AAC Blocks Project Report

Description

You can immediately download the AAC Blocks project report in pdf format. You need to explore the AAC Block manufacturing project report if you plan to start one of India’s most successful and evergreen businesses. An entrepreneur can buy the  AAC Block project report PDF on very short notice from our website by simply adding the business plan to the product basket and making a nominal payment. As a businessman, you will be glad to know that you can buy the personalized project report that we customize according to your needs by paying an extra amount. Our experts are well qualified to research a business type with full knowledge and sources and grab important and useful information about our products. 

AAC (Autoclaved Aerated Concrete) is a fire-resistant, lime-based cemented building block gaining attraction in new markets across the world. AAC has gained recognition in new areas around the world as a single-component building material. This lightweight building material is made by autoclaving a predetermined mixture of fine siliceous materials such as finely pulverized sand or fly ash with a binder such as Portland cement or lime.

AAC Block Project Report PDF

This project report will help you prepare a project report as per your objectives. This report will also help study the project and gather information about the project.

The weight of Autoclaved Aerated Concrete (AAC) block is four times lighter than that of conventional concrete. Its unique structure, consisting of millions of microscopic pores, provides maximum solidity at a low weight. Aerated concrete offers excellent thermal protection due to the poor heat conductivity of air. It protects against cold and heat, allowing for single-shell structures that provide more space, save time, and reduce costs, all of which are significant factors for builders or property developers.

AAC Concrete block project report pdf is well written by experts and designed to provide you with complete details about this profitable startup. You will get the information in detail in this project report. You can download it by making a nominal payment and use it as a roadmap throughout the set-up journey. Whenever you face any problem in settling down with this business, you can look into the project report for solutions to all your troubles.

Market Overview

Fly ash is readily available and of an acceptable grade. Users believe that the most significant attributes of blocks are strength, durability, finish, availability, and pricing.

Traditional manufacturers have shown a high level of willingness to employ fly ash in their products. Technical support and increased product awareness among the general public are thought crucial for supporting the transition in production procedures.

Customers who contact producers show a strong preference for fly ash products. To promote the usage of fly ash bricks and blocks, increased media awareness and favourable policies are viewed as critical. Currently, the cost of fly ash blocks is comparable to that of cement blocks and normal bricks. On the other hand, these blocks have greater strength, fire resistance, earthquake resistance, low weight, reduced breakage, and save 40% on structural costs.

Because coal-fired power plants generate 60% of the country’s electricity, the country has a large supply of fly ash, which amounts to 60 million tonnes per year. Despite these attempts, the current situation is terrible, with barely 5% of the country’s total ash being used in various industries or goods. The need for building bricks increases day by day as the population grows and construction activities increase in response to the rising standard of life.

Characteristics of AAC

• AAC which stands for aerated Concrete has moderate insulation roughly R-10 for an inch of wall and R-12 for 10 inches of a wall. For every inch of material thickness, AAC has a value of R as 1.25.
• AAC has a high thermal mass that shows low transmission and cuts cooling and heating expenses.
• AAC construction can be airtight so that energy loss because of air leakage is prevented.
• AAC is a soundproofing barrier.
• If you are using eco-friendly material in building then you can design your dream house by not only saving the environment but by saving money too.
• Autoclaved Aerated Concrete blocks and bricks are superior than other materials that may generate environmental issues like burnt clay bricks.
• AAC is ecological and inexpensive and can be used as a traditional building material.
• The colour is greyish-white.
• It is 50% lighter than normal red bricks.
• Fire resistant for at least 2 to 6 hours because their thickness is good.
• Thermal efficiency is 3 times more than clay bricks.
• It costs 1/3 of the normal brick cost.

Benefits of AAC Blocks

The advantages are the high strength-to-weight ratio, low thermal conductivity, temperature and humidity stability, and fire resistance. Residential, multistory buildings, commercial and industrial development can all benefit from AAC products. Sand, lime and water are natural elements that are used to create these items. The building industry’s autoclaved aerated concrete sector is currently in the midst of a massive expansion cycle.

Customers are looking for lower costs, so the autoclaved aerated concrete industry must use competitive techniques. AAC is not a new building system. However, it is in India for the first time. Though relatively unknown in India, autoclaved aerated concrete (AAC) is now one of the numerous “green” or “environmentally friendly” building products on the market. As a result of the need, it is an excellent enterprise to invest in for entrepreneurs.

The drawback of AAC Manufacturing

Here are the major drawbacks of manufacturing AAC.

• AAC has a high manufacturing cost as per unit cost as compared to other concrete.
• As the number of manufacturers is limited for AAC, the price will skyrocket as the distance of the factory from the target audience.
• The strength of AAC is almost the same as other concrete.
• The contractors are not very familiar with AAC.

How to start an AAC block business in India?

To start and run a plant of AAC block manufacturing, you need to arrange the required land and building, raw materials, working capital etc.

Land and Building

It looks awkward if you consider land and building after all the other requisites of this business. You can arrange land or building on lease initially. Here is the checklist for the same. The choice of land and building depends on the capacity of your plant. If the production capacity of your plant is 50 cubic meters for a day then you need to arrange a land of 4000 square feet. This much space would be needed to match your requirements. The cost of land would be around Rs 1.5 crores and it varies from region to region.

Plant and Machinery

If you have to manufacture AAC blocks, you need to arrange heavy machinery and diesel to run them. You can start the manufacturing by buying other materials from silos and making blocks. The process of manufacturing AAC blocks needs to be clean and perfect. You can use equipment to do so. We can use automatic technology for this plant as it will take the cost to more heights. Machines won’t do all the work that humans can do.

The cost of plant and machinery will depend on the production capacity again and will also vary from one location to another. The cost depends on the condition of the market at this point.

Working Capital

You need to keep some cash to bear the monthly expenses of your business. This cash is known as working capital. It involves the cost of materials, the salary of employees and water or electricity charges. Rs 50 to Rs 60 lakh is the minimum requirement for AAC block manufacturing units running on a large scale. The expenses depend on the price of cement also. If it goes high, the expense increases too.

You need to invest Rs 4 crore as capital investment for this business. The set-up cost is based on your business plan.

Which is better, a brick or an AAC block?

AAC blocks are better than conventional bricks as AAC block is eco-friendly whereas traditional red brick is harmful to the environment. AAC blocks have less material wastage and have high thermal and sound insulating properties and these days recommended to use more.

Price of AAC blocks in the market

The price of an AAC block of size 8 by 8 by 24 inches costs around Rs 160 to Rs 200 per square foot. It is more than the normal concrete available in the market. The cost of standard concrete is Rs 150.

You may get cheap labour to manufacture AAC because of its low weight and ease of handling. Cost may vary from place to place and is affected by local labour rates as well.

How to make AAC block at home?

There are a lot of things you need to consider when you have to start this business from your home.

The first factor to be considered is your location. If your home is at a location where transportation is easy, you can start this business from your home.

Land Acquisition

A space of 60 by 120 is the minimum requirement to start this business. If you have this much open space in your home and you feel it fit for this business then you can proceed further. You need to make space that is fit for keeping blocks and other materials.

The location should be not in the swampy area as it will affect the block dryness and humidity won’t make things work well.

Purchase Diesel Lister for AAC Block Manufacturing

You would need power for block mould machine. There are single and double cylinders available in this machine. You can buy single cylinders as single ones use less diesel and power all equipment correctly.

You need to buy the original listers. If you are not able to identify which one is original, then consult someone who knows about it.

Sink a borehole

You would require a lot of water to be used in making AAC blocks. It is used to mix cement and sand and to wet the mould blocks also. Blocks must be watered daily so you need boreholes to store water.

Buying water from outside is not a good idea.

Get a moulder for a block

Diesel lister and moulder are different. A moulder is a machine that is used to mould the blocks. You can call it a vibrating machine also. This machine makes the noise you hear from an ACC blocks plant.

Make a wooden block carrier

Wooden block carriers are used to carry cement blocks from moulders to their drying point. It is made by carpenters and you need around 1000 of them. You need to arrange durable wood as a raw material for it. You must manufacture handy block carriers.

Hire Employees

You need to hire five workers to operate one machine. Hire two mixing men who would deal with the work of mixing the sand and cement and allow it to go into the moulder. You need additional staff as a supervisor and cashier to handle other stuff.

You need to hire two loaders and a driver who will help to load your truck and drive it. If you arrange the truck on rent then you need not hire them.

Set up the complete working area for manufacturing AAC blocks

You need to get a roof shed ready where you can keep the diesel lister and moulding machinery to work. You need a shed to keep the machine safe from getting drenched. You need not get a wall constructed, just a shed roof can work well.

Get a supply of Cement

Cement is the major raw material. You need to get it in good quantity as you won’t go to buy it every day. You need to arrange raw materials for at least a week’s manufacturing. You need to buy the cement that is quick to dry. Usually, all cements work the same.

You need to construct some space as a room where you can store the manufactured cement and sell it from there only. Cement block industry entrepreneurs also sell cement. Thus you can also start a cement supply business along with it. You can get the sand, stone dust that is the residue of granite and normal mud sand. You can mix them all and make cement and sell it.

Supply of Diesel

A diesel supply of 25 to 30 litres is required to run the lister machine for a day. It depends on the number of hours your machine operates a day and its power. You need to keep a good standby supply of diesel and keep it as a raw material in your location.

When you have all these requirements fulfilled, you are all set to run your AAC block industry at your home in the open space. Do not forget to do the marketing of your business and ensure the quality of your product. If your AAC blocks are not strong, then the building that would be constructed using them would also not be strong. Over-mixing of cement and sand leads to disaster.

Why do cracks occur in AAC blocks?

Because of the Haphazard arrangement of the AAC blocks, changes in the positioning of the beams, changes in the skeletal movements, and a shift in water contents or because of temperature variation, cracks develop within the AAC blocks.

How to start an AAC block business in India? 

You can start an AAC Blocks Business in India by arranging the raw materials needed for the production of AAC blocks. 

Fly-Ash: This raw material has been carefully examined throughout this Project profile. However, Thermal Power Plants have access to this unused raw resource. This item is exempt from all kinds of taxes. Only the entrepreneurs are responsible for transportation costs.

Lime: Proper aeration of the product requires the application of active-powered lime. We can acquire the active lime directly in phase one.

In phase 2, we can consider backward integration and constructing a lime-powering unit on-site to gain a competitive edge and a lime-burning kiln within the industrial grounds.

However, the project finances do not cover the cost of powering the unit and the limestone furnace. Different lime varieties are available, and the design of the mix can be chosen using the raw components to achieve the highest quality possible.

OPC: The main binder material for this project is OPC cement. It will increase the strength of the bricks while also improving the consistency of the quality.

It also assures that the same is more cost-effective. The use of OPC will become standard. Another major benefit of employing OPC (in comparison to alternative binders) is its widespread availability through a statewide network of cement companies’ retail outlets.

Use of AAC Blocks Project Report

The main objective of this AAC Blocks project report is to provide information to potential new entrepreneurs in the manufacturing of AAC blocks. This document covers marketing, finance, and various other aspects of the AAC Blocks business. These reports will help you prepare a project report as per your objectives. This report will also help study the project and gather information about the project.

Is plastering required in AAC blocks?

No, AAC blocks have a plain surface and wire cut, and because of that, no plastering is required in the internal walls, and only painting or putty is very effective still. External plastering is required.

Are AAC blocks cost-effective?

It shows that the total cost savings in public building materials are around 46.3 per cent when AAC blocks are used instead of regular bricks. It reveals the cost-effectiveness of structures developed utilising AAC blocks with buildings designed using regular bricks.

How to Download AAC Blocks Project Report 

The process of downloading the project report for the manufacture of AAC blocks is straightforward. Following are the steps to be followed to download the report. First of all, add the desired report to the basket. The second is to checkout. The third is to pay. There is an option to download the project report immediately after payment.

How To Manufacture AAC Blocks?

COAL FLY ASH

Coal fly ash is brought to the slug preparation pond by wheel loader, mixed with rated water to generate suitable coal fly ash concentration slurry and then pumped into the slurry tank for storage and use.

QUICK LIME

The powder is moved to the lime powder silo for storage after entry into the plant and is ready for the lift.

GYPSUM

During the slurry preparation, the gypsum in the storehouse is added in the necessary proportion to the slurry pond.

CEMENT

The cement is sent by tank truck to the factory and pumped immediately into the cement silo used.

PASTE OF ALUMINUM POWDER

Until necessary, the purchased aluminium powder paste is kept in the warehouse. It is lifted, weighed and blended with an aluminium mixer to the second level of the batching structure to make 5% suspending liquent when necessary.

SCRAPE AND WASTE SLURRY

Wastewater will be put into the ball mill for use as groundwater from the casting machine cleaning. The scrape is smoothed and pumped from the cutting machine into a waste slurry container for use.

CASTING, MIXING, and BATCHING

In the loading facility to be measured, coal fly ash is pumped from the lower slurry tank to an electronic scale. The control system will cut off the pump to cease pumping slurry when the slurry concentration reaches the batching requirement. The measured slurry is unloaded directly into the casting mixer.

A single screw conveyor at the bottom of each silo will transport lime and cement to an electronic scale in the batching plant. Once the measurement has reached the appropriate amount, it is sent to the casting mixer by a screw conveyor.

To manufacture each mould-suspended liquid one by one, the aluminium powder is manually measured and added to the aluminium blender.

The last suspended fluid is immediately transferable into the casting mixer. The slurry temperature should be up to a suitable process temperature before casting. The mould is carried out using a ferry car to the bottom of the mixer.

CUTTING AND GROUPING

When the green block has reached the appropriate strength after pre-curing, the crane will transport it to the cutting machine section.

The green block is cut to the proper size after the removal of the mould.

After cutting, the green block is carried to the curing trolley for grouping by crane with the base plate in front of the autoclave. Each autoclave has seven trolleys, each with 14 pieces of the green block.

AUTOCLAVED AND FINISHED PRODUCT

The green block is then winded into the autoclave for curing after grouping. The total curing time is around 12 hours, with a pressure of approximately 1.2 Mega Pascal and a temperature of roughly 1850°C. After the product is cured and transferred to the store yard, the autoclave will be removed.

RETURNING TO THE BOTTOM PLATE, MIXING WITH THE MOLD AND OILING

After unloading, with the help of the crane, the side plate on the trolley is lifted to the returning rail and comes back to the side of the cutting machine, from here, it joins with the mould and comes back to the mould returning the line which needs to be cleaned and lubricated before again use.

For whom is the AAC Block mini plant project report format useful?

1. CA Chartered Accountants
2. Tax Consultants
3. Small Business Owners
4. Students
5. Engineers
6. Who wants to self-study

In addition to those who want to prepare project reports themselves.

AAC Block Plant Project Report Sample Format

In our project report format, we have covered technical details, diagrams, flow charts etc. as and when required or deemed fit to include. We can also help you prepare in-depth financial calculations which are necessary for the Investor/bank.

You will get the project report data for AAC Blocks in PDF which you can use easily. You can also modify the information according to your needs. You will be able to access the data easily according to your requirements. Additionally, you can easily convert the data to PDF format.

Comparison between ACC blocks v/s CLC blocks v/s red clay bricks in House Construction.

Contents Of AAC Blocks Mini Plant Project Report

Conclusion 

From the previous data and discussions, we conclude the cost-effectiveness of using AAC blocks for construction work.

Autoclaved Aerated Concrete (AAC) is made of natural raw components, standard and widely available. As a result, it is both resource-efficient and environmentally benign.

There are no contaminants, byproducts, or harmful waste products produced by the energy used in the manufacturing process. AAC’s workability aids in the reduction of waste in the workplace.

Based on the results of the experiments done in this study, the AAC block’s compressive strength is higher than that of conventional clay bricks. This makes it suitable for creating walls framed with RCC.

AAC blocks have a density of 1/3 that of ordinary clay bricks, and there is no change in wet conditions. It aids in the reduction of the structure’s dead load.

Because both sides of an AAC block wall are plane, the necessary thickness of plaster is relatively low, resulting in a 50% savings in cement and sand requirements for plaster construction.

Building costs are decreased by up to 20 per cent as the dead wall load is minimized on the beam and light components are reduced.

Frequently Asked Questions on AAC BLOCK PLANT PROJECT REPORT PDF