PAVERS BLOCK MANUFACTURING
[CODE NO.4078]
Paving block or paver block is one of the few most popular surface treatment options for exterior pavement applications. These blocks are known to be aesthetically pleasing and are much comfortable to walk on. These blocks are known to be very durable and are easy to maintain as well. It is important to study the types of paver blocks, which are most importantly two kinds, mentioned below.
The two types of paver blocks are (a) Concrete paving block, (b) Clay paving block. The concrete blocks are manufactured as per standard sizes and thus, can be interchanged easily. Also, it should be noted well that a typical concrete block has two kinds of surfaces - a smooth surface as well as a rough surface. The concrete types are most suitable for heavy duty applications and are able to support braking forces as well as substantial loads. Various colors are available with concrete blocks and typically come from metallic oxides. There is a high possibility of these colors to fade away completely. Thus, it is very important for an individual to be careful whilst selection of the appropriate color for the block. The concrete paving blocks are most suitable for driveaways, pavements, and others.
As mentioned, the second type of paver block are the clay paving blocks. These are available as rectangular brick shaped blocks used for specific purposes. Custom shapes are available for specific projects. Clay blocks are available in natural color only and the possibility of color fading is not there when it comes to these blocks. The clay paving blocks are used for pillars and walls.
There exist four generic shapes of paver blocks and these are well described below:
TYPE A: These are paver blocks with plain faces that are vertical – do not interlock with each other when paved in any pattern.
TYPE B: These are alternating corrugated / curved and plain faces, which lock with each other along the corrugated faces when made in any kind of pattern.
TYPE C: These are paver blocks with corrugated or curved faces which lock into each other along with vertical faces when made in any kind of pattern.
TYPE D: These are ‘L’ or ‘X’ shaped blocks that have corrugated or curved faces along each other with vertical faces paved in any kind of pattern.
It is worthwhile to note the possible advantages of paver blocks. These blocks do not need any kind of special maintenance as compared to asphalt or concrete surfaces. Water washing can assist in keeping these blocks absolutely bright and clean. Paver blocks are known to be adequately interlocked and are very durable in nature as these can easily last for about 20 years. These blocks can withstand high vehicular load as well.
Paver blocks, as mentioned before, are available in different colors and shapes, which make them extremely versatile in nature. These blocks have their applications in commercial as well as residential premises. These blocks are knon to be skid-resistant as well as slid-resistant. These blocks can be used in any kind of weather conditions. These blocks are easy to install and do not need any kind of special equipment for installation purposes.
COST ESTIMATION
Plant Capacity 17,000 Nos/Day
Land & Building (4000 sq.mt.) Rs. 4.70 Cr
Plant & Machinery Rs. 66 Lac
Working Capital for 3 Months Rs. 75 Lac
Total Capital Investment Rs. 6.20 Cr
Rate of Return 36%
Break Even Point 42%
INTRODUCTION
ADVANTAGES AND LIMITATIONS
HOWEVER, IMPORTANT LIMITATIONS OF THE TECHNIQUE
ARE THE FOLLOWING:
PHYSICAL REQUIREMENTS
APPLICATION OF ICBP TECHNOLOGY
SHAPES AND CLASSIFICATIONS
MATERIALS
PAVING BLOCKS
BEDDING AND JOINT FILLING SAND
BASE AND SUB BASE MATERIALS
CONSTRUCTION OF INTERLOCKING CONCRETE BLOCK PAVEMENT
SEQUENCING OF OPERATIONS
PAVEMENT TYPES
PAVER PROPERTIES
PAVER DIMENSIONS
PAVING STRENGTH
MINIMUM BREAKING LOAD
COMPRESSIVE STRENGTH OF PAVERS
DURABILITY
SLIP RESISTANCE
ABRASION RESISTANCE
MOISTURE EXPANSION
EFFLORESCENCE
PITTING DUE TO LIME
COLD WATER ABSORPTION
RAW MATERIALS FOR CONCRETE PAVER
DETAILS AND COMPARISON OF PAVER BLOCKS
PAVER BLOCKS
COMPARISON OF PAVERS TO IPS
B.I.S. SPECIFICATION
SPECIFICATION OF PRECAST CONCRETE BLOCKS FOR PAVING
1 SCOPE
2 REFERENCES
3 TERMINOLOGY
FIG. 1 EXAMPLES OF ARRIS (BEVELLED, ROUNDED, CHAMFERED)
CHASED SIDE FACE AND DRAW
4 MATERIALS
4.1 CEMENT AND CEMENT ADMIXTURES
4.2 AGGREGATES
4.3 ADMIXTURES
4.4 PIGMENTS
4.5 WATER
5 GRADE DESIGNATIONS OF PAVER BLOCKS AND DESIGN
OF CONCRETE BLOCK PAVEMENT
TABLE 1: RECOMMENDED GRADES OF PAVER BLOCKS FOR
DIFFERENT TRAFFIC CATEGORIES (CLAUSES 5 AND 9.1.4)
NOTES
6 PHYSICAL REQUIREMENTS
6.1 GENERAL
6.2 OBLIGATORY REQUIREMENTS
TABLE 2: RECOMMENDED DIMENSIONS AND TOLERANCE FOR PAVER BLOCKS (CLAUSES 6.2.2.1, 6.2.2.2, 6.2.3 AND 9.1.2)
TABLE 3: COMPRESSIVE STRENGTH REQUIREMENTS OF CONCRETE
PAVER BLOCKS (CLAUSES 6.2.5.2 AND 9.L.4)
7 TEST METHODS
8 SAMPLING
TABLE 4: SAMPLING REQUIREMENTS (CLAUSE 8.5)
9 ACCEPTANCE CRITERIA
10 MARKING
OVERVIEW OF CONSTRUCTION INDUSTRY IN INDIA
THE NATIONAL INFRASTRUCTURE PIPELINE (NIP)
GOVERNMENT INITIATIVES
CONCLUSION
MARKET OVERVIEW OF PAVER BLOCKS
PRODUCT MARKETING
SECTOR & INDUSTRY ANALYSIS
SECTOR CHARACTERISTICS AND OVERVIEW
UNORGANIZED SECTOR – MACHINE BLOCKS
UNORGANIZED SECTOR – HAND MADE BLOCKS
ENVIIRONMENTAL & PROTECTION ASPECTS
MARKET INFORMATION
MARKET POTENTIAL
EXPORTS AND IMPORTS OF PREFAB CONSTRUCTION BLOCKS
TECHNICAL DETAILS FOR PAVERS BLOCKS
DESIGN MIX CONCRETE:
PAVER BLOCK MAKING MACHINE:
WEIGH BATCHING & MIXING EQUIPMENT:
CURING:
LABORATORY
RAW MATERIALS
CEMENT
AGGREGATES
WATER
OTHER MATERIALS
PAVERS BLOCK CHARACTERISTICS
PAVER BLOCK DIMENSIONS
TESTING OF PAVER BLOCKS
FOR 80MM PAVER TILES
FOR 60MM GRASS PAVER TILES
LAYING OF PAVER BLOCKS
PRIMING
BEDDING SAND COURSE
LAYING OF INTERLOCKING PAVER BLOCK:
INITIAL COMPACTION
JOINT FILLING AND FINAL COMPACTION
EDGE RESTRAINT USING KERB BLOCK
UNIFORM INTERLOCKING SPACES
SKILLED LABOUR
LAYING PATTERN:
DESIGN OF PAVNG BLOCK
DESCRIPTION OF LAYERS & BASIC ENGINEERING DESIGN REQUIREMENTS
SUBGRADE
BASE COURSE
TYPICAL GRADING FOR BASE COURSE MATERIALS
BEDDING COURSE
TYPICAL GRADING FOR BEDDING COURSE MATERIALS
RECOMMENDED SPECIFICATIONS FOR CLAY PAVERS
EDGE RESTRAINTS
DRAINAGE
PAVER LAYING PATTERNS
JOINTS BETWEEN PAVERS
TYPICAL GRADING FOR JOINTING SANDS
TOLERANCE ON COURSE LEVELS
CROSSFALLS
STEEP GRADIENTS
MANUFACTURING PROCESS OF PAVERS BLOCKS
RAW MATERIAL REQUIRED FOR THE MAKING OF PAVER BLOCKS
MANUFACTURING PROCESS OF CONCRETE PAVERS
WET CAST TECHNIQUE
HYDRAULICALLY PRESSED TECHNIQUE
QUALITY CONTROL AND STANDARDS
A) INDIAN STANDARD SPECIFICATION
B) QUALITY REQUIREMENTS
PROS AND CONS OF WET CAST AND HYDRAULIC PRESS TECHNIQUES
WET CAST PRODUCTION
IMAGE COURTESY OF ARMCON LTD.
OTHER WET CAST LANDSCAPE PRODUCTS
MULTI-TONED TRAVERTINE EFFECT FLAG FROM BRADSTONE
WET-CAST CHANCERY WALLING FROM MARSHALLS
WET-CAST SLEEPER-EFFECT PAVING FROM ATLAS/BRETT
HYDRAULIC PRESS PRODUCTION
PIMPLE TEXTURE
SIMPLIFIED MANUFACTURING PROCESS
CURING AND PACKING
REKERS CONCRETE BLOCK MACHINE
PRESS AND MOULD FROM CHANDLA INDUSTRIES
HOMOGENOUS AND FACE MIX PRODUCTS:
TYPICAL "THROUGH-COLOUR "BRITISH BLOCK
FACE-MIX BLOCK
PAVING TEXTURES
BARFACE PAVING IN RED
DIAMOND PATTERN CLAY PAVERS
HOBNAIL PAVING
RIVEN SANDSTONE FLAGS - INDIAN IMPORTS
RIVEN-EFFECT CONCRETE FLAGS FROM WESTMINSTER STONE
RIVEN-EFFECT CLAY PAVERS FROM BAGGERIDGE
NATURAL TEXTURES:
SAWN YORKSTONE FLAGS
HEAVILY RIVEN STONE FLAGS
CROPPED GRANITE SETTS
STANDARD TEXTURES:
CONCRETE
CHAMFERED EDGE AND SPACER LUGS MOULD-FORMED
ON SMALL ELEMENT PAVER
VARIOUS SHAPES AND DECORATIVE SURFACE TEXTURE
ON MOULDED CONCRETE BLOCK
BULL-NOSE AND HALF-BATTERED PROFILE TO MOULDED
CONCRETE ROAD KERB
CLAY:
HANDMADE CLAY PAVERS
MOULDED STAR-PATTERN CLAY PAVERS
WIRECUT MIXED-SIZE CLAY PAVERS
SECONDARY PROCESSES:
TUMBLED-TYPE PAVERS
HEAVILY TEXTURED PAVERS
SECONDARY PROCESSES:
THE MOST POPULAR SECONDARY PROCESSING TECHNIQUES ARE:
TUMBLING
TYPICAL TUMBLED CONCRETE PAVER
LAID IN COURSES, THE EFFECT IS A 'TRADITIONAL' LOOK
NEWLY-LAID DIRTY TUMBLED PAVERS
SHOT BLASTING:
SHOT-TEXTURED FLAG (MARSHALLS' SAXON)
SHOT-TEXTURED KERB (MARSHALLS' CONSERVATION)
SHOT-TEXTURED FLAGS IN 3 COLOURS
SHOT-TEXTURED BLOCK PAVER
DISTRESSED MEDITERRANEAN RUSTIC PAVERS FROM STONE & STYLE
TUMBLED CHINESE GRANITE ON MESH BACKING
TUMBLED RED GRANITE SETTS
TUMBLED YORKSTONE SETTS
BUSH HAMMERING:
BUSH-HAMMERED GRANITE
BUSH-HAMMERED CONCRETE
BUSH-HAMMERED DECO FLAG
BUSH-HAMMERED "CORNISH" BLOCK PAVERS FROM FORMPAVE
BUSH-HAMMERED CONCRETE PAVERS LAID TO FOOTPATH
POLISHING:
MILANO GROUND/POLISHED PAVING FROM ACHESON-GLOVER
VERONA GROUND/POLISHED PAVING
"PERFECTA" HEXAGONAL GROUND PAVING FROM MARSHALLS
POLISHED GRANITE FLAGS 450X450MM
POLISHED GRANITE BLOCKS 200X100MM
WASH-TO-EXPOSE:
SPECIFICATIONS FOR ORDINARY CONCRETE
FINE AGGREGATES
COARSE AGGREGATES
PRESCRIBED MIXES FOR ORDINARY STRUCTURAL CONCRETE
FREE WATER: CEMENT RATIO
PROCESS FLOW DIAGRAM
PROCESS OUTLINE OF PAVERS BLOCK (MANUAL PROCESS)
PRINCIPLES OF PLANT LAYOUT
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
6. TRANSPORTATION:
7. WASTE DISPOSAL:
8. LABOR:
9. REGULATORY LAWS:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME ATTACK:
14. FLOOD AND FIRE CONTROL:
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
1. DEPRECIATION:
2. FIXED ASSETS:
3. WORKING CAPITAL:
4. BREAK-EVEN POINT:
5. OTHER FIXED EXPENSES:
6. MARGIN MONEY:
7. TOTAL LOAD:
8. LAND AREA/MAN POWER RATIO:
PROJECT IMPLEMENTATION SCHEDULES
INTRODUCTION
PROJECT HANDLING
PROJECT SCHEDULING
PROJECT CONSTRUCTION SCHEDULE
TIME SCHEDULE
SUPPLIERS OF PAVING BLOCK
SUPPLIERS OF PORTLAND CEMENT
SUPPLIERS OF STONE CHIPS
SUPPLIERS OF DG SETS
SUPPLIERS OF WATER PUMP
SUPPLIERS OF PALLETS
SUPPLIERS OF MOULDS
PLANT AND MACHINERY SUPPLIERS FOR PAVERS BLOCKS
CHINA SUPPLIER OF AUTOMATIC PAVING BLOCK MAKING MACHINE
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
