Ministry of Urban Development and Poverty Alleviation Government of India 2001rt) = = rx oS PS =) P| = co = Fe) =| I ee I 4 5 s = = Ss 5 a = ry = o = oS Cr) —_ a 3 Py o a 9 timber becomes scarce, concrete door and window frames are becoming popular among the most important products in the building construction activity. There is a need for a large number of production units at decentralised locations to replace traditional timber frames. Demand is increasing due to increase in building construction, and other development projects. industrialisation BETTER QUALITY, SPEEDY PRODUCTION Precast Concrete Door/Window made out o rames (chaukhats) are Sement, sand, aggregates mixed in suitablo proportions to obtain the desired th alongwith fibre land super-plast s vibrated for some time in the vibrating table to be extensively used in all building co si on activities as substitute fertional timber door window frames. Conerete door and window frames com pare in strength, du ity and quality with traditional tm ber door & window frames at a s tantial cost saving, Commercial levels of production can be taken up a level of investment and with minima aining. This ne productio methodology based on the use of patente cchaukhat making machine ensures speedier product quality machine is capable of casting four door frames c omponents using limited unskilled workforce. Or dow frames per day. Precast concrete dooriwindow frames ‘are 30-40% cheaper than ordinary sal wood chaukhats and 10-15% cheaper than angle iron frames, Mass scale production with the help of unskilled jork-force is ideally suited for deployment at locate building ntres with power and water connet ‘The assembly using in-built bolts and nuts and erection at project site is very simple. In fact the top member of door window frames can be so designed as to do away with the necessity of providing lintels over door/window openings during construction. Individual vertical, horizontal elements are cast, handled and transported separately, but easily assembled at the location of use in the structure, etd Produces concrete door/window frames of all cos Cee aa a ocd Pe Cee eee CRU eee Approximate Power requirement per table is 2.0 HP. eeu ee ce oa Rae etd Mee aa ccna a ete tee eee ut a ee) cd See ee Eee aL car) Dea ADVANTAGES OF CONCRETE DOOR & WINDOW FRAMES: Conservation of forest reserves of timber. Termite and white ant proof. High quality, long lasting and durable. ‘Much cheaper than timber alternatives. High rate of production. I requirement of raw materials. Fire proof, Water proof Produced utilising unskilled labour. Save on the cost of lintels. Limited mechanisation resulting in high per capita output. Possibility of using waste industrial product like flyash, blast furnace slag, etc. Process is far superior to other methods of casting door/window frames in a complete “U" or Rectangular shaped mould resting on flat surface, with nominal bars, concrete cast/compacted by manual tamping. Such frames are more difficult to handle / transport.‘SETTING UP A PROJECT Project Cost 1, Installed capacity 6000 Frames per annum (300 working days) 2. Saleable produc 14.40 lakhs 3.) Fixed capital 7.44 lakhs. il) Working capital 2.62 lakhs 4, Employment Potential 11 persons Raw materials & Inputs a. Cement 75 tonnes b. Coarse sand Trout. . Aggregates 154 cu.mt . Admixtures Ls. ©. Poly Propylene fibre LS. 1. Stool 24 tonnes g. Consumables Ls. h. Electricity, Water 6. Annual cost of production Rs.12.42 lakhs 7. Profitability (per annum) As. 1.98 lakhs. 8. Profit on sales 14% 9. Retum on investment 20% 10, Break even point 50% Plant/Machinery Requirements Conerete Mixer; door/window frame making ma- chines; Tach welder; Transfer trolley/whee! barrow Tools Inserts; Water supply lines and sprinkier; Electrical equipment fittings; Orfice equipment furniture; Testing equipment Properties a. Size All standard sizes, . Section - 100 mm x 60 mm ¢. Dooriwindow chaukhat conforming to 1S:6523. 1983 d. Termite proofifire proof/water proof Additional Information Source of technology BMTPC information & Guidance BMTPC, Building Centres Finance HUDCO, NHB, IDB! ICICI, IFCI, SICOM Plant & Machinery _Indigenous Suppliers of plants/ Mis Victor Electricals & machinery Machinery Manufacturer 3616, Netaji Subhash Marg, Darya Ganj New Delhi-1 10 002 Machines Developed by BMTPC Mozhines Proerrocement is a highly versatile form sisting of cement mortar and inforcement. Ferrocement can be easily simply fabricated into almost any shape, is more ble than most woods, cheaper than steel, and its raw materials are easily available nt is increasingly being struction te ‘cepted as an appropriate cost-etfectiv different applications in housing and building, Building Centre: ning under HUDCO hav promoting the use of this material. Excellence ferrocement stru Aurovill @ application and ter quality duction span of 6.1 met high load be city, non-porous surface and Uniform thickness throughout. The machine is fabricated in close collaboration with Development Alternative: Deere aan Uk De Uke eee oR uu WN aay ST aoe) Flexibility in cutting, driling and jointing Reig eter De dy af Se, ‘+ Production Capacity 5 channels per day by replacing mould {6600 x 1150 x 1500 mm 1000 kgs. upto 6.1 mtr: + Size ‘Weight of machine * Length of Channel ‘Cross section size 25 mm thickness “Type Heavy duty ‘=Power requirement 4HP. Electrical, 8 phase 440 volts. + Energy source ‘+ Compaction by Mix: Vibration technique 1 coment : 3 coarse sand ‘+ Compressive strength 150 kg/sq.cm‘SETTING UP APROJECT Project Cost 1. Installed capacity 2. Saleable product 3. i, Fixed Capital ii. Working capital 4. Manpower requirement 5. Raw materials & Inputs Cement Coarse sand Steel Chicken mesh Welded mesh Galvanised binding wi Consumables Electiicity, Water ‘Annual cost of production Profitability (per annum) Profit on sales 9. Return on investment 10.Break even point 5400 mts/annum (300 working days) 12.96 lakhs 6.34 lakhs 2.39 lakhs 9 persons 80 tonnes 150 cu.mt, 10 tonnes 10,800 squmts. 1450 sq.mts ire 0.54 tonne Ls 11.18 lakhs 1.78 lakhs 14%, 20% 50% Plant & Machinery Requirements Ferrocement roofing channel making machine; Ex- tra shell moulds; Transfer trolley/wheel barrow; Gan- try girder; Tools/Inserts; Water supply lines and sprin- ler; Testing equipment; Office equipment; Electric connectionftings; Concrete mixer Product specifications Length of channel! Clear Bay Length Rise of arch Shell thickness Bottom nib dimensions Bottom steel depends on span/applications Mesh reinforcement Cement mortar mix Water-cement ratio Weight per meter length Additional Information Source of technology Information & Guidance Finance Plant & Machinery Suppliers of Plant & Machinery Upto 6.1. mtr 750 mm 290 mm 25 mm 40x45 mm 8 mm to 16 mm * GI chicken wire mash of hexagonal pattern of 22 gauge, 12 mm opening throughout the shell + MS square welded mesh of 25 mm ‘opening along crown of channel 1:3 (cement: Coarse sand) 0.45-0.55 70 kgs BMTPC, DA BMTPC, DA, Building Centres HUDCO, NHB, IDBI, ICICI, IFCI, SICOM Indigenous Mis Victor Electricals & Machinery Manufacturer 3616, Netaji Subhash Marg, Darya Ganj Now Delhi-110 002 Machines Developed by BMTPCAlternate Station Hydraulic Brick Press ‘SALIENT FEATURES: Suitable for production of clay/clay tlyashiclay cement lyash sand lime gypsum bricks “apable of producing 10000 bricks per day in 8 hours shift Bricks produced are of accurate dimer excellent surface finish Develops 100 toi compaction Flyash, lime sludge, river silt & non-agriculture indy soil can be used for producing bricks The green bricks have excellent strength and n Quick drying of bricks becaus moistu content Low power consumption, quirement Heavy duty machine offer tion with low maintenance. Ultimate value addition with reduction in pro- duction cost. Gaeta) eg) Options Drona) Drees indexing erro Electrical, 9 phase, 440 volts emus eae ey Raa) Pe RR ony 7000 kgs Size of brick Pret) Ne a cd Beamon) Crys 100% Ordinary Clay Clay Flyash Bricks COO ane Pea ene ui icy Senay Clay eaters eS ou e yu aac eee) cee) oT Se Ce ae et eto eo eee ely Pen otal ek a) Cais Cee eos‘SETTING UP A PROJECT Project Cost 1. Installed capacity 3 milion bricks per annum 2. Capacity at 80% 24 million bricks Lilsation (200 working days) 3. Saleable product 38.40 lakhs 4. i) Fixed capital 26.87 lakhs. i) Working capital 6.61 lakhs 5. Employment Potential 13 persons 6. Raw materials & Inputs a. Flyash 2592 tonnes . Coarse sand 1620 cum ©. Lime 960 tonnes 4. Gypsum 336 tonnes e. Consumables us £. Electricity, Water 9.Tools & dies Ls 7. Annual cost of production Rss 82.88 lakhs 8 Profitability (per annum) Ris. 5.52 lakhs 9. Profit on sales 14% 10, Return on investment ‘16% 11, Break even point 54% Plant/Machinery Requirements Pan mixer; Alternate station hydraulic brick making machine; Belt conveyor with box feeder; Positive feeder, Pallet trolleys; Welding machine; Wooden pallets; Wheel barrows; Tools & dies; Water supply lines and sprinkler, Electrical equipment fittings Office equipmentfting; Testing equipment Additional Information Source of technology BMTPC Information & Guidance BMTPC, Building Centres. Finance HUDCO, NHB, IDBI ICICI, IFCI Plant & Machinery Indigenous ‘Suppliers of plants/ M/s Naldehra Building Centre 1970, HIG Flats Housing Board Colony Sector 29 Faridabad (Haryana) Machines Developed by BMTPCPa 2 = — S 1] s Es [= S B = s = z By a C] z = —} S Sj i=} i-5 E | ith the increasing consciousness about preservation of natural rain forests, large girth logs of exotic species lke teak, rose- wood etc., are no more available in required quantities. The future has to be processing of plantation timbers like rubber wood and poplar wood. Plantation timbers are small girth logs and the trees are usually felled when still immature. The juvenile timber leads to growth stresses which manifest themselves in the form of misbehaviour of timber even after drying. It is therefore necessary to end join smaller sections of plantation timbers to make them up to usable lengths. Recognising the need for such a process, BMTPC has developed a complete line of finger jointing and shaping machine. PROJECT OBJECTIVES To indigenously design and develop a set of machines for finger jointing treated and seasoned plantation timber to obtain long and usable lengths. ‘These machines are available at the lowest possible cost so that this technology can be propagated to even the smallest of processors of plantation timbers, + The machine is capable of processing both soft woods and hard woods, + Thelargest dimension to be processedis 100x155 mm. + The machine is capable of both face finger jointing as well as butt finger jointing + The machine is capable of utilising both thermoplastic and thermo setting resin adhesive systems. MACHINE DESCRIPTION The finger jointing line consist of 2 machines. A. The Finger shaper B. The Press ony ee ers ot Cece tere Pee rac] pe ee ener Pere etre Cee ey Brea arty Cee ce Tey Cee eat eee ee es ee cree a eee Tag Ca Finger Shaping Machine Max. timber section (thick x wide) Finger cutting diameter Power requirement Air prossu Aicrequrement(@ 6 cyl/min) Dimensions (HxWxD) 400 mm x 155 mm 160mm 17.5 kw (10 HP) Skglem* 300 Umin. 1300%750x650 mm ‘Net weight (approximate) 300 kgs Finger Jointing Press ‘Timber pressing length Max. timber section (thick x wide) Max. pressing power Power requirement Diameter of cross cut saw blade Saw blade bore diameter 2500 mm (standard) 100 mm x 185 mm 10 tons 1x 2hp,1x3hp 305 mm 25mm 6 kglem? 60 Umin. 11350x1220x3150 Ar pressure Air requirement Dimensions (HxWxL) Net weight (approximate) 700 kas Not 1._ Presses for lengths above 2500 mm can also manufactured. 2. The demonstration of machine can be seen at IPIRTI, “Tumkur Road, Bangalore -560 022‘SETTING UP A PROJECT Manufacture of finger jointed lumber Equipment Cost Rs. in lakhs 1. Finger Jointing Line 8.05 2. Dust extraction unit 0.30 3. Compressor 360 limin capacity & pipeline 0.50 4, Tooling 4.70 Total 10.50 Production Capacity Average size of input timber 4" x 1.8" x tft Length of ouiput timber ett Shaper capacity : Cycle time including clamping 10 Sec. and unclamping No. of pieces shaped/min 6 No. of pieces shaped/shitt 2880 Volume of timber shaped/shift 120 oft Shaper capacity with 100 oft/shitt fatigue allowance Press capacity Cycle time 60 sec. No. of cyclesishitt 480 cycles, Volume of timber processed/shitt 160 cft Capacity of finger jointing line 100 cttishift Net sales value Assuming a value addition Rs, 5000/day of Rs. 50/cft or Rs. 16 lakhs/year Processing Cost Cost of glue Rs. 1500/day @ Rs. 100g or Rs. 4.5 lakhs/annum Cost of power Rs. 0.76 lakhs/annum @ Rs. 3.00/unit Total labour cost Rs. 1.40 lakhs/annum, Tooling LS. Rs. 1.50 lakhs/annum Maintenance LS. Rs. 0.50 lakhs/annum Total processing cost Rs. 8.66 lakhs Payback period at 80% capacity 2.07 utilisation (years) Machines Developed by BMTPC@ 4 — = 7) = ‘— J i = 4 = = ~ 4 I [==] oe E at = i os na c= a Ss = i ecognising the heavy expenditure involved in setting up of sand-lime flyash brick manufac: turing based on imported machinery and autoclaving process, a simple machine for production of sand-lime-bricks has been developed. Itis a low cost hydraulic pre chine which can be used for pro: duction of such bricks within the norms of small scale indu ies which will encourage many more entrepre- neurs with low financial up production Units in the vicinity of thermal power stations. TECHNICAL SPECIFICATIONS: Production capacity pacity to s 750 bricks/hr. No. of bricks per station 2 nos Standard finished brick size 230x110x70 mm Effective thrust 120 ton, Etfective compacting pressure 240 Kg/sq.cm. Piston diameter 250 mm Normal working pressure 260 bar Compression ratio 18:1 Motor 5HP. Labour force required 4 Over all size of the machine ——2.5x1.3x1.4M Weight of the machine 2000 Kg ‘SPECIFICATIONS OF PRODUCT Brick size (standard) 230x1 10x70 mm Fly ash - percentage 75-80% Sand - 10% to 15% + stabiliser Lime - 8% to 10° Compressive strength upto 150 kg/sq. cm. From cost point of view, these bricks are comparable to conventional burnt clay bricks. OPERATIONAL CONTROLS: ‘The press offered is having motorised power pack and all operations wil be automaticaly controlled through set of push buttons. Necessary safely devices are in- builtin hydraulic & electrical systems to safeguard the machine from over ses J site sezection Patereuircticcany eee ror) Pxeopeeer a Sern ure) een Sener ees ears eee kes litle competition with conven- Pentere td arene eee eects Te tT . = Economical, energy efficient substitute to con- ventional burt clay bricks. Self employment of entrepreneurs without need of high capital Itdoes not require great skill and concept can be adopted by unskilled persons withltle quid- ance. Disposal of fly ash being generated by ther- mal power stations and saving of prime lands, Better finish and smooth surfaces resulting in saving of mortar upto 7%. Better compactness and strength. Suitable for construction with all kind of mor- tars, Excellent physical properties such as durabi ity, shrinkage, water absorption and thermal insulation etc. Very short manufacturing cycle, having no ef- fect of weather conditions thus making bricks available round the year. Saving in erosion of top precious agriculturalSETTING UP A PROJECT Project Cost 1. Installed capacity 27 lakhs bricks/annum (200 working days) 2, Saleable product 35.10 lakhs 2. i. Fined 26.93 lakhs i 5.78 lakhs. Manpower requirement 10 persons 5. Raw materials & Inputs, a. Flyash 5400 tonnes b, Fine sand 563 cu.mt c. Lime 600 tonnes d. Pigment Ls e. Consumables Ls. 1 Electricity g. Water h. Toolsidies Ls Annual cost of production 29.69 lakhs Profitability (per annum) 5.41 lakhs Profit on sales Return on investment 0.Braak even point Plant & Machinery Requirements Double shaft mixer with conveyor Hydraulic press Brick trolleys - 20 nos, Autoclaves - 2 nos Boiler (750 kg/hr) Tools Water supply lines and sprinkler Testing equipment Office equipmentiurniture Electric connection/fittings Additional Information Source of technology BMTPC Information & Guidance BMTPC Finance HUDCO, NHB, IB! IcIcl, IFC Plant & Machinery Indigenous Suppliers of Plant Mis Projects & & Machinery Engineering Services Plot No. 15, Phase - I. Industrial Estate, Yamuna Nagar Haryana - 135 001 Machines Developed by BMTPCTTT CVE eC Qe LUC e Te TT he Council's is very keen to promote use of better alternatives to Bumt Clay Bricks for load bearing walling masonry work in various type of constructions. With the increasing demand of construction indus obtain bricks of good quality, con strength. The intention being to promote equally npetitive friendly, sa and exploit use There are many states in India where quality bricks are not use of the quality of soil there and stone at In these areas Solid/Hollow con used for walling. The areas finding increasing ai ales of India, Himachal Pradesh, Rajasthan, Andhra Pradesh, Kerala and Hilly areas of U.P. and Tamil Nadu. Inorder to manufacture solid/hotlo blocks (of different shapes and tone bloc and also large size aggregate blocks on small scale level, the Council has developed a standing type portable concrete block making machine. This machine can be used even under space constrain conditions. The strength of blocks produced with this machine is 70-100 ke Be Sy it is becoming materials whi ronment kind of blocks plance are North eastem concret Standing type portable mact eee en ie eee blocks or 1500 bricks per day CoA enero) Cee cl cay Pe eu Cee ee ae a Pee ete) eeu Sueur ay No casting platform is required ee eg ee un oy Most suitable for hilly areas Pee RE See Mee as ced tion of solid concrete biocks to achieve desired Era SU Cue Ween eu a} UN ed ees ge eso SCC SMe Se] eeu ee ogee ete 7 MACHINE SPECIFICATIONS + Production Capacity (per day) + Size of machine * Weight of machine + Size of block/brick Solid block Hollow block Brick + Type + No. of block/bricks ‘one operation + Energy source 00 solidihollow concrete blocks or 1500 bricks 900x900x1800 mm 500 kgs 300x200x150mm 400x200x200mm, 190x90x80mm Portable, standing type 2 nos conerete blocks or 6 nos. concrete bricks Electrical, 3 phase, 440 volts 3HP Pressure vibration + Power requirement + Compaction byTEA eS ‘SETTING UP A PROJECT Project Cost 1. Instaled capacity a) (per annum) ) 75,000 Hollow blocks 2. Capacity at 80% a) 60,000 Solid blocks utilisation ) 60,000 Hollow biocks (per annum) (300 working days) 3. Saleable product 19.20 lakhs 4. i) Fixed capital 4.25 lakhs il) Working capital 3.75 lakhs 5. Employment Potential 6 persons 6. Raw materials & Inputs a. Cement 200 tonnes . Coarse sand 5560 cum! ©. Aggregates, 645 cut 4. Ballast 442 cunt . Consumables us. {, Electricity, Water 7. Annual cost of production Rs.16.35 lakhs 8. Profitability (per annum) Rs. 2.85 lakhs 9. Profit on sales 15% 10. Retum on investment 36% 11.Break even point 51% Plant/Machinery Requirements Concrete Mixer; Solid concrete block machine (standing type), Extra mould for hollow block; Transfer trolley/ wheel barrow: Tools; Wooden pallet; Water supply lines and sprinkler; Electrical equipment fitings; Office equipment furniture; Testing equipment Additional Information Source of technology BMTPC. Information & Guidance BMTPC, Building Centres Finance HUDCO, NHB, IDB, ICICI, IFCI Plant & Machinery Indigenous ‘Suppliers of plants/ Mis Vietor Electricals & machinery Machinery Manufacturer 3616, Netaji Subhash Marg, Darya Ganj New Delhi-110 002eA UOT CUE Ca ‘SALIENT FEATURES: + Produces C-section beams(Rafter) of all up to a span of 360mm, Capable of casting 4 C-section beams of size 150mm x 100mm or 3 C-section beams of 300 mm x 150mm per day Capacity can be increased by replacing the mould Compaction of concrete mix with vibration technique Unskilled labour is required for manufacture. Less labour requirement Compressive strength of 250kg/cm2 can be achieved Welded mesh, chicken mesh are used to achieve economy ‘The machine can be conveniently shiftedSETTING UP A PROJECT Project Cost 1. Installed cap. 4500 C-Beams per annum (300 working day i) Fixed capital ii) Working capital Employment Potential 11 persons Raw materials & Inputs a. Cement 124 tonnes b. Coarse 260 cu.mt ©. Admixtures d. Poly propylene fibre e. Steel 1. Welded mesh ty, Water Annual cost of production Rs.17.99 lakhs Rs, 2.86 lakhs Profit on sales Return on investmer ak even point Plant/Machinery Requirements Concrete Mixer; C-Beam making machine ; Extra ‘moulds for C-Beams; Welding machine; Transfer trolley'wnee! barrow; Tools; Gantry girder; Water and sprinkler; Electrical equipment ting equip ment Additional Information Source of technology BMTPC Information & Guidance BMTPC, Building Centres Finance HUDCO, NHB, IDB ICICI, IFCI Plant & Machinery Indigenous ‘Suppliers of plant Mis Victor Electricals & machinery Machinery Manufacturer 3616, Netaji Subhash Marg, Darya Ganj New Dethi-110 002 * Production capacity 4 C-Beams of size Pe eae ule Eee eae iuh eek Th Sree art) roevonr) Pe Sto) Gatti) Sem ae el Ortigia’ Electrical, 3 phase ee ea Vibration technique oid Dune oe ea Machines Developed by BMTPCFerrocement Wall Panel machine SALIENT FEATURES Wee eae Aaa | * Produces wall panel units of size 1200mmx Imm or 1 x1200mm or any oth Which are used as a tive to brick ing 4 walling uni placing the mould Compaction of concrete mix by vibration tech- nique cement walling units produced with the ma- chine are 20 to 30% cheaper than conventional brick work Suitable for small scale Industry Welded mesh is used to achieve economy * Production Capacity 4 walling units per day of size 1200mmx300mm ‘or 1200 mmx1200mm, *Size ofmachine Depend upon the size of walling units to be manu- factured /+Weight of machine 600 - 800 Kags. = Cross section size 25 mm thickness + Power requirement 2HP = Energy source Electrical, 3 phase 440 volts. [+ Compaction by Vibration technique + Mix 1 cement : 3 coarse sand + Compressive strength 150 kg/sq.om‘SETTING UP A PROJECT Project Cost 1. Installed capacity 1200 panels per annum (300 working days) 2. Saleable produ 4.80 lakhs i) Fixed capital 6.14 lakhs il) Working capital 0.96 lakhs Employment Potential 5 persons Raw materials & Inputs, a. Cement 6.5 tonnes b. Coarse sand 54 cu.mt cc. Admixtures Ls. d. Poly propylene fibre LS. e. Welded mesh 2050 sq.mt. 4. Consumables Ls. @. Electricity h. Water 6. Annual cost of production Rs.3.71 lakhs 7. Profitability (per annum) Rs. 1.09 lakhs 8. Profit on sales 15% 9. Retum on investment 23% 10.Break even point 56% Plant/Machinery Requirements Concrete Mixer; Wall panel making machine; Extra moulds for wall panels; Welding machine; Transfer trolley/wheel bar- row; Tools; Gantry girder; Water supply lines and sprinkler Electrical equipment fittings; Otfice equipment/ furniture; Test- ing equipment Additional Information Source of technology BMTPC Information & Guidance BMTPC, Building Centres Finance HUDCO, NHB, IDBI. ICICI, IFCI Plant & Machinery Indigenous Suppliers of plants/ Mis Victor Electricals & machinery Machinery Manufacturer 3616, Netaji Subhash Marg, Darya Ganj New Dethi-110 002 Machines Developed by BMTPC‘A RCC PLANK CASTING MACHINE (CP-1) ER Nam a CP/CJ-1 mar Salient Features + Suitable for product planks which are used as an alternative to RCC slabs * Capable of castiny 300 mm per day * Capacity can be increased by replacing moulds * Compaction of concrete by vibration techniques * Can produce high quality of RCC pi skilled labour * The roofing panels produced by the machine are 30-40%, cheaper than conventional RCC slabs. ‘+ Greatly reduces the construction time, Machine specifications n capacity: § roofing planks per day n of pre 19 5 rooting planks of size 1500x inks with un- + Size of machine 1600x600x750 mm * Weight of machine — : 500 kgs + Type Portable + Mix 1 cement:2 coarse sand:4 aggregate of size 10 mm & below + Energy source Electrical, 3 phase, 440 volts + Power requirement: 2HP * Compressive strength: 150 kg/cm? B RCC JOIST CASTING MACHINE (CI-1) ient Features + Suitable for production of precast RCC joists upto a span of 4500 mm which are used as an altemna- tive to timber and steel joists. + Produces 4 nos joists of size 150 x 150 mm or 400 x 125 mm or any other sizes per day. + The machine uses vibration techniques + Capacity can be increased by replacing the mould + High quality RCC joist can be produced by un- skilled labour. + The joists produced by the machine are 25-30% cheaper than conventional steel or timber joist. + Reduces construction time thus saving in con- struction cost. Machine specifications ‘+ Production capacity : 4 joists per day per mould ol i cS = 7) Ss = a I = Pa J o = Rn — (-) a] C ae i Ss a i-ay a — a = S i oS eo 4 Pa) J or) o “4 ie + Size of machine 4550x1600x750 mm ‘+ Weight of machine: 550 kgs = Type Portable + Mix 4:24 + Energy source Elec. 3 phase 440 volts + Power requirement: 2HP = Compressive strength : 150 kg/m?‘SETTING UP A PROJECT Project Cost 1. Installed capacity a) 6000 planks and (per annum) ) 3600 joists (300 working days) 2. Saleable product, 25.63 lakhs 3. i) Fixed capital 7.84 lakhs il) Working capital 4.97 lakhs 4, Employment Potential 17 persons 5. Raw materials & Inputs a. Cement 133 tonnes bb. Coarse sand 180 cu.mt c. Aggregates 60 cu.mt 0. Admixtures Ls. e. Poly propylene fibre LS. f. Steel 53 tonnes g. Consumables Ls. h. Electricity, Water 6. Annual cost of production Rs.22.15 lakhs 7. Profitability (per annum) — Rs. 3.48 lakhs 8. Profit on sales, 14% 9. Return on investment 27 10. Break even point % Plant/Machinery Requirements Concrete Mixer; RCC plank casting machine; Extra moulds for RCC planks; RCC joist casting machine; Extra mould for FCC joists; Tach welder; Transfer trolleylwheel barrow; Tools; Gantry girder; Water supply lines and sprinkler; Electrical equipment fittings; Office equipment furniture; Testing equip- ment Additional Information source of technology BMTPC Information & Guidance BMTPC, Building Centres Finance HUDCO, NHB, IDB! ICICI, IFCI Plant & Machinery Indigenous Suppliers of plants/ M/s Vietor Electricals & machinery Machinery Manufacturer 3616, Netaji Subhash Marg, Darya Ganj New Dethi-110 002re) = = o os = > _ — I = = o = o & col ry = o i= S = SF (x) — a 3 Py ry i = ‘SALIENT FEATURES * Suitable for production of L-panels for slope roof: ing which are used as an altemative to RCC slabs. + Produces 2 L-panels of size 4000 mm x 380 mm in aday + The capacity can be increased by replacing the mould + High quality L-panels are produced by unskilled labour + The panels produced with the machine are 30%. Cheaper than conventional RCC slab. + Reduces construction time by 20% + L-panels can be used in high rainfall area + Savings in consumption of concrete and steel are 25% and 30% respectively. * Suitable for small soz le industry + Compaction of concrete is done through high amplitude vibrations + The L-panels are also suitable for temporary con’ struction MACHINE SPECIFICATIONS ‘+ Production capacity 2 Lpanels per day per ‘mould Size of machine 4200x800x750 mm, Weight of machine 750 kgs Size of L-panels 4000x380x120x30 mm thickness Mix 1 cement:2 coarse sand:4 aggregates (size 10 mm & below) Energy source Electrical, 3 phase, 440 volts Power requirement 2HP Compaction by Vibration technique Compressive strength 150 kg/cm?Perspective View of L-Panel for Slope Roofing ‘SETTING UP A PROJECT Project Cost 1. Installed capacity 3000 L-panels per (200 working days) 2. Saleable product 13,05 lakhs 3. i) Fixed capital 5.96 lakhs i) Working capital 2.4tlakhs 4. Employment Potential 11 persons 5. Raw materials & Inputs 2. Cement 72 tonnes ». Coarse sand 98 cumt ©. Aggregates 496 cu.mt d.Admixtures Ls . Poly propylene fibre LS. f. Steel 16.5 tonnes 9. Consumables Ls A, Electricity i, Water 6. Annual cost of production Rs.11.20 lakhs 7. Profitability (per annum) — Rs. 1.84 lakhs 8 Profit on sales 14% 9. Return on investment 22% 10. Break even point 50% Plant/Machinery Requirements Concrete Mixer; L-panel making machine; Extra moulds for L- panels; Tach welder; Transfer trolleyiwhee! barrow; Tools; Gantry girder; Water supply lines and sprinkler; Electrical equipment fitings; Orfice equipment/ furniture; Testing equipment Additional Information Source of technology BMTPC Information & Guidance BMTPC, Building Centres Finance HUDCO, NHB, IDBI ICIcl, IFC! Plant & Machinery Indigenous Suppliers of plants/ M/s Victor Electricals & machinery Machinery Manufacturer 3616, Netaji Subhash Marg, Darya Ganj New Delhi-110 002 Machines Developed by BMTPCCAA OCLC ee 5 to 30% of all timber is consumed in build and housing. This in turn amounts to 15 to 20% the c building in the form of door and window frames, shutters, partition walls et India's National Forest Policy of 1988 bans felling of forest timber from state notified forest and Natural forests. Since then timber is being imported from Afr ‘can and far eastern countries for panel products and ‘sawn timber requirements of building and allied activ ties The Government of India has already banned us of timber in building works of Gentral Public Works De. partment, from Aprif'93, There Is a great world wide demand of wood substi tutes which have the workability and durability proper: ties equivalent to timber for construction. Door shut ters made from ferrocement- a versatile form of RCC — ccan replace traditional timber. There is an immediate need of a large number of production units for manu: facture of ferrocement door shutters at decentralised ali Till now Ferrocement Door Shutters are manufac: tured in India by manual methods of casting, In order to further propagate this technology for wide scale appli lion and with a view to introduce mechanisation for od 2100mm x 800mm This hydraulic machine is capable of casting 12 Door si of standard size in a day by replacing the mould. To reduce weight of the Door Shutters, the thick of the shutters has been reduced to 15mm,‘Production Capacity 12 door shutters per day Hydraulic type portable machine 2450x 1200x 1800mm 500 kgs (Approx) 210mm x 900 mm Electrical, 3 phase 440 volt. * Size of machine ‘+ Weight of machine * Moulding Area + Energy source Compaction by ‘Hydraulic pressure- vibration tech- * Size of Door Shutter 2100mm x 910mm * Power requirement 1 cement : 3 coarse sand ‘SALIENT FEATURES + Capable of casting 12 door shutters per day of standard size by replacing the mould Suitable for small scale industry Low investment with High return Welded mesh is used to achieve economy In built provision for hinges, tower bolt and L- drop. No casting platform is required Generation of employment opportunities Steel ribs all around the shutter for providing strength. Machines Developed by BMTPC.EER Te Ge CUT ete i ETH he Counci's introduc traditional me! to meet the need of production of clay fiyash bric the Council has developed two types of machines - one a hydraulic press and the other a mechani press for the manufacture of clay flyash bricks, with a capacity of producing 10,000 bricks per day. Mixing of flyash with clay has been one of the inhibiting parameters in the use of flyash in clay brick making. The process developed uses a semi-dry hydraulic press and mechanised mixing system for manufacture of clay-flyash bricks using all types of soils (including black cotton soil) and flyash continuously Capacity of the press: 10,000 bricks per day (designed plant capacity) No. of bricks cast per rotation of the press: 6 Nos No. of bricks per hour: 1080 No. Casting pressure on the ram of Hydraulic cylinder: Varies from 150 Kg/em® - 240 Kg/em’ Were Mg eI toaSALIENT FEATURES Ee we iL le for cutting of steel bars upto 25 mm diameter and steel pipes upto 80 mm diameter to suit the requirement. * Auto coolant circulation facility * Most suitable for construction sites, * Less mainte ance & power requirement Bar and Pipe Cutting Machine MACHINE SPECIFICATIONS + Production capacity Imm to. 25 mm bar. steel pipe upto 80 mm dia 8mm cut -80 pes/minute 12mm cut -25 pesiminute 25mm cut - 2 pes/minute ¥" cut - 10 pos/minute 2" cut - 5 pesiminute 3" cut - 1 pos/minute (depending upon feeding speed) * Energy Transmission Hand stick operated cut- ting with auto coolant cit- culation + Size of machine 910x580x1000mm ‘+ Weight of machine Approx. 90 kgs ‘= Power requirement 2.5 HP Energy source Electrical, 3 phase, 440 volts: Body & base MS and Cl fabricated body on 50 mm angle and 3 mm plate with industrial paint 2 HP 4 pole Induction Mo- tor, 1500 RPM to provide pulley ratio 1:3.5 for final RPM of cutter 4500 Cutting toot Parting wheel of 8" to 12" 2to4mm thick, 1” holding hole * Water pump 1/4 HP, 4 pole, 4 LPMa 5 an = = = 2 = e Cy = = (== ead i) — i oy s a Ss [—} t=) = = [J oI =) J I 4 he brick and tile industry consumes millions of tonnes of coal for firing of bricks. Due to the scarcity of good quality of long flame variety of coal, the brick and tile units are being given the lowest quality of coal. A huge expendi- ture is involved on firing of bricks. In addition to these the system of stoking by hand is a major source of pollutant emitted by the brick units due to incomplete combustion. The quality of bricks manufactured is also to a larger extent related to how consistently and regularly fuel is added to the kiln. In manual stoking there Is no control on this and this results in over-fired or under-fired bricks, both of which result in losses to the brick unit. The combustion in a brick kiln is depend upon the air supply, fuel, ignition temperature, ignition delay, rate of combustion inside the kiln and thermal quenching on the flame. In order to optimise the combustion proc: cesses itis necessary to optimise these parameters. All this can be achieved by stoking the coal continuously in minute quantities instead of 20 minutes or half hourly intervals and also by stoking with a fuel which has been reduced to a finger grain size instead of the size that is normally used. ‘THE PRESENT SYSTEM OF FIRING ‘Two fireren are stoking together for a duration of 15 to 20 minutes and then they sit down for another 20 min Te cs-1 Firing is more regular and quality of bricks and tiles is better. Fuel consumption is less, resulting in ‘complete burning of fuel with minimum of excess air. + Greater speed of fire travel is possible with increased output and decreased heat loss. Cheap, dusty coal can also be used. Number of fire holes can be reduced. Complete absence of any unburnt fuel. Accumulation of fuel at bottom can be avoided. Total absence of black smoke which will help to combat the menace of pollution. Recovers its cost by way of direct savings in one year's time.tutes. During the period of stoking, airs in short supply and because of almost 1.25 kg of added per fire hole per minute and use of big: ger size lumps, it practically becomes impossi- ble for a proper air fuel mixture to form. Sec- ondly, when the fuel is not being fed, the air Which is passing through the kiln has a cooling effect on the bricks and thus prolongs the firing time required. The stoking of large quantities at a time also lead to accumulation of the fuel at the kiln bottom which comes out as unbumt fuel Hence the need is felt for a simple machine chieve the objective of feeding minute quantity of coal ata regular interval and on which a better control can be exercised com: pared to the firemen. which e To overcome the above, the Council had de: veloped an automatic coal stoker for feeding the coal in Bull Trench’s kiln for brick and tile industry, ‘THE DESIGN OF COAL STOKER ‘The stoker is basically designed as a small screw conveyor fitted with a coal hopper and connected to the feed hole through a vertical pipe with inspection lid at the top. Th conveyor is rotated with the help of a ratchet and pawl arrangement, and all stokers fitted on one row of feed holes are connected to a com: ‘mon variable speed drive. The arrangement is such that the ingress of air from outside is com: pletely eliminated. One stoker is placed on each feed hole. A minimum of three rows of stokers are required for one brick kiln, Generally a brick kiln has ten feed holes in one row (bigger kilns have more). Thus one kiln will require 30 nos. of stokers and three nos. drive units. The ca- pacity of one stoker is 0.75 cft"/,hr. and weight 35 kgs. The use of coal stokers will ing consumption of coal, in improv- ing percentage of frst class bricks due to more efficient flame spread and burning of bricks in the kiln. This device has been greatly appreci- ated and welcomed by a number of brick kilns owners, Machines Developed by BMTPC rs ereCea Ce Eg ST i] a CJ ] =) 4 oe i =} = na SALIENT FEATURES * Suitable for crushing stone/boulders/coal/bricks at construction site to obtain crushing size 6 mm to 25 mm, Suitable for manufacturers of concrete blocks, rural road contractors and brick field operators. Can be easily shifted from one place to another even in hilly regions. Diesel engine of equivalent horse power can also be fitted in place of electric motor. Suitable for small scale industry in rural as well as urban areas. Capable of crushing medium hardness stone and all types of coal Heavy duty machine with low maintenance. MACHINE SPECIFICATIONS * Production capacity 1a) Coal - 400 cft. per day b) Stone 200-320 cft per day * Size of machine 1650 x 1040 x 1600 mm ‘+ Weight of machine 1 MT approx. + Type Stationary, mobile UT Crushing size Energy Transmission Energy source Power requirement Body AS 1714 ‘6mm to 25mm Through jaw plates, Electrical, 3 phase, 440 volts 4) Electrical -7.§ HP b) Diesel - Eqv. Engine MS plate heavy duty ‘Annealed and painted‘SALIENT FEATURES + Aversatile stone cutting, grinding, driling and polishing machine for semiprecious stones, furniture and decorative items. (One machine can be used for four opera- tions like cutting, drilling, polishing and grind- ing. Capable of cutting, grinding, driling and pol- ishing the stones such as granite, agate, etc. Most suitable for rural and cottage industry Less electricity consumption Low capital investment and high return Can generate lot of employment in rural ar- eas ‘One motor may be used in horizontal and vertical directions for various operations No maintenance Both ends of the machine can be used for various operations MACHINE SPECIFICATIONS ‘+ Production capacity Depend upon the WT COUT CTC type of stone to be processed Energy source Electrical, single or 3 phase, 220 volts or 440 volts Power requirement 2 HP for single phase 1 HP for three phase ‘Man power 2 persons The motor of the machine is provided with vari able RPM which can be used for different pur poses as follows: RPM Purpose 450 Leather polish and grinding 1000 Drilling of hole 1.5" to 3" @ 2000 Cutting blade of 14" and diiling upto 0.5" to 0.5 6 4000 Cutting blade of 8° & and driling upto 0.5" 9PGCE ECT ULC TUTTO E LEG ELC TL CL gnising the urgent need for an appropri ‘and cost ing technolo: north-eastern and other bambot gions and disasters prone area veloped a technology for manufac corrugated roofing sheets. This would be an alternative for sheets posses excellent phys chanical properties and are based on renewab sources requiring low energy. It may also find use as value added products in the areas as an aesthetically pleasing material Suitable coating composition both inbuilt dur ing the manufacturing of sheets as well as post appli- cation compositions have been dé make the sheets resistant to ultra-violet radiat Roofing sheets in size 1.8 mx0.9 m and 1.81 mt ane day light hydraulic hot press and comme ‘model of the press have been deSe Ces Seca) ea Ea) Oia Aes Sera ce Oates’ co) Dees SUD) SNC! 2 (iting) Sem NC) ae eet) ed eed 0.4 mmisee ee a ORC) En co Machines Developed by BMTPCRCO Cet) ‘SALIENT FEATURES Suitable for production of high quality flyash sand lime gypsum bri lid/hollow concrete block conerete bricks and interlocking concrete pavers! ties. Three models having different production capaci- ties have been developed. The production capaci- ties of these machines are: 1. Small level production : 3000 bricks 2. Medium level production : 5000 brict 3. High level production : 7000 bricks/day Solidollow concrete block and interlocking con- crete paversitiles of different shapes & designs can algo be manufactured in the same machine by re- placing the mould, ‘The bricks/blocks/pavers produced with the ma: chines are of uniform shape and precise dimen: sions. No expensive flooring is required for installation of, machines. The mix is compacted through hydraulic pressure and unique bi-directional vibrations in the machine, Low maintenance Unparalleled cost effective quality production. Multi product and multi feed to match growing demand of bricks/blocks/paver Less power consumption, Optional on feeding and unloading equipment. Develops 10-30 tonnes vibro-hydraulic pressure during compaction depending upon the type of ma-MACHINE SPECIFICATIONS Small Size Machine (AS 189) + Production capacity {3000 bricks per day or 400 soliholiow concrete blocks per day or 800 paving iesiblocks por day + Size of machine 1470x1370x2300 mm + Weight of machine 2000 kgs. * Size of brick/blockipaver Brick 280x 115.x75 mm Solid block. '300x200x150 mm Hollow block 400x200x150 mm Paver Any standard size & shape + No. of bricks/blocks/pavers per cycle Bricks ‘40s. Solid/Hollow blocks 1n0 Paving blocks 2 nos. + Type Light duty machine + Energy Transmission Vibration & hydraulic pres: + Energy source Electrical, 3 phase, 440 volts + Power requirement 3HP * Compressive strength: 80 150 kglcm’ + Compaction by Develops 10 tons of vibro hydraulic pressure Medium Size Machine (AS 1818) * Production capacity 15000 bricks per day or 1000 solid/hollow con crete biocks per day or 2500 paving blocksitiles per day + Size of machine 2500x2000x2300 mm + Weight of machine 3500 kgs. * Size of brick/blocl/paver Brick 290x1 15x75mm Solid block 300x200%150 mm Hollow block 400x200x150 mm Paver ‘Any standard size & shape + No. of bricks/blocks/pavers per cycle Bricks 6 nos. Solidmnoliow blocks 2 nos. Paving blocks 4 nos. + Type Medium duty machine + Energy Transmission Vibration & hydraulic pres- + Energy source Electrical, 3 phase .440 volts + Power requirement 7HP + Compressive strength: 80 - 150 kgfom? + Compaction Develops 15 tons of vibro- hydraulic pressure + Options Feeding and unloading equipment can be in- stale, Machines Developed by BMTPCRe UE Cast Large Si + Production capacity Machine (AS 1824) '000 bricks por day or ize of machine Weight of machine Size of brick/block/paver Brick Solid bloc No. of bricks/b Bricks lidhollow blo Paving blocks pe Heavy duty, automat Vibration & hydraulic pros- Energy source Electrical, 3 ph volts Power requirement 12HP comprossi 80 - 150 kg/cm’ Compaction Develops 20 tons of vibro- hydraulic pressure Automatic & continuous t pallets, hy- Energy Trans! Others insertio draulic removal of pallets, Baia ened eck Saree! coenty Bichon ee (Concrete ee aoe Te Ee Ned Utlisation (per annum) 80,000 sold concrete bocks 2,00,000 pavers 3, Saleable product Ea et) rant erat a eed Beco! Creat Ar) rears ona Pe anny oe caer Ese fe. Coarse sand et ers Poet reece rie ey ars eet cee 8. Profitability (per annum) Rs. 3.69 lakhs Cae a Oa enor cs ee ad BE en eS Per Na CRED RSs eee ei ae an Cee eco eae ie ced ens ea Nei tc eo Water supply lines & sprinkler; Electrical equipment! fitings; Office equipment/turniture; Testing equipment Cec omen eny ar utente BMTPC Exes tate cee’ leo ns ICICI, IFC! ny rns er aod Norco LON ete’ ceca aor) Cee ae) rele)Pe DET a ene eee cura URC CR ea I) development, transfer and investment emu ce eee ig environment-friendly & energy-efficient UCTS eta n ys} Peer oe Rete aie ic og Derren TT UT ULC te cre materials SC CRC uum cL tae Breuer escent cost-effective innovative building materials BUT Tet sub caer ee Er) Pen ercd 2.To undertake such activities as required for promoting manufacturing of new waste-based COC uC uae td Cee CaM Ua Rieti o eect eu ec up production units in different urban and ru- Pate aes EOP ET gta Cee De eu aU a ati’ ee ue eae eu ce PUL Re ee Cr ie) Pee CU am Cu eu ris CRC eee esau | Rue THRUST AREAS + Improving the policy environ- ment for sustained growth of low cost building materials, produc- tion and availability. Promotion of production units of building materials / components based on Flyash, Redmud, Phosphogyp residue and other wastes & by- products. um, agricultural Modernisation of small scale and village level building materials production units in rural and ur- ban areas. Promoting economy in construc- tion costs. Formulation of standards for lo- cal building materials. Strengthening industrial exten- sion Services for attracting more investment in building materials sector by working with National and International agencies Upscaling of technologies, know-how ac tion and dissemination Assessing vulnerability and risk in natural disaster prone areas. Promoting construction technologies. Global technology search and encouraging joint ventures in building materials and construc- tion sector. aster resistant Machines Developed by BMTPCOpen prefab systems based on an appropriate production level and. small, ‘easy-to-handle elements with rationalised production methods have at- {racted the attention of housing experts as an important option for arrest- ing the rapialy ising Costs of material and labour. Partial prfabricaion is useful for practically every part of a building - foundations, walling sys- tems, doors and vito fing’ Systems, lintels, staircase elements and all kinds of too's and hardware. Employment generation in the manufacturing process is a major benefit of this approach. BMTPC actively encourages the setting-up small, med- tum and large-scale production units based on appropriate production and investment levels. To achieve these Objectives, a number of machines hhavelbeén developed by BMTPC, and many new machines are under de- velopment, in collaboration with R&D institutions and private manufac- turers and entrepreneurs. b BMTPC offers sreineeaeet 4 vast range of technology op- tions to help the efforts somos te up production units in different regions, ~— pe for further details please contact __ Executive Director _ Building Materials and Technology Promotion Council "Core 5A, First Floor, india Habitat Centre, Lodhi Road New Delhi 110 003 Tel : 91-11-01 9967, 463 8097,463 6747: Fax: 91-11-901 0145, 4642849; E-Mail: bmtpe@ del2.vsni.net.in Web Site : http:/iwwwcbmipc.org