CHELSEA CONCRETE Brief Introduction

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  • A Brief Introduction

    CHELSEA BLOCKS AND PIPES PRIVATE LIMITED Plot No 11, Sector 5, Industrial Estate, Phase II, G.C. Bawal (Haryana)

    Tele No: 0124 4556500 FAX No: 0124 4103537 Email: rishabhjain@chelseamills.com

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    INDEXTopic PageNo.1. Introduction 32. ProductionandLocationofPlant 33. Rawmaterial 33.1. CementConsumption 43.2. FlyAshConsumption 54. Products 54.1. SolidConcreteBlock 64.1.1. AdvantagesofSolidConcreteBlocks 64.2. HollowConcreteBlock 74.2.1. AdvantagesofHollowConcreteBlocks 74.2.2. StructuralAdvantage 84.2.3. ConstructionalAdvantages 84.3. Pavers 94.3.1. GrassyPavers 104.3.2. AdvantagesofPavers 104.3.2.1. Versatility 104.3.2.2. Durability 114.3.2.3. Economical 114.3.2.4. EnvironmentallyFriendly 114.3.2.5. WeatherResistant 115. GreatinvestmentforDevelopers,IndividualhomesandFarmHouses. 126. WhataretheadvantagesofusingconcreteblocksoverconventionalClaybricks? 12

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    1. IntroductionWeareaGarmentexportcompanybasedinGurgaon.WehavebeensupplyinggarmentstotheleadingnamesinglobalretaillikeGAP,bananarepublic,OldNavy,Armaniexchangeetc.forover30 years. In our endeavor to diversify,we have selected the production and Supply ofGreenBuildingintheNCR.Thelineofproductswewillbeintroducingfirst,areConcreteFlyashBlocksandHighendPavers.Wewillbemanufacturing theseproductsusingstateoftheart,Germanplantandmachinery.

    2. ProductionandLocationofPlantWeareusingstateoftheArtGermanmachineryfromHessGroup,GermanywithCapacitytoproduce30,000concreteBlocksandover5000M2ofPaversevery8Hours.WehaveestablishedourplantinBawal,Haryana.

    3. RawMaterialsRequired

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    3.1. CementConsumptionConcreteisamixtureofordinarycement,mineralaggregate(sandandstonechips)andwater.Thewaterusedinpreparingtheconcreteservestwo

    Purposes:

    (1)Itcombineswiththecementtoformahardenedpaste

    (2)Itlubricatestheaggregatestoformaplasticandworkablemass

    Thewaterthatcombineswiththecementvariesfromabout22to28%ofthetotalamountofmixingwaterinconcrete.Mineralaggregates(sandandstonechips)arenormallydividedintotwofractionsbasedon theirparticle size...Natural sand isoftenusedas fineaggregate in cementconcretemixture.Coarseaggregateare crushed stonechips.Themaximumsizeof thecoarseaggregatethatmaybeusedincementconcretehollowblocksis12.5mm.However,theparticlesizeof thecoarseaggregateshouldnotexceedone thirdthicknessof the thinnestwebof thehollow blocks. Ordinary Portland cement is the cementingmaterial used in cement concretehollowblocks.Cementisthehighestpricedmaterialperunitweightoftheconcrete.Hence,thefine and coarse aggregates are combined in such proportions that the resulting concrete isworkableandhasminimumcementcontentforthedesiredquality.

    ApproximateofCementConsumptioninourPlantCementConsumptionPerDay2Shift 100Tons

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    3.2. FlyAshConsumptionFlyashimprovesblockmanufacturingintwobasicways.Itgivesproducersthestrengthrequiredand,atthesametime,theaddedplasticitythatflyashcontributestotherelativelyharshblockmixesassuresimprovedfinishandtexture;bettermoldlife,andbetter,sharpercorners.Additionalbenefitsofflyashinblockincludereducedpermeabilityandshrinkage,increaseddurabilityandvirtualeliminationofefflorescence.It isusedasreplacementofcementandtothatextantthevolumeoftheproductwillreduceastheflyashwillhavelowerweightoncompaction.

    ApproximateofFlyAshConsumptioninourPlantFlyAshConsumptionPerDay2Shift 80Tons

    4. ProductsIn present construction scenario, concrete blocks are well accepted masonry unit to buildfoundations,walls,arches,andcorbelsetc.Atypicalconcreteblock,proposedbythecompany,isequivalentto9bricksthusconstructionisfasterthanwithothermasonryunits.Themortarusedisalsolesswhichresults incostsaving.Concreteblockshavebeenextensivelyusedisalsolesswhichconventionalroofingsystemslikefiredbricks,dressedstoneandcompressedearthblocksforcompositewallconstruction.

    Acceptabilityofconcreteblocksisveryhighinurbanareasforalltypesofbuildings.Itisapopularwallingmaterialformajorqualitieslikelowmaintenance,insulationandstrengthforinstitutionaland industrialbuildings.Thedurabilityofacementbasedproduct ismakingconcreteblocksapreferredchoiceinruralareasaswell.TheincreaseinconstructionactivitiesaswellasthehugedemandofconcreteproductsinIndiamainlyinNorthIndiaisamajordecisivefactortosetupafactoryintheregion.ThisfacilitywillmainlybetoproduceconcreteblocksusingFlyAshanditsBlocks,interlockingpavers,andotherlandscapingproducts.

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    4.1. SolidConcreteBlock

    Strength and durability are special characteristics of solid concrete blocks. As a core buildingmaterial,ithasstoodthetestoftimeandisnowmeetingtheneedsofmoderndesigners.Solidblocksareidealforstructuralapplicationlikefoundations,loadbearingwallsandstructures.Thesecanalsobeusedforprotectionagainstfireandforsoundinsulation.

    Products Dimension(mm)

    Strength(N/mm)

    UValue(w/mk)

    Weight(kgs)

    Density(kg/cu.m)

    FireResistance

    (hrs)

    SoundInsulation

    (db)

    SolidBlock

    400X200X200

    1520 1.5 3234 2000 6 48

    4.1.1. AdvantagesofSolidConcreteBlocks

    Lightweight

    Highloadbearingcapacity

    Fasterconstruction

    Thermalinsulation

    Resistanttoearthquake

    EcoFriendly

    Savinginsteelreinforcement

    Lesscementconsumption

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    4.2. HollowConcreteBlock

    HollowconcreteblocksareprecastmasonryunitsmadeoutofOpCement,aggregate,flyashandconcretemixwith4hollowcavities andare intended foruse in theconstructionofboth loadbearing and nonload bearing wall structures. One can use dry concreting method formanufacturing these hollow blocks using variotronic compaction which is a patented systeminvolving state of the art vibration coupled with compression. These hollow blocks neverdisintegrateduringtheirlifetimeanddelivertroublefreeperformance.Itisveryeasyandfasttoconceal electrical and sanitary service lines within these hollow blocks. The tool required forconductingisdoublebladewallchaser.

    ProductsofferedbythecompanyMainVariant

    Product Size

    HollowBlock 200*400*200

    SolidBlocks 200*400*200

    Paver 100*200*60

    4.2.1. AdvantagesofHollowConcreteBlocks

    1. HighlyDurable:Thegoodconcretecompactedbyhighpressureandvibrationgivessubstantialstrengthtotheblock.Propercuringincreasecompressivestrengthoftheblocks.FarexceedingISOcodes

    2. LowMaintenance,Colorandbrillianceofmasonrywithstandsoutdoorelements.

    3. LoadBearing,strengthcanbespecifiedaspertherequirement.

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    4. FireResistant

    5. Providethermalandsoundinsulation:Theairinhollowoftheblock,doesnotallowoutsideheatorcoldinthehouse.Soitkeepshousecoolinsummerandwarminwinter.

    6. EnvironmentFriendly,flyashusedasoneoftherawmaterials.

    7. Lowerinsurancerates.

    4.2.2. StructuralAdvantages

    1. In this construction system, structurally, eachwall and slab behaves as a shearwall and a

    diaphragm respectively, reducing the vulnerability of disastrous damage to thestructure/building,duringthenaturalhazards.

    2. Due to the uniform distribution, this construction system can safely resist lateral or cyclicloading, when compared to other conventional masonry construction systems. Thisconstructionsystemhasalsobeenprovedtoofferbetterresistanceunderdynamic loading,whencomparedtootherconventionalsystemsofconstruction.

    4.2.3. ConstructionalAdvantages

    1. Noadditionalformworkoranyspecialconstructionmachineryisrequiredforreinforcingthehollowblockmasonry.

    2. Onlysemiskilledlaborisrequiredforthistypeofconstruction.

    3. It is a faster and easier construction system, when compared to the other conventionalconstructionsystems.

    4. Itisalsofoundtobeacosteffectivedisasterresistantconstructionsystem,asexplainedinthereport.

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    4.3. PaversThefastmovingproductintheconstructionsegmentnowisPaver

    Paversaremadefromaverydrymixofgravel,sand,cementandcolor.Paversaresaidtohavezeroslump.Themoretheslump,theweakertheconcrete.ThereforethePaversmanufacturedwill be high on strength and this is ensured through slump tests. A slump test is done in alaboratorytotestthestrengthofconcrete.Asurfaceistestedforstrengthbyplacingapointloadontoitandexertingadirectforceuntilitfails.Thepressureiscalculated,andthatisthefailingpoint.Thepaverswillhave60mmthicknesshaveacompressivestrengthofarangeM40toM50whichcanessentiallybeusedforaveryheavydutytrafficasperIScodesrecommendations

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    4.3.1. GrassyPavers(OtherPavers)

    GrassyPaversareenvironmentallyfriendly.Theyallowthedrainageofstormwaterbackintotheundergroundsoilratherthanintostormdrains.Thishelpskeepplace/propertyhydratedandreducesrunoffintolocalsewersystems.Theyprovidethestrengthofpavementwiththenaturalbeautyofgrasswhilesimultaneouslyeliminatingsoilcompaction,reducingreflectiveheatandallowingforallweatheraccessibilityataverycosteffectiveprice.Inadditiontotheenvironmentalbenefits,GrassyPaverscancarryweightoffiretenders.

    4.3.2. AdvantagesofPavers4.3.2.1. Versatility

    Concretepaversareanidealchoiceforbothresidentialandcommercialapplications, includingsurfacecoveringfordriveways,parkinglots,promenades,sidewalks.Interlockingconcretepaversaresensibleandaestheticallyattractivechoiceforalloutdoorsurfaces.Theyhavenonskidsurfaceandaresafetowalkevenwhentheyarewet.

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    4.3.2.2. Durability

    Pavers'combinationofstrength,resilientabrasionresistance,andflexibilitydeliverhighlydurable,crackproofpavementabletohandlealltypesofwheeledtrafficandpedestrianswithverylowmaintenance requirements. Areas surfaced with concrete pavers are immediately useable,guaranteeingaquickprocessofanyapplicationandcontractjobs,whichisespeciallyimportantwhen resurfacing highly populated areas.Whether for new construction or resurfacing of oldunsightly or damaged surfaces, consider the valuable benefits of interlocking pavers.Manufacturedtotightdimensionaltolerances,paversarestrongerthanregularpouredconcretesurfacesandmoredurablethanblackasphalt.Theycantakemoreabuseandlastforgenerations.A segmental paving system allows for expansion and contraction without producing surfacecracks,unlikemonolithicconcretesurfacesandstampedconcrete.

    4.3.2.3. Economical

    When consideringmaintenance and replacement costs, pavers offer an economical longterm

    alternative toother typesofpavement.Theycanbe laid inalmostanyweatherconditionandrequirenogroutedjoints,mortar(otherthanperimeterreinforcement),andconcretesubbaseorcuringtime.Wewillconsidertheinitialinstallationcostsandthelongtermmaintenancecostsinvolved,soastogetanestimateoftheoverallcostsoftheprojectathand.

    4.3.2.4. EnvironmentallyfriendlyPavers are made of natural aggregates without petroleumbased products. Water percolates

    throughjoints,preventing lessrunoff.Thismakespaversanenvironmentallysafeproductandenablesustoallpitchinandbegreen.

    4.3.2.5. WeatherResistantPaverscanbeusedinallclimatesandcanbewalkedonimmediatelyuponcompletion.Cracking,

    which is commonwith traditional asphalt and concretepavements, isnot an issuewith theseinterlockingconcretepaversduetothejointsbetweenthepavers.Interlockingconcretepaversare a flexible systemand allow formovement. They are almost indestructible. This pavementsystemmovesinunisonwiththeearth'susualtendencytoswellandcontractoverthelongterm,thusavoidinganyseriousdamage.Incolderclimateswheresnowisacommonelement,concretepaversaretheidealchoice.Concretepaversresistdeteriorationoffreezingandthawingcyclesanddeicingsaltsbetterthanasphaltandordinarypouredinplaceconcrete.Snowcanbeplowed,blown,orshoveledjustlikeasphaltorconcretepavements.Thebeveledorchamferededgesof

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    paverspreventplowsorshovelsfromcatchingontheedge.Othermethodsofsnowremovalcanalsobeappliedtothesepavers.Deicingproductssuchascalcium,chloride,orsaltwillnotharmthepavers.Electricorliquidsnowmeltingsystemsworkwellunderconcretepavers,eliminatingsnowremovalwhilereducingsliphazards.Darkercoloredpaverscanalsoaidinacceleratingthemeltingprocess.

    5. GreatinvestmentforDevelopers,Individualshomes andFarmHouses.Interlockingconcretepaverswillenhancetheaestheticsandvalueofplace/property.Offeringa

    wideselectionofcolors,shapesandfinishes,theseproductsenhanceanyarchitecturalstylefromCraftsmantoContemporaryandMissiontoMediterranean.Allofthesewilladdimmediatevalueto any place /property for several key factors. One, they are guaranteed for life and themanufacturerbackedwarrantycanbetransferredfromoneownertothenext.Second,theyarebeautifulpiecesoffunctionalartthatwilladdcurbappealtoanystylehome.Inturn,theyhelpsellthehousequicker.Third,theyareenvironmentallyfriendlyandanythingthateachofuscandotohelpourenvironmentisagreatinvestmentforallofus.

    6. Whataretheadvantagesofusingconcreteblocksover conventionalclaybricks?Concrete blocks have a proven track record and are used extensively in developed countries.Uniformityofblocksandbiggersizeblockseaseupthespeedofconstructionandsavesmortarsin themasonry.Thedensityof theblockscanbevariedtomake ita loadbearingornonloadbearingblockasperstructuraldesignsandthisallowsthearchitectsandstructuralengineerstoexperimentwithmoredesignstomeetdifferentcompressivestrengthsofthematerial.Concreteblocksofferbettersoundinsulationandexcellentfireprotection,Hollowblocksofferbetterheatinsulation, and it can be further enhanced by adding polystyrene insert in between them forreducingtheairconditioningload.

    Themanufacturingofredclaykilnbricksinvolvesuseofscarcefertileagriculturallandandtheseclaysbricksareagainburnedinthekilncausingairpollution.Theseproductionsitesarealsofoundwanting in terms of human safety as amajor chunk of brick kilnmanufacturing in India is inunorganizedsector.SoIwouldstatethatenvironmentallyalsoconcreteblockscoresoververypositivelyoverredclaybricks.HESSalwayslooksintoaturnkeyprojectaspertheclientsneedfromtimetotime.

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