PROJECT REPORT INTERLOCKING BRICKS PURPOSE OF THE DOCUMENT This particularr pre feasibii lity is regarding Manufacturing of Interlocking bricks The objective of the pre feasibility is primarily to facilitate potential entrrepreneurs in project identification for investment and in order to serve this objective; the document covers various aspects of the project concept development, startup, marketing, and finance and business management [We can modify the project capacity and project cost as per your requirement. We can also prepare project report on any subject as per your requirement..] Prepared By: M/S Institute for Industrial Development A unit of M/S Samadhan Samiti 27/1/B Gokhle Marg Lucknow 226001 Social Media : Youtube: http://www.youtube.com/entrepreneurindiatv Facebook: http://www.facebook.com/samadhaniid Twitter: http://www.twitter.com/samadhaniid Website:http://www.industryincubator.co.in, http://www.entrepreneurindia.tv
INTERLOCKING BRICKS Concept of Interlocking Blocks The block's sizes are modular and rectangular (250 mm length, 210 mm wide and125 mm high) in shape. Corner or junction block is required to maintain right angle corner or a proper T junction. The interlocking block is different from conventional blocks or bricks since they do not require mortar for its laying work. Because of this characteristic, the process of building walls and other structures are faster as the blocks are laid dry and lock into place. Almost any type of building can be constructed with interlocking blocks, which has projection and depression to key each other. The toe blocks have flat bottom and partly projected top to properly rest on the base mortar and at the same time receive the middle blocks to rest on it. The middle blocks have bottom depression and top projection to receive subsequent middle blocks and finally the top blocks. Before placing or forming the first course in a mortar bed, the blocks must be laid dry on the foundation around the entire building (that is, the forming process), in order to ensure thatt they fit exactly next to each other, the main design constraints being that the plan should be rectangular and all wall dimensions and openings must be multiples of the length of the block type used. The concept of interlocking blocks is based on the following principles: (a) The blocks weree shaped with protruding parts, which fit exactly into recess parts in the subsequent lateral blocks and blocks placed above, such that they are automatically aligned horizontally and vertically respectively thus block assembling is possible without specialized block laying skills (b) Since the blocks can be laid dry, no mortarr is required and a considerable amount of cement and cost of labour are saved
(c) each block could necessarily be provided with vertical holes, which serve four purposes (i) to reduce the weight of the block (ii) to insert steel rods or bars for reinforcement (iii) to act as conduit for electrical and water/fluid piping etc (iv) to pour liquid mortar or grout into the holes, which run through the full height of the wall. Thus, sealing the wall and making a permanent solid wall, increasing its stability otherwise could be solid interlocking blocks without vertical holes. Shapes & Sizes A variety of interlocking blocks have been developed during the past years, differing in shapes and sizes, depending on the required strengths and uses. The system developed has the following shapes and forms: (i) (ii) (iii) (iv) (v) (vi) Full blocks (300 x 125 150 x 100 mm) for all standard walls (single or double block thick). Half blocks (150 x 125 150 x 100 mm), which can be molded to size, or made by cutting freshly molded full blocks in half. Channel blocks, same sizes as full and half blocks, but with a channel along the long axis, into which reinforcing steel and concrete can be placed to form lintels or ring beams. The vertical sides of the blocks can be flat or have recesses, and the vertical grout holes can be square or round. Inserts for electrical switch housing and conduits as well as water piping outlets can be incorporated. Special blocks for window sills. Composition of Interlocking Brick The composition of block depends on the availability of materials and its use. The major components of interlocking block include: Cement: Cement has the property of setting and solidifying upon mixture with water. Cements are widely used in construction firms in design of structures, and having varieties, with Portland cement as the most common type of cement in general usage. It is a basic component of concrete, block, mortar or plaster. Cement consists of a mixture of oxide of calcium silicon and aluminum. Portland cement is made by heating limestone (a source of calcium) with clay and grinding this product (called clinker) with a source of sulphate most commonly called gypsum.
Water: Water combines with cement and aggregates to begin the process of hydration, and adequate water cement ratio provides good consistency. The cement paste glues the aggregate together, fills voids within it and allows it to flow more easily. The use of clean pure water is always recommended for use in block production to prevent adverse harmful effect of salt, turbidity and other impurities. Impure water used to make block can cause problem when setting or in causing premature failure of interlocking block walls. Aggregates: Fine and coarse aggregates made up the bulk of interlocking block mixture. Various types were explained above under properties and types of soil. It can occur naturally or made artificially in industries (uncrushed or crushed). The size of aggregate affects the strength and load bearing capacity of interlocking block. Advantages of Interlocking Block The advantages of interlocking Block are: (i) Construction with interlocking block saves time and ample amount of mortar concrete compared to conventional masonry block laid with mortar (ii) Areas prone to earthquake uses hollow interlocking block with the strength improved with grout and reinforcement throughout the height of the wall to resist the effect of earthquake, thus, providing adequate structural stability against collapse (iii) Having formed the base course, other course can be assembled by unskilled labour (iv) Dismantling of the blocks in case of temporary structure does not incur much damages as in blocks laid with mortar (v) Cost of construction is relatively less. Process of Manufacture The process of Manufacture of interlocking bricks involves the following steps: a) Proportioning b) Mixing c) Compacting d) Curing e) Drying
Sample Project Financials Name of Project: Manufacturing of Interlocking Tiles Capacity: 50000 per month Type of Plant: Semi Automatic Power Vibrator Type Method 9.5 HP Interlock Vibrator M 860 Hydraulic Hollow Block Size of Moulds No. of Blocks Per Stroke No of Blocks Per Hour 400x200x100mm 16x8x4 10 Nos 400 to 500 Nos 400x200x150mm 16x8x6 6 Nos 300 to 350 Nos.
(A) INTERLOCKING BRICKS COMPUTATION OF PRODUCTION Manufacturing Capacity per day 2000 No. of Working Days 300 Total no. of Tiles per annum 600000 Tiles per Day Type of Bricks % Capacity No. of Brick P.A. 80 m.m. 60% 360000 60 m.m. 20% 120000 40 m.m. 20% 120000 CALCULATION OF SALES 80 M.M. Year Y1 Y2 Y3 Y4 Y5 Y6 % Utilization 60% 65% 70% 75% 80% 85% Opening Stock 21,600 25,560 27,756 29,776 31,778 Production 216,000 234,000 252,000 270,000 288,000 306,000 216,000 255,600 277,560 297,756 317,776 337,778 Less : Closing Stock 21,600 25,560 27,756 29,776 31,778 33,778 Sales (Quantity) 194,400 230,040 249,804 267,980 285,998 304,000 Rate per Brick 12.00 12.00 12.00 12.00 12.00 12.00 Sale Amount (in Lacs) 23.33 27.60 29.98 32.16 34.32 36.48
60 M.M. Year Y1 Y2 Y3 Y4 Y5 Y6 % Utilization 60% 65% 70% 75% 80% 85% Opening Stock 7,200 8,520 9,252 9,925 10,593 Production 72,000 78,000 84,000 90,000 96,000 102,000 72,000 85,200 92,520 99,252 105,925 112,593 Less : Closing Stock 7,200 8,520 9,252 9,925 10,593 11,259 Sales (Quantity) 64,800 76,680 83,268 89,327 95,333 101,333 Rate per Brick 10.00 10.00 10.00 10.00 10.00 10.00 Sale Amount (in Lacs) 6.48 7.67 8.33 8.93 9.53 10.13 40 M.M. Year 2012 2013 2014 2015 2016 2017 % Utilization 60% 65% 70% 75% 80% 85% Opening Stock 7,200 8,520 9,252 9,925 10,593 Production 72,000 78,000 84,000 90,000 96,000 102,000 72,000 85,200 92,520 99,252 105,925 112,593 Less : Closing Stock 7,200 8,520 9,252 9,925 10,593 11,259 Sales (Quantity) 64,800 76,680 83,268 89,327 95,333 101,333 Rate per Brick 8.00 8.00 8.00 8.00 8.00 8.00 Sale Amount (in Lacs) 5.18 6.13 6.66 7.15 7.63 8.11 GROSS SALE 34.99 41.41 44.96 48.24 51.48 54.72
CALCULATION OF RAW MATERIAL CONSUMED Year Y1 Y2 Y3 Y4 Y5 Y6 % Utilization 60% 65% 70% 75% 80% 85% 80 m.m. Production 216,000 234,000 252,000 270,000 288,000 306,000 Raw Material /per Tiles 5.00 5.00 5.00 5.00 5.00 5.00 Total Cost 10.80 11.70 12.60 13.50 14.40 15.30 60 m.m. Production 72,000 78,000 84,000 90,000 96,000 102,000 Raw Material /per Tiles 4.00 4.00 4.00 4.00 4.00 4.00 Total Cost 2.88 3.12 3.36 3.60 3.84 4.08 40 m.m. Production 72,000 78,000 84,000 90,000 96,000 102,000 Raw Material /per Tiles 3.00 3.00 3.00 3.00 3.00 3.00 Total Cost 2.16 2.34 2.52 2.70 2.88 3.06 TOTAL COST OF RAW MATERIAL 15.84 17.16 18.48 19.80 21.12 22.44
PROJECTED BALANCE SHEET STATEMENT Particulars Y1 Y2 Y3 Y4 Y5 Y6 Y7 LIABILITIES Capital Fund 11.50 11.50 11.50 11.50 11.50 11.50 11.50 Reserve & Surplus 1.07 2.15 4.43 7.85 12.35 17.80 Unsecured Loan Term Loan 25.00 22.50 17.50 12.50 7.50 2.50 TOTAL (A) 36.50 35.07 31.15 28.43 26.85 26.35 29.30 ASSETS FIXED ASSETS Gross Assets 35.00 35.00 35.00 35.00 35.00 35.00 35.00 Less : Depreciation 4.50 8.40 11.78 14.72 17.27 19.49 35.00 30.50 26.60 23.22 20.28 17.73 15.51 CURRENT ASSETS Raw Material 2.38 2.57 2.77 2.97 3.17 3.37 Finished Goods & WIP 3.30 4.05 4.50 4.82 5.15 5.47 Sundry Debtors 3.50 4.14 4.50 4.82 5.15 5.47 Cash & Bank Balance 1.50 1.82 0.96 1.51 2.71 4.61 9.59 TOTAL CURRENT ASSETS 1.50 11.00 11.73 13.27 15.33 18.08 23.90 LESS: CURENT LIAB. Creditors & Expenses 1.43 2.17 3.06 3.76 4.46 5.11 Working Capital Loan 5.00 5.00 5.00 5.00 5.00 5.00 NET CURRENT ASSETS 1.50 4.57 4.55 5.21 6.56 8.62 13.79 TOTAL ASSETS 36.50 35.07 31.15 28.43 26.85 26.35 29.30
STATEMENT OF COST OF PRODUCTION AND PROFITABILITY Particulars Y2 Y3 Y4 Y5 Y6 Y7 A. Gross Sale 34.99 41.41 44.96 48.24 51.48 54.72 NET SALES 34.99 41.41 44.96 48.24 51.48 54.72 B. COST OF PRODUCTION Raw Material & Consumable 15.84 17.16 18.48 19.80 21.12 22.44 Power Expense 2.14 2.32 2.49 2.67 2.85 3.03 Repair & Maintenance 0.70 0.77 0.85 0.93 1.02 1.13 Wages & Salary 3.36 3.70 4.07 4.47 4.92 5.41 Factory Expenses 0.70 0.83 0.90 0.96 1.03 1.09 COST OF PRODUCTION 22.74 24.77 26.79 28.84 30.95 33.10 Add :Op. Fin. Goods 3.30 4.05 4.50 4.82 5.15 Less : Cl. Fin. Goods 3.30 4.05 4.50 4.82 5.15 5.47 TOTAL (B) 19.43 24.03 26.34 28.51 30.62 32.78 C GROSS PROFIT (A B) 15.56 17.38 18.63 19.72 20.86 21.94 D Salary to Staff 2.88 3.17 3.48 3.83 4.22 4.64 Selling & Administrative Expenses 1.05 1.24 1.35 1.45 1.54 1.64 Interest on Term Loan 3.46 2.89 2.19 1.49 0.79 0.13 Interest on Working Capital Loan 2.00 3.50 3.50 3.50 3.50 3.50 Depreciation 4.50 3.90 3.38 2.94 2.55 2.22 TOTAL (D) 13.89 14.70 13.90 13.20 12.60 12.13 E. NET PROFIT (C D) 1.67 2.68 4.72 6.52 8.26 9.81
CONSUMPTION OF POWER & FUEL POWER Power Requirement 15 KVA Working Day 300 Working Hours 12 Total Power Cost 297,000.00 Add : Minimum Charges 20% 59,400.00 356,400.00 Total consumption for Power & Fuel (In Lacs) 3.56 Year % Value Y2 60% 2.14 Y3 65% 2.32 Y4 70% 2.49 Y5 75% 2.67 Y6 80% 2.85 Y7 85% 3.03
BREAK EVEN CALCULATION Capacity utilization 60% PARTICULARS TOTAL VARIABLE EXP FIXED EXP AMOUNT % AMOUNT % AMOUNT Raw Material & Consumable 17.16 100% 17.16 0% Power Expense 2.32 90% 2.08 10% 0.23 Repair & Maintenance 0.77 90% 0.69 10% 0.08 Wages & Salary 3.70 85% 3.14 15% 0.55 Factory Expenses 0.83 100% 0.83 0% Salary to Staff 3.17 90% 2.85 10% 0.32 Selling & Administrative Expenses 1.24 100% 1.24 0% Interest on Term Loan 2.89 0% 100% 2.89 Interest on Working Capital Loan 3.50 100% 3.50 0% Depreciation 3.90 0% 100% 3.90 INCOME 39.47 31.50 7.97 Sale 41.41 41.41 Contribution = (Sales Realization Variable Cost) 9.91 BREAK EVEN POINT (AFTER DEPRECIATION) Fixed Assets X 100% = 7.97 X 60% 48% Contribution 9.91 BREAK EVEN POINT (BEFORE DEPRECIATION) Fixed Assets X 100% 4.07 X 85% 25% Contribution 9.91