Detailed Project Report on PRODUCTION OF CONCRETE BASED PRODUCTS (PAVING BLOCKS AND TYPES, BRICKS AND TYPES, TILES AND TYPES, CHEQUERED TILES, PRECAST SLABS/WALLS, CURB STONES/FLAGSTONES TERRAZZO, CHIPS & PEBBLES, GRC & FRP PRODUCTS)

Interlocking Concrete Block Pavement (ICBP) has been extensively used in a number of countries for quite some time as a specialized problem-solving technique for providing pavement in areas where conventional types of construction are less durable due to many operational and environmental constraints. ICBP technology has been introduced in India in construction, a decade ago, for specific requirement viz. footpaths, parking areas etc. but now being adopted extensively in different uses where the conventional construction of pavement using hot bituminous mix or cement concrete technology is not feasible or desirable. The paper dwells upon material, construction and laying of concrete block pavement as a new approach in construction of pavement using Interlocking Concrete Paver Blocks.

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ENGINEERS INDIA RESEARCH INSTITUTE
4/54, Roop Nagar, Delhi-110007 (India)
Phone: [phone]
E-mail: [email protected]
Website: www.eiriindia.org




PRODUCTION OF CONCRETE BASED PRODUCTS (PAVING
BLOCKS AND TYPES, BRICKS AND TYPES, TILES AND
TYPES, CHEQUERED TILES, PRECAST SLABS/WALLS,
CURB STONES/FLAGSTONES TERRAZZO, CHIPS &
PEBBLES, GRC & FRP PRODUCTS)
[EIRI/EDPR/4740] J.C. 2960XL


Interlocking Concrete Block Pavement (ICBP) has been extensively used in a
number of countries for quite some time as a specialized problem-solving
technique for providing pavement in areas where conventional types of
construction are less durable due to many operational and environmental
constraints. ICBP technology has been introduced in India in construction, a
decade ago, for specific requirement viz. footpaths, parking areas etc. but now
being adopted extensively in different uses where the conventional construction of
pavement using hot bituminous mix or cement concrete technology is not feasible
or desirable. The paper dwells upon material, construction and laying of concrete
block pavement as a new approach in construction of pavement using Interlocking
Concrete Paver Blocks.

Concrete paver blocks were first introduced in Holland in the fifties as
replacement of paver bricks which had become scarce due to the post-war
building construction boom. These blocks were rectangular in shape and had
more or less the same size as the bricks. During the past five decades, the block
shape has steadily evolved from non-interlocking to partially interlocking to fully
interlocking to multiply interlocking shapes. Consequently, the pavements in
which non-interlocking blocks are used are designated as Concrete Block
Pavement (CBP) or non-interlocking CBP, and those in which partially, fully or
multiply interlocking blocks are used are designated as 'Interlocking Concrete
Block Pavement (ICBP).

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CBP/ICBP consists of a surface layer of small-element, solid un-reinforced pre-
cast concrete paver blocks laid on a thin, compacted bedding material which is
constructed over a properly profiled base course and is bounded by edge
restraints/kerb stones. The block joints are filled using suitable fine material. A
properly designed and constructed CBP/ICBP gives excellent performance when
applied at locations where conventional systems have lower service life due to a
number of geological, traffic, environmental and operational constraints. Many
number of such applications for light, medium, heavy and very heavy traffic
conditions are currently in practice around the world.

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CONTENTS

INTRODUCTION

ADVANTAGES AND LIMITATIONS

HOWEVER, IMPORTANT LIMITATIONS OF THE TECHNIQUE ARE THE
FOLLOWING:

PHYSICAL REQUIREMENTS

APPLICATION OF ICBP TECHNOLOGY

SHAPES AND CLASSIFICATIONS

MATERIALS

PAVING BLOCKS

BEDDING AND JOINT FILLING SAND

BASE AND SUB BASE MATERIALS

CONSTRUCTION OF INTERLOCKING CONCRETE BLOCK PAVEMENT

SEQUENCING OF OPERATIONS

PAVEMENT TYPES

PAVER PROPERTIES

PAVER DIMENSIONS

PAVING STRENGTH

MINIMUM BREAKING LOAD

COMPRESSIVE STRENGTH OF PAVERS

DURABILITY

SLIP RESISTANCE

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ABRASION RESISTANCE

MOISTURE EXPANSION

EFFLORESCENCE

PITTING DUE TO LIME

COLD WATER ABSORPTION

HISTORY OF PAVING:

APPLICATIONS OF PAVING BLOCK PA

VINGCK PAVING

ROADS

COMMERCIAL PROJECTS

INDUSTRIAL AREAS

DOMESTIC PAVING

SPECIALIZED APPLICATIONS

INDUSTRIAL AREAS

DOMESTIC PAVING

SPECIALIZED APPLICATIONS

INDUSTRIAL AREAS

DOMESTIC PAVING

SPECIALIZED APPLICATIONS

ROADS:

COMMERCIAL PROJECTS

INDUSTRIAL AREAS

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DOMESTIC PAVING

SPECIALISED APPLICATIONS

PATTERNS IN CONCRETE PAVING BLOCKS –

SHAPES –

ARISTOCRAT

SATINPAVE

CONLEAF

CLASSIC COBBLE

CLOVER TIFFANY

HONEYSTYLE

COROLOCK, DOUBLE ZIG ZAG

COROLINK

COMPARISON OF CONCRETE PAVING BLOCKS WITH OTHER TYPE OF
PAVEMENT

ADVANTAGES OF PAVING BLOCKS –

REQUIREMENTS FOR CONCRETE PAVING BLOCKS

PROPERTIES:

MAINTENANCE FREE

RECOMMENDED GRADES OF PAVER BLOCKS FOR DIFFERENT TRAFFIC
CATEGORIES

RESOURCES

MAIN RESOURCES

RAW MATERIALS AND CONSUMABLES

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RAW MATERIALS FOR CEMENT CONCRETE BLOCKS

RAW MATERIALS FOR CEMENT CONCRETE TILES AND MOSAIC FLOORING
TILES

COMPARATIVE ANALYSIS OF SOURCES AND PRICES OF CRITICAL INPUTS &
CONSUMABLES

THE PLANT

SELECTION OF TECHNOLOGY

PROCESS TECHNOLOGIES USED

FACTORS INFLUENCING THE CHOICE OF TECHNOLOGY

TECHNOLOGY RECOMMENDED

CEMENT CONCRETE TILES AND MOSAIC FLOORING TILES SECTION:

PARTICULAR OF MACHINE

PROCESS OF MANUFACTURE

CEMENT CONCRETE BLOCKS

MOBILE STACKING DEVICE

PALLET HOPPER

DRY MIX CONVEYO R

CEMENT SCALE:

ONE SET OF CEMENTS SCREWS

PNEUMATIC GROUPS

MIXING PLANT

AUTOMATIC FACE MIXING AND BATCHING

SEMI AUTOMATIC FACE MIXING AND BATCHING

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WET MIX CONVEYOR

SPECIFICATION OF FORK LIFT

SPECIFICATION OF LOADER

PECIFICATION OF COOLING TOWER

LIST OF EQUIPMENT FOR LAB

SPECIFICATION OF COMPRESSIVE TESTING MACHINE

VIBRO-HYDRAULIC PRESS

PAVER BLOCKS

PROCESS FLOW CHART

CEMENT CONCRETE TILES AND MOSAIC FLOORING TILES

PROCESS FLOW CHART

FINISHED PRODUCT

PROCESS AND QUALITY CONTROL

PHYSICAL TESTS:

TESTING EQUIPMENT’S:

TECHNICAL KNOW-HOW

ENVIRONMENTAL IMPACT

ENVIRONMENTAL ASPECT OF MANUFACTURING PROCESS

WASTE GENERATED AND MITIGATION MEASURES

WASTE GENERATED DURING CONSTRUCTION PHASE AND MITIGATION
MODES

WASTE GENERATED DURING PROJECT OPERATION PHASE AND MITIGATION
MODES

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ADVANTAGES/APPLICATIONS

APPLICATIONS OF PRESTRESSED CONCRETE POLES

B.I.S. SPECIFICATIONOF PRODUCTS

MARKET OVERVIEW

PRESTRESSED CONCRETE MARKET DEFINITION

PRECAST CONCRETE POLE MARKET SIZE

MARKET DYNAMICS

PRESTRESSED CONCRETE MARKET SHARE BY REGION 2022 (%)

PRESTRESSED CONCRETE MARKET MAJOR PLAYERS ARE:

INDIAN MANUFACTURING INDUSTRY

INTRODUCTION

MARKET SIZE

INVESTMENT

GOVERNMENT INITIATIVES

IN THE UNION BUDGET 2023-24:

IN THE UNION BUDGET 2022-23:

ROAD AHEAD

PROCESS FLOW DIAGRAM

PRE CAST CONCRETE COMPONENTS & EQUIPMENTS

PRE-STRESSED COMPONENTS

PRE-STRESSED CONCRETE POLES

EQUIPMENT FOR MANUFACTURING

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FLY ASH BRICKS/ BLOCKS & CONCRETE BRICKS/BLOCK / PAVER MAKING
MACHINE

MAJOR ADVANTAGES:

FOR BLOCK MACHINE

AUTOMATIC PALLET STACKING DEVICE

WOODEN PALLET

FOR BATCHING & MIXING PLANT)

DISCHARGE CONVEYOR FOR BASE MIX

SUPPLIERS OF PAVING BLOCK

SUPPLIERS OF PORTLAND CEMENT

SUPPLIERS OF STONE CHIPS

LABORATORTY EQUIPMENTS MANUFACTURERS

D.G. SET MANUFACTURERS & SUPPLIERS

FIREFIGHTING EQUIPMENTS MANUFACTURERS & SUPPLIERS

SUPPLIERS OF WATER PUMP

SUPPLIERS OF PALLETS

SUPPLIERS OF MOULDS

PLANT AND MACHINERY SUPPLIERS FOR PAVERS BLOCKS

CHINA SUPPLIER OF AUTOMATIC PAVING BLOCK MAKING MACHINE

SUPPLIERS OF OTHER PLANT & MACHINERY

MACHINERY

MATERIAL HANDLING EQUIPMENTS

SUPPLIERS OF RAW MATERIALS

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CEMENT

STEEL WIRES

OTHER PLANT & MACHINERY MANUFACTURERS

SUPPLIERS OF INTENSIVE SAND MIXTURE AND MULLER

SUPPLIERS OF SAND SIEVING MACHINE

SUPPLIERS OF MOLDING BOXES

SUPPLIERS OF DRILLING, LATHE, TAPING MACHINES

SUPPLIERS OF EOT CRANE

SUPPLIERS OF POWER TRANSFORMERS

SUPPLIERS OF ELECTRICAL PANEL

SUPPLIERS OF ELECTRIC MOTOR

SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS

SUPPLIERS OF PLATFORM WEIGHING MACHINE

SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS

SUPPLIERS OF FIRE FIGHTING EQUIPMENTS

SUPPLIERS OF JIGS AND FIXTURE

FINAL PRODUCTS

PRINCIPLES OF PLANT LAYOUT

STORAGE LAYOUT:

EQUIPMENT LAYOUT:

SAFETY:

PLANT EXPANSION:

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FLOOR SPACE:

UTILITIES SERVICING:

BUILDING:

MATERIAL-HANDLING EQUIPMENT:

RAILROADS AND ROADS:

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

1. RAW-MATERIAL SUPPLY:

2. MARKETS:

3. POWER AND FUEL SUPPLY:

4. WATER SUPPLY:

5. CLIMATE:

SPECIFIC FACTORS

6. TRANSPORTATION:

A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES

7. WASTE DISPOSAL:

8. LABOR:

9. REGULATORY LAWS:

10. TAXES:

11. SITE CHARACTERISTICS:

12. COMMUNITY FACTORS:

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13. VULNERABILITY TO WARTIME ATTACK:

14. FLOOD AND FIRE CONTROL:

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

1. DEPRECIATION:

2. FIXED ASSETS:

3. WORKING CAPITAL:

4. BREAK-EVEN POINT:

5. OTHER FIXED EXPENSES:

6. MARGIN MONEY:

7. TOTAL LOAD:

8. LAND AREA/MAN POWER RATIO:

PROJECT IMPLEMENTATION SCHEDULES

INTRODUCTION

PROJECT HANDLING

PROJECT SCHEDULING

PROJECT CONSTRUCTION SCHEDULE

TIME SCHEDULE

GENERATION AND MANAGEMENT OF WASTES

SOLID WASTES

LIQUID WASTES

GASEOUS EMISSION

OTHERS

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INDUSTRIAL WASTE MANAGEMENT

SEWERAGE SYSTEM

ANTICIPATED ENVIRONMENTAL IMPACTS

CONSTRUCTION PHASE

OPERATION PHASE

MITIGATION MEASURES (PROPOSED)

HEALTH SAFETY & ENVIRONMENT

SAFETY & OCCUPATIONAL MEASURE (STORAGE/HANDLING OF RAW
MATERIAL & PRODUCT)

SAFETY DATA SHEETS

ENVIRONMENTAL/SAFETY LIABILITY

PRE-PROJECT ACTIVITIES

PROPOSED IMPLEMENTATION SCHEDULE

PROJECT FINANCIALS

BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)

CONCLUSIONS:

PLANT LAYOUT

STATUTORY APPROVALS FROM GOVERNMENT

DOCUMENTS REQUIRED FOR LICENSE S

LIST OF DOCUMENTS:

SWOL ANALYSIS

STRENGTHS

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ORGANIZATION CHART

IMPLEMENTATION SCHEDULE

ADDRESSES OF RELEVANT GOVERNMENT OFFICES

ADDRESSES OF FINANCIAL INSTITUTIONS

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APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)

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COST ESTIMATION

Plant Capacity 10 MT/Day

Land & Building (2 Acres) Rs. 1.50 Cr

Plant & Machinery Rs. 2.36 Cr

Working Capital for 2 Months Rs. 74.64 Lac

Total Capital Investment Rs. 4.78 Cr

Rate of Return 21%

Break Even Point 71%