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Sample AAC Project for Dongyue-India Clients

AUTOCLAVED AREATED CONCRETE BLOCKS PROJECT EXECUTION SUMMERY All figures in Rs. Lakhs

Phase-1 Phase-2 Phase-1


(First (2nd (3rd Semi Auto Automatic Auto Items executions- executions- executionsTotal Module Module (Fly ash Based AAC lines Gestation Gestation Gestation AddON- Project Fixed Project period-2 period-6 period-2 ) Fixed costs landing Costs Months min) 718.52 732.92 747.32 Months min) 0.00 133.10 133.10 Months min) 0.00 0.00 133.10

50000 CM/Annum AAC Plant 100000 CM/Annum AAC Plant 150000 CM/Annum AAC Plant

718.52 866.02 1013.53

60.00 60.00 60.00

778.52 926.02 1073.53

Working Capital Rs. Lakhs 50000 CM/Annum AAC Plant 44.37 100000 CM/Annum AAC Plant 88.75 150000 CM/Annum AAC Plant 133.12 Please see the fixed inner sheets for details

If we need sand base AAC add on, we need to add a 150 KW ball mill and a block separator Extra. Even we may need 2 more autoclaves to reach max production of 1,5 Lakhs CM as the steam curing period is at least 25% more

Assumptions for Sample Project Profile As land costs vary widely, this has been excluded Customs duties considered as per rates applicable during 2010-11 10% depreciations of Land & Buildings considered & 15% on machinery USD exchange rate taken as Rs. 45/Sea Fare, Truck charges, C/F charges as per the prevailing charges is considered The shed area and office area for guidelines only. Clients can have their own luxury as per the needs. The work shed and office space and fabrication charges considered as CPWD averages. The Machinary Commissioning and Civil charges are considered @ 5% of its landing price For clarity Phase 2 expansion is considered in Year 2 and Phase 3 expansion in Year-3 The raw material rates pertains to a specific place and may vary from place to place Block sale price indicated in this Project is exfactory. All taxes and transport extra as applicable Intrest and oppurtunity cost is considered at 13% as per the Prevailing rates Disclaimer This Project Profile is supplied free of cost to all prospective AAC clients This FULL document can be distributed free of cost to any one, without any sort of permission This Document cannot be sold to anyone for any purpose( neither soft copy nor hard copy) This Project Profile is A GENERALISED profile and do not represent any one unit in particular. This is for guiding prospective client, and helping them to understand the project well This can also serve a basis for Clients Chartered Account for making a DPR for them This template with a little variation can be used to get the DIC EM-1, Pollution control NOC, and other Docs This document do not in any way bind, restrict or force any data on Dongyue Company or N.G.Reddy The AAC project being Modular, there can be client specific needs, which may not be mentioned herein. As the raw materials vary widely, so also does the mix designs we suggest. So final costing may vary. The Price basics for China Machinery, and Indian side machinery is just for reference purpose. Even the quantity of items is approximate, and can vary from case to case basis The civil costs can vary depending location, and the clients rapport and grasp on the field The fabrication costs can depend a lot on clients ability to handle the things on his own, and Steel Prices The speed of execution of project totally depends on Clients skills to Coordinate the Indian suppliers We can take up the client specific Project profile on a Nominal Payment basis We are attempting to get the AAC units bundled in a group for CDM benefit to earn Carbon Credits

Prepared by Project Consultant. N.Gangadhar Reddy (Ph-9437123235, ngreddy2000@yahoo.com)

Sample AAC Project for Dongyue-India Clients

A
1 2 3 4 5

Work Shed for different Size AAC Units


Length Mt
24.00 6.00 18.00 16.00

Mandatory Items Item Descriptions sl No


Pre curing Room Mould Turning Ares Cutting Area Boiler Area Total Mandatory workshed Areas

widthe Mt
16.50 16.50 16.50 8.00

total Sft
3960 990 2970 1280 9200

Optional---Raw Material Area


6 Raw Material Handling Section 12.00 16.67 2000

Autoclave block waiting Bay


7.a 7.b 7.c For 50000 CM/annum plant For 100000 CM/annum plant For 150000 CM/annum plant 30.00 30.00 30.00 8.00 14.00 20.00 2400 4200 6000

Work Shed & Instllation Area Summery


Total Area (acers ) 2.50 3.00 3.50 Shed Area (sft) 13600 15400 17200 Plant Area (sft) 18400 23800 29200

Workshed & Plant Area Summery


1. Minimum Area for 50000CM Plant 2. Minimum Area for 100000CM Plant 3. Minimum Area for 150000CM Plant

Note: 1. The Autoclave out bay shed and Autoclave Area shed is optional 2. Autoclave out bay shed is equal to Autoclave waiting Bay area 3. Autoclave shed area is equal to 60% of Autoclave waiting Bay area 4. Blocks Storage area workshed is also optional.

Installation Schedule

Installation Schedule for 150000 CM/Year capacity AAC plant on autoclaves & Major Items Sl. No Items Phase-1 Phase-2 Phase-3 Autoclaves Complete Kit along with 1 Body, Steam Pipes, Cyllinder and 2 2 2 Insulation, safety devices, Rails 2 Moulds 12 4 4 3 Side Pallets 50 50 50 4 Steam Traullies 25 25 25

D
1 2 3 4 5 6 7 8 9 10 11 12

Indian Total Duty Obligation Calculations


CIF Price (=FOB Price+Sea Fright+ Sea Insurance) Landing Overheads by Indian Costoms Basic Customs Duty (84708410) sub total-1 CVD (Counter Valing Duty) Deducational cess Sub total-2 Customs cess on total duty sub Total-3 Aditional customs cess Grand Total EFFECTIVE Percentage of tax on imports over CIF price % value 1% 7.50% 10% 3% 3% 4% 100.00 101.00 7.58 108.58 10.86 0.33 119.76 0.56 120.32 4.81 125.13 25.13%

Prepared by Project Consultant. N.Gangadhar Reddy (Ph-9437123235, ngreddy2000@yahoo.com)

Sample AAC Project for Dongyue-India Clients

E
Details of Machinary From (Both India and China ) Installation in a 3 Phase Split Item
Items imported from ChinaFOB price ( Fully Automatic Module ) Containers needed Avg Sea frieght + Insurance CIF price Customs + CVD + Surcharge, and other taxes Landing Price Landing price in INR Clearing and liasoning charges per B/L Destuffing and road frieght charges on trawler basis 45 25.13% 1500

Rate

Unit
US$ nos US$ US$ US$ US$ Rs.

Phase-1
613,556 12 18,000 631,556 158,710 790,265 35,561,943

Phase-2
89,018 2 3,000 92,018 23,124 115,142 5,181,396

Phase-3
89,018 2 3,000 92,018 23,124 115,142 5,181,396

Rs.

12,000

12,000

12,000

30000

Rs.

360,000

60,000

60,000

Total Chinise Machine at site Price

Rs.

35,933,943

5,253,396

5,253,396

Total Indian Machines FOR Prices (approxmate USD equvalent)

USD

364,896

164,960

164,960

Total Indian Parts prices in INR * Grand total Machinary Installation & commissioning including civil works Total Machinary commissioned charges at site Total Machinary commissioned costs in Lakhs INR

45

Rs.

16,420,320

7,423,200

7,423,200

Rs. 5% Rs.

52,354,263 2,617,713

12,676,596 633,830

12,676,596 633,830

Rs.

54,971,976

13,310,425

13,310,425

Lakhs Rs.

549.72

133.10

133.10

* India Side Procurement includes Boiler, Autoclaves, Surrry Tank Body, Loader, Forklift, and Other unfabricated MS items

Prepared by Project Consultant. N.Gangadhar Reddy (Ph-9437123235, ngreddy2000@yahoo.com)

Sample AAC Project for Dongyue-India Clients

F
Sl No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Fixed Cost Calculations


Details Land 4 Acers @ Rs. Own Land Land Devolopment @ Rs. 3 Lakhs/Acer Stores & workShed 17200 sft @ Rs.800/office 1000 sft 500 sft x 3 floor rcc or MS struct Mis fixed assets Transformer/geneset/Electric Installations & charges Water Source--Boor Well with Pump Plant & Machinary(with Installation)Phase-1 (1st Year) Plant & Machinary(with Installation)Phase-2 (2nd yr) Plant & Machinary(with Installation)Phase-3 (3nd yr) Prilimnary exp Preoperative Contingency Total Fixed Cost
0.00 15.00 137.60 8.00 15.00 5.00 50.00 2.00 549.72 133.10 133.10 5.00 15.00 5.00 1073.53

Promote Seed r's Margin Funding in %


100.00 50.00 30.00 30.00 30.00 40.00 25.00 25.00 25.00 25.00 25.00 40.00 40.00 40.00 0.00 7.50 41.28 2.40 4.50 2.00 12.50 0.50 137.43 33.28 33.28 2.00 6.00 2.00 284.66

Bank Loan
0.00 7.50 96.32 5.60 10.50 3.00 37.50 1.50 412.29 99.83 99.83 3.00 9.00 3.00 788.87

Prepared by Project Consultant. N.Gangadhar Reddy (Ph-9437123235, ngreddy2000@yahoo.com)

Sample AAC Project for Dongyue-India Clients

G
1 a b c d e f g h i j k L

Working Capital Calculation


Costing Per Month Raw materials/ CM particulars Fly Ash lime OPC Cement (Tanker load) Aluminium power Gypsium RM/CM Power(KWH) Coal (Kg) Other Consumables Total add Wastage @ 1% Raw material per CM Raw Materials per month at 80% capacity Labour/Month Skilled Labour Semi Skilled Labour Un skilled Labour Total Labour/Month Officeial staff/Month Managers & accounts Supervisors Other staff Total Labour/Month 1st Year Capacity at 80% production Quantity T 0.45 0.09 0.07 0.0005 0.005 0.62 9.00 30.00 50000 40000 rate/tonne 150 5000 5000 230000 550 6 4 24000 in Rs. Amount 67.50 450.00 350.00 115.00 2.75 985.25 54.00 120.00 50.00 1,209.25 12.09 1,221.34 Rs. Tons in Rs.

Rs. Rs. Rs. Rs. Rs. Rs. Rs. Rs. Rs. Rs. Rs. Rs.

CM

3333.33

4,071,141.67

2 a b c d 3 a b c d 5 6 7 8 9 a b c d 10 11 12 * i ii iii

Nos 5 5 10

Lab/Month 6000 5000 4000

Tot sal/day Rs. 30,000.00 Rs. 25,000.00 Rs. 40,000.00 Rs. 95,000.00 Tot sal/day Rs. 20,000.00 Rs. 32,000.00 Rs. 24,000.00 Rs. 76,000.00 Rs. Rs. Rs. 20,182.99 91,619.96 83,333.33

Rs.

95,000.00

Nos 2 4 4

Lab/Month 10000 8000 6000

Rs. Rs. Rs. Rs. Rs.

76,000.00 20,182.99 91,619.96 83,333.33 4,437,277.95

Insuraance per Month ( at 0.3% per annum ) Maintainance per Month ( at 2% per annum ) Office Overheads(Post+phone+Net+travel+stanry) @ Rs. 25/CM Total Expences per Month Working Capital for 1 Cycle Curing Line 2 days Cerdit Period 14 days Stock holding 14 days Total = 30 Days Working Capital for 1 Cycle (30 days=1 month)- 1st year Working Capital for 1 Cycle (30 days=1 month)- 2nd year Working Capital for 1 Cycle (30 days=1 month)- 3nd year Note Installed Capacity in phase-1 (1st Year ) is 50000 CM/annum capacity adition in phase-2 (2nd Year ) is 50000 CM/annum capacity adition in phase-3 (3rd Year ) is 50000 CM/annum

Rs. Rs. Rs.

4,437,277.95 8,874,555.91 13,311,833.86

Prepared by Project Consultant. N.Gangadhar Reddy (Ph-9437123235, ngreddy2000@yahoo.com)

Sample AAC Project for Dongyue-India Clients

H
1 2 3 4 1 2 3 4

DEPREATIATION
Item
Block Land & Building Added Land & Buildi ngs Depreaciation on building/shed and other constructions except land Year end Block Block Machinary Block Added in the Year Depreaciation on machinary & equipments Year end Block 15% 1st Yr 165.60 0.00 10% 16.56 149.04 601.72 0.00 90.26 511.46 2nd year 149.04 0.00 14.90 134.14 511.46 133.10 76.72 567.85 3rd Year 134.14 0.00 13.41 120.72 567.85 133.10 85.18 615.77 4th Year 120.72 0.00 12.07 108.65 615.77 0.00 92.37 523.41 5th Year 108.65 0.00 10.87 97.79 523.41 0.00 78.51 444.90 Remarks

I
1 2 3 4 5 6 7

Debt Service Coverage Ration ( D.S.C.R )


Bank Loan Intrest on Bank Loan Repayment Aditional Loan in Year Profits before TAX Profits after Tax (33%) Profit After Tax 689.04 89.57 0.00 0.00 249.99 82.50 167.49 689.04 89.57 172.26 99.83 709.64 234.18 475.46 616.61 80.16 172.26 0.00 1147.13 378.55 768.57 444.35 57.77 172.26 0.00 1256.72 414.72 842.00 272.09 35.37 172.26 0.00 1387.22 457.78 929.44

33%

D.S.C.R

4.06

2.51

3.75

4.37

5.08

9 Average DSCR

3.95

Note D.S.C.R = ( Profit After Tax + Depreciation + Intrest on Trrm Loan ) / (Intrest on Term Loan + Term Loan Repayment )

Prepared by Project Consultant. N.Gangadhar Reddy (Ph-9437123235, ngreddy2000@yahoo.com)

Sample AAC Project for Dongyue-India Clients

J Project Cost, Profitability Calculation & Ratios


J1
1 2 3

Project Cost
Total Fixed Capital Total Working Capital Project Cost Machinary Utilisation assumed/production Cost of production per year Working capital for 12 months Depreaciation on building/shed and other constructions except land equipments Intrest and Oppurtunity Cost Total cost of production (30 days)

1st Yr 2nd year 3rd Year 4th Year 5th Year 807.32 940.42 1073.53 1073.53 1073.53 44.37 88.75 133.12 144.21 155.30 851.69 1029.17 1206.65 1217.74 1228.83 CM/ 140000 year

J2 E 1 2 3 4 5

40000

80000

120000

130000

532.47 10 percent 15 percent 13 percent 16.56 90.26 110.72 750.01 1000.00 2808.00 5000.00 25.88

1064.95 14.90 76.72 133.79 1290.36 2000.00 10000.00 51.75

1597.42 13.41 85.18 156.86 1852.87 3000.00 15000.00 77.63

1730.54 12.07 92.37 158.31 1993.28 3250.00

1863.66 10.87 78.51 159.75 2112.78 3500.00

J3 Sales per year @ Rs. 2500/CM Note : Sales inclusive of VAT & Excise Expected CER Generated J4 Note : Carbon Credit Revenue (Apprx) CERs @8 CM=1 CER, 50000 CM=6666 CER @ 11.5 Euros@60 INR Analisis J5 J6 J7 J8 J9 1 2 3 4 5 6 7 Total Revenue Net Profit/year Net Profit Ratio Rate of return on investment Fixed cost (Per annum) Depreatiation (Full) Insurance (0.3% on Fixed costs) Intrest on investment (Full) 25% Power 30% of wages &50% salary Other Overheads (Full) Total fixed cost

16250.00 17500.00 84.09 90.56

25% of CERs deducted as transactional and operational costs. CER revenues for Guidelines only. Not computed in Profitability of this report

1000.00 249.99 25.00 29.35 106.82 2.42 110.72 5.40 7.98 10.00 243.34 49.33

2000.00 709.64 35.48 68.95 91.62 2.82 133.79 10.80 15.96 20.00 275.00 31.66

3000.00 1147.13 38.24 95.07 98.59 3.22 156.86 16.20 23.94 30.00 328.82 22.28

3250.00 1256.72 38.67 103.20 104.44 3.22 158.31 17.55 25.94 32.50 341.95 21.01

3500.00 1387.22 39.63 % 112.89 % 89.38 3.22 159.75 18.90 27.93 35.00 334.18 19.41 %

J10 Break Even Point (B.E.P)

Note :
1 2 3 Net Profit Ratio = (Net Profit / Net Sales) x100 Rate of Return on Investment = (Net Profit / Project Cost) x 100 Break Even Point ( B.O.P )= (Fixed Cost / (Fixed Cost + Net Profit)) x 100

Prepared by Project Consultant. N.Gangadhar Reddy (Ph-9437123235, ngreddy2000@yahoo.com)