PROFILE

Proprietor : Arun Choudhary

Firm Name : Madhav Plant

Business Address : Shivpura Kheda, Chandrawati Ganj, Main

Road Sanwer, Indore, M.P.

Residential Address : Ram Mandir Square, Potlod, Indore, M.P.

Father’s Name : Kamal Choudhary

Contact No. : 9009752930

Date of Birth : 09/09/1999

Educational Qualification : Graduate

Project : Project on Manufacturing of Concrete Blocks

Term Loan : 10,00,000

Interest rate on Term Loan : 10.50%

INTRODUCTION
A concrete block is primarily used as a building material in the construction of walls,
Boundaries, Footpaths. It is sometimes called a concrete masonry unit (CMU). A concrete
block is one of several precast concrete products used in construction. The term precast
refers to the fact that the blocks are formed and hardened before they are brought to the
job site. Most concrete blocks have
one or more hollow cavities, and
their sides may be cast smooth or
with a design. In use, concrete blocks
are stacked one at a time and held
together with fresh concrete mortar
to form the desired length and height
of the wall.

The business can range from small-

scale, manual operations to large-scale automated plants, depending on the required
production capacity and investment. Key aspects include market research, business
planning, location selection, equipment acquisition, raw material and sourcing.

RAW MATERIALS
The concrete commonly used to make concrete blocks is a mixture of powdered portland
cement, water, sand, and gravel. This produces a light gray block with a fine surface texture
and a high compressive strength. A typical concrete block weighs 38-43 lb (17.2-19.5 kg). In
general, the concrete mixture used for blocks has a higher percentage of sand and a lower
percentage of gravel and water than the concrete mixtures used for general construction
purposes. This produces a very dry, stiff mixture that holds its shape when it is removed
from the block mold.

Lightweight concrete blocks are made by replacing the sand and gravel with expanded clay,
shale, or slate. Expanded clay, shale, and slate are produced by crushing the raw materials
and heating them to about 2000°F (1093°C). At this temperature the material bloats, or
puffs up, because of the rapid generation of gases caused by the combustion of small
quantities of organic material trapped inside.

A typical light-weight block weighs 22-28 lb (10.0-12.7 kg) and is used to build non-load-
bearing walls and partitions. Expanded blast furnace slag, as well as natural volcanic
materials such as pumice and scoria, are also used to make lightweight blocks.
In addition to the basic components, the concrete mixture used to make blocks may also
contain various chemicals, called admixtures, to alter curing time, increase compressive
strength, or improve workability. The mixture may have pigments added to give the blocks
a uniform color throughout, or the surface of the blocks may be coated with a baked-on
glaze to give a decorative effect or to provide protection against chemical attack. The glazes
are usually made with a thermosetting resinous binder, silica sand, and color pigments.

THE MANUFACTURING PROCESS

The production of concrete blocks consists of four basic processes: mixing, molding, curing,
and cubing. Some manufacturing plants produce only concrete blocks, while others may
produce a wide variety of precast concrete products including blocks, flat paver stones, and
decorative landscaping pieces such as lawn edging. Some plants are capable of producing
2,000 or more blocks per hour.
The following steps are commonly used to manufacture concrete blocks:-

 Mixing
The sand and gravel are stored outside in piles and are transferred into storage bins in the
plant by a conveyor belt as they are needed. The cement is stored outside in large vertical
silos to protect it from moisture. As a production run starts, the required amounts of sand,
gravel, and cement are transferred by gravity or by mechanical means to a weigh batcher
which measures the proper amounts of each material.

As a production run starts, the required amounts of sand, gravel, and cement are
transferred by gravity or by mechanical means to a weigh batcher which measures the
proper amounts of each material

After the dry materials are blended, a small amount of water is added to the mixer. If the
plant is located in a climate subject to temperature extremes, the water may first pass
through a heater or chiller to regulate its temperature. Admixture chemicals and coloring
pigments may also be added at this time. The concrete is then mixed for six to eight
minutes.

 Molding
Once the load of concrete is thoroughly mixed, it is dumped into an inclined bucket
conveyor and transported to an elevated hopper. The mixing cycle begins again for the next
load.
From the hopper the concrete is conveyed to another hopper on top of the block machine
at a measured flow rate. In the block machine, the concrete is forced downward into molds.
The molds consist of an outer mold box containing several mold liners. The liners determine
the outer shape of the block and the inner shape of the block cavities. As many as 15 blocks
may be molded at one time.

When the molds are full, the concrete is compacted by the weight of the upper mold head
coming down on the mold cavities. This
compaction may be supplemented by air
or hydraulic pressure cylinders acting on
the mold head. Most block machines also
use a short burst of mechanical vibration
to further aid compaction. The compacted
blocks are pushed down and out of the
molds onto a flat steel pallet.

 Curing
The pallets of blocks are conveyed to an automated stacker or loader which places them in
a curing rack. Each rack holds several hundred blocks. When a rack is full, it is rolled onto a
set of rails and moved into a curing kiln.

The kiln is an enclosed room with the capacity to hold several racks of blocks at a time.
There are two basic types of curing kilns. The most common type is a low-pressure steam
kiln. In this type, the blocks are held in the kiln for one to three hours at room temperature
to allow them to harden slightly.

 Cubing
The racks of cured blocks are rolled out of the kiln, and the pallets of blocks are unstacked
and placed on a chain conveyor. The blocks are pushed off the steel pallets, and the empty
pallets are fed back into the block machine to receive a new set of molded blocks.

If the blocks are to be made into split-face blocks, they are first molded as two blocks joined
together. Once these double blocks are cured, they pass through a splitter, which strikes
them with a heavy blade along the section between the two halves.

This causes the double block to fracture and form a rough, stone-like texture on one face of
each piece. The blocks pass through a cuber which aligns each block and then stacks them
into a cube three blocks across by six blocks deep by three or four blocks high. These cubes
are carried outside with a forklift and placed in storage.
MARKET POTENTIAL
The market for concrete blocks, particularly hollow concrete blocks, demonstrates
significant potential for growth in the coming years. The simple concrete block will continue
to evolve as architects and block manufacturers develop new shapes and sizes. These new
blocks promise to make building construction faster and less expensive, as well as result in
structures that are more durable and energy efficient.

Concrete Blocks are also used in construction of boundaries and foothpath near roads, thus
it widens the scope for Government tenders and residential colonies contracts. Rapid
urbanization worldwide, especially in developing economies like China and India, is fueling
demand for housing, commercial, and industrial construction, directly impacting the
demand for concrete blocks. The residential sector is a major consumer, with the increasing
population and rising disposable incomes driving housing construction in many regions.

The global concrete blocks and

bricks market has substantial
growth potential, with a projected
market size of USD 566.41 billion
by 2029. This growth is driven by
increasing construction activities
worldwide, particularly in
emerging markets and regions like
Asia Pacific. The market is expected to expand at a compound annual growth rate (CAGR) of
6.3% between 2022 and 2029, according to one report.

LOCATION
The shop/selling point is located at the commercial area and having a prominent location
for getting good visibility. The unit here mentioned is situated in a owned building situated
at Shivpura Kheda, Chandrawati Ganj, Main Road Sanwer, Indore, M.P.

There will not be any problems if the required power, transportation and communication
facilities are available. Then without any doubt one can easily say that the land selected is
very suitable for these type of units.
PROMOTER
Name: Arun Choudhary

Address: Ram Mandir Square, Potlod, Indore, M.P.

Qualification: Graduate

Experience: 5 years

LAND & BUILDING

The unit will be set up in a owned building. We have already considered the suitability of
the location. The power, Transportation, Communication facility etc are available.

Hence without doubt one can say that the site selected is very suitable for these types of
units.

MACHINERY AND EQUIPMENTS

The machinery and equipments are enlisted in the economics of the project. This include
Machinery & equipments, Furniture etc. The cost of the machinery is 15,00,000. The
selected machinery can be made available from authorized suppliers of these items.

STAFF & LABOUR

The unit will be operated in one shift. The staff and labors needed for the unit will be
selected from locally. The details of staff & labours are enlisted in the economics of the
project.

OTHER EXPENSES
The probable other experiences are considered in the economics of the project. It include
Repair & Maintenance, Electricity Charges, Wages, Communication, Selling Expenses, Other
Preliminary Expenses etc.
MEANS OF FINANCE

Term Loan 10,00,000

Margin Money 5,00,000

Total Cost of Machinery 15,00,000