Project Profile

Flyash Bricks & Pavement Tiles

( COMBINED )

Product: Flyash Bricks & Pavement Tiles

Product Code (Based on NIC -2004) for Bricks & Tiles: 26921
Product Code: (Based on ASICC -2000) for Bricks & Tiles: 29102

Production Capacity:
Quantity : 24,00,000 nos of bricks Value Rs.37,20,000

Month & Year of Preparation : December 2010

Prepared by :
Branch MSME Development Institute
New Colony, RAAGADA-765001 (Odisha)
Phone/Fax: 06856-222268
Email: brdcdi-raya@dcmsme.gov.in

INTRODUCTION :
Fly ash, Lime calcined gypsum and sand, with requisite quantity of
water is mixed in proper proportions which produces slow setting
cement, the resultant mass pressed is in to bricks of any desired strength.
These bricks can be used in building constructional activities instead of
common burnt clay bricks. These bricks are lighter in weight and
stronger than common burnt clay bricks. The present generation or fly
ash in India by thermal power stations is more than 100 million tones per
annum. One kilogram of coal of fired yields fly ash ranging from 200 to
500 grams. At present only 6% fly ash being utilized.
Pavement Tiles are building components with an enhanced used
and adaptability at low cost. The pavement tiles are used for laying hard,
durable and attractive flooring in the courtyards, pavements, walkways,
car parking and similar locations. The paving stones are made by using
fly ash and cement aggregates at very high pressure to give a hard faced,
strong and durable stone like product with or without beveled edges.
These stones do not require a sole concrete and needs just a consolidated
sand bed for the support. No boding or pointing is necessary and does
not require any cement. Paving stones offer the advantage of removing
from the position and replacing when ever needed for laying any
pipelines etc. and hence eliminates any maintenance expenditure on the
flooring. These stones can withstand the weight of a loaded truck and
will last for a longtime. They are comparatively cheaper compared to
concrete and other tiles.
MARKET :
180 billion tones of common burnt clay bricks are consumed
annually approximately 340 billion tones of clay about 5000 acres of
top layer of soil dug out for bricks manufacture, soil erosion, emission
from coal burning or fire woods which causes deforestation are the
serious problems posed by brick industry. The above problems can be
reduced some extent by using fly ash bricks in dwelling units.
Demand for dwelling units likely to raise to 80 million units by
year 2015 for lower middle and low income groups, involving an
estimated investment of $670 billion, according to the Associated
Chamber of Commerce and Industry (Assocha). Demand for dwelling

units will further grow to 90 million by 2020, which would requires a

minimum investment of $890 billion. The Indian housing sector at
present faces a shortage of 20 million dwelling units for its lower middle
and low income groups which will witness a spurt of about 22.5 million
dwelling, units by the end of Tenth plan period. There is ample scope for
fly ash brick and block units.

BASIS AND PRESUMPTION :

The process of manufacture is on the basis of single shift of eight
hours per day with three hundred working days in a year.
I.
To achieve full plant capacity it requires 1 year after trial
production.
II.
Labour and wages mentioned in profile are as per the
prescribed minimum wages.
III. Interest rate at 14% considered in the project profile.
IV. Operative period of project is around 10 years considering
technology obsolesce rate and period of repayment of loan.
IMPLEMENTATION SCHEDULE :
Project implementation will take a period of 8 months from the
date of approval of the scheme. Break-up of activities with relative time
for each activity is shown below :Nature of activities time period in months (Estimated)
I.
Scheme preparation & approval : 0-1
II.
SSI provisional registration : 1-2
III. Sanction of loan : 2-5
IV. Building construction, water, power arrangements : 3-4
V.
Placement of order for M/c : 4-5
VI. Installation of machines : 6-7
VII. Power connection : 6-7
VIII. Trial run : 7-8
IX. Commencement of production : 9 onwards.
PROCESS OF MANUFACTURE :

Fly ash (70%) Lime (10%) Gypsum(5%) and sand (15%) are
manually fed into a pan mixer where water is added in the required
proportion for homogeneous mixing. The proportion of raw material
may vary, depending upon quality of raw materials. After mixing, the
mixture is shifted to press. The bricks are placed on wooden pallets and
transported to open area where they are dried and water cured for 21
days. The bricks are tested and sorted before dispatch.
The manufacture of pavement tiles consists of following process :
Grinding the fly ash/lime/gypsum compound in a pan-mixer
to make a cementius compound.
Grinding the necessary materials and pigments along with
cement in a ball mill, which is used for the top-coat.
Feeding the above materials into the machine and making
the product by compressing the aggregates.
Removing and staking the products for curing.
Delivering the product.
INSPECTION AND QUALITY CONTROL :
The Bureau of Indian Standards has formulated and published the
specifications for maintaining quality of product and testing purpose. IS :
12894 : 2002. Compressive strength achievable : 60-250 Kg/Cm.Sq.
Water absorption : 5-12%; Density : 1.5 gm/cc Coefficient of softening
(depending upon water consistency factor) Unlike conventional clay
bricks fly ash bricks have high affinity to cement mortar though it has
smooth surface, due to the crystal growth between brick and the cement
mortar the joint will become stronger and in due course of time it will
become monolithic and the strength will be consistent.
PRODUCTION CAPACITY PER ANNUM :
Quantity : 24,00,000 nos of bricks Value Rs.37,20,000
MOTIVE POWER : 40 HP.
POLLUTION CONTROL :
The technology adopted for making fly ash bricks is eco-friendly.
It does not require strength or auto-calving as the bricks are cured by

water only. Since firing process is avoided. There are no emissions and
no effluent is discharged. Facial masks and dust control equipment may
bek provided.
ENERGY CONSERVATION :
General precautions for saving electricity are followed by the unit
by providing energy meter. This products are low energy consumption
since no need of fire operation in the production unlike conventional
bricks.
Thus considerable energy could be saved not only in
manufacturing activities but also during the construction.
MACHINERY UTILISATION :
The plant and machinery has to be utilized 75% in the first kyear
kand 80% -95% in the second and third years.
FINANCIAL ASPECTS :
1. FIXED CAPITAL :
A.

Land & Building :

Land 1 Acre

Built up area :
RCC structure 500 sq. ft. @ 500/
Shed 75X40 = 3000 sq.ft.@ 150/
Boundary, fencing, gate, water arrangement,
Fly ash pond, curing tank L.S.

Rs. in Lakhs
2.00
2.50
4.50
Total :

B.
Machinery and Equipments:
i) For Fly Ash Bricks:
1. Pan Mixer, 20 HP
1
2. Brick making machine, Cap. 30 T, 15 HP 1
4.25
3. Conveyor belt, 3 HP
1 set
4. Wheel barrows, 250 Kg.
2
5. Hydraulic pallet truck manual, 500 Kg.
2
6. Wooden pallets (3X2) (72 bricks/pallet) 100
ii) For Pavement Tiles:
1. Pan Mixer
1

3.50
10.50

3.10
1.60
0.09
0.50
0.40
1.25

2. Tile making machine, 3 HP

1
3. Moulds
6
4. Stalking trays, 200 Nos. @ Rs. 120/iii) General Equipments :
1. Testing equipment
2. Energy conservation equipment
3. Pollution equipment
4. Office furniture

2.00
1.50
0.24
0.10
0.05
0.15
0.37

Installation & Electrification 10%

Freight, tax, insurance etc. 10%

2.00
2.00
19.60

Total :
C.
Sl.
No.
01.
02.
03.
04.
05.

Working Capital per month :

i) Raw Material per month :
Description
Unit
Brick

Fly Ash
Lime
Gypsum
Sand
Granite
(6mm)
06. Cement

Tile

MT
MT
MT
MT
chips MT

420
60
30
90
-

26
4.3
1.1
7.4
22.1

100
1000
1000
100
150

Total
(Rs. in
lakhs)
0.45
0.64
0.31
0.10
0.03

MT

1.5

2250
Total :

0.03
1.56

ii) Salaries and Wages per month :

Sl.No.
Description
No(s)
01.
Manager
1
02.
Supervisor
1
03.
Skilled Worker
3
04.
Unskilled Worker
4
05.
Watchman/ Peon
3

Rate

Salary (Rs.)
5,000
4,000
3,000
2,500
2,000
Total :
Add perquisites 15%
Total :

iii) Utilities per month :

Total (Rs.)
5,000
4,000
9,000
10,000
6,000
34,000
5,100
39,100

Qnty.
Rate (Rs.) Total (Rs.)
Power 50 HPX.75X150 4500 KW 4.00
18,000
Water 5000 Ltrs./day
125 KL 50.00
6,250
Total :
24,250
iv) Other expenses :
Postage & Stationery
Repair & Maintenance
Travelling & Transportation
Sales expenses

Insurance

Telephone

Misc. Expenses

Rs.
1,500
1,500
3,000
1,500
1,000
1,500
2,000
12,000

Total :

Working Capital per month = (i) + (ii) + (iii) + (iv) = 2.31

Working Capital for 3 months
=
6.93
D.

Total Capital Investment :

Fixed Capital
Working Capital

Rs. in Lakhs

Total :
Or say

32.10
6.93
39.03
39.00

D.

Cost of Production per year :

Recurring expenditure

27.72
Depreciation on Machinery & Equipment @ 10% 1.49
Depreciation on Building @ 5%

0.53
Depreciation on office furniture, tools
& equipments @ 20%

0.13
Interest on capital investment @ 14%
5.46
Total :
35.33

F.

Sales :
Fly ash bricks 24.00 lakhs @ Rs. 1.50
Pavement tiles 1.20 lakhs @ Rs. 10.00

G.

Profitability :
Profit per annum ( F E)

Rs. in lakhs

..
Total :
..

36.00
12.00
48.00
12.67

% of profit on sales = Profit X 100

Sales
= 26.4%
H.

Break-even Point :
(% of production envisaged)
i) Fixed Cost :
40% of salary & wages
40% of utilities
40% of other expenses
Insurance
Total Depreciation
Interest on investment
ii) Profit per annum :
BEP(%) = Fixed Cost X 100
Fixed Cost + Profit

I.

Total :

1.87
1.16
0.53
0.12
2.15
5.46
11.29

12.00
= 11.29 X 100 = 48.48%
11.29 + 12.00

List of suppliers of machinery & equipments :

1. M/s. Engineers Enterprises,
89, Bharathiar Road,
Ganapathy Maniyakaranpalayam Road,
Near IEC Bus Stop, Ganapathy,
COIMBATORE 641 006,
Phone : 0422-2530639, 2530788,2532260
Fax: 0422-2531893,2532260
Email : engineer@md3.vsnl.net.in
2. M/s. Kiran Engineers,
69, JRD Tata Industrial Estate,
Auto Nagar, VIJAYAWADA- 520 007,
Phone : 0866-2544416
Email : vijwtprrao@sancharnet.in / crewind@sify.com

II. List of suppliers of Raw Materials:

Locally available