Clc block( light weight bricks)machine detail -...

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Clc block( light weight bricks)machine detail Chamunda welding works co. Blocks: Chamunda welding works Cellular Lightweight Concrete Bricks are produced by adding millions of Micro-Sized air bubbles into a cement based mixture. The addition of millions of air bubbles is achieved by using a Proprietary Foam Generator to produce highly stable and injecting the Foam directly into a concrete mixer containing a sand/ cement/ fly ash/ water slurry. The amount of cement, sand (if included), water. Fly-Ash and foam included in the Light weight Cellular concrete mix design depends on the required properties (i.e. strength, thermal conductivity or durability). Also, depending on the required CLC density and variance, an appropriate mixer is selected. The hardened material consists of small-enclosed air bubbles thereby resulting in a light weight stable cellular material with densities ranging from as low 300kg/m3 to 1800Kg/m3. The Hardened Material Consists Of Small-Enclosed Air Bubbles Thereby Resulting In A Lightweight Stable Cellular Material With Densities Ranging From As Low 300kg/M3 To 1800 Kg/M3. Good Curing gives strength and dimensional stability to Bricks. Bricks are cured either by air curing or high-pressure steam curing procedure. Because of great- Engineered properties, chamunda welding works Bricks have become popular in wide range of applications in construction sector. Advantages of Chamunda welding works Bricks High Thermal Insulation. Low thermal conductivity. Thermal Performances 5 times better than clay bricks & 10 times better than RCC Interiors remain cool in summer and warm in cold wintry days.

Transcript of Clc block( light weight bricks)machine detail -...

Clc block( light weight bricks)machine detail

Chamunda welding works co. Blocks:

Chamunda welding works Cellular Lightweight Concrete Bricks are produced by adding millions of Micro-Sized air bubbles into a cement based mixture. The addition of millions of air bubbles is achieved by using a Proprietary Foam Generator to produce highly stable and injecting the Foam directly into a concrete mixer containing a sand/ cement/ fly ash/ water slurry. The amount of cement, sand (if included), water. Fly-Ash and foam included in the Light weight Cellular concrete mix design depends on the required properties (i.e. strength, thermal conductivity or durability). Also, depending on the required CLC density and variance, an appropriate mixer is selected. The hardened material consists of small-enclosed air bubbles thereby resulting in a light weight stable cellular material with densities ranging from as low 300kg/m3 to 1800Kg/m3. The Hardened Material Consists Of Small-Enclosed Air Bubbles Thereby Resulting In A Lightweight Stable Cellular Material With Densities Ranging From As Low 300kg/M3 To 1800 Kg/M3. Good Curing gives strength and dimensional stability to Bricks. Bricks are cured either by air curing or high-pressure steam curing procedure. Because of great-Engineered properties, chamunda welding works Bricks have become popular in wide range of applications in construction sector.

Advantages of Chamunda welding works Bricks

○ High Thermal Insulation. ○ Low thermal conductivity. ○ Thermal Performances 5 times better than clay bricks

& 10 times better than RCC ○ Interiors remain cool in summer and warm in cold wintry days.

○ Savings in recurring energy costs in air-conditioning. ○ Ideal material for applications in cold storage rooms. ○ Good Sound Insulation ○ Up to 37-42db sound reduction based on thickness. ○ It is possible to achieve even higher values depending upon

the thickness and the plaster. ○ Savings in recurring energy costs in air-conditioning. ○ Can fulfill required STC (Sound Transmission Class) rating. ○ Reduction of Dead Load ○ 1/3rd the density of clay bricks. ○ Economic design: savings in cement and steel. ○ Enables faster construction. ○ Suitable for low-soil bearing capacity & seismic zones. ○ Facilitates construction of unplanned walls any where anytime.

Fire Protection Chamunda welding works Bricks offer great fire protection. With a just 100mm thickness of wall 1000 kg/m3, chamunda block offers fire endurance for heat transmission for 4 hours without releasing any toxic fumes during.

Enhances Carpet Area An engineered block, it can be offered in any thickness as per the construction design. By using 150 mm thick Bricks in place of 9 inch brick, the customer gets an additional 2% to 3% carpet area. The savings on account of additional carpet area gained is more than the cost of Bricks

Other Advantages of chamunda welding works: Chamunda welding works offers economical POP or putty finish in internal partition walls.

○ Accurate size and shapes help in reducing plastering costs. ○ Better finishing of walls offers good amount of reduction in paints. ○ Eco-friendly. ○ Speedier Constructions. ○ Ease of Workability. ○ Universal Acceptability.

Size (in Inches)

Size (in mm) No of bricks / m3

Weight (Kg’s)

Prod. Cost

Market Price

24 * 8 * 4 600 * 200 * 100

83 9.5 – 10 38 – 45

24 * 8 * 6 600 * 200 * 150

55 14.5 – 15 57 – 65

24 * 8 * 8 600 * 200 * 200

41 19 – 19.5 76 – 85

24 * 8 * 9 600 * 200 * 225

36 22 – 22.5 95 - 105

Can select size as per your choice for making Bricks, Paver and Blocks….

Plant-1

Quotation for CLC –Chamunda welding works

Clc plant 4500 to 6000 block per shift (8 hours) Mixer type: Material will be mix and forward to mold automatically

10hp.Crompton Company motor with high capacity gear box. Raw material mixer capacity 1000kg. of one time mix to 2 minute.

And foaming generator of 5hp. ……………………………………………………………………………………………………… Hopper 10 running fit with 2hp. Motor automatic trolley type. ............................................................................................................................................................. Mould can be choices from any mentioned below: Size in inch for block. Size in mm for block. Size in inch for brick, size in mm for brick 24x8x4 600 x 200 x 100 9x4x3 225 x 100 x 75 24x8x6 600 x 200 x 150 9x6x3 225 x 150 x 75 24x8x8 600 x 200 x 200 24x8x9 600 x 200 x 225 This complete mould set of 100 piece of any one size One mould have 15 pcs block and 60 pcs bricks …………………………………………………………………………………………………………… Open close mould with hydraulic machine and railway platform, Easily movable moulds …………………………………………………………………………………………………………….

Other detail of chamunda welding works machinery mfg. co.

Place of Origin: India Total plant Power: 31 hp. Mfg. Capacity: 10 sets/month

Processing: Brick and block Production Line

Brand Name: chamunda welding works (Construction machinery mfg. co.)

Method: Hydraulic Pressure Type: Block Making Machine

Brick block Raw Material: Concrete crush, foaming, fly ash, cement, water,

Automatic: Yes

Model Number: 2009/05/212

Certification: Corporation of Morbi

Main Technology: Vibration with pressure

Forming fashion: Table vibration, Vibration and hydraulic

Color: Blue & White & any choice

Vibration frequency: 1400 per min.

Pallet dimension: 15mm

Heap area 8000 sq. feet.

Material: Ms. Plate LEBBER REQUWIRMANT – 4 TO 6 MAN…

Quotation for CLC –Chamunda welding works

Parts:

Mixer (1000 K.G) with Motor capacity 10 H.P (Crompton or AVR Brand) with High capacity gearbox.

Foam Generator : 1 H.P (400 Liter capacity)

3 Conveyer belt : (25 feet) with 2 H.P motor each

2 conveyor Belt : (18 Feet) WITH 2 H.P Motor each,

Total 4 hopper : (3 Hopper of 800 keg & 1 Hopper of 1000 Kegs)

Panel Board : (Siemens Company Made)

Air compressor : 1 H.P (Toyota Company Made)

About Molds-

Normal mold we will provided : 100 Molds

(Each mould contain 16 Block or 60 Bricks)

Wire cutting mould: we will provide 25 Pieces of mould

Building Technology why use clc light weight bricks in construction? Why use clc light weight bricks or foam concrete bricks? Clc is cellular weight blocks where we can use for load bearing structure and frame

structure .its a other alternative for red brick and fly-ash bricks. Why we use clc bricks? 1)CLC is a light weight brick where water absorption is less compare to redbrick and flyash brick. 2)High thermal insulation 3)Compressive strength is more than other bricks 4)Environmental friendly. 5)Quantity of cement is less when making a wall why because 6) clc bricks life span is more than other bricks Clc block size can make according to our requirements In India generally block can make Clc Size per cubic meter 4*8*24 – 83nos. clc blocks. 6*8*24 – 55nos.clc blocks. 9*8*24 – 50nos. clc blocks. If we take one clc block size a red brick comes around for each clc block 4*8*24 - 10.6 red bricks 6*8*24 - 7.1 red bricks How we compare clc bricks with red bricks when we meet customer? If we take the size 4*8*24 market price now in India is ~4275 Rs per each cubic meter Red bricks market price now in India (pune) is 3925 Rs per each cubic meter its varies city to city . So the first question comes from customer why i spend more money for clc bricks?

Here is the solution Take an example: 1 unit wall brick construction with clc and red brick Clc bricks for 1 unit wall construction red bricks for 1 unit wall construction Clc bricks for 1 unit wall construction Red bricks for 1 unit wall construction 1) clc bricks for 1 unit wall around 75 bricks 2) red bricks for 1unit wall comes around 560 bricks 1) quantity of cement and sand requires for moror 1unit wall-clc cement : 1 bag cement sand : 4bag sand price : 290Rs for cement 150 Rs for sand ---------------------------------- Total 440 Rs/- ----------------------------------- 2) quantity of cement and sand requires for motor 1unit wall-red cement : 2.5 bag cement sand : 10 bag sand price : 725 Rs cement 400 Rs for sand ---------------------------------- Total 1125 Rs /- ----------------------------------- 3) Plastering: ½ inch plastering is Enough for CLC Cement : 1.5 bag cement Sand : 6 bag sand Price : 450 Rs for cement

225 Rs for sand ---------------------------------- Total 675 Rs/- ----------------------------------- 3) Plastering: 1.5 inches plastering is needed for red Cement : 3.5 bag cement Sand : 14 bag sand Price : 1015 Rs for cement 525 Rs for sand ---------------------------------- Total 1540 Rs/- ----------------------------------- Total cost for plastering and motor joints For clc bricks 675 + 440 = 1115Rs Total cost for plastering and motor joints For red bricks 1125 + 1540 = 2665Rs Red bricks for 1 unit wall price is 7.5 * 560 = 4200RsClc bricks for 1 unit wall price is 57*75 =4275Rs If we subtract clc price from red brick price 4275 4200 ------ 75 Now add plastering and motor joints price Ie 2665 75 --------- 2590 per unit wall save with using CLC blocks. --------- So at the end of the 1 unit wall construction the price we are spending for red bricks as almost same as clc bricks apart from that contractor can construct the building less time then red brick construction. So finally customer can happy. To get good product in the market to build is home Note : The above calculation we are giving for construction a building with clc its varies cities and cities . Foam generator These are the technical specification of foam generator foam generator: 1)1hp single phase motor suguna (spm 100) 2)foam out put 300-400 lts/min 3)automatic time setting to off the motor 4)inside walls are 1/2" used 5)digital foam generator 6)foam lancing unit 7) Daily take 100 cubic meters with our foam generator 8) we recomended foaming agent 80g/l to90g/l

Foaming Agent Foaming agent is our unique enzyme based foaming agent. This Foaming Agent is manufactured in a unique fermentation process and not through the main used method of acid hydrolyzes. Our Making process enables us to separate exactly the needed proteins for specific characteristics (stability, foaming characteristics, etc.) according to their molecular weight. This method leads to excellent products with advanced characteristics and competitive prices. It causes no chemical reaction with the surrounding matrix but serves solely as wrapping material for the air to be encapsulated in the concrete (mortar)

Features: 1. protein based foaming agent 2. it is used for cellular light weight bricks/blocks or foam concrete bricks/blocks 3. foam density 80-90gms/lts 4. ratio around 1:45 ratio 5. Foam generated with our protein based foaming agent with mixing of air and water is stable. it is added into cement slurry and blended with blender to form a homogeneous dispersion. 6. Is safe for use and has no harmful effect on human being. It can be successful treated in biological waste water treatment systems after proper dilution. 7. Stability: Stability of bubbles is 1.0 to 3.0 hours, depending upon the temperatures and environmental conditions Stable, long-lasting foam blanket provides excellent burn back resistance. Suitable for use with fresh or sea water. Compatible with standard proportioning and air aspirating foam making equipment. Suitable for use with foam compatible dry powder extinguishing agents. 8. It is used for cellular light weight bricks, wall panels and roof insulation. FOAM CONCRETE Technological Comparison Parameters Burnt Clay Brick Hollow Bricks Foam Concrete Basic Raw Material Agricultural soil, coal or wood for firing Cement, sand, fly ash, lime Cement, sand , fly ash, & aggregates foam & water Production Process and Setup Kilns Mobile or Stationary plant On-site Production Dry Density kg/m3 1800-2000 1900-2100 300-600/ 800-1000 /1200-1800

Compressive Strength kg/cm2 30-80 30-150 4-10 / 25-35 / 125-250 Applications Load bearing & Non-load bearings Load bearing & Non-load bearings walls Thermal insulation, Partitions, Load & Nonload bearings Pre cast block size 229*114*70 mm 400*200*200/100 mm 600*300*100/150/200 Cast-in place Not- Feasible Not-Feasible Any shape, any size, any density Compaction during production Yes Yes None Aging No Yes Gain strength with age Thermal Conductivity W/mK 0.7 1.1 0.16 for 500 kg/m3 0.21 for 800 kg/m3 0.28 for 1000 kg/m3 Sound Insulation Normal Better Superior Ease of working Normal Difficult Can be cut, sawn, nailed, drilled Eco Friendliness Process creates smoke, uses high energy, wasting agricultural lands Low energy, No smoke Pollution free, Green product, Least energy, Reuse of Industrial wastes Popular applications Thermal Insulation: Foam concrete of density between 250 - 550 kg/m3 is primarily used for thermal insulation or fire protection. It uses only cement (or with a small proportion of sand), water and foam and can easily be pumped into moulds of varying orientations. Void Filling: Foam concrete of density between 600 - 800 kg/m3 is used for void-filling, such as in landscaping (above/underground construction), filling voids behind archways and refurbishing damaged sewage systems, as well as producing masonry units. Block Production: Foam concrete of density ranging from 800 to 900 kg/m3 is primarily used in the production of

blocks and other non-load bearing building elements such as balcony railings, partitions, parapets, etc. Precast Walls & Floor Screeds: Foam concrete of density ranging from 1100 - 1400 kg/m3 are commonly used in prefabricated and cast in place walls, either load-bearing or non-load bearing. It can also be successfully used for floor screeds. Load Bearing & Slabs: Foam concrete of density between 1600 - 1800 kg/m3 would be recommended for slabs and other load-bearing building elements where higher strength is obligatory. Materials which are used in light weight bricks or foam concrete bricks 1)Cement 2) fly ash 3)foaming agent Cement is the major roll to get good quality of light weight bricks What are the steps to be considered when stacking of cement at our site? Cement is available in 43 and 53 grades 1. 53 grade cement is used for high strength buildings 2. It takes less setting time compare to 43 grade 3. More finer than 43 grade Stacking of cement 1. cement bags should not be stored in open place 2. it should not be exposed to rain 3. maximum 12 bags should be stacked vertically in column 4. the cement bag should be placed at the height of 15 cm from the floor level 5. the cement bag should be keep away from walls in a room. 6. It should not be contacted with walls 7. Cement bag should be stacked according to there batch number. 8. Cement bag should be used earlier stacked bags first rather than then freshly stacked bags 9. All cement bags should covered with taurplilines How to test water absorption for light weight bricks or foam concrete bricks? 1. first check the weight of the light weight brick = w1 2. weight of the brick after 24 hrs immersed in water = w2 3. water absoption = w2-w1/ w1 * 100 4. result < 10% by weight if light weight brick absorb more then 10 percent it means observing more water Labour charges for one month Labour Scale per day One month ~ pay Skilled labour-1no 300 per day 7,500 /- Unskilled labour-8nos 200 per day 40,000 /- Management labour-2nos 370 per day 18,500/- Labour charges --- A = 66,000/- Machinery details Quotation for CLC plant. Sr no. Product / items Qty. Specification Price (Rs) 1 Integrated CLC Unit Mixer (IFM-1100) 1.3 m3 with Digital load sensors set 1 SET 40 To 50 m3

Capacity Total power=20HP REQUIRED 3,77,000 2 GEAR MOTOR `KAVITSU’ MAKE, ISO 9001:2000) 1 Set 10HP 88,000 3 Foam Generator (IFG-1) 1 Set Tulja make 1,60,000 4 Compressor (3HP) ISO9000 1 no Sai Sales corporation 50,000 5 Control Panel. ( All Relays & switches L&T make) 1 no Tulja make 1,60,000 6 Belt conveyor –(ISC 1000) 1 no Tulja make (3HP) 1,10,000 7 Foam concrete testing equipment on site 1 no 8 Tool Kit. 1 set 9 High speed water discharging system (2HP) 1 no 10 Free( Foaming agent 100 ltr & System Erection 53,000 Total 9,98,000 Rupees in word - Nine Lacks Ninety Eight Thousand only Terms & Conditions:- Customer should be provided 3phase Power supply with cables & motor starter up to control panel of the machine. Price: - Ex-Works Morbi Gujrat Warranty: - One Year Against all manufacturing defects. Transportation, Octri :- To Pay Basis. Erection & Training :- Training will give free of charges but Clients should arrange for the transportation & Accommodation for the team. Taxes :- As Applicable. Payment Terms :- 50%Advance along with Purchase order, 45% Before delivery of the machine & 5 % against Delivery Packing & Forwarding:- 2 % if required Delivery:- 5 - 8 Weeks after receiving purchase order & advance payment. Quotation Valid:- 30 Days. “WE EXPECTING YOUR VALUBLE ORDERS “ Thanks & Regards For ChamundaA WeldinG WorkS Proprietor (Gopal P. Nakum)