Manufacturing Cost of Pre-stressed, Precast Concrete Hollow Core Load Bearing Planks

Load Bearing Slabs / Planks for Affordable Housing & Residential / Commercial Construction Projects
By Precast Extrusion Plant, Mixer, Batching & Dosing & Concrete Transport System (Mobile Plant)

Total Minimum investments in Plant & Machinery is Rs. 1.23 Cr & subsequently upgrade to highest capacity with investment of maximum 3 Cr. Land required about 2 to 3 – Acre (Rented or Owned extra investment), having length to width ratio of 3:1. Power 125 Kw. List of Imported Machinery (1). Extrusion Machine for Load bearing Hollow core slabs for Ceiling, Roofs for Affordable housing, Residential & Commercial project -average 7 Sizes. Supporting machinery: - (2). Complete Batching plant 35 CBM Automatic Computer control with suitable 3 bin Batching & Dosing – 1 set (3). Heavy-duty Stressing Machine – 1 set. (4). Universal Mini Dumper for Transport of concrete mix – 2 Nos. (5). Slab Cutting Machine – 1 Nos. (6). Pay-off stand – 3 nos. (7). Gantry Crane 16 Ton with extended arms on both side & Lifting Beam 1 set. (8). Other misc. items like Woollen carpet & Plastic cover for slab, Anchors / wedges Etc. & Balance Common expenses for Land Development, Set-up of plant & machinery, making Well-levelled Concrete platform (making similar to good concrete road) for extrusion of slab, 6 Beds open to sky of size 140 meter X 12 meter, Abutment frames, other Civil work etc. Only Extrusion Machine need to be purchased for various size of Slab, rest all other Set-up & Supporting machinery is same. (Total Minimum investments in plant & Machine are Rs. 1.23 (with 120 x 1200 Machine) to 3 Corers (with all extrusion Machine + Common Supporting Machine + Cost of Common Expense).
Please Note: - Also produce other products like concrete Wall panel for Partition Walls, Boundary wall panels, Multi-extruded elements like Supporting ‘H’ column, Beam, Column, Fencing post, Sq. poles, Lintel, Purlin, ‘T’ Beam & etc.

Manufacturing Cost for Hollow Core Slabs/ Planks Used for Affordable Housing / Residential & Commercial Projects.

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Assumptions, Consideration & Conclusion for above Manufacturing Cost Analysis: -

1. Production Cycle for extrusion of slab: - 1st day of month produce slabs on Lane no 1st, 2nd & 3rd and on 2nd day allow for curing & on 3rd day after sufficient curing Cut, Lift & Clean and start casting on same lane from 4th day of month. Go on repeating this. Now on Lane no 4Th, 5th & 6th produce slab on 2nd day of month and on subsequent day allow for curing. Now on 4th day after of the month after sufficient curing Cut, Lift & Clean and start casting on same lane on 5th day of month. Go on repeating this. In a month you produce 10 days on 1st, 2nd & 3rd lanes & 10 days on 4th, 5th & 6th lanes. (Production time consumed for 130-meter long slabs is less than 2 hour & slab cutting about 5 minutes per cut.) Total production per month on 130 meter long casting bed X 95% (efficiency) = output will be 124 running meters X 3 lane X 10 days + 3 lane X 10 days = 7440 Running meter X 1.2 meter width of slab = 8900 Sq. mtr. Average Production per day is 345 Sq. mtr.
   Production per Year is 345 X 300 days working per year = 1,03,500 Sq. mtr with 6 lane casting bed.
2. Zero Slump Dry Concrete having Water Cement Ratio of 0.3%, is required continuously In order to produce Good quality of Planks, we suggest Automatic Computer control Batching plant having Dual Cylindrical Mixer with 3 Bin Batching& Dosing with Moisture probes, Hopper for Additive agent + Metering pump for Cement + Additive + Water, 2 Silos having Cement conveying screws & Control cabinet etc.
3. Plant set-up - In a 4 – 6 weeks. Open to sky. Slabs Extruded are Naturally Cured under our hot & humid climate. Being concrete bed, it can be set-up on the main road of Project site there by, Reduce hassle & Cost of Transport of precast element + Save on Taxes & Govt. duties. One can call this plant is as good as Mobile plant.
4. Start with lowest investment initially, than upgrade the plant to highest capacity.
5. Investment payback: for example Approx. minimum Market price for extruded slab of 200mm x 1200 mm is around Rs. 1,300 Sq. mtr less cost as above is Rs. 1,040 Sq. mtr, hence Profit is say Rs. 260 per Sq. mtr. Investment payback is by Use / Sale of 6 months production of slab i.e. 51,000 m2 (5,48,000 ft2). (Investment return varies with products & volumes).
6. Precast plant Comparison: European plant V/S. Chinese Plant (Jugaad Plant) as follow Etc.:-
   A). Investment is 5 times higher than Chinese Plant.
   B). Manufacturing Cost is 1.35 times higher than Chinese Plant.
   C). Return on Investment will be 36 / 40 months & Chinese Plant will be within 6 to 8 Months.
   D). Interest Carrying Cost is 4 times higher than Chinese Plant.
   E). Cost for Plant Amortizing & Depreciation is 4 times higher than Chinese Plant