Professional Documents
Culture Documents
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PROJECT DETAILS
Name of the proposed enterprise
Unit Address
PROMOTER’S DETAILS
Name of the Proprietor
Spouse Name
Gender Date of Birth Age
Communication Address
Permanent Address
PRIMARY PROPERTY
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FREEHOLD LEASEHOLD
DESCRIPTION OF THE PROPERTY
S.No. Description Reg. Date Doc. No.
1
BOUNDARIES
North
South
East
West
Extent In SQM In SFT In CENTS
TECHNICAL ASPECTS
AAC Blocks AAC Blocks also known as autoclaved cellular concrete ( ACC )
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or autoclaved lightweight concrete ( ALC ), was invented in
the mid-1920s by the Swedish architect and inventor Johan
Axel Eriksson. It is a lightweight, precast building material
that simultaneously provides structure, insulation, and fire and
mold resistance. AAC products include AAC blocks , AAC U
Blocks AAC wall panels , AAC floor and roof panels ,
and AAC lintels .
Lightweight
AAC blocks are about 50% lighter than clay bricks of
equivalent size. This translates into less dead weight of a
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building and allows entire structure to be lighter therefore
reducing amount of steel and concrete used in structural
components like beams, columns and roof/floor slabs.
Easy Workability
AAC blocks are very easy to work with and can be cut
accurately reducing the amount of waste generated.
Environmental Impact
Manufacturing of AAC blocks and panels does not consume
high amount of energy. Moreover since AAC blocks are light
weight, it saves energy required for transportation and leads
to reduced CO2 emissions by transport vehicles. Since AAC
blocks are made from fly ash – an industrial waste product –
generated by thermal power plants, it offers a low cost and
sustainable solution for today and tomorrow. AAC blocks are a
requisite for green buildings.
Easy Transportation
It is easy to transport AAC blocks as it does not suffer from
high transit breakage usually associated with clay bricks.
Longevity
AAC blocks do not lose strength or deteriorate over time.
Buildings constructed with AAC blocks do not require routine
repairs that are required for buildings using clay bricks.
Thermal Insulation
AAC blocks and panels offer excellent thermal insulation. This
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reduces recurring cost of energy required for heating and
cooling. Better thermal insulation also allows usage of smaller
HVAC than required conventionally.
Fire Resistance
Due to high fire resistance offered by AAC blocks, structures
made from AAC blocks have higher rate of survivability in case
of fire.
Sound Insulation
Sound absorption properties of AAC makes it ideal material for
reducing ambient noise. AAC blocks are well-suited for
establishments like hospitals and offices situated in noisy
areas.
High Survivability
Millions of air pockets in AAC blocks cushion structure from
major force and prevents progressive collapse of a building.
AAC structures are known to maintain structural integrity
despite of seismic activity (earthquakes), heavy rains,
extremely low temperature and salty air.
Manufacturi-
ng Process
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Key ingredient for manufacturing Autoclaved Aerated Concrete
(AAC) blocks is silica rich material like fly ash, pond ash or
sand. Most of the AAC companies in India use fly ash to
manufacture AAC blocks. Fly ash is mixed with water to form
fly ash slurry. Slurry thus formed is mixed with other
ingredients like lime powder, cement, gypsum and aluminium
powder in quantities consistent with the recipe. Alternately
sand can also be used to manufacture AAC blocks. A ‘wet’ ball
mill finely grinds sand with water converting it into sand
slurry. Sand slurry is mixed with other ingredients just like fly
ash slurry.
Limestone powder
Lime powder required for AAC production is obtained either by
crushing limestone to fine powder at AAC factory or by directly
purchasing it in powder form from a vendor. Although
purchasing lime powder might be little costly, many
manufacturers opt for it rather than investing in lime crushing
equipment like ball mill, jaw crusher, bucket elevators, etc.
Lime powder is stored in silos fabricated from mild steel (MS)
or built using brick and mortar depending of individual
preferences.
Cement
53-grade Ordinary Portland Cement (OPC) from reputed
manufacturer is required for manufacturing AAC blocks.
Cement supplied by ‘mini plants’ is not recommended due to
drastic variations in quality over different batches. Some AAC
factories might plan their captive cement processing units as
such an unit can produce cement as well as process lime.
Such factories can opt for ‘major plant’ clinker and
manufacture their own cement for AAC production. Cement is
usually stored in silos.
Gypsum
Gypsum is easily available in the market and is used in
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powder form. It is stored in silos.
Aluminium powder/paste
Aluminium powder/paste is easily available from various
manufacturers. As very small quantity of Aluminium
powder/paste is required to be added to the mixture, it is
usually weighed manually and added to the mixing unit.
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mixture might start hardening and choke up the entire unit.
Before casting, moulds are coated with a thin layer of oil. This
is done in order to ensure that green-cake does not stick to
moulds. While slurry is mixed and poured into greased
moulds, Aluminium reacts with Calcium Hydroxide and water
to form Hydrogen. Millions of tiny Hydrogen bubbles are
released due to this reaction. This leads to formation of tiny
unconnected cells causing slurry mix to expand. Such
expansion may be twice its original volume. This process is
very similar to rising of idli or dhokla dough. It must be noted
that bubbles generated during AAC blocks manufacturing
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process are unconnected and closed bubbles unlike open
bubbles of CLC blocks. Bubble size is usually 2-5mm. These
cells are the reason behind light weight and insulating
properties of AAC blocks. Once rising process is over, green-
cake is allowed to settle and cure for some time. This ensures
cutting strength required for wire cutting.
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Once a mould is out of pre-curing room, it is lifted by a crane
or rolled on tracks for demoulding operation. Lifting or rolling
green cake is determined by technology deployed.
Manufacturing process can be broadly classified as flat-cake
and tilt-cake based on how green cake is demoulded and sent
to cutting line.
While all previous processes like raw material preparation,
dosing & mixing and casting are pretty much same across all
technologies, demoulding and cutting process vary vastly
depending on technology provider. Differences in demoulding
and cutting process are also evident from different types of
moulds required by different technology provider.
Primarily cutting process may be classified as flat-cake and
tilt-cake based on how green cake is demoulded and sent to
cutting line.
E.g. In flat-cake technology, green cake travels horizontally
through all processes. Moulds used in such technology have 1
bottom plate and single set of mould wall that covers 4 sides.
Mould lies in horizontal position as mould wall is lifted
vertically. Green cake is then sent for cutting and from there
on to steam curing lying horizontally. Since flat-cake
technology is not widely used, we’ll do a comparison of flat-
cake vs tilt-cake system at a later stage.
Most commonly used technology among most European and
Chinese vendors is tilt-cake technology. In this technology,
mould has a side plate (aka bottom plate) and mould walls.
During demoulding, mould is tilted by 90o and unlocked
leaving green cake sitting vertically on side plate. Crane slowly
separates mould from green cake. Green cake remains vertical
as it passes through the cutting machines.
Usually tilt-cake technology uses two cutting machines.
Horizontal cutting machine is used in the first stage, while
vertical cutting machine is used in second stage.
Horizontal cutting machine does not have any moving parts.
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Cutting operation is achieved by moving green cake through
horizontal cutting machine. It has a profile plate that scrapes
sides of green cake to give it an even finish. Once profiling is
done, horizontal cuts are made through green cake using
stationary steel wires. These wires can be adjusted offline to
get desired height of AAC blocks or panels. Depending on
client preference, some horizontal cutting machines may sport
a top crust removal device shaped like an arrow.
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Raw Fly Ash Fly Ash is generated as waste in Coal/Lignite
Materials & based furnaces. Indian coal is of low grade
Availability having ash content as high as 45% in
comparison to imported coals which have low
ash content of the order of 10-15%. Large
quantity of ash is, thus, being generated and
its creating severe pollution problem. To
mitigate this problem, Power Plants are
supplying Fly Ash at free of cost.
Available Sources:
Simhadri Thermal Power Station,
Parawada, Visakhapatnam District.
JK Paper Mills, Rayagada, Odisha State.
Lime Stone Available in Piduguralla, Gunturu District
Powder
Gypsum Available at Coromandel Fertilisers,
Visakhapatanam, Tanfac Industries,
Cuddalore, Tamilnadu.
Cement 53 Grade Ordinary Portland Cement (OPC);
available everywhere
Aluminum Available in Visakhapatnam
Powerder
Comparison of
Parameter AAC Block Clay Brick
AAC Blocks Vs
Burnt Clay 625x240x75 to
250mm
Bricks
600x200x75 to 230x75x115m
Size
250mm | or as per m
customer
requirement
3.0 to 4.0
Compressive 2.5 to 3.0
N/mm2(IS 2185,
strength N/mm2
Part-3)
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550-650
Dry density 1950 kg/m3
kg/m3(oven dry)
2 to 6 hour
Fire resistance (Depending on 2 Hour
thickness)
50db for
Sound reducing 45db for 200mm
230mm thick
index thick wall
wall
Mortar
1.40 bag of
consumption per 0.5 bag of cement
cement
M3 with 1:6
Thermal
0.16 W/mk 0.81 W/mk
conductivity
Approx 25%
Energy saving reduction in air No such saving
conditioner load
Uniform and
Quality Normally varies
finished
AAC Blocks Dimension No. of Blocks
100 mm (4’’) 83
per 1 M³
110 mm (4.5’’) 72
150 mm (6’’) 55
200 mm (8’’) 41
225 mm (9’’) 37
AAC Blocks Dimension No. of Blocks
100 mm (4’’) 117
per 1 MT
110 mm (4.5’’) 90
150 mm (6’’) 76
200 mm (8’’) 58
225 mm (9’’) 52
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PROJECT COST
S. No. Description of Component Rs. in Lacs
1 Land
2 Site development 7.00
3 Civil structures
Description Size Unit Rate (Rs.)
i. Casting shed 140’X60’ 350.00 29.40
ii. Office room & 20’X14’ 900.00 2.52
Quality Lab
iii. Boiler Shed 40’X20’ 750.00 6.00
TOTAL CIVIL STRUCTURES COST 45.92
ROUNDED (A) 46.00
BATCHING SECTION
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Sl.No Description
4 Length : 8000mm
Power Rate : 5.5 Kw
Capacity : 25 Ton/Hr.
With Universal Inlet & Universal outlet
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CUTTING & MOULDING SECTION
Required
S.No. Description
Quantity
DeMoulder
Capacity : 4-6m3 / hr
Upper Moulds(0.9m3)
7 Height : 700 mm Required
Length : 1225 X 1225 mm 30 No
Body : HR Steel
Required
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CUTTING SECTION MACHINERY COST (II) 62.88
COMMISSIONING & ERECTION COST (III) 33.16
BOILER SECTION
Required
S.No. Description
Quantity
2 Ton IBR Packaged Boiler (17.5
Kg High Pressure Boiler)
for Autoclaves upto 2 Nos
Chimney
IBR Pipe Line work from Boiler to
Chambers
Insulation Work
1 Water Pumps 1 Set
Safety & Other Valves
Pressure Gauges
Steam & Other Valves
Pressure & Temperature Gauges
Includes Erection & All Necessary
Accessories
Total : (D)
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