INGREDIENT USED FOR THE MANUFACTURE OF READY MIX DRY MORTARS    
COST ANALYSIS OF VARIOUS TYPES OF MORTORS AND    COMPARISON WITH ONVENTIONAL
IN-SITU MORTARS                                
ADVANTAGES OF READY MIX DRY MORTARS OVER THE CONVENTIONAL IN-SITU MORTAR    
 CONCEPT OF READY MIX MORTAR AS A SUBSTITUTE FOR THE    CONVENTIONAL IN-SITU
(MADE AT SITE) MORTAR                                
MARKETING/ADVERTISING REQUIRED FOR THIS    KIND OF BUSINESS        
POSSIBILITY/VIABILITY TO SET UP THE PLANT AT A  DISTANCE OF 500 TO 1000 KMS
FROM THE MARKET BEING TARGETED                            
MARKETING OF THIS PRODUCT READY MIX DRY MORTAR VIS A VIS RETAIL & BULK (MASS
CONSTRUCTION)    
GENERAL PUBLIC PERCEPTION OF PRODUCT IN INDIA                    
PLANT LAYOUT                                    
 RAW MATERIALS CALCULATIONS                            
SUPPLIERS OF PLANT & MACHINERIES (INDIAN)                    
SUPPLIERS OF PLANT & MACHINERY (IMPORTED)                    
SUPPLIERS OF RAW MATERIALS                            
SUPPLIERS OF PLANT & MACHINERY (IMPORTED)                    
SUPPLIERS OF RAW MATERIALS                            
                                     

APPENDIX – A:

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET