CLC BRICK

CLC BRICK MAKING

PLANT

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 CLC BRICK

1. CLC BRICK

CLC is called as Cellular Light Weight Concrete and it is also called as Foam
Concrete. Cellular Light Weight Concrete (CLC) is a version of light weight concrete that is
produced like normal concrete under ambient conditions. CLC Blocks are a cement-bonded
material made by blending slurry of cement. Stable, pre-formed foam manufactured on site
is injected into this slurry to form foam concrete. Fresh foam concrete looks like a milk-
shake and the volume of slurry in the foam dictates the cast density of the foam concrete.

CLC blocks are a cement-bonded material made by blending slurry of cement. Stable,
pre-formed foam manufactured on site is injected into this slurry to form foam concert.
Fresh foam concrete looks like a milk-shake and the volume of slurry in the foam dictates
the cast density of the foam concrete.

1.1 ADVANTAGES OF CLC BRICK PLANT

 Low Investment
 Quick returns
 Future product for Construction Industries
 Green Product
 Less competition in market
 Can earn more percentage of profit
 Easy to handle operations of the plant and can be owned without major engineering expertise

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 CLC BRICK

1.2 ADVANTAGES OF CLC BRICK

 Light in Weight : CLC blocks are very lightweight with density ranging from 300 to 1800
Kg/m3. Three times less weight then clay or fly ash brocks.
 Eco friendly : CLC blocks are Environment-friendly. Foam concrete is eco- friendly
material as fly ash and other industrial waste material are used in part of manufacturing
blocks to protect the environment. The production process of CLC or its use does not release
any harmful effluents to ground, water or air. CLC, due to its low weight is ideal for making
partitions. The use of CLC for this purpose will reduce the need for plywood partitions. This
consequently will result in reduction in deforestation and will benefit environment.
 Sound Insulation : CLC Blocks are excellent for Sound insulation which keeps the house
cool in Summer and warm in Winter saving energy/electricity for cooling and heating. It is
possible to achieve even higher values depending upon the thickness of block.
 Thermal Insulation : Thermal insulations as a 100mm thick CLC wall, the equivalent
thickness of dense concrete wall would have to be more than 5 times thicker and ten times
heavier.
 Lower Water Absorption : The water absorption of this material in relatively lower than
any other materials. This compares much better than concrete 50% and ordinary brick,
which has water absorption of around 50% to 80%. The low water absorption property of
these blocks will help to reduce the cracks in the walls.
 Fire Protection : Foam concrete blocks offers grate fire protection. With a just 100mm
thickness of wall with density of 1000 kg/m3, offers fire endurance for heat transmission for
4 hours without releasing any oxic fumes during the fire. Fire rating of cellular concrete is
far superior to that of brickwork or dense concrete.
 Easy to Handling : Foam concrete blocks are easy and quick to install, thus minimizing
construction costs. They require no minimal maintenance, which reduces long- term costs.
Foam concrete blocks are saving in cement, sand, water, labour, energy & time.

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 CLC BRICK

1.3 APPLICATIONS

 Acoustic construction
 Precast exterior walls
 Roof insulation and waterproofing
 Green construction
 Additional floors to existing structure
 Building material for highrises
 Air-conditioned buildings
 Low cost housing
 Subways

2.1 RAW MATERIAL

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CLC BRICK

2.2 PROCEDURE OF MAKING CLC

Aqueous foam is produced from the foam generators (IFG) and injected into slurry of
cement, fly ash and water in foam concrete mixture (IFM). It creates many small air cells
which are uniformly distributed throughout the concrete and create cellular from 300kg/m3
to 1800kg/m3 with compressive strength between 5kg/cm2 to 200kg/cm2. The volume of air
cells in foam concrete determines the density and strength. The final mixture is then used for
different applications without any vibration or compaction. Fly ash which is a waste-product
at thermal power stations. The foam concrete is thus a green building material.

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CLC BRICK

CLC FOAM GENERATOR & COMPRESSOR

CLC BLOCKS

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CLC BRICK

2.3 COMPARISON BETWEEN CLC BLOCKS AND BRICKS

PARAMETERS CLC BLOCKS BURNT CLAY BRICKS

Basic raw materials Cement, fly ash, water Top agricultural soil,
and foam primary energy input
Dry density kg/m3 600/800 1900
Ageing Gains strength with age No
(Like conventional
concrete)
Sound insulation Superior Normal
Eco friendliness - Pollution free - Creates smoke
- No primary energy - high energy
consumption consumption
- Consumes fly ash (an - wastes agricultural land
hazardous industrial waste - soil erosion
material) - banned in more and
more countries
Thermal Insulation High thermal insulation Normal thermal insulation
Compressive strength Compressive strength is Compressive strength is
more than other bricks. less
Water absorption capacity CLC is a light weight Redbricks and fly-ash
block where water brick absorb more water
absorption is less as than CLC blocks
compared to redbrick and
fly-ash brick

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CLC BRICK

2.4 COMPARISON BETWEEN CLC BLOCKS AND AAC BLOCKS

PARAMETERS CLC BLOCKS AAC BLOCKS

Basic raw materials Cement, fly ash, water and Cement, lime, specially
foam grinded sand, aeration
compound, high primary
energy input
Production process and set- Using ribbon mixer and foam Produced only in well
up generator established plant, equipped
with steam boiler and high
pressure auto-claves

Dry density kg/m³ 600/ 800 400/ 700

Compressive Strength 30- 40 20- 40
kg/cm2
Usage Thermal insulation , Non-load bearing panels and
partitions, non-load bearing blocks
blocks
Aging Gains strength with age (like No aging Loses strength, if
conventional concrete) not protected against
humidity
Thermal conductivity 0.09 – 0.12 (depending on 0.09-0.15 (depending on
(W/mK) density) density)
Eco friendliness - Pollution free
- No primary energy
consumption
- Consumes fly ash (an
hazardous industrial waste
material)

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CLC BRICK

3. FINANCIAL ASPECTS

3.1 OVER VIEW

SL NO DESCRIPTION
1. Production capacity of one system 30 cubic meter per day
2. Volume of one brick ( 600 x 200 x 200 ) 0.024 cubic meters
3. Bricks produced per day 1230 Nos
4. Bricks Produced per month 30750 Nos
5. Bricks per Year 369000 Nos
6. Market price of CLC brick ( 600 x 200 x 200 ) IN 80 - 100 Rupees
KERALA
7. Cost of production per 1 brick 53.06 Rs

3.2 FIXED CAPITAL

SL DESCRIPTION AMOUNT(Rs.)
NO
1 BUILDING COST FOR 5000 SQ FEET & CURING YARD 40,00,000.00
2 OVERHEAD WATER TANK 50,000.00
TOTAL 40,50,000.00

3.3 MACHINERY AND EQUIPMENT

SL DESCRIPTION QUANTITY RATE AMOUNT
NO
1. CELLULAR LIGHT WEIHT 1
CONCRETE MIXER MACHINE
WITH 5 HP MOTOR 5,50 ,000.00 5,50,000.00
2. FOAM GENERATOR 1 No 1,20,000.00 1,20,000.00
3. BELT CONVEYOR WITH 1 No 3,65,000.00 3,65,000.00
HOOPER
4. 5 HP AIR COMPRESSOR 1 No 1,65,000.00 1,65,000.00
5. HYDRAULIC TROLLEY 4 No 40,000.00 1,60,000.00
6. CONVENTIONAL DIES 150 Nos 16,000.00 24,00,000.00
TOTAL 37,60,000.00

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CLC BRICK

3.4 RAW MATERIAL COST PER MONTH

SL NO MATERIAL QUANTITY RATE AMOUNT(Rs.)
1 CEMENT 150 TONNE 6000 9,00,000.00
2 FLY ASH 450 TONNE 600 2,70,000.00
3 FOAMING AGENT 900 KG 150 1,35,000.00
4 WATER 187500 LITRE 30,000.00
5 MOULD RELEASING 750 KG 18,750.00
AGENT
TOTAL 13,53,750.00

3.5 SALARIES & WAGES PER MONTH

SL NO DESIGNATION NO SALARY(Rs.) AMOUNT(Rs.)

2. PRODUCTION 1 15,000.00 15,000.00
SUPERVISOR
3. MACHINE OPERATOR 1 15,000.00 15,000.00
4. UNSKILLED WORKERS 12 12500.00 1,50,000.00
5. OFFICE ASSISTANT 1 12,000.00 12,000.00
6. WATCH MAN 1 10,000.00 10,000.00
TOTAL 202,000.00

3.6 UTILITIES PER MONTH

SL NO DESCRIPTION AMOUNT(Rs.)
1. Power 21 HP 1230 Units 25,000.00
2. WATER 6,000.00
TOTAL 31,000.00

3.7 LAB & TOOLS

SL.NO. DESCRIPTION AMOUNT(Rs.)

1. CUBE TESTING MACHINE 85,000.00
2. PRESSURE WASH 200 BAR 45,000.00
3. TOOLS & HYDRAULIC LINE SPARES 1,25,000.00
TOTAL 2,55,000.00

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CLC BRICK

3.8 OTHER EXPENSES PER MONTH

SL DESCRIPTION AMOUNT(Rs.)
NO
1. Postage and stationery 2,000.00
2. Repairs and maintenance 20,000.00
3. Traveling and transportation 10,000.00
4. POL 5,000.00
5. Insurance 5,000.00
6. Telephone 3,000.00
TOTAL 45,000.00

Fixed capital and Machinery 80,65,000.00

One month Recurring Expenditure 16,31,750.00
Sea worthy wooden wooden base Packing and transport 1,30,000.00
charges up to Indian port 2%
TOTAL PROJECT COST INCLUDING ONE MONTH 98,26,750.00
RECURRING EXPENDITURE

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