Tuesday 9 December 2014

Techno-Economic Feasibilty of Compressed Stablized Bricks for Self Help Groups (SHGs)



Objective


This project focuses on development model advocating a Livelihood for the community in the project area but through commercial route

Introduction

Inter-locking bricks are the future trend in construction. These unique eco-friendly bricks provide excellent load bearing capacity and huge savings on construction time as well as labour and cement cost.

Stabilized Compressed Earth Blocks (SCEB), are soil-based walling material, stabilized with variable (say 5% to 10 %) range of stabilizers that provide a cost-effective and environmentally-sound alternative to bricks. SCEB overcomes the need of firing of bricks at high temperatures by compressing the soil through manual or mechanical means.

While interlocking is a definite advantage as given below, blocks can be made non - interlocking (plain) to be used with conventional mortar. The machines enable mobile options and can be set up at site of construction also to save on transportation of blocks.

The advantages of inter locking block over the brick are many some of them are:
  • Inter locking brick, saves in handling of number of pieces per cum. Lesser joints mean lesser mortar and labour. If interlocking blocks are used than mortar can be saved even further.  
  • These blocks are even shape and size in width / height resulting in even construction and minimal undulations and no need of plaster covering  
  • Blocks have bevelled edges, walls can be kept exposed saving in plaster 
  • Interlocking blocks can be used dry stacked or with minimal mortar slurry resulting in faster construction and no need of post construction curing or waiting for wall to dry for painting etc 
  • Re-usable masonry if blocks are dry stacked Blocks result in minimal wastage. 
  • Blocks are available in width size of 220 mm (9") , 150 mm( 6") or 115 mm (4.5") , thus addressing most of the wall construction requirements 
  • Interlocking bonding results in shear key, lesser maintenance cost and easy workability 
  • Due to absence / minimal mortar, it is possible to reduce density of masonry structure and reduce wall dead weight. 
  • Very ideal solution for practically all kinds of wall

Market opportunity



Very recently a Green Tribunal has been set up by Government of India is effectively deterring unhealthy and bad projects with respect to climate change & environment. This has tremendous significance in legal parlance for continuity of even traditional businesses. The local traditional brick kilns are on the verge of closure. Incidentally a blanket ban on soil / sand mining is very effective in the State of UP and is having similar fate in other states of India. Whereas the raw material input in the current project is fly ash / RHA / Brick Kiln Rubbish / stone dust ( a by- product of mining industry) are all fundamentally a waste products are captured in the present project.



The demand supply imbalance for reasons above of the clay fired bricks is a disturbingly negative rather creates a big void in building material demand which on the other hand is a boon for this project; the brick supply void can be bridged through the supply of the present material.

If we underline besides the normal market inroad as above and the strategic initiatives of the Shakti Group too encourage substantial construction work.



The two pronged situation is fundamentally such a huge market even at local level that we are currently in no position to meet 100% demand. The market is guaranteed. However, the Pan India brand and business development, particularly across the country in rural India could be a significant venture.


 Capacity of Unit and Annual Returns

S. No.
Particulars
Unit
Details
1
Production of Bricks per day
No
400
2
Production of Bricks per month ( in 25 Days)
No
10000
3
Production of Bricks (Annual)
No
120000
4
Selling Prices of bricks
Rs. per Bricks
19
5
Gross Value of Returns
Rs.  
2280000

  Project Cost


S. No.
Particulars
Details
Amount     (Rs. )
1
Plant and Machinery

150000.00
2
Installments and Commissioning

15000.00
3
Training of machine operation and Maintenance

15000.00
4
Civil Works

10000.00
5
Land (Own)

0.00

Total of Fixed Cost

190000.00
6
Salary and wages (10 SHG, @ 200 x 25 days
25 days
50000.00
7
Raw Material
30 Days
100000.00
8
Machine Maintenance
LS
2000.00
9
Other



Total Working Capital

152000.00

Total Cost of Project

342000.00

  Economics Returns

                                                                                                ( Rs. in Lakh)
S. No.
Particulars
I YEAR
II YEAR
III YEAR
IV YEAR
V YEAR
VI YEAR
VII YEAR
VIII YEAR
IX YEAR
X YEAR
A
INPUT Cost











Pant and Machinery
3.42










Raw Material
12.00
12.00
12.00
12.00
12.00
12.00
12.00
12.00
12.00
12.00

Salary and wages
6.00
6.00
6.00
6.00
6.00
6.00
6.00
6.00
6.00
6.00

Maintenance
0.24
0.24
0.24
0.24
0.24
0.24
0.24
0.24
0.24
0.24

Land and building
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00

Total of Input Cost
21.66
18.24
18.24
18.24
18.24
18.24
18.24
18.24
18.24
18.24
B
GROSS RETURNS











Finished Compressed Stabilized Bricks
22.8
22.8
22.8
22.8
22.8
22.8
22.8
22.8
22.8
22.8

Total of Output Cost
22.80
22.80
22.80
22.80
22.80
22.80
22.80
22.80
22.80
22.80












C
NET RETURN
1.14
4.56
4.56
4.56
4.56
4.56
4.56
4.56
4.56
4.56

Present Worth of Cost
112.28
Present Worth of Benefit
136.08
NPV
23.80
BC Ratio
1.21

 Repayment Schedule

                                                                                                            ( Amount in Rs.)
Year
Loan
Deduction in Principal
Outstanding as on 31 March
Interest @07%
Gross surplus
Total repayment
Net surplus
1
190000
38000
152000
13300
114000
45980
68020
2
152000
38000
114000
10640
456000
45980
410020
3
114000
38000
76000
7980
456000
45980
410020
4
76000
38000
38000
5320
456000
45980
410020
5
38000
38000
0
2660
456000
45980
410020

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