CLC (CELLULAR LIGHTWEIGHT CONCRETE):
INTRODUCTION
It is a version of lightweight concrete that is produced like normal concrete under ambient conditions. It is p
(constituting 26% - 34 % content) + water, which is further mixed with the addition of pre-formed stable foam
mixture is either poured or pumped into assembled moulds of blocks or formwork of reinforced structural el
filling. The foam imparts free flowing characteristics to this slurry due to ball bearing effect of foam bubbles
the moulds /forms without requiring any kind of vibration or compaction.
MARKET
Concrete block-manufacturing industry finds a boom-time in Bangladesh to seize bulk of the Tk 90-billion b
friendly and [Link] the government has decided to ban the use of the traditional bricks in the next thre
kilns create, people are looking to the eco-friendly construction material to come up to their [Link] a resu
steady growth of the modern manufacturing [Link] of the present brick-field owners and new entrep
an industry-insider told the [Link] to experts, the current market size of the country's brick industry i
grabbed a share of the market amounting to nearly Tk 2.0 [Link] groups like Concord, Mir Group,
cent of the concrete-block market in their [Link] large factories invested Tk 300-500 million each
[Link], there are midsize players having invested Tk 50-60 million each for setting up a factory, in
procured from China for Tk 50 [Link] the fully automated factories' owners, Concord is the market
five biggies are selling Tk 150 million worth of concrete- block products annually in the takeoff stage of the
use manual machines to manufacture concrete [Link] to the industry forecast, hollow blocks wil
[Link] the scenario, there is a huge investment potential in this sector while the number of manufactu
adds that big real-estate groups like them had started such an initiative to cater for their own construction p
full capacity," says the official, who prefers not to be [Link] to the FE, architect Hasan Shahriar Kh
construction compared to the traditional [Link] is cost-effective, as a unit of hollow block covers the space
costing less than the total price of five bricks at Tk [Link] is also convenient in terms of weight as a single blo
architect [Link], constructing a wall with hollow blocks requires far less cement than the quanti
sound-and heat-insulation capacity due to the vacuum inside and it is lighter than the traditional bricks, Mr
concrete blocks, say [Link] is learnt that LGED, the government agency for building road infras
herringbone roads, the insiders told the FE while explaining the increasing demand for the blocks in future.
Portland cement, stone dust and sand - all easily [Link] traditional brick fields use soil from crop
like the brick fields -- a huge relief for the [Link], the mushrooming of the concrete block an
there is no law to regulate the industry, warn the [Link] the fringe areas of the country, many manual bu
reluctant to supply products there due to high transportation [Link] small players, which are mushroom
inspection,
DURABLOCK-CLC Blocks in order to ensure quality production and to address safety concerns, opines architect Khan.
Advantages
[Link] Bricks have excellent compressive strength in excess of regular clay bricks / solid blocks, guarantee
[Link] strength is 15 to 20% of compressive strength.
[Link] Bricks density is 800kg/m2 which reduces dead load on structures.
[Link] saving in foundation and structure savings upto 30% on beam costs.
[Link] earth quake resistance properties.
[Link] construction. CLC blocks are easily cut to custom size requirements on size using basic power-too
[Link] saving of labor. Faster construction directly relates to reduction in labor requirement. CLC Bricks of
[Link] Air conditioning expenses. Air-conditioning energy requirements can be 5 times lower than con
[Link] fumes in case of fire.
[Link] acoustic barrier. More peace of living, No disturbance from your neighbor’s home theatre.
[Link] accurate and smooth walls Suction in plastering.
[Link] for any finish on walls — external plastering, tiling, cladding, internal tiling, dry lining, spray plaster o
13. Easy handling. Lightweight CLC is easy to transport and stock.
INVESTMENT The project calls for an investment of Rs. 120.00 Lakhs to set up a unit to manufacture 130 TPD of CLC B
plant and machinery required for the project are indigen
Table I: Project Cost (Rs. Lakhs)
Sl. No Description
1 Land & Land Development
2 Buildings & Civil Works
3 Plant & Machinery
4 Moulds
5 Contingencies
6 Preliminary & Pre-Operative Expenses
7 Margin Money for Working Capital
Total
MECHINERY
Machinery Specification Power Consumption
Mixer 1.0 Cubic 7.5 HP
Foam Generator 200 Lt/Min 1 HP
Air Compressor 300 Lbs 2 HP
Moulds 15 Cubic M
TOTAL POWER 10.5 HP
RAW MATERIALS Cement, Fly Ash, Foaming agent, Moulds Releasing Oil
CURING SYSTEMS Natural water curing system.
LAND 2000 Square Meter
LABOUR 10 Nos
OUTPUT 15 Cubic Meter
SIZE Quantity
24 X 8 X 9 36
1 CUBIC METER 24 X 8 X 8 40
24 X 8 X 6 53
24 X 8 X 4 80
Raw Materials Required for 24 X 8 X 9 — 1000 Blocks:
MATERIAL QTY UNIT
CEMENT 75 BAG
FLYASH 6.75 TON
FOAM 15 KG
LABOUR 10 NO
POWER 1 DAY
WASTE OIL 10 LTR
Profit Margin for 15 M3 Per Day Plant:
Particulars Rate M3
Market Rate 3500 15
Production Cost 1855 15
Transport Cost 200 15
Admin Cost 50 15
Profit
HTWEIGHT CONCRETE):
e under ambient conditions. It is produced by initially making a slurry of Cement +Sand + Fly Ash
addition of pre-formed stable foam in an ordinary concrete mixer under ambient conditions. The
rmwork of reinforced structural elements or poured onto flat roofs or voids for thermal insulation or
all bearing effect of foam bubbles enabling it to easily flow into all corners and compact by itself in
o seize bulk of the Tk 90-billion brick market, as the new-generation building blocks are eco-
e traditional bricks in the next three years in phases because of the environmental hazards brick
come up to their [Link] a result, the demand for concrete blocks is on the rise-so is the silent but
brick-field owners and new entrepreneurs are switching to concrete blocks, including hollow blocks,
ze of the country's brick industry is over Tk 90 billion -and concrete-block makers have already
s groups like Concord, Mir Group, BTI, and Meghna are the market leaders right now with 20 per
invested Tk 300-500 million each for setting up an automated concrete block-manufacturing
n each for setting up a factory, industry-insiders say, adding that an automated unit could be
s' owners, Concord is the market leader with annual revenue of around Tk 360 [Link] four to
nnually in the takeoff stage of the green [Link] addition, there are several small players which
dustry forecast, hollow blocks will take over at least half the traditional brick market in five
or while the number of manufacturers is comparatively lower, says a senior official of [Link]
cater for their own construction projects."The market is growing like anything and we are selling at
FE, architect Hasan Shahriar Khan said that hollow blocks have many advantages in building
t of hollow block covers the space of five traditional bricks, he adds.A hollow block costs Tk 35,
in terms of weight as a single block weighs 10-11 kg against the 15-20 kg weight of five bricks, the
es far less cement than the quantity needed for erecting a brick-made [Link] bricks have more
ter than the traditional bricks, Mr Khan pointed [Link] government agencies are now using the
ent agency for building road infrastructure, is planning to use concrete blocks on its 12,000-km
g demand for the blocks in [Link] materials used in the concrete-block industry include
onal brick fields use soil from croplands and woods, concrete-block production needs no burning
hrooming of the concrete block and hollow block industry might lead to deterioration of quality as
as of the country, many manual builders have started block production as the big factories are now
all players, which are mushrooming at the grassroots level, need to be regulated through
ncerns, opines architect Khan.
ay bricks / solid blocks, guarantees min. Compressive strength of 3N/mm2.
sts.
nts on size using basic power-tools.
labor requirement. CLC Bricks offer highest thermal insulation making cool summers and warm wint
nts can be 5 times lower than conventional structures. CLC Bricks are fire resistant.
our neighbor’s home theatre.
al tiling, dry lining, spray plaster or anything of your choice.
o manufacture 130 TPD of CLC Bricks and 120 TPD of BLOCKS with 300 days of operations. The
equired for the project are indigenously available.
tion Amount (In lakhs)
200
100
10.5
17.5
1.5
9
15
72.5
RATE AMOUNT
275 20625
350 2362.5
130 1950
250 2500
100 100
30 300
27837.5
Per Day Per Month (25 Days) Per Year (300 Days)
52500 1312500 15750000
27825 695625 8347500
3000 75000 900000
750 18750 225000
20925 523125 6277500
Quotation
Injection Inside Applicative
Molding Molding price Molding
No. Description Picture Material Weight molding molding injection On Off Cycles Remark
qty (USD) finish time
cycle material molding
PBT+20% glass fiber(4115-
R-injection molding-E27- 226U24)conformance to [Link] plastic injection
1 8g 1pcs 20±2s S136 120T $6,850 500000
A50-porcelain white-3W-IBU RoHs,Reach,PAHs molding
requirements [Link] runner
PC(DF8235-
160Tblow
WH3120)conformance to [Link] molding
2 R-blow molding-A50-IBU 8g 1pcs 22±2s S136 molding $17,100 500000
RoHs,Reach,PAHs [Link] runner
machine
requirements
PBT+20%glass fiber(4115-
R-injection molding-E27- 226U24)conformance to
3 9.5g 1pcs 20±2s S136 120T $7,100 500000 [Link] plastic injection
A55-porcelain white-5W-IBU RoHs,Reach,PAHs
molding [Link] runner
requirements
PC(DF8235-
160Tblow
WH3120)conformance to [Link] molding
4 R-blow molding-A55-IBU 9.6g 1pcs 22±2s S136 molding $17,100 500000
RoHs,Reach,PAHs [Link] runner
machine
requirements
R-injection molding PBT(4115-226U)conformance [Link]-plastic
5 aluminum-housing-LED- to RoHs,Reach,PAHs 9.5g 1pcs 30±2s S136 120T $8,100 500000 injection molding
BPZ220-7-IBU(A60-115) requirements [Link] runner
110T
R-heat sink-LED-BPZ220-7- AL1060
6 7.5g 1pcs 1.9s CR12MOV punching $9,970 500000 [Link] molding
IBU(A60-115) (T=0.8mm)
machine
R-injection molding PBT(4115-226U)conformance [Link]-plastic
7 aluminum-housing-LED- to RoHs,Reach,PAHs 11g 1pcs 30±2s S136 120T $8,100 500000 injection molding
BPZ220-9-IBU(A60-120) requirements [Link] runner
110T
R-heat sink-LED-BPZ220-9- AL1060
8 8.7g 1pcs 2s CR12MOV punching $10,980 500000 [Link] molding
IBU(A60-120） (T=0.8mm)
machine
PC(DF8235-
160Tblow
WH3120)conformance to [Link] molding
9 R-blow molding-A60-IBU 11.6g 1pcs 22±2s S136 molding $17,990 500000
RoHs,Reach,PAHs [Link] runner
machine
requirements
45 workdays
Injection Inside Applicative
Molding Molding price Molding
No. Description Picture Material Weight molding molding injection On Off Cycles Remark
qty (USD) finish time
cycle material molding
R-injection molding PBT(4115-226U)conformance [Link]-plastic
45 workdays
10 aluminum-housing-13W- to RoHs,Reach,PAHs 10.2g 1pcs 30±2s S136 160T $9,100 500000 injection molding
E27-A70(125) requirements [Link] runner
110T
R-heat sink-LED-BPZ220- AL1060
11 8.2g 1pcs 2s CR12MOV punching $10,980 500000 [Link] molding
13-IBU(A70-125) (T=0.8mm)
machine
R-injection molding PBT(4115-226U)conformance [Link]-plastic
12 aluminum-housing-15W- to RoHs,Reach,PAHs 12.1g 1pcs 30±2s S136 160T $9,480 500000 injection molding
E27-A70(135) requirements [Link] runner
160T
R-heat sink-LED-BPZ220- AL1060
13 10.66g 1pcs 2s CR12MOV punching $12,500 500000 [Link] molding
15-IBU(A70-135) (T=0.8mm)
machine
PC(DF8235-
160Tblow
R-blow molding-housing- WH3120)conformance to [Link] molding
14 16g 1pcs 22±2s S136 molding $18,880 500000
A70-IBU RoHs,Reach,PAHs [Link] runner
machine
requirements
R-punch-vapour chamber-
AL1060 60T punching
15 LED-BPZ220-13-natural 3.7g 1pcs 1.8s CR12MOV $5,170 500000 [Link] molding
(T=0.8mm) machine
color-IBU
R-punch-vapour chamber-
AL1060 60T punching
16 LED-BPZ220-15-natural 4.04g 1pcs 1.8s CR12MOV $5,983 500000 [Link] molding
(T=0.8mm) machine
color-IBU
R-injection molding PBT(4115-226U)conformance [Link]-plastic
17 aluminum-housing-LED- to RoHs,Reach,PAHs 16g 1pcs 30±2s S136 160T $9,980 500000 injection molding
BPZ220-18-IBU(A80) requirements [Link] runner
160T
R-heat sink-LED-BPZ220- AL1060
18 14g 1pcs 2s CR12MOV punching $11,650 500000 [Link] molding
18-IBU(A80) (T=0.8mm)
machine
PC(DF8235-
160Tblow
R-blow molding-housing- WH3120)conformance to [Link] molding
19 20.4g 1pcs 22±2s S136 molding $20,590 500000
A80-IBU RoHs,Reach,PAHs [Link] runner
machine
requirements
R-punch-vapour chamber-
AL1060 60T punching
20 LED-BPZ220-18-natural 5.63g 1pcs 1.9s CR12MOV $6,390 500000 [Link]
(T=0.8mm) machine
color-IBU
Note for finish time：The drawing confirmation before
Total 20pcs US$223,993 signed PI，sample approved then start the mass
production,mass production take around 45 workdays.
Instructions
[Link] structure: the molding is hard mould, the inner mould is inlaid, the inner cavity carries water to cool.
[Link] based on client's sample or drawing,unit price will be recalculated provided the molding structure is modified.
[Link] adjustment will be according to sample requirement and drawings which confirmed by both parties.
Injection Inside Applicative
Molding Molding price Molding
No. Description Picture Material Weight molding molding injection On Off Cycles Remark
qty (USD) finish time
cycle material molding
[Link] time counted from the date sample confirmed by both parties,drawings confirmed by both parties before sumbitting sample
[Link] terms：50％ deposit,the balance paid before delivery.
[Link] Validity:10 days from date of quotation