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Easy workability AAC is very easy to work with and can be cut accurately reducing the amount of waste generated. Single product solution Buildings constructed with AAC do not require separate insulation products reducing construction cost, energy footprint and environmental impact of buildings. Environmental impact Manufacturing of AAC does not have high energy requirements. Moreover since AAC is light weight, it also saves energy required for transportation and leads to reduced CO2 emissions by transport vehicles. Since AAC is made from fly ash an industrial waste product generated by thermal power plants, it offers a low cost and sustainable solution for today and tomorrow. AAC is a requisite for green buildings. Easy transportation It is easy to transport AAC as it does not suffer from high transit breakage usually associated with clay bricks. Longevity AAC does not lose strength or deteriorate over time. Buildings constructed with AAC do not require routine repairs that are required for buildings using clay bricks. Thermal Insulation AAC offers excellent thermal insulation. This reduces recurring cost of energy required for heating and cooling. Better thermal insulation also allows usage of smaller HVAC than required conventionally. Shorter Project Duration Buildings can be built with AAC 50% faster compared to clay bricks. This translates to lower project completion times benefiting project developers. Fire Resistance Due to high fire resistance offered by AAC, structures made from AAC have higher rate of survivability in case of fire. Sound Insulation Sound absorption properties of AAC make it ideal material for reducing ambient noise. AAC is well-suited for establishments like hospitals and offices situated in noisy areas. High survivability
Comparison between Autoclaved Aerated Concrete (AAC) blocks and clay bricks
Serial
1 2 3 4 5 6 7 8 9 10 11 12 13
Parameter
Soil Consumption Fuel Consumption CO2 Emission Labour Production Facility Tax Contribution Size Variation in Size Compressive Strength Dry Density Fire Resistance (8" wall) Cost Benefit Energy Saving
AAC Blocks
Uses fly ash which is a thermal power plant waste product & thus no consumption of top soil One sq ft of carpet area with AAC blocks will consume 1 kg of coal One sq ft of carpet area will emit 2.2 kg of CO2 Organized sector with proper HR practices State-of-the-art factory facility Contributes to government taxes in form of Central Excise, VAT and Octroi 625 mm x 240 mm x 100-300 mm 1.5 mm (+/-) 3.5-4 N/m2 550-700 kg/m3 Up to 7 hours Reduction in dead weight leading to savings in steel and concrete Approximately 30% for heating and cooling
Clay Bricks
One sq ft of carpet area with clay brick walling will consume 25.5 kg of top soil One sq ft of carpet area with clay bricks will consume 8 kg of coal One sq ft of carpet area will emit 17.6 kg of CO2 Unorganized sector with rampant use of child labour Unhealthy working conditions due to toxic gases Does not contribute to government exchequer 225 mm x 100 mm x 65 mm 5 mm (+/-) 2.5-3 N/m2 1800 kg/ m3 Around 2 hours None None
The first step of AAC production is grinding of silica rich material (sand, fly ash, etc) in ball mills. For different materials, different processing is adopted, such as dry grinding (into powder), wet grinding (into slurry) or mixed grinding with quicklime (CaO). There are two methods for mixed milling. One is dry mixing to produce binding material, and the other method is wet mixing. Since most quicklime is agglomerate, it should be crushed and then grinded. Gypsum is normally not ball milled separately. It is grinded with fly ash or with quicklime, or it could be grinded with the same miller for quicklime in turn. Other supplementary and chemicals are also have to be prepared. Raw material storage assures the continuous production and material stability. The continuous production guarantees the non-stop & on-time supply, and the material stability guarantees the quality of products, since the raw material might come from different sources, with different qualities. Raw material preparation & storage is the pre-step for proportioning batching. This pre-step guarantees the raw material meet the standard for AAC production, and it is also finishes the storage, homogenization and aging process. It is the basic process that assures the smooth production and production quality.
Cutting
During this process, the pre-cured block goes through cutting and shaping, into different size & shapes as per requirements. The high workability and large variety of sizes make AAC production more suitable for massive production with higher mechanization. Cutting can be done mechanically or manually. With a cutting machine, the production efficiency and dimensional accuracy is easily achieved.
Autoclaved Curing
After cutting into the desired sizes & shapes, green AAC blocks are transferred into autoclaves. Autoclaves are used for steam curing under pressure. AAC must be pre-cured and steam cured to finish the physical and chemical changes, and then to achieve enough strength for desired usage. A batch of AAC blocks is steam cured for 10-12 hours at a pressure of 12 bar and temperature of 190C. In hot and humid conditions, AAC blocks undergo last stages of hydro-thermal synthesis reaction to transform into a new product with required strength and various physical performances. Autoclaved curing imparts inherent properties and performance of AAC.
Grouping
Grouping could be the last step of AAC production (in some AAC plant, the AAC will be further processed into panels after leaving autoclaves). After the cured AAC leaves the autoclaves, inspection and packaging is done.
Total
15.96
26,01,56,500 1832.71
Capital Expenses
S. No. 1 2 Parameter Bank Loan Cash Loan Value 100000000 (13%, 8 years) 30000000 (15% annual) Frequency 12 12 Annual Cost 16,80,726 3,75,000 EMI 2,01,68,706 45,00,000 Rs./m3 134.46 30.00
Grand Total
28,48,25,206 1997.17
10
Cost (Rs/m2)
Building Cost
11
Chapter-6: Bottomline
S. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 Parameter Production Cost Excise Duty @ 12.36% VAT @ 4% Dealer Commission Transportation Cost Price Selling Price Profit Rs./m3 Daily Profit Annual Profit (Before Tax) Annual Profit (After Tax) Project Cost Break Even Point
Profitability
Costs (Rs./m3) 2,000.00 247.20 112.36 150.00 100.00 2,609.56 3,500.00 890.44 4,45,220.00 13.36 9.08 20.00 30 months Amount (Rs. Crore)
12