Precast, Pre-stressed Concrete Hollow Core Load Bearing Slabs / Planks
Comparison: - Why Chinese Plant & Machinery (Jugaad Plant) is most Economical & Simple Smart Solution Compared to any European or American Plant & Machinery
| Sr.No. | Description | European machineries | India Precast Machineries |
|---|---|---|---|
| 1 | Plant Installation | In Heavy Industrial shed with minimum 2 cranes | Open to sky. With 1 crane only |
| 2 | Area required to set-up plant etc. | 4 / 6 Acres. Storage of slab is done outside the Shed. Additional crane required in the yard | 2 / 3 Acres. Storage of slab is done adjacent to Extrusion bed with same crane having extended arms |
| 3 | Extrusion of slab | On Very expensive Steel casting Bed | On Smooth & well-levelled Concrete platform / floor |
| 4 | Bed Length & No. of beds | Bed Length: 130 meters. No. of Casting Beds: 5 | Bed Length: 130 meters. No. of Casting Beds: 3 + 3 |
| 5 | Out of 300 working days in a year how many days Extrusion of Hollow core slabs is done? Average production / Year |
Extrusion is done on all 5 beds for 300 working days in a year. Production can be daily as steam is passed Underneath steel beds through Boiler for steam Curing. Which is Very costly & consumes high power too. Total production / year is 1,33,000 in Sq. mtr. |
Extrusion is done on 3 beds for 240 working days in a year. 1St day Extrusion is done on 3 beds & 2Nd day allow for Natural curing & 3Rdday for Cutting, Lifting & Cleaning. Balance 3 beds extrusion is done on subsequent day & repeats as above. Total production / year is 1,03,500 in Sq. mtr. |
| 6 | Investment in Precast Extrusion M/c having width of 1200 mm + Supporting m/c + Common expense for Set-up Plant for Residential project & Commercial Projects | Cost of 6 (3+3) Extrusion M/c having thickness of 1). 120, 150 & 200 for Residential is of Rs 3 Cr (3 M/c) 2). 250, 300, 380 for Commercial is of Rs 4 Cr (3 M/c) Plus Rs. 8 to 15 Cr for steel Casting beds, Concrete Batching Plant, Cranes, Supporting M/cs. etc. |
Cost of 6 (3+3) Extrusion M/c having thickness of 1). 120, 150, 200 for Residential is of just Rs 57 lac (3 M/c) 2). 250, 300 380 for Commercial is of Rs 1.16 Cr (3 M/c) Plus Rs. 1 to 1.5 Cr for Concrete Casting beds, 35 CBM Concrete Batching Plant, Cranes, Supporting M/cs, etc. |
| 7 | Import duty Value & spares | High on import value, So High on spares | Low on import value there by Low on spares |
| 8 | Requirement Power & Consumption | 750 KW. Consumption is Very high as there are lot of high rated capacity machines + 3 Cranes + Steam Boiler for curing + Shed illumination. | 125 KW. Consumption is Low. Simple m/c. Only 1 Crane + Open to sky hence Natural curing, No Boiler + No illumination required. |
| 9 | Type & Design of Extrusion M/c. | Modular Design. Highly Computerized & Automated. Made to counter their climate & to offset the cost of highly paid manpower. | One size One Machine. Simple Start & Stop Functionality. Needs basic Technical Manpower to operate & maintain. |
| 10 | Hopper’s Capacity & Height & Concrete Mix Delivery system | 1.5 CBM. Height of Hopper is Very high, Costly to feed Concrete Mix by Shuttle system + Overhead cranes or With Overhead Crane & Skip Bucket. | 1 CBM. Height of hopper is Very Low, Easy to feed Concrete Mix By Mini Dumpers which are also cheap & Used for Pulling steel strand + other construction activity. |
| 11 | Concrete Mix Delivery Time & Cost of Maintenance + Power. |
Very High + Very Costly & High on Maintenance & Power consumption. | Very fast + Cheap. Low on Maintenance & No power is consumed. It operates on Diesel. |
| 12 | Concrete Batching plant | Hi-fi Batching plant (Very costly). Installed at the height of 30 feet so that concrete can be deliver by shuttle system & overhead crane. Difficult to clean. Concrete Mix Result good | Simple Batching plant & Specific to its Requirement. Installed at 8 feet height & discharge concrete mix straight into Mini Dumper & Easy to clean. Concrete Mix Result is same as same Raw material is used |
| 13 | Cost of Curing of Concrete slab | Very high as done by Steam Curing | Very Low as Natural curing in Hot & Humid Climate. |
| 14 | Investment | 6 times higher than Chinese Plant. | Only 1.23 Cr to 3 Cr. Because of Jugaad plant |
| 15 | Manufacturing Cost | 1.35 times higher than Chinese Plant | Natural curing + investment is low etc. |
| 16 | Return on Investment | 36 / 40 months | 6 to 8 Months |
| 17 | Interest Carrying Cost | 4 times higher than Chinese Plant | Because of Low on Investment |
| 18 | Cost Amortizing & Depreciation | 4 times higher than Chinese Plant | Because of Low on Investment |
| 19 | Time to set up Plant | 36 weeks for steel beds & Shed Required | 6 weeks Concrete beds & no shed. |
| 20 | Flexibility of shifting plant | Very difficult in case of Labor Unrest | Very simple & Easy. It is as good as Mobile plant & can be installed at project site. |
| 21 | Price of Extrusion M/c | 4 to 5 times higher than Chinese Plant. | Simple Start stop m/c No computer controls. |
| 22 | Cost of Common Supporting M/c | 5 times higher than Chinese Plant | Economical design & low profit margin |
| 23 | Price of Batching Plant | 4 times higher than Chinese Plant | Simple Batching plant & Specific to its Requirement |
| 24 | Production of Hollow core Slab | 1.2 times higher than Chinese Plant | Natural curing Takes time Hence less production. |
| 25 | Maintenance Cost | 3 times higher than Chinese Plant | Simple design, easy to maintain with local parts |
| 26 | Labor requirement | 2 times higher than Chinese Plant | No highly skilled labor is required. |
| 27 | Slab Cutting Cost | 3 times higher than Chinese Plant | Simple design, easy to maintain with local parts |
| 28 | Handling & Storage Cost | 2 times higher than Chinese Plant | Crane design has extended arms to store slab next to casting bed. |
Advantages of our Extrusion Machines
- One Slab Size One Machine & Low on Investment
- Low on height, hence easy feeding by Mini Dumper
- High frequency Intense vibration - quality slab; excellent compaction; good bonding with steel strands; early strength with good strand bond
- Extremely Simplified - Simple Start / Stop function & very low on maintenance
- Less Power Required
- Extrusion being open to sky, hence it is very Economical on Investment & Curing.
Download Production Cost per Square Meter for Pre-stressed, Precast Concrete Hollow Core Load Bearing Slabs / Planks & Comparison with European Machines(Click to download PDF File)
