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An Introduction to HCLC
(Heated Cellular Light Weight Concrete)
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| Details of Merits are being Provided here under- |
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| 1. High Thermal Insulation- |
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These blocks have appx. 1/3 density that of Conventional Building Blocks. |
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It has very low specific conductivity. This makes heating or cooling (Air Conditioning) very efficient. |
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Generates regular saving on energy and global warming. |
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| 2.Light Weight - |
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| With an approximate density of (450-550)Kg/M3, which is only one third of the weight of equivalent hollow concrete blocks and half of the weight of light weight aggregate block, it reduces the loads on the concrete structure and foundation of the building substantially. This saves construction time and the total materials required for the construction of the entire buildings (saving 33% of dead load when using HCLC Thermalite for the hourdi slabs and walls). |
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| 3. Superior Fire Resistance- |
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| A 10 cm thick HCLC Thermalite block provides a fire resistance value of 4 hours and 15 cm block 6 hours in accordance with BS-5628-3- approximately twice more protection than the normal concrete. Therefore, Thermalite is particularly suited for fire walls and fire protection of structural steel. |
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| 4. Compressive Strength- |
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| The block has an average compressive strength of (28-35) kg/cm2 which
is superior to most types of light weight blocks, 25% more stronger than other products of the same density.
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| 5.Workability- |
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| It can be sawed, nailed and drilled easier than wood, by suitable tools
available for this purpose. It results in less wastage and keep the site clean.
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| 6.Economical, Easier & Quicker to install- |
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| Construction time is substantially reduced while Thermalite blocks are
used. Thermalite blocks are large and lighter than conventional blocks and hence can be installed at a quicker rate. Blocks are laid flush utilizing thin joint mortar hence reducing mortar and plastering cost and eliminating thermal bridging.
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| 7.Sound Insulation and absorption- |
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| The cellular structure of HCLC Blocks provides superior sound absorption and insulation, both of which depend on density and porosity. The air porosity of the material will have significant effect on the performance of the wall. The aerated structure of Thermalite consists of millions of very small non-interconnected air cells giving very low air porosity. This gives a high resistance to the passage of air borne sound relative to density. |
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| 8.Environmentally Friendly- |
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| Non-existence of toxic substances, less consumption of fuel, electricity and nominal wastage during production, saving of electricity in large in Thermalite building - all these advantages of Thermalite reduces the
environment pollution. In fact, wherever Thermalite is used, energy is saved.
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| 9.High Resistance to Air and Water Penetration- |
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| The HCLC Thermalite products, because of their cellular and discontinuous microstructure, are superior to the normal concrete in resistance of water penetrability & thus the external surface of HCLC Thermalite walls provides superior resistance to air and moisture penetration than the traditional masonry products. Thermalite is manufactured from non-biodegradable materials, which does not rot nor attract mould, keeping interiors clean and durable. |
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| 10.Durability & Dimensional Stability- |
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| The HCLC products have been in use for nearly 70 years. Since then, the
production has spread to most parts of the world and the material has proved its durability under extremely different climatic and chemical conditions. The linear expansion coefficient of Thermalite is approximately 0.02%
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| Project at a Glance (Flyash or Sand) |
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| Capacity 25000 CBM (in shape of blocks of 0.75 density and size 600x200x200) Equivalent to 2.5 crores ordinary brick of density 1.9 size 230x110x75 |
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| S.No |
Description |
Estimated Cost (Rupees in Crores) |
| 1. |
Land 1 acres |
Actual |
| 2. |
Plant Equipments & Machines |
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| 2.1 |
HCLC Budget Offer
(Details Annex-I)
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1.39 |
| 2.2 |
HCLC Budget Offer (Details Annex-2) (Without Sand) |
1.16 |
| 3. |
Building Civil Work |
0.50 |
| 4. |
Loaders & Forklift |
.35 |
| 5. |
Working Capital 3000 CBM/Month @Rs1500/Per CBM |
0.45 |
| 6. |
Salary & Wages/Month |
0.05 |
| 7. |
Annual Sales 25000 CBM per year @Rs2900/CBM |
8.00 |
| 8. |
Annual Variable cost for 23000+(Including 2% wastage & wages)23460 CBM x1500/CBM |
4.50 |
| 9. |
Annual Salary Rs.0.05 x 12 |
0.60 |
| 10. |
Annual Maintenance Cost |
0.20 |
| 11. |
Transportation |
.40 |
| 12. |
Miscellaneous |
.25 |
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Gross Profit before depreciation |
6.00 |
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Power- 75 KW |
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| 25000cbm/year flyash/sand block making machine allocation table |
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| Direct Labour & Raw Material Cost/CBM (Vary from Place to Place) |
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| By Flyash Route |
Rs |
By Sand Route |
Rs |
500 Kg. Flyash
125Kg x 6 Cement
Additives Cacl2
Foaming Agent
D/RM
Energy (25 Units x 5)
(Install Power 75 H.P.)
Labour
Steam (Apprx.)
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500.00
750.00
150.00
150.00
125.00
75.00
100.00
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500 Kg. Sand
125Kg x 6 Cement
D/RM
Energy (40 Units x 6)
(Install Power 100 H.P.)
Labour
Steam (Apprx.)
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175.00
750.00
240.00
80.00
100.00
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1850.00
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1345.00
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| Extra- Cost of Interest & Depreciation + Maintenance Local Condition Charges |
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| Click on links to know more details. |
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Description
Conveyor material mix shifting 34 feet 24" endless felt with Gear Box and Electrical Power 3 ph., 440 volt. 5 H.P.
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Quantity:
1 No.
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Rate (INR) : 2,30,000.00 |
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Amount (INR) : 2,30,000.00 |
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Description
Load Cell with digital display & platform 500 Kgs weighing capacity
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Quantity: 1 No.
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Rate (INR) : 30,000.00 |
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Amount (INR) : 30,000.00 |
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Description
Mixer U Type Heavy duty steel structure Power 10 H.P. Mixing Capacity 6-7 CBM/Hr., with Special Alloy, replaceable liners.
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Quantity: 1 No.
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Rate (INR) : 5,50,000.00 |
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Amount (INR) : 5,50,000.00 |
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Description
Foam Generator to be coupled with 5 H.P. 3 Ph. 440V, 50 Hz
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Quantity: 2 Nos.
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Rate (INR) : 1,25,000.00 |
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Amount (INR) : 2,50,000.00 |
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Description
Heavy Duty Compressor 5 H.P. 3 Ph. 440 Volt with Motor & Starter Operating pressure 6-11 Kgs (Auto On/Off).
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Quantity: 1 No.
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Rate (INR) : 55,000.00 |
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Amount (INR) : 55,000.00 |
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Description
Operating Pannel to monitor quantity of water, foam and mixing time without connecting cables.
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Quantity: 1 No.
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Rate (INR) : 1,75,000.00 |
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Amount (INR) : 1,75,000.00 |
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Description
Ball Mill (only for sand route) Capacity 5-6 Tonnes/Hour, Sand Input Size= 25mm. Output = 180 UM.
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Quantity: 1 No.
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Rate (INR) : 11,90,000.00 |
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Amount (INR) : 11,90,000.00 |
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Description
Power 30 H.P. Silo for storage loading unloading system 20 Tonnes.
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Quantity: 1 No.
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Rate (INR) : 4,00,000.00 |
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Amount (INR) : 4,00,000.00 |
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Description
Balls(only for sand route) 10 MT of special cast iron assorted size Spherical from +100mm to 50mm
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Quantity: 10 MT.
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Rate (INR) : 6,90,000.00 |
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Amount (INR) : 6,90,000.00 |
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Description
Mould- Reinforced stiff Walled Special Alloy Steel 1000x1000x600mm
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Quantity: 90 Nos.
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Rate (INR) : 16,000.00 |
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Amount (INR) : 14,40,000.00 |
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Description
Mould Trollies to carry HCLC blocks of 1000X1000X600 mm
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Quantity: 200 Nos.
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Rate (INR) : 14,000.00 |
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Amount (INR) : 28,00,000.00 |
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Description
Mould Track System on C-channel 75x45 cross members 2 every meter total length 200 meter with siling rope
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Quantity: 600 M.
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Rate (INR) : 1,900/-
Running meter Two parallel Tracks (40x40 M.S. Squire) with cross members each meter
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Amount (INR) : 11,40,000.00 |
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Description
Winches with Rope 2H.P.3ph.440V.electric breack motor,30meter steel rope.
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Quantity: 3 Nos.
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Rate (INR) : 1,50,000.00 |
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Amount (INR) : 4,50,000.00 |
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Description
Cutting Machine 6 H.P. 3 Ph. 440V high carbon wires, Automatic operation, Heavy duty steel structure with operating pannel
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Quantity: 1 No.
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Rate (INR) : 7,50,000.00 |
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Amount (INR) : 7,50,000.00 |
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Description
Overhead Crane Travel 10 Meters Height 4 Meters 3 Axis Travel Capacity 2 MT. with Structure.
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Quantity: 1 No.
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Rate (INR) : 8,55,000.00 |
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Amount (INR) : 8,55,000.00 |
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Description
Trolley Shifter Heavy Duty Structure with Wheel Brake
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Quantity: 4 Nos.
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Rate (INR) : 25,000.00 |
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Amount (INR) : 1,00,000.00 |
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Description
Boiler 800 Kgs.per Hr Diesel / Gas Based IBR standard with water pump (Outsource).
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Quantity: 1 No.
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Rate (INR) : 9,90,000.00 |
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Amount (INR) : 9,90,000.00 |
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Description
Water Softener 1500 Lits/Hr. rezin Changing salt System
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Quantity: 1 No.
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Rate (INR) : 1,50,000.00 |
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Amount (INR) : 1,50,000.00 |
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Description
Pipeline for Steam distribution with lagging
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Quantity: 1 System
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Rate (INR) : 4,00,000.00 |
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Amount (INR) : 4,00,000.00 |
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Description
Other fabrication at site 10 MT.
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Quantity: 70/Kgs.
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Rate (INR) : 10,000.00 |
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Amount (INR) : 7,00,000.00
(Provision)
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Description
Miscellaneous Equipments like Pump, Lab Equipment
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Quantity:
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Rate (INR) : |
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Amount (INR) : 2,00,000.00
(Provision)
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Description
Steam Curing Chamber 150Sqm.
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Quantity: .
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Rate (INR) : |
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Amount (INR) : 4,00,000.00
(Provision)
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Note- Images and technical specifications may be different from the actual equipments and descriptions. Installation consultation charges extra @20% of equipment value minimum Rs.25 lacs. Cost of
1. international travelling, local travelling lodging & boarding (good and mutually acceptable standard)
2. Add Rs.2,000.00/day/person for local maintenance charges.
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