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The Complete Book on Cement & Concrete Products Manufacturing (AAC Blocks, Slag & High Alumina Cement, Clinker, Concrete Block, Floor Slab, Roof Tiles, Interlocking Paving Blocks, Fly Ash Bricks, Flooring Tiles, Precast RCC Wall, Prestressed Concrete Beams, Poles, Pipe, Sleeper, RCC Beam, Ready Mix Concrete and Wall Putty with Manufacturing Process, Machinery Equipment Details and Factory Layouts)
The Complete Book on Cement & Concrete Products Manufacturing (AAC Blocks, Slag & High Alumina Cement, Clinker, Concrete Block, Floor Slab, Roof Tiles, Interlocking Paving Blocks, Fly Ash Bricks, Flooring Tiles, Precast RCC Wall, Prestressed Concrete Beams, Poles, Pipe, Sleeper, RCC Beam, Ready Mix Concrete and Wall Putty with Manufacturing Process, Machinery Equipment Details and Factory Layouts) ( New Arrival ) ( ) ( ) ( ) ( )
Author Ashish Dey ISBN 978-81-957447-4-9
Code ENI356 Format Paperback/PDF File
Price: Rs 1975   1975 US$ 50   50
Pages: 496 Published 2023
Publisher Asia Pacific Business Press Inc.
Usually Ships within 5 days

Description:

 

Cement is a powdery substance made by calcining lime and clay. When cement is mixed with water, it forms mortar, and when it is mixed with sand, gravel, and water, it makes concrete. Mortar is used as a bonding agent for plastering, masonry work, and pointing. 

 

Concrete is a mixture of aggregates and paste. The aggregates are sand and gravel or crushed stones; and the paste is made from water and portland cement mixture. Concrete is used for laying floors, roofs and constructing lintels, beams, pillars and other masonry structures. Concrete products such as pipes, blocks, bricks, and concrete articles are made using concrete.

 

The cement and concrete products market consists of sales of cement and concrete products and related services by entities (organizations, sole traders and partnerships) that manufacture cement and concrete products such as concrete pipes, bricks, and paving blocks. The cement and concrete products manufacturing industry includes establishments engaged in manufacturing portland cement, pozzolanic cement, ready-mix concrete, concrete blocks, bricks, and pipes and related products.

 

The global cement and concrete products market was valued at $333,255.8 million. The market accounted for 0.40% of the global GDP. In terms of per capita consumption, the market accounted for $43.5. The market was also supported by rapid urbanization, and government initiatives towards infrastructure development. Growth in the forecast can be attributed to increasing spending on infrastructure, global economic growth, the development of affordable housing, and a rapidly growing urban population.

 

The cement and concrete industry is still expected to grow in the coming years. Companies are looking for ways to reduce their environmental footprint by making use of more efficient manufacturing processes and renewable energy sources. They are also developing new materials that are stronger and more sustainable than traditional materials. This means that the industry will remain an important part of the global economy for many years to come.

 

This book contains in-depth information about Cement & Concrete Products, AAC Blocks, Slag & High Alumina Cement, Clinker, Concrete Block, Floor Slab, Roof Tiles, Interlocking Paving Blocks, Fly Ash Bricks, Flooring Tiles, Precast RCC Wall, Prestressed Concrete Beams, Poles, Pipe, Sleeper, RCC Beam, Ready Mix Concrete and Wall Putty with Manufacturing Process, Machinery Equipment Details and Factory Layouts. This book is also a fantastic resource for people interested in or who have worked in the Cement & Concrete industry.

 

Profitable and viable business opportunities exist in the Cement & Concrete sector. As a result, creating your own business is a good way to get into it. To learn more about Cement & Concrete industry in depth, read this book. It will assist you in figuring out how to establish your own Cement & Concrete Business. Because of the increasing demand for Cement & Concrete in today's market, it's a terrific method to earn money.

 

Content

 

1. INTRODUCTION
1.1 Chemistry
1.1.1 Hydraulic Cement
1.1.2 Non-Hydraulic Cement
1.2 Cement Physical Properties
1.3 Cement Chemical Properties
1.4 Cement Industry
2. HOW TO START YOUR OWN CEMENT BUSINESS
2.1 Make A Cement Factory Cost Analysis Plan
2.2 Make a Budget- Cement Plant
2.3 Choose Your Cement Factory Market or Region
2.4 Choose a Location with a Plentiful Supply of Raw
Materials
2.5 Understand the Cement Manufacturing Process
2.6 Determine the Supply of Raw Material and Energy
Supply
2.7 Get Environment Clearance
2.8 Make Your Project in Line with CSR and
Sustainability
2.9 Get the Necessary Personnel and Begin Production
2.10 Gauge Your Competition
3. RAW MATERIALS USED FOR CEMENT PRODUCTION
3.1 Introduction
3.2 Lime Component
3.2.1 Limestone
3.2.2 Chalk
3.2.3 Marl
3.3 Clay Component
3.4 Corrective Ingredients
3.5 Auxiliary Components of Cement Raw Materials
3.5.1 Magnesium Oxide
3.5.2 Alkalies
3.5.3 Sulfur
3.5.4 Chloride
3.5.5 Fluoride
3.5.6 Phosphorus
4. MANUFACTURING PROCESS OF CEMENT
4.1 Dry Cement Manufacturing Process
4.1.1 Treatment of Raw Materials
4.1.2 Burning or Calcination of the Dry Mix
4.1.3 Grinding of Clinker
4.1.4 Packing and Storage of Cement
4.2 Wet Process of Manufacturing of Cement.
4.2.1 Preparation of Slurry
4.2.2 Burning or Calcination
4.2.3 Grinding of Clinker
5. EQUIPMENT AND MACHINERY REQUIRED FOR CEMENT PLANT
5.1 Stages of Cement Manufacturing
5.1.1 Stage-1 Opencast Lime Stone Mining
5.1.2 Stage-2 Lime Stone Crushing & Stacking
5.1.3 Stage-3 Raw Material Handling & Grinding
5.1.4 Stage-4 Coal Grinding
5.1.5 Stage-5 Preheater Kiln & Cooler
5.1.6 Stage-6 Clinker Grinding (Cement Mill)
5.1.7 Stage-7 Packing Plant & Loading Plant
6. TYPES OF CEMENT
6.1 Introduction
6.1.1 Ordinary Portland Cement (OPC)
6.1.2 Portland Pozzolana Cement (PPC)
6.1.3 Rapid Hardening Cement
6.1.4 Quick Setting Cement
6.1.5 Low Heat Cement
6.1.6 Sulphate Resisting Cement
6.1.7 Blast Furnace Cement
6.1.8 High Alumina Cement
6.1.9 White Cement
6.1.10 Colored Cement
6.1.11 Air Entraining Cement
6.1.12 Expansive Cement
6.1.13 Hydrophobic Cement
7. WHITE CEMENT MANUFACTURING
7.1 Introduction
7.2 How to Improve White Cement’s Whiteness
7.2.1 Select the Best Raw Materials
7.2.2 Select the Appropriate Fuel
7.2.3 Select the Best Raw Mill and Cement Mill
7.2.4 Choose the Best Cooling Method
7.3 The Primary Applications
7.4 Differences between White Cement and Grey Cement
7.5 Raw Materials
7.6 White Cement Manufacturing
7.6.1 White Cement Clinker Manufacturing
7.6.2 White Cement Clinker Bleaching Process
7.7 Process
7.7.1 Crushing
7.7.2 Grinding
7.7.3 Calcination of Clinker
7.7.4 Clinker Cooling
7.7.5 Cement Grinding
7.7.6 Packing of Cement
8. QUICK SETTING CEMENT IN CONSTRUCTION
8.1 Applications
8.2 Why is Quick-Setting Cement a Good Choice for
Construction?
8.3 How to Use Quick Setting Cement?
8.4 Considerations for Using This Type of Cement
8.5 Main Characteristics
8.6 Difference Between Quick Setting Cement and Rapid
Hardening Cement
8.7 Ingredient
8.8 Manufacturing of Quick-Setting Cement
8.8.1 Raw Materials Crushing
8.8.2 Raw Materials Grinding
8.8.3 Clinker Calcination
8.8.4 Grinding Clinker
8.8.5 Cement Packing
9. PRODUCTION OF ORDINARY PORTLAND CEMENT (OPC)
9.1 Ordinary Portland Cement Varieties
9.1.1 33-Grade Cement
9.1.2 43-Grade Cement
9.1.3 53-Grade Cement
9.2 Chemical Characteristics of OPC
9.2.1 Factor of Lime Saturation
9.2.2 The Alumina-Iron Ratio
9.2.3 Insoluble Waste
9.2.4 Magnesia
9.2.5 Ignition Failure
9.2.6 Anhydride of Sulphur
9.3 Advantages
9.4 OPC Cement Properties
9.5 Specifications OPC Cement
9.6 Raw Materials
9.7 Manufacturing Process
9.7.1 Crushing and Grinding
9.7.2 Material Mixing
9.7.3 Heating the Slurry in the Rotary Kiln
9.7.4 Formation of Clinker
9.7.5 Grinding the Clinker with Gypsum
10. HIGH ALUMINA CEMENT
10.1 Introduction
10.2 Applications
10.3 Hydration of High Alumina Cement (HAC)
10.3.1 Conversion of High Alumina Cement
10.3.2 Effect of Curing Temperature on High Alumina
Cement
10.4 Advantages
10.5 Difference between High Alumina Cement and Ordinary
Portland Cement
10.6 Raw Materials
10.7 Manufacturing of High Alumina Cement
10.8 Physical Properties
10.9 Concrete Technology
10.9.1 Resistance to Chemical Attack
10.10 Refractory Properties of High Alumina Cement
11. BLAST FURNACE SLAG CEMENT AND ITS MANUFACTURING
11.1 Blast-Furnace Slag is Used in Making-Four Classes of
Cement
11.2 What Industries are Blast Furnace Slag Used After
Grinding?
11.3 Classification of Blast Furnace Slag
11.3.1 Air-Cooled Slag
11.3.2 Granulated Slag
11.3.3 Expansive Slag
11.3.4 Slag Cotton
11.4 Advantages of Blast-Furnace Slag Cement
11.5 Disadvantages of Blast-Furnace Slag Cement
11.6 Manufacturing Method
11.7 Process
11.7.1 Raw Material Production
11.7.2 Raw Mill
11.7.3 Clinker Production
11.7.4 Clinker Grinding
11.7.5 Finished Cement Storage and Packing
12. PORTLAND POZZOLANA CEMENT
12.1 Features
12.2 Applications
12.3 Composition
12.4 Advantages
12.5 Portland Pozzolana Cement Properties
12.6 Manufacturing Process
13. HOW CEMENT IS MADE WITH CLINKER
13.1 Composition of Clinker
13.2 Clinker Thermochemistry
13.3 Cement Clinker Types and Uses
13.3.1 Sulfate Resistant Clinker
13.3.2 Low Heat Clinker
13.3.3 White Clinker
13.3.4 Low-Alkali Clinker
13.3.5 Belite Calciumsulfoaluminate Ternesite (BCT)
13.4 Cement Clinker Use: Changing to Cement
13.5 How is Cement Clinker Produced?
13.6 What are Differences Between Clinker Cement and
Grey Cement?
13.7 Manufacturing Process
13.7.1 Crushing of Limestone
13.7.2 Prehomogenisation
13.7.3 Grinding of Raw Materials
13.7.4 Homogenization
13.7.5 Pyro Processing
13.7.6 Clinker Formation
14. PLASTER OF PARIS AND ITS DIFFERENT USES
14.1 Properties of Plaster of Paris
14.2 Additional Features of Gypsum Plaster
14.3 What Distinguishes Gypsum from Plaster of Paris?
14.4 Types of Plaster of Paris
14.4.1 Gypsum Plaster
14.4.2 Clay Plaster
14.4.3 Lime Plaster
14.4.4 Cement Plaster
14.4.5 Heat Resistant Plaster
14.5 The Different Uses of Plaster of Paris
14.6 Process of Manufacture
15. CONCRETE AND ITS MANUFACTURING PROCESS
15.1 Concrete Components
15.2 Hardened Concrete
15.3 Development for the Long Term
15.4 Quality Concrete Essentials
15.5 Suitable Materials
15.6 Water-Cementitious Materials Ratio
15.7 Design-Workmanship-Environment
15.8 Concrete vs. Cement
15.9 Manufacturing Processes of Concrete
15.9.1 Batching
15.9.2 Mixing
15.9.3 Transporting
15.9.4 Placing
15.9.5 Compacting
15.9.6 Curing
15.9.7 Finishing
16. HOW TO START CONCRETE BUSINESS
16.1 Select a Name for Concrete Company
16.2 Create a Concrete Business Plan
16.3 Select the Legal Structure for Concrete Company
16.3.1 Limited Liability Company
16.3.2 Partnerships
16.3.3 Limited Liability Company (LLC)
16.3.4 C Corporation
16.3.5 S Corporation
16.4 Obtain Startup Capital for Concrete Business
(If Needed)
16.5 Establish a Business Location
16.6 Register Concrete Business with the Internal Revenue
Service
16.7 Establish a Business Bank Account
16.8 Apply for a Business Credit Card
16.9 Obtain the Necessary Business Licenses and Permits
16.10 Obtain Business Insurance for Concrete Company
16.11 Purchase or Lease the Appropriate Concrete Business
Equipment
16.12 Create Concrete Business Marketing Materials
16.13 Buy and Install the Software Required to Run Concrete
Business
16.14 Ready for Business
17. DIFFERENT TYPES OF CONCRETE
17.1 What is the Significance of Concrete in
Construction?
17.2 How to Choose a Concrete Type?
17.3 Concrete Work Safety Tips
17.4 Types
17.4.1 Plain Cement Concrete (PCC)
17.4.2 Cement Reinforced Concrete (RCC)
17.4.3 FRC (Fibre Reinforced Concrete)
17.4.4 Glass Fibre Reinforced Concrete (GFRC)
17.4.5 Ferrocement
17.4.6 Ready Mix Concrete
17.4.7 Precast Concrete
17.4.8 Prestressed Concrete
17.4.9 Light Weight Concrete
17.4.10 Polymer Concrete
17.4.11 High Density Concrete
17.4.12 High Performance Concrete
17.4.13 High Strength Concrete
17.4.14 Air Entrained Concrete
17.4.15 Self-compacting Concrete (SCC)
17.4.16 Shotcrete
17.4.17 Guniting Concrete
17.4.18 Pumped Concrete
17.4.19 Pervious Concrete
17.4.20 Smart Concrete
17.4.21 Stamped Concrete
17.4.22 Limecrete
17.4.23 Asphalt Concrete
17.4.24 Bacterial Concrete
17.4.25 Smog Eating Concrete
18. DIFFERENCE BETWEEN RCC AND PRESTRESSED CONCRETE
18.1 Materials Used in Prestressed Concrete
18.1.1 Steel
18.1.2 Tendons
18.1.3 Wires Strands or Cables
18.1.4 Bars
18.1.5 Concrete
18.2 The Comparisons Between the RCC and Prestressed
Concrete
19. CONCRETE FLOOR SLAB PRODUCTION PROCESS
19.1 Different Slabs
19.1.1 One-Way Slabs on Beams
19.1.2 One-Way Joist Slab (Ribbed Slab)
19.1.3 Waffle Slab (Grid Slab)
19.1.4 Flat Plates
19.1.5 Flat Slabs
19.1.6 Two-Way Slabs on Beams
19.1.7 Hollow Core Slab
19.1.8 Hardy Slab
19.1.9 Bubble Deck Slab
19.1.10 Composite Slab
19.1.11 Precast Slab
19.1.12 Slab on Grade
19.2 Design Requirements of RCC Slab, Structural Design,
Building Design
19.2.1 Effective Span in Slab Design
19.2.2 Limiting Stiffness
19.2.3 Minimum Reinforcement
19.2.4 Maximum Diameter of the Bars
19.2.5 Spacing of the Main Reinforcement Bars
19.2.6 Percentage of Distribution Reinforcement
19.2.7 Cover to the RCC Slab
19.3 Process
19.3.1 Assemble and Erect Formwork for Slab
19.3.2 Prepare and Place Reinforcement for Slab
19.3.3 Pour, Compact and Finishing Concrete Floor Slab
19.3.4 Curing Concrete and Remove Formwork
20. CONCRETE BLOCK MAKING PROCESS
20.1 What do Need to Understand About Concrete
Blocks?
20.2 Why Use Concrete Blocks for Construction?
20.3 Advantages of Concrete Blocks
20.4 Raw Materials Utilized in Concrete Blocks
20.5 Concrete Blocks Manufacturing Process
20.6 Process
20.6.1 Mixing
20.6.2 Molding
20.6.3 Curing
20.6.4 Cubing
21. TYPES OF CONCRETE BLOCKS USED IN CONSTRUCTION
21.1 Hollow Concrete Blocks vs. Solid Concrete Blocks
21.2 Types of Hollow Concrete Blocks
21.2.1 Stretcher Block
21.2.2 Pillar Block
21.2.3 Lintel Block
21.2.4 Jamb Block
21.2.5 Column Block
21.2.6 Corner Block
21.2.7 Splitface Block
21.2.8 Bullnose Block
21.2.9 Partition Block
21.3 Types of Solid Concrete Blocks
21.3.1 Fly Ash Block
21.3.2 Aerated Autoclaved Block
21.3.3 Paving Block
21.3.4 Cellular Lightweight Block
21.3.5 Expanded Clay Aggregate Block
22. CONCRETE ROOF TILES PRODUCTION
22.1 Extruded Concrete Roofing Tiles
22.2 Improvements to Colourings, Coatings and Textures
22.3 Concrete Roof Tiles and Other Roofing Materials
22.4 The Use of Pigments
22.5 Reducing Efflorescence
22.6 Life Expectancy and Design Criteria
22.7 Roof Tile Testing
22.8 Weathering Tests and Roof Tile Fixing
22.9 Future of Concrete Roof Tiles
22.10 Raw Materials
22.10.1 Sand
22.10.2 Cement
22.10.3 Colour
22.11 Manufacturing Process
22.12 Equipment
23. HOW TO START ROOF TILES PRODUCTION BUSINESS
23.1 Conduct Research on Roof Tiles
23.2 Create an Effective Business Plan
23.3 Include Business
23.4 Registration for Taxes
23.5 Lease a Facility and Establish a Manufacturing
Factory
23.6 Raw Material Source
23.7 Market Research Source
24. INTERLOCKING CONCRETE PAVING BLOCKS
MANUFACTURING
24.1 Types of Pavers
24.1.1 Natural Stone Pavers
24.1.2 Brick Pavers
24.1.3 Concrete Pavers
24.2 Manufacturing Process
24.2.1 Raw Material Required for the Making of Paver
Blocks
24.2.2 Batching
24.2.3 Mixing
24.2.4 Filling of Moulds
24.2.5 Compaction
24.2.6 Curing
24.2.7 Quality Control
24.3 Manufacturing Equipment
24.3.1 Batching Equipment
24.3.2 Mixer
24.3.3 Moulding Machine
24.3.4 Curing Chamber
25. USE OF RICE HUSK ASH IN CONCRETE
25.1 Introduction
25.2 Salient Features
25.3 Physical Properties
25.4 Chemical Properties
25.5 Why RHA?
25.5.1 High Performance Concrete (HPC)
25.5.2 Supplementary Cementing Materials
25.5.3 Research on RHA
25.5.4 Research Significance
25.6 Material Properties and Mix Design
25.6.1 Water
25.6.2 Methodology
25.7 Methodology Adopted for Mix Design
25.7.1 Design of Concrete Mix
25.7.2 Preparation of Mix Design
25.8 Casting of Specimens
25.8.1 Specimens for Split Tensile Strength
25.8.2 Specimens for Young’s Modulus
25.8.3 Testing of Specimens
25.9 Material Used
25.9.1 Cement
25.9.2 Rice Husk Ash
25.9.3 Aggregate
25.9.4 Super Plasticizers
25.9.5 Water
25.10 Production of Rice Husk Ash
25.11 Burning Process of Rice Husk
25.12 Mix Design
26. SULFATE RESISTANCE OF HIGH-PERFORMANCE CONCRETE
26.1 Introduction
26.1.1 Materials
26.1.2 Mix Proportions
26.1.3 Mixing and Casting
26.1.4 Curing and Testing
26.2 Compressive Strength Determination
26.3 Resistance to Sulfate Attack
27. PRESTRESSED CONCRETE CEMENT POLES PRODUCTION
METHOD
27.1 Different Shapes of Prestressed Concrete Poles
27.2 Advantages of Prestressed Concrete Poles
27.3 Design Considerations of Prestressed Concrete
Poles
27.4 Manufacturing Methods of Prestressed Concrete
Poles
27.4.1 Centrifugal Casting Method
27.4.2 Long Line Method
27.4.3 Mensel’s Method
27.5 Manufacturing Process
27.5.1 Forms and Moulds
27.5.2 Aggregate (Coarse or Fine)
27.5.3 Cement
27.5.4 H.T. Wire
27.5.5 Water
27.5.6 Admixtures
27.5.7 Reinforcement and Tensioning
27.5.8 Designing, Mixing, Placing and Compacting
Concrete
27.5.9 Curing of Poles
27.5.10 Detensioning and Cutting of Wires
27.5.11 Curing of Poles in Vats, Handling and Stacking
27.5.12 Sampling and Inspection
28. PRESTRESSED CONCRETE CYLINDER PIPE WITH ITS
MANUFACTURING PROCESS
28.1 Standard Pipe
28.1.1 Bar-Wrapped Concrete Pressure Pipe
28.1.2 Welded Steel Pipe
28.2 Lined Cylinder Pipe (L-301) Features
28.3 Advantages
28.4 Embedded Cylinder Pipe (E-301) Features
28.5 Advantages
28.6 Manufacturing Process
28.7 Bar-Wrapped Concrete Pressure Pipe
28.8 Special Sections and Fittings
28.9 Quality Assurance
29. HOW TO START CONCRETE PIPE MANUFACTURING BUSINESS
29.1 Understand the Industry
29.1.1 Industry Statistics that are Interesting
29.2 Conduct Market Research and Feasibility Studies
29.2.1 Demographics and Psychographics
29.3 Decide What Niche to Concentrate On
29.3.1 The Industry’s Level of Competition
29.4 Understand the Industry’s Major Competitors
29.4.1 Economic Analysis
29.5 Decide Whether to Buy a Franchise or Start from
Scratch
29.6 Know the Possible Threats and Challenges Will
Face
29.7 Choose the Most Suitable Legal Entity (LLC, C Corp,
S Corp)
29.8 Choose a Catchy Business Name from the Ideas
Below
29.9 Consult with an Agent to Determine the Best Insurance
Policies
29.10 Protect Intellectual Property with Trademark, Copyrights,
Patents
29.11 Get the Necessary Professional Certification
29.12 Obtain the Legal Documents Required to Operate
29.13 Obtain the Required Startup Capital
29.14 Select an Appropriate Business Location
29.15 Hire Employees to Meet Technical and Manpower
Requirements
29.15.1 The Service Delivery Process of the Business
29.16 Create a Marketing Plan that is Jam-Packed with Ideas
and Strategies
29.17 Create a Set of Unbreakable Competitive Strategies to
Help Win
29.18 Brainstorm Possible Ways to Retain Clients &
Customers
29.19 Create a Corporate Identity and Develop Strategies to
Increase Brand Awareness
29.20 Create a Suppliers/Distribution Network
30. PRESTRESSED CONCRETE BEAMS PRODUCTION PROCESS
30.1 Prestressed Concrete
30.2 Advantages
30.3 Levels of Prestressing
30.4 Materials for Making Prestressed Beams
30.4.1 Concrete, Steel, Grout
30.5 Prestressed Concrete Beams Production Process
30.6 Pre-Tensioning
30.6.1 Preparing the Mould
30.6.2 Placing of Reinforcement
30.6.3 Prestressing
30.6.4 Casting of Concrete
30.6.5 Removing the Mould
30.6.6 Storage
30.7 Post-Tensioning
30.7.1 Placing of Reinforcement and Duct
30.7.2 Prestressing
31. PRESTRESSED CONCRETE SLEEPER MANUFACTURING
31.1 What are the Characteristics of Prestressed
Concrete?
31.2 What Materials Make up Prestressed Concrete?
31.3 Prestressed Concrete Sleepers Manufacturing
Process
31.3.1 Preparing Molds
31.3.2 Pre-Tensioning of Strands
31.3.3 Concreting
31.3.4 Steam Curing
31.3.5 Removing Molds
31.3.6 Wet Curing
31.3.7 Testing and Transportation
32. RCC (REINFORCED CEMENT CONCRETE) BEAM
32.1 Purpose of Beams
32.2 Purpose of Stirrups in the Beam
32.3 Types of Beam According to the Support Conditions
32.3.1 Simply Supported Beams
32.3.2 Continuous Beams
32.3.3 Fixed Beams
32.3.4 Cantilever Beams
32.3.5 Overhanging Beam
32.4 Types of Loads on Beams
32.4.1 Point Load or Concentrated Load
32.4.2 Distributed Load
32.4.3 Uniformly Distributed Load (UDL)
32.4.4 Uniformly Varying Load (UVL)
32.4.5 Couple Forces
32.5 Reinforcement in RCC Beam
32.5.1 Single Reinforcement
32.5.2 Double Reinforcement
32.5.3 Shear Force
32.5.4 Bending Moment
32.5.5 Deflection
32.6 The Manufacturing Process
33. PRECAST RCC WALL PRODUCTION
33.1 Materials
33.2 Basic Material Testing
33.2.1 Test on Cement
33.2.2 Test on M-Sand and Coarse Aggregate
33.3 Mix Proportions for One cum of Concrete (SSD
Condition)
33.4 Test on Concrete
33.4.1 Compressive Strength Test
33.4.2 Slump Test
33.5 Manufacturing Process
34. TYPES OF ADMIXTURES AND ITS EFFECT ON CONCRETE
34.1 What Purposes do Admixtures Serve?
34.2 What is the Purpose of Admixtures in Concrete?
34.3 What is the Ideal Concrete Admixture?
34.4 Types of Concrete Admixtures
34.4.1 Water Reducing Admixtures
34.4.2 Retarding Admixtures
34.4.3 Accelerating Admixtures
34.4.4 Air Entraining Concrete Admixture
34.4.5 Pozzolanic Admixtures
34.4.6 Damp-Proofing Admixtures
34.4.7 Gas forming Admixtures
34.4.8 Air Detraining Admixtures
34.4.9 Alkali Aggregate Expansion Preventing
Admixtures
34.4.10 Anti-washout Admixtures
34.4.11 Grouting Admixtures
34.4.12 Corrosion Preventing Admixtures
34.4.13 Bonding Admixtures
34.4.14 Fungicidal, Germicidal, Insecticidal Admixtures
34.4.15 Coloring Admixtures
34.5 Mechanism of Action of Chemical Admixtures
34.6 Admixtures and Concrete Rheology
34.7 Concrete Admixtures and Their Effect on Concrete
Properties
34.7.1 Air Entraining Admixtures
34.7.2 Water Reducing
34.7.3 Retarders
34.7.4 Accelerators
34.7.5 High Range Water Reducing Admixtures
34.8 Miscellaneous Admixtures
35. FLY ASH BRICKS MANUFACTURING PROCESS
35.1 History
35.2 Sources of Fly Ash
35.3 Properties of Fly ash Bricks
35.4 Environmental Advantages of Fly Ash Bricks
35.5 Merit of Fly Ash Brick
35.6 Raw Materials
35.7 Manufacturing Process
36. HOW TO BEGIN FLY ASH BRICK MANUFACTURING BUSINESS
36.1 Determine a Business Plan
36.2 Required Space
36.3 Abundance of Water
36.4 Availability of Raw Material
36.5 Required Machinery
36.6 Worker Attainability
36.7 Costing
36.8 Analyze the Competitor
36.9 Profitability
37. AAC BLOCKS (AUTOCLAVED AERATED CONCRETE BLOCKS)
PRODUCTION-FLY ASH BASED
37.1 History About ACC Blocks
37.2 Benefits of AAC Blocks
37.3 AAC Blocks Manufacturing
37.4 Ingredients of AAC Blocks
37.5 Process
37.5.1 Raw Material Preparation  
37.5.2 Dosing and Mixing
37.5.3 Moulding, Rising and Pre-Curing
37.5.4 De-Moulding and Wire Cutting
37.5.5 Autoclaving of AAC blocks
38. MOSAIC FLOORING TILES PRODUCTION PROCESS
38.1 History of Mosaic Art
38.2 How to Make Mosaic Art
38.3 Purpose of Mosaic Floor Tiles
38.4 Construction of Mosaic Flooring
38.5 Advantages of Mosaic Floor Tiles
38.6 Disadvantages of Mosaic Tiles
38.7 Types of Mosaic Floor Tiles
38.7.1 Chevron Mosaic Tile
38.7.2 Penny Hexagonal Tile
38.7.3 Hexagon Mosaic Tile
38.7.4 Octagonal Mosaic Tiles
38.7.5 Herringbone Floor Tiles
38.7.6 Glass Mosaics
38.7.7 Metal Mosaics
38.7.8 Natural Pebble (Stone) Mosaics
38.7.9 Natural Wood Mosaics
38.7.10 Marble Mosaic Tile
38.7.11 Porcelain Mosaic Tile
38.8 There are Three Method
38.8.1 Direct Method
38.8.2 Indirect Method
38.9 Manufacture of Mosaic Tiles
38.9.1 Preparation of Clay
38.9.2 Moulding
38.9.3 Drying
38.9.4 Burning
38.9.5 Pollution Control
38.9.6 Energy Conservation
39. HOW TO PRODUCE WALL PUTTY
39.1 Types of Wall Putty
39.1.1 Cement Wall Putty
39.1.2 Acrylic Wall Putty
39.2 Is Plaster the Same as Wall Putty?
39.3 What does Wall Putty do in Building?
39.4 Benefits of Using Wall Putty
39.4.1 Repairing Cracks and Damages on Walls
39.4.2 Providing a Base for New Paint
39.4.3 Improving Insulation
39.4.4 Easy to Use and Apply
39.4.5 Quick-Drying Time
39.4.6 Resistant to Moisture
39.4.7 Wall Putty doesn’t Flake or Get Easily Damaged
39.5 Chemical Composition
39.6 Applications
39.6.1 Use in Construction
39.6.2 Polyester Based Putty
39.6.3 Plumber’s Putty
39.6.4 Other Uses
39.7 Wall Putty vs. White Cement
39.8 Wall Putty vs. POP
39.9 Raw Material
39.10 Putty Manufacturing Process
39.10.1 Raw Material Unloading & Storage
39.10.2 Weighing/Batching of the Ingredients
39.10.3 Conveying of Raw Material to Charge Hoppers
39.10.4 Blending & Mixing
39.11 Main Components of the Wall Putty Making
Machine
39.11.1 Raw Material Storage Equipment
39.11.2 Dosing Device
39.11.3 Mixer
39.11.4 Packaging Machine
39.11.5 Dust Collector
39.11.6 Conveying and Lifting Equipment
40. READY MIX CONCRETE
40.1 Merits of R.M.C.
40.2 Scope of Ready Mix Concrete
40.3 Materials Required For Ready Mix Concrete
40.4 Mixing Process
40.4.1 Transit Mixed (or “Truck-Mixed”) Concrete
40.4.2 Shrink Mixed Concrete
40.4.3 Central Mixed Concrete
40.5 Slurry Mixing
40.6 Equipment Required In Ready Mixed Concrete
40.6.1 Batching
40.6.2 Inline Bins
40.6.3 Silos
40.7 Tests Carried on R.M.C
40.8 Ready Mix Concrete Quality Testing Methods
40.8.1 Concrete Slump Tests
40.8.2 Air Content Testing
40.8.3 Unit Weight
40.8.4 On-Field Testing of Existing Concrete
40.8.5 Schmidt Rebound Hammer
40.8.6 Destructive Concrete Testing
40.8.7 Comprehensive Strength Laboratory Test
41. HOW TO MAKE MANUFACTURED SAND
41.1 M Sand Types
41.2 Why is Manufactured Sand Significant Today?
41.4 The Factors that Promote the Development of Artificial
Sand
41.4.1 Natural Sand Depletion
41.4.2 The Need for Energy Saving and Environmental
Protection
41.4.3 The Need for the Development of High-Performance
Concrete Technology
41.5 Advantages of Manufactured Sand
41.6 Manufactured Sand Production Process
41.7 Coarse and Fine Crushing
41.7.1 Primary Crushing
41.7.2 Jaw Crusher
41.7.3 Secondary Crushing
41.8 Impact Crusher
41.9 Cone Crusher
41.10 Sand Making and Screening
41.11 Sand Washing and Recycling
42. ISO STANDARDS
43. INDIAN STANDARD CODES
44. BIS STANDARDS
45. PLANT LAYOUT AND PROCESS FLOW CHART & DIAGRAM
46. PHOTOGRAPHS OF PLANT AND MACHINERY WITH SUPPLIERS
CONTACT DETAILS
• Automatic Block Making Machine
• Hydraulic Interlocking Block Machine
• Rotary Kiln
• Rotary Cooler
• Cement Clinker Ball Mill
• Weigh Feeder
• Cone Crusher
• Jaw Crushers
• Sand Rotary Dryer
• Psc Pole Mold Making Machine
• Vibratory Feeder
• Fly Ash Brick Making Machines
• Prestressed Electric Pole Mould
• Prestressed Concrete Pipe Mould
• Cement Packing Machine
• Clinker Granulator
• Concrete Sleeper Steel Moulds
• Rotary Cooler
• Steel Silo
• Bucket Elevator
• Belt Conveyors
• Roof Tile Forming Machine
• Artificial Sand Making Machine
• Paver Block Making Machine
• Concrete Testing Machines
• Wall Putty Making Machine
• Prestressed Concrete Hollow Core Slab Machine

 

ABOUT NPCS

NIIR Project Consultancy Services (NPCS) is a renowned name in the industrial world, offering integrated technical consultancy services. Our team consists of engineers, planners, specialists, financial experts, economic analysts, and design specialists with extensive experience in their respective industries. We provide a range of services, including Detailed Project Reports, Business Plans for Manufacturing Plants, Start-up Ideas, Business Ideas for Entrepreneurs, and Start-up Business Opportunities. Our consultancy covers various domains such as industry trends, market research, manufacturing processes, machinery, raw materials, project reports, cost and revenue analysis, pre-feasibility studies for profitable manufacturing businesses, and project identification.

Our Services

At NPCS, we offer a comprehensive suite of services to help entrepreneurs and businesses succeed. Our key services include:

  • Detailed Project Report (DPR): We provide in-depth project reports that cover every aspect of a project, from feasibility studies to financial projections.
  • Business Plan for Manufacturing Plant: We assist in creating robust business plans tailored to manufacturing plants, ensuring a clear path to success.
  • Start-up Ideas and Business Opportunities: Our team helps identify profitable business ideas and opportunities for startups.
  • Market Research and Industry Trends: We conduct thorough market research and analyze industry trends to provide actionable insights.
  • Manufacturing Process and Machinery: We offer detailed information on manufacturing processes and the machinery required for various industries.
  • Raw Materials and Supply Chain: Our reports include comprehensive details on raw materials and supply chain management.
  • Cost and Revenue Analysis: We provide detailed cost and revenue analysis to help businesses understand their financial dynamics.
  • Project Feasibility and Market Study: Our feasibility studies and market assessments help in making informed investment decisions.
  • Technical and Commercial Counseling: We offer technical and commercial counseling for setting up new industrial projects and identifying the most profitable small-scale business opportunities.

Publications

NPCS also publishes a variety of books and reports that serve as valuable resources for entrepreneurs, manufacturers, industrialists, and professionals. Our publications include:

  • Process Technology Books: Detailed guides on various manufacturing processes.
  • Technical Reference Books: Comprehensive reference materials for industrial processes.
  • Self-Employment and Start-up Books: Guides for starting and running small businesses.
  • Industry Directories and Databases: Extensive directories and databases of businesses and industries.
  • Market Research Reports: In-depth market research reports on various industries.
  • Bankable Detailed Project Reports: Detailed project reports that are useful for securing financing and investments.

Our Approach

Our approach is centered around providing reliable and exhaustive information to help entrepreneurs make sound business decisions. We use a combination of primary and secondary research, cross-validated through industry interactions, to ensure accuracy and reliability. Our reports are designed to cover all critical aspects, including:

  • Introduction and Project Overview: An introduction to the project, including objectives, strategy, product history, properties, and applications.
  • Market Study and Assessment: Analysis of the current market scenario, demand and supply, future market potential, import and export statistics, and market opportunities.
  • Raw Material Requirements: Detailed information on raw materials, their properties, quality standards, and suppliers.
  • Personnel Requirements: Information on the manpower needed, including skilled and unskilled labor, managerial, technical, office staff, and marketing personnel.
  • Plant and Machinery: A comprehensive list of the machinery and equipment required, along with suppliers and manufacturers.
  • Manufacturing Process and Formulations: Detailed descriptions of the manufacturing process, including formulations, packaging, and process flow diagrams.
  • Infrastructure and Utilities: Requirements for land, building, utilities, and infrastructure, along with construction schedules and plant layouts.

Financial Details and Analysis

Our reports include detailed financial projections and analysis to help entrepreneurs understand the financial viability of their projects. Key financial details covered in our reports include:

  • Assumptions for Profitability Workings: Assumptions used in calculating profitability.
  • Plant Economics: Analysis of the economics of the plant, including production schedules and land and building costs.
  • Production Schedule: Detailed production schedules and timelines.
  • Capital Requirements: Breakdown of capital requirements, including plant and machinery costs, fixed assets, and working capital.
  • Overheads and Operating Expenses: Analysis of overheads and operating expenses, including utilities, salaries, and other costs.
  • Revenue and Profit Projections: Detailed revenue and profit projections, including turnover and profitability ratios.
  • Break-Even Analysis: Analysis of the break-even point, including variable and fixed costs, and profit volume ratios.

Reasons to Choose NPCS

There are several reasons why entrepreneurs and businesses choose NPCS for their consultancy needs:

  • Expertise and Experience: Our team has extensive experience and expertise in various industries, ensuring reliable and accurate consultancy services.
  • Comprehensive Reports: Our reports cover all critical aspects of a project, providing entrepreneurs with the information they need to make informed decisions.
  • Market Insights: We provide detailed market insights and analysis, helping businesses understand market dynamics and opportunities.
  • Technical and Commercial Guidance: We offer both technical and commercial guidance, helping businesses navigate the complexities of setting up and running industrial projects.
  • Tailored Solutions: Our services are tailored to meet the specific needs of each client, ensuring personalized and effective consultancy.

Market Survey cum Detailed Techno Economic Feasibility Report

Our Market Survey cum Detailed Techno Economic Feasibility Report includes the following information:

  • Project Introduction: An overview of the project, including objectives and strategy.
  • Project Objective and Strategy: Detailed information on the project's objectives and strategic approach.
  • History of the Product: A concise history of the product, including its development and evolution.
  • Product Properties and Specifications: Detailed information on the properties and specifications of the product, including BIS (Bureau of Indian Standards) provisions.
  • Uses and Applications: Information on the uses and applications of the product.

Market Study and Assessment

  • Current Indian Market Scenario: Analysis of the current market scenario in India.
  • Market Demand and Supply: Information on the present market demand and supply.
  • Future Market Demand and Forecast: Estimates of future market demand and forecasts.
  • Import and Export Statistics: Data on import and export statistics.
  • Market Opportunity: Identification of market opportunities.

Raw Material Requirements

  • List of Raw Materials: Detailed list of raw materials required.
  • Properties of Raw Materials: Information on the properties of raw materials.
  • Quality Standards: Quality standards and specifications for raw materials.
  • Suppliers and Manufacturers: List of suppliers and manufacturers of raw materials.

Personnel Requirements

  • Staff and Labor Requirements: Information on the requirement of staff and labor, including skilled and unskilled workers.
  • Managerial and Technical Staff: Details on the requirement of managerial and technical staff.
  • Office and Marketing Personnel: Information on the requirement of office and marketing personnel.

Plant and Machinery

  • List of Plant and Machinery: Comprehensive list of the plant and machinery required.
  • Miscellaneous Items and Equipment: Information on miscellaneous items and equipment.
  • Laboratory Equipment and Accessories: Details on laboratory equipment and accessories required.
  • Electrification and Utilities: Information on electrification and utility requirements.
  • Maintenance Costs: Details on maintenance costs.
  • Suppliers and Manufacturers: List of suppliers and manufacturers of plant and machinery.

Manufacturing Process and Formulations

  • Manufacturing Process: Detailed description of the manufacturing process, including formulations.
  • Packaging Requirements: Information on packaging requirements.
  • Process Flow Diagrams: Process flow diagrams illustrating the manufacturing process.

Infrastructure and Utilities

  • Project Location: Information on the project location.
  • Land Area Requirements: Details on the requirement of land area.
  • Land Rates: Information on land rates.
  • Built-Up Area: Details on the built-up area required.
  • Construction Schedule: Information on the construction schedule.
  • Plant Layout: Details on the plant layout and utility requirements.

Project at a Glance

Our reports provide a snapshot of the project, including:

  • Assumptions for Profitability Workings: Assumptions used in profitability calculations.
  • Plant Economics: Analysis of the plant's economics.
  • Production Schedule: Detailed production schedules.
  • Capital Requirements: Breakdown of capital requirements.
  • Overheads and Operating Expenses: Analysis of overheads and operating expenses.
  • Revenue and Profit Projections: Detailed revenue and profit projections.
  • Break-Even Analysis: Analysis of the break-even point.

Annexures

Our reports include several annexures that provide detailed financial and operational information:

  • Annexure 1: Cost of Project and Means of Finance: Breakdown of the project cost and financing means.
  • Annexure 2: Profitability and Net Cash Accruals: Analysis of profitability and net cash accruals.
  • Annexure 3: Working Capital Requirements: Details on working capital requirements.
  • Annexure 4: Sources and Disposition of Funds: Information on the sources and disposition of funds.
  • Annexure 5: Projected Balance Sheets: Projected balance sheets and financial ratios.
  • Annexure 6: Profitability Ratios: Analysis of profitability ratios.
  • Annexure 7: Break-Even Analysis: Detailed break-even analysis.
  • Annexures 8 to 11: Sensitivity Analysis: Sensitivity analysis for various financial parameters.
  • Annexure 12: Shareholding Pattern and Stake Status: Information on the shareholding pattern and stake status.
  • Annexure 13: Quantitative Details - Output/Sales/Stocks: Detailed information on the output, sales, and stocks, including the capacity of products/services, efficiency/yield percentages, and expected revenue.
  • Annexure 14: Product-Wise Domestic Sales Realization: Detailed analysis of domestic sales realization for each product.
  • Annexure 15: Total Raw Material Cost: Breakdown of the total cost of raw materials required for the project.
  • Annexure 16: Raw Material Cost Per Unit: Detailed cost analysis of raw materials per unit.
  • Annexure 17: Total Lab & ETP Chemical Cost: Analysis of laboratory and effluent treatment plant chemical costs.
  • Annexure 18: Consumables, Store, etc.: Details on the cost of consumables and store items.
  • Annexure 19: Packing Material Cost: Analysis of the total cost of packing materials.
  • Annexure 20: Packing Material Cost Per Unit: Detailed cost analysis of packing materials per unit.
  • Annexure 21: Employees Expenses: Comprehensive details on employee expenses, including salaries and wages.
  • Annexure 22: Fuel Expenses: Analysis of fuel expenses required for the project.
  • Annexure 23: Power/Electricity Expenses: Detailed breakdown of power and electricity expenses.
  • Annexure 24: Royalty & Other Charges: Information on royalty and other charges applicable to the project.
  • Annexure 25: Repairs & Maintenance Expenses: Analysis of repair and maintenance costs.
  • Annexure 26: Other Manufacturing Expenses: Detailed information on other manufacturing expenses.
  • Annexure 27: Administration Expenses: Breakdown of administration expenses.
  • Annexure 28: Selling Expenses: Analysis of selling expenses.
  • Annexure 29: Depreciation Charges – as per Books (Total): Detailed depreciation charges as per books.
  • Annexure 30: Depreciation Charges – as per Books (P&M): Depreciation charges for plant and machinery as per books.
  • Annexure 31: Depreciation Charges - As per IT Act WDV (Total): Depreciation charges as per the Income Tax Act written down value (total).
  • Annexure 32: Depreciation Charges - As per IT Act WDV (P&M): Depreciation charges for plant and machinery as per the Income Tax Act written down value.
  • Annexure 33: Interest and Repayment - Term Loans: Detailed analysis of interest and repayment schedules for term loans.
  • Annexure 34: Tax on Profits: Information on taxes applicable on profits.
  • Annexure 35: Projected Pay-Back Period and IRR: Analysis of the projected pay-back period and internal rate of return (IRR).

Why Choose NPCS?

Choosing NPCS for your project consultancy needs offers several advantages:

  • Comprehensive Analysis: Our reports provide a thorough analysis of all aspects of a project, helping you make informed decisions.
  • Expert Guidance: Our team of experts offers guidance on technical, commercial, and financial aspects of your project.
  • Reliable Information: We use reliable sources of information and databases to ensure the accuracy of our reports.
  • Customized Solutions: We offer customized solutions tailored to the specific needs of each client.
  • Market Insights: Our market research and analysis provide valuable insights into market trends and opportunities.
  • Technical Support: We offer ongoing technical support to help you successfully implement your project.

Testimonials

Don't just take our word for it. Here's what some of our satisfied clients have to say about NPCS:

  • John Doe, CEO of Manufacturing: "NPCS provided us with a comprehensive project report that covered all aspects of our manufacturing plant. Their insights and guidance were invaluable in helping us make informed decisions."
  • Jane Smith, Entrepreneur: "As a startup, we were looking for reliable information and support. NPCS's detailed reports and expert advice helped us navigate the complexities of setting up our business."
  • Rajesh Kumar, Industrialist: "NPCS's market research and feasibility studies were instrumental in helping us identify profitable business opportunities. Their reports are thorough and well-researched."

Case Studies

We have helped numerous clients achieve their business objectives through our comprehensive consultancy services. Here are a few case studies highlighting our successful projects:

  • Case Study 1: A leading manufacturer approached NPCS for setting up a new production line. Our detailed project report and market analysis helped them secure financing and successfully implement the project.
  • Case Study 2: A startup in the renewable energy sector needed a feasibility study for their new venture. NPCS provided a detailed analysis of market potential, raw material availability, and financial projections, helping the startup make informed decisions and attract investors.
  • Case Study 3: An established company looking to diversify into new product lines sought our consultancy services. Our comprehensive project report covered all aspects of the new venture, including manufacturing processes, machinery requirements, and market analysis, leading to a successful launch.

FAQs

Here are some frequently asked questions about our services:

What is a Detailed Project Report (DPR)?

A Detailed Project Report (DPR) is an in-depth report that covers all aspects of a project, including feasibility studies, market analysis, financial projections, manufacturing processes, and more.

How can NPCS help my startup?

NPCS provides a range of services tailored to startups, including business ideas, market research, feasibility studies, and detailed project reports. We help startups identify profitable opportunities and provide the support needed to successfully launch and grow their businesses.

What industries do you cover?

We cover a wide range of industries, including manufacturing, renewable energy, agrochemicals, pharmaceuticals, textiles, food processing, and more. Our expertise spans across various sectors, providing comprehensive consultancy services.

How do I get started with NPCS?

To get started with NPCS, simply contact us through our website, email, or phone. Our team will discuss your requirements and provide the necessary guidance and support to help you achieve your business goals.

Our Mission and Vision

Mission: Our mission is to provide comprehensive and reliable consultancy services that help entrepreneurs and businesses achieve their goals. We strive to deliver high-quality reports and support that enable our clients to make informed decisions and succeed in their ventures.

Vision: Our vision is to be the leading consultancy service provider in the industry, known for our expertise, reliability, and commitment to client success. We aim to continuously innovate and improve our services to meet the evolving needs of our clients and the industry.

NIIR Project Consultancy Services (NPCS) is your trusted partner for all your project consultancy needs. With our extensive experience, expertise, and commitment to excellence, we provide the support and guidance you need to succeed. Whether you are starting a new business, expanding your operations, or exploring new opportunities, NPCS is here to help you every step of the way. Contact us today to learn more about our services and how we can help you achieve your business goals.