cement blocks siddesh
TRANSCRIPT
CONTENTS
(1) Introduction
(2) Firm Profile
(3) Product Profile
(4) Methods of Construction
(5) Marketing and Sales Promotion
(6) Analysis of Survey Findings
(7) Suggestions and Conclusion
Annexes
Questionnaire
Bibliography
1
Chapter – 1
INTRODUCTION
Introduction
Objective
Scope of the study
Methodology
Limitation of the Study
2
INTRODUCTION
Shimoga is a city, which is growing in all trades at a
good speed. So as the construction industries too.
Hence in order to make this industry in par with other
developing cities in economy, faster construction
method the so called concrete blocks are the subjects
chosen to make people their mind towards the usage of
these blocks.
Concrete blocks are the composite mixture of
cement, sand and stone aggregates. In the year 1979
BSI approved the usage of concrete blocks. Economy is
the word, which sounds in everybody and anybody who
wants to build his house. Hence to achieve this hollow
blocks are the only solution.
As we need an alternative to every item hollow
blocks are the answer for the conventional bricks. Blocks
3
are made in three grades namely Grade A, B and C. The
grade A and B are load bearing blocks. Grade C is non-
load bearing. Another material, which is now, used
masonry increasingly in the concrete blocks. The
reasons are being machine made mostly is more uniform
in dimensions, as greater degree of reliability and
quality, faster in construction.
Objectives of the study:
This project report on manufacturing and marketing
of hollow blocks has the following objectives.
To study the various construction material with their
implications on their economy.
To know about the alternate construction material and
implementation of these material practically.
To study the advantages and disadvantages over the
conventional materials which are being used.
To study the possible decrease of construction time.
4
To suggest measures, to improve the performance of
both men and material.
Scope of the study:
The scope of this project report is confined to the
usage of new construction materials, comparison of
economy, various problems towards achieving efficiency
with the conventional materials, user-friendly aspects.
Methodology:
The date collected for the preparation of this
project report include both primary and secondary data.
Primary data has been collected from many
practicing engineers, professional qualified contractors,
consultants, manufacturers, and practical observations.
Secondary data comprises of journals, books,
magazines, and newspapers and IS code.
5
Limitation of the study:
As this is more technical and professional subject, it
is rather difficult to deal and understand each and every
step of manufacturing of hollow blocks.
The inferences have been drawn and the
information collected from the firm.
6
CHAPTER - 2
FIRM PROFILE
History and Nature
Financial Resources
Origination Chart
Numbers of workers working under the
factory
7
FIRM PROFILE
History and nature of Factory
History of Factory
Athani Concrete Blocks is situated in
Bommankatte, i.e., via Keerthi Nagar, Shimoga and
office R.M.R. Road, Durgigidi, Simoga.
In the year 1994, July the project was filed and
applied to the bank. And in the middle of September
1994, the bank sanctioned the term loan for the
placement of orders of machinery. The machinery,
electrification, commissioning were arrived and started
the trial production at the end of November 1994. And
finally in the 1994 December, the production was
commercially started.
Now it has developed wide market with the help of
good relation with public and leading civil engineers,
builders and contractors in and around shimoga.
8
Office: R.M.R Road, Durgigudi, Shimoga 577 202
Phone : 08182 - 226159
9
Nature of Factory: -
The Athani Concrete Blocks manufactures are
manufacture- two kind of blocks they are
(1) Hollow Concrete Blocks &
(2) Solid Concrete Blocks.
The installed capacity is
8”*8”*16” - 1440 blocks per 6Hrs,
6”*8”*16” – 1800 blocks per 6Hrs,
4”*8”*16” – 2880 blocks per 6Hrs.
The total working days per months are 25days, in
a year; the Athani factory manufactures more than
36,72,000 blocks per year.
Athani Manufacturers cover
(1) Shimoga district,
10
(2) Chickmagalure,
(3) Hassan district,
(4) Devangere district, and other cities.
The sizes of concrete blocks manufactured by
Athani factory are as follows: -
(1) 8”*8”*16 - 45%
(2) 6”*8”*16 - 43%
(3) 4”*8”*16 - 12%
The raw materials required for the manufacturing
of concrete blocks are – cement, jelly, quarry dust, sand
and water.
The Regular Manpower Working –
(a) Machine Operator – 2
(b) Concrete Mixing Operator – 1
(c) Trolley Operator – 2
(d) Loaders for mixer – 4
(e) Curing Purpose – 2 (female)
11
(f) Supervisor and technicians
The minimum area (Platform) required is –
50”*100”
Organization Chart
Proprietor
Supervisor Supervisor
Storekeeper Storekeeper
Skilled Labors Unskilled Labors
(a) Masons (a) Helper
(b) Mortar mixers (b) Waterman
(c) Machine Operators (c) Male coolies
(d) Drivers (d) Female coolies
12
Manpower recruitment: -
Following are the labors – Supervisory and personnel requirements for the unit
Sl.No.
Labors-supervisory
Number of workers
Total Rs./month
1 Supervisor @ 3500/month
1 3,500
2 Machine Operator @ 1,200/month
2 2,400
3 Mixer Operator @ 1,200/month
1 1,200
4 Semi skilled operator for moldings machine and mixer (sandy) @ 1,000/month
1 1,000
5 Unskilled workers Molding
machine Mixer Batching Curing HandlingEach at Rs. 900/month
22834
1,800 1,800 7,200 2,700 3,600
Total 24 25,200
13
Financial Resources: -
The following were the major activities in the
implementation of this management unit. –
a. Preparation of Project
report and filing of loan
application to bank
July 1994
b. Sanction of term loan from
bank and placement of
orders for machinery
Mid September
1994
c. Arrival of machine End October
1994
d. Commercial Production December
1994
The following were the major activities in the
implementation of this manufacturing unit-
14
Cost of the project and means of finance (Rupees in lakhs) I. Land Own II. Plant and Machinery
(a) Machinery(b) Rain and Moulds(c) Mixer(d) Electrification(e) Generator (20Kva)
1.93 0.35 0.45 1.50
III. Vehicle 5.85 IV. Civil works
(a) Godown for cement store
(b) Platform for pressing
(c) Water supply for curing
0.50 2.50 0.055
V. Bore well 0.70 VI. Deposits with telephone 0.04 VII. Preliminary and pre operative Expenses
0.20
VIII. Interest during implementation 0.20 IX. Contingencies @ 5% on office And Machinery
0.24
X. Working capital 5.08 XI. M/s on fixed deposits 1.13 Total cost of the project 21.22 Proprietors investment – 25% 05.31Bank Loan – 75% = 15.91
15
Explanatory note on cost of the project: -
(1) Plant and Machinery
The estimated cost of plant and machinery works
out to Rs. 4.04 lakhs.
(2) Miscellaneous fixed assets
It is proposed that to procure office equipment’s
table, chairs, almirahs etc, a sum of Rs. 25,000 is
provided for this purpose in the project cost.
(3) Deposit with telephone
A sum of Rs. 4,000 is earmarked in the project
costs towards deposit to be 0paid to telephone
department.
(4) Preliminary and pre operative expenses
A sum of Rs. 20,000 is included in the project cost
to cover the following expenses like traveling, service
charges towards the preparation of feasibility report,
16
printing, stationery, postage, telephones and other
miscellaneous expenses.
(5) Interest during implementation
A sum of Rs. 20,000 has been provided towards
interest during the pre-commission period.
(6) Contingencies
A sum of Rs. 24,000 (5% on plant and machinery) is
included in the project cost in order to take care of
unforeseen expenditures and also escalation in prices
and
Machinery.
(7) Working capital margin
The working capital requirement is utilization has
been worked out and is given vide annex-
The working capital margin is based on 1-month
requirement of raw material like Portland cement and 2
17
weeks requirement of other raw material viz., sand and
jelly, 3 weeks goods in process, 2 weeks finished goods
in stock, 1 month bills receivable and 1 month working
expenses.
(8) Proprietor Contribution
The proprietor’s contribution works out to Rs.
5,31,000, which is 25% of the cost of the project. This
has also been included in the means of finance.
18
CHAPTER - 3
PRODUCT PROFILE
Production and Manufacturing of H.C.B.
Particulars of the product
In fracture of the product
Process Details-Hollow Concrete Blocks
Requirement of Raw Materials & Consumables
Cost of Production
19
PRODUCT PROFILE
Production and Manufacturing of Hollow Concrete
Blocks
The raw material viz. Sand, Portland Cement,
Quarry Dust, Jelly, Granite aggregates are mixed in the
required proportion with adequate water in the hydraulic
concrete mixer. The concrete mix is fed to the “Minato”
molding machine, which moulds the concrete mix into
concrete blocks on the casting yard as per the mould,
fitted on the machine. After each lying of the blocks, the
machine moves forward for next laying. These blocks
are left on the yard for a period of 24 hours of initial
setting and later the blocks are stacked to 6 to 8 layers
for curing, sprinkling water for the period of 21 days and
left for drying for a period of one week does curing.
After curing the blocks are removed from the curing yard
for dispatch.
20
The technology of manufacture cement hollow
concrete blocks is in vibratory compaction and “Egg
laying’’ type which comes along with the molding
machine.
Process flow chart for the Hollow Concrete Blocks
are given below
Matching of raw materials
↓
Mixing in concrete mixer with water
↓
Molding a blocks
↓
Stacking for curing
↓
Dispatch of finished goods
21
Requirement of Raw Materials and consumables:
The Major raw materials required are Portland
cement, sand, and granite, aggregate: -
(1) Portland Cement:
The requirement of Portland cement will be about
9,330 bags for 4.50 lakhs Hollow Concrete Blocks of the
given product mix. Presently Portland cement is
available in the open market from dealers as well as
from the manufacturers as non-lavvy cement. The
landed cost of cement at the works is -
175+ 25 (12.5% VAT)
Total= 200 per bag
(2) Sand: -
The requirement of sand will be about 58.135 cft
for 4.50 lakhs hollow concrete blocks of the given
product mix. The sand is available from the nearby river
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beds and the transportation cost will be minimum and
ten the cost of sand is Rs. 5 per cft.
(3) Granite aggregate:
Granite aggregate of size 10mm and below is
required to an extent of 69,695 cft for 6 lakhs hollow
concrete blocks of the given product mix.
(4) Other Consumable:
The consumable are oil, grease, cotton, and waste
etc. that are required for cleaning the moulds etc. The
lump sum provision of 1% of 23,86565 has been made at
100% capacity utilization.
The requirements of the above raw materials
have been worked out at recommended concrete mix of
1:5:6: for hollow concrete blocks and also taking into
account 2% breakage and wastage in the process as
recommended by the manufacturer of the machinery
23
Annual requirements of raw materials and consumables at 100% capacity
utilization:
Sl.No
.
Materials Quantity Price Total
1 Portland
cement
9330
bags
135/bag 12,59,55
0
2 Sand 58,135cf
t
5/cft 2,90,67
5
3 Granite
aggregate
69,695cf
t
12/cft 8,36,34
0
Total
Other
consumable
at 1%
23,86,56
5
23,86
5
Total 24,10,43
0
24
Total requirement of concrete at 100% capacity
utilization: -
No. Of blocks: - 3,82,500(per year)
Sl.No
.
Block
size
Quantit
y
Concrete
requirement
per block cft
Total
requirement
of concrete
cft
1 8”*8”*16 1,46,000 0.36767 53,679.82
2 6”*8”*16 73,000 0.2524
6
18,429.
58
3 4”*8”*16 73,0
00
0.1682
8
12,284.
44
4 Other solid
blocks
73,0
00
0.1682
8
12,284.
44
25
Explanatory solution: -
(1) Size: – 8”*8”*16 (30mm shell thickness) Volume = Volume of blocks-volume of voids
= 16,000-(5.5cm*15.5cm*17.0cm) 4cc
= 16,000-5797cc
= 10,203cc
= 0.3603155cft
Assuming 2% wastage, -- The requirement of
concrete for the above size block = 0.36767cft
(2) Size: -6”*8”*16 (22mm shell thickness)
Volume= Volume of blocks-volume of voids
= 1,200-(4.2*17.8*16.7) 4cc
= 1,200-1,994cc
= 7,006cc
= 0.2474145cft
Assuming 2% wastage, - 0.25246cft concrete per
block
26
(3) Size: - 4”*8”*16 (22mm shell thickness)
Volume = Volume of blocks-volume of voids
= 8,000-(5.6*17.8*16.7) 4cc
= 8,000-3,330cc
= 4,670cc
= 0.1649194cft
Assuming 2% wastage - 0.16828cft concrete
required per block
For 353cft of ready concrete in the ratio 1:5:6, the
requirement is 28.25 bags of cement, 176cgt of sand
and 2121cft of granite aggregate. Hence the total
requirement of raw material at 100% capacity is as
follows—
Cement = 09,330bags
Sand = 58,135 cft
Granite Aggregate = 69,695 cft
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Particulars of the product: -
(1) Capacity
The capacity of proposed unit will be to produce
1,500 hollow concrete blocks per day of 8 hrs shifts. It is
assumed that the plant functions for 300 days in a year.
This capacity is decided by the block-molding machine
(capacity – 200 blocks per hour of size 8”*8”*16”) in
case of hollow concrete blocks.
(2) Economic factors
The proposed unit has been envisaged in tiny scale
units, the capacity of the entrepreneur to invest and
here managerial capacity. A unit of above-mentioned
capacity has been found to be an economically viable
size.
(3) Nature of products
28
Normally hollow concreter blocks are produced in
two ranges of shell thickness of 22mm and 30mm.
Indian standards institutions has brought out on issued
vide is 2185-1967, further revised as is 2185-part 1 in
1979. Prescribing requirements regarding dimensions,
tolerances, material surface-texture, mix visual
examination and other physical requirements for load
bearing hollow concrete blocks.
(4) Product Planning
The unit envisages operating a single shift basis
with and working hours per day. The machines are so
balanced that none of the machine are kept idle. The
utilized capacity is proposed to be built unto maximum
of 80% from the third year and onwards with 66.66%
capacity utilization in the first year and 73.33% capacity
utilization in the second year of operation.
(5) Marketing Demand
29
Based on the general demand pattern, the
following product mix is assumed in working out the
project report.
Concrete Blocks
Hollow Concrete Blocks Solid Concrete Blocks
(a)8”*8”*16 – 55% (a) 8”*8”*16 – 40%
(b)6”*8”*16 – 45% (b) 6”*8”*16 – 35%
(c) 4”*8”*16 – 00% (c) 4”*8”*16 – 25%
100% 100%
Cost of Production: -
Cost of Production & Profitability
Cost of production, profitability and cash flow has
been projected for period of 8years from the
implementation of the project and the same are given.
From this projection, it is evident that the unit will be in
a position to pay back borrowings comfortably.
30
Sl.No. Size per block
Weight per block
Rate per block
1 8”*8”*16” 23kgs Rs.13.002 6”*8”*16” 18kgs Rs.11.003 4”*8”*16” 18kgs Rs.11.00
Explanatory note on cost of production and
profitability: -
(1) The unit will be operating at a capacity utilization of
70% in the first year of operation, 80% in the second
year of operation and 85% from 3rd year and onwards.
(2) The cost of raw material and consumables has been
calculated in previously.
(3) Labor and supervisory charges are assumed to
increase every year by an amount equal to 5% of
salaries of the first year and the provision of 20% of
salaries is made towards social benefits.
(4) A lump sum provision of Rs. 10,000, 12,000 and
15,000 is made towards repairs and maintenance of
31
plant and machinery for the first, second and third
year of operation respectively.
(5) A provision of Rs. 4,000 is made towards taxes.
(6) A sum of Rs. 9,000 is also provided towards
insurance on plant and machinery.
(7) A provision of Rs. 8,000, 10,000 and 12,000 is
made towards miscellaneous expenses for the first,
second and third year of operation respectively.
(8) A sum of Rs. 5000 is provided towards profession
and consultancy fees in each year of operation.
(9) A lump sum provision of Rs. 5,000, 7,000 and 9,999
is made towards postage telegram and telephone
expenses for the first, and second and thirds year of
operation respectively.
(10) A sum of Rs. 20,000, 25,000 and 30,000 is provided
towards selling and distribution overheads during first,
second and third year of operation respectively.
(11) The rate o interest on term loan is taken at
14.5%per annum
(12) An interest rate of 15% per annum is taken on
working capital loan.
32
(13) Depreciation on plant and machinery is taken at
13.57%.
33
Chapter – 4
Methods of Construction
Methods of Construction
Traditional Wall construction
Puddle soil construction
Unburnt Bricks Construction
Burnt Bricks Construction
Bamboo reinforce mud wall
Introduction of Hollow Blocks in structures
Advantages and disadvantages
34
Methods of Construction
Methods of Construction
In an ancient time in Shimoga traditional wall
construction is the only the way of construction of the
buildings, house and other walls. Now a day some of
the other materials are available in use for the new
construction. Concrete Blocks, Clay Hollow Bricks, Table
Molded Bricks, are the new constructional materials.
Hence it is essential need to under stand the other
Traditional as well as Modern Methods that adopted by
our people from the long time. Some of the other
constructional Materials are as follows.
Soil has been used extensively as a material for
wall construction in traditional houses in India and
abroad. It is one of the material that easily available in
every place and low cost and other factors lead to it’s
35
wide spread in allover India. And also some of the other
traditional wall construction are easy/simple and they
are acquired their importance every were.
Soil is used in various forms for wall construction
like—
(a) Puddle Soil,
(b) Unburnt bricks,
(c) Burnt bricks,
(d) Bamboo reinforced mud.
Traditional wall constructions
(a) Puddle Soil Construction: -
In this type of construction there are mainly two
activities-soil preparation and construction of the wall.
The soil preparation consists of mixing the appropriate
quantity f water with the soil to get a consistency such it
36
can be easily puddle. Some times chopped paddy straw
or some grasses are added. This mix is use for
constructing the wall. The thickness of the wall varies
between 1.5 to 2.0 feet. The height of the wall raised
per day will be around 1.0 to 1.5 feet. For the
construction of such walls no special skills and tools are
required.
The major disadvantages of this type of
construction are:
(a) The wall becomes very thick leading to the
reduction of available floor space.
(b) Susceptibility to erosion, when exposed to rain.
(c) Needs frequent maintenance.
(b) Un burnt Bricks construction: -
Unburnt bricks are often used for construction of
wall of houses with light roofs such as tiled and thatched
roofs. There are bricks made by using wooden moulds
37
and bricks made by cutting a sheet of soil into blocks.
The former type is most commonly used.
(1) Preparation of un burnt bricks using wooden
mould:
These bricks are made on fairly level ground. The
soil and water are mixed thoroughly, such that the soil is
in plastic state and easily workable.
This plastic soil is then dashed into a wooden mould
and kept on the level ground. The top of the mould is
finished with hand and it is then immediately removed
leaving the fresh bricks on the ground. This process is
continued. The bricks are left on the ground for a day or
two for drying. Then these bricks are stacked and dried
in sun for few more days before using for construction of
walls. The wooden moulds used will have two
compartments to permit moldings of tow bricks at a
time.
38
The size of these bricks will be
23cm*11.4cm*7.5(“9*41/2*3’’). The walls constructed
with these bricks will normally have a minimum
thickness of 34cms(13.5inches). These walls are
normally constructed using mud mortar.
(2) Unburnt Bricks made without using wooden
moulds: -
In this case the plastic soul (prepare by thoroughly
mixing water and soil) is spread on the fairly level
ground in the form of a sheet of uniform thickness. This
sheet of soil is then cut into blocks by slicking in two
mutually perpendicular directions using a knife. These
blocks are slightly bigger in size than unburnt bricks
made by using wooden moulds. After drying in sun for a
few days the blocks will be ready for wall construction.
These walls are also built using mud mortar.
The Major disadvantages are: -
(1) Poor erosion resistance against rain,
(2) The walls need frequent maintenance and
39
(3) The walls are thick leading to sacrifice of available
floor space.
(c) Bamboo reinforces mud walls: -
The bamboos of 1-to12.0cms diameters are stacked
until the foundation at spacing of 60cms. Bamboo of
smaller diameter (3cm) is interwoven with the vertical
bamboos. This arrangement roughly resembles a grid.
The space between horizontal bamboos will be around
15cms this forms the main structure of the wall. The
plastic soil (soil mixed with water thoroughly) is pressed
by hand on wither side of the bamboo grid, such that if
penetrates well into the interstices of the bamboo grid,
This whole bamboo supporting structure is curved with
sol this is completely built by hands without using any
tools. This type of wall construction is faster compared
to the puddle soil construction the wall thickness will be
approximately 20to30cms. This method of construction
is similar to wattle and daub construction.
40
The major disadvantages are: -
The bamboo’s supporting structure inside the wall is
susceptible to termite attach,
Poor erosion resistance against rain,
Needs frequent maintenance and
Bamboo has become scarce and costly.
Modern Method of Construction
Burnt Brick Construction: -
Burning at high temperature renders the soil
immune to strength loss saturation ad suppresses the
erosion resistance. Burning has been practiced since
ancient times to improve the properties of building
materials such as bricks and tiles. The performance of
well-burnt bricks used for wall construction. They are
country Bricks and table molded bricks. The process of
manufacturing differs with each type: -
41
Country Bricks: -
The preparation of these bricks is similar to that of
unburnt bricks, as explained earlier. These are burnt
after drying in sun for a few days. The burning is carried
out in clamps using firewood; Sometimes coal is also
used for burning. The bricks and the firewood are
stacked in alternate layers in clamps. Each bricks (size
2cm*11.4cm*7.5) consumes about 0.32kgs of firewood.
This is equivalent to 2kwh of thermal energy. Mud
mortar or cement mortar can be used for the
construction of wall thickness will generally be
34cms(13.5inches).
Table Molded Bricks: -
The preparation of these bricks is almost similar to
the country bricks. Here metal moulds are used and the
bricks are prepared on table. The fresh bricks are
immediately removed from the table and stacked in a
42
different place for drying. These bricks are burnt in
bulls’ trench kilns. In these kilns the heart lost during
cooling of the bricks is utilized for preheating of the next
set of bricks. Hence these kilns have a better thermal
efficient than clamps. Normally coal is used as a fuel in
such kilns table molded bricks consumed about 0.20kgs
of coal per bricks. The table-molded bricks have better
shape and strength compared to country bricks. Mid
mortar or cement mortar can be used for the
construction of walls using these bricks.
Even though the performance of burnt bricks wall
is quite satisfactory, the bricks consume significant
amount of fuel energy. The energy crosses emphasizes
on conservation of firewood and coal. Hence
constructing bricks houses alone cannot satisfy the
present housing demand.
43
Advantages and Disadvantages Bricks: -
Advantages: -
No specific skilled labor is required, as it is of the
oldest construction methods in practice,
Size and Weight are convenient for picking up,
placing,
It can be cut to any shape with very little effort and
most of the times, it is cut by trowel only,
Defects in masonry are easily rectifiable,
Maintenance is easy,
It can be used most conveniently; brick wall can be
used as load bearing walls,
Reasonably resistant against fire, chemicals, weather
and insects,
Modular construction is possible with less effort,
Elevation treatment is possible with special kind of
bricks,
44
Very easy to chase the wall for laying electrical and
water supply conduits,
Walls can be nailed.
Disadvantages: -
In the manufacturing process of bricks, earth is the
chief raw material. Hence the fertile earth is being
used.
To manufacture bricks, for burring charcoal and coal
are being used. Hence smoke is lot, thereby less
environmental friendly,
Since most of the bricks are manufactured
conventionally, the dimensions Are non-uniform,
Labors intensive,
Cement mortar consumption is high, as number of
joints is more.
Direct use of soil (without burning) for construction
in any of the explained above has explained above has
certain disadvantages. The performance of these walls
is not every satisfactory. The performance of burnt
45
bricks wall is quite satisfactory. However burnt bricks
consume significant amount of fuel energy.
Introduction of Hollow Concrete Blocks
Hollow Concrete Blocks are mainly used in framed
structures for walls in high rise buildings, industrial
sheds and temporary structures like compound walls,
labors shed etc. Even though the load bearing Hollow
Blocks can be manufactured.
There is no demand in the market for these blocks
as still people are under the pressure that they are weak
as they are hollow. Hence in this aspect to make the
usage of these blocks in structures, there is a market
need to convince people and make them to make their
mind to use these blocks for individual houses also.
Advantages and disadvantages of Hollow Concrete
Blocks: -
Advantages:-
They are more uniform in dimensions, quality and
strength,
46
Builders concern about quality and reliability of supply
is lessened as most of the block manufactures are
from organized trade,
Usage of mortar is less, as a number of joints are less,
Less weight for a given volume of masonry,
Plaster is not necessary if, quality of workmanship is
good,
Offers greater resistance to heat and sound
transmission,
They are economical,
Less labor intensive,
Since the raw materials is cement, sand and
aggregates, no wastage of fertile earth,
As there is no coal and charcoal being used, it is
environmental friendly.
47
Disadvantages: -
(1) Being hollow it is difficult to repair,
(2) It cannot be used for elevation purposes,
(3) Difficult to pickup and place in position as the sizes
are large,
(4) It cannot be used for load bearing structures
without getting special kind of blocks,
(5) Recession for electrical and water conduits is
practically not possible.
48
Chapter – 5
MARKET POTENTIAL
Demand And supply
Marketing and Distribution
Market Arrangement
49
MARKET POTENTIAL
Demand And Supply
It has been estimated that the housing requirement
cater to the net addition in the population in the seventh
plan period will be 16.2 million dwelling units which over
and above the already existing backlog of 24.7 million
dwelling units (2005). In addition to this, with growing
impacts given to industrialization, the demand for
construction from the commercial sector is also on the
increase. If, these requirements are to be met, it will
demand a production of 55, 00 corers of bricks by 2005.
For making first class burnt clay bricks, clay soil of
Celtic aluminum are best suited. The alluvial belt
suitable for making good quality bricks is mainly
confined to the plans of North India. Other area,
excepting isolated pockets near to the coastal region,
are comprised of different grades of black soils, red soils,
or laetrile soils which are either unsuitable for making
50
bricks or render bricks of poor quality. Black soils and its
derivatives and mixture do not make good bricks, as
these soils swell enormously when wetted and
consequently shrink upon drying producing cracks in the
bricks. Wet soils are of low plasticity and succumb to
lime bursting upon firing. The laterite is non-plastic and
can not be molded in plastic form. Due to this the bricks
produced in the states of Madhya Pradesh, Maharashtra,
Andhra Pradesh and Tamil Nadu are of poor quality
having a comprehensive strength of 30kgs per sq.cm,
compared to the strength of 70kgs per sq,cm and above
for the bricks manufactured I the northern region.
Coal is another important input for the manufacture
of bricks and this important input is becoming scarce
and costly which inturn results in the frequent hike in the
cost of bricks.
Hollow concrete blocks being a variable alternative
for bricks can easily capture the market for bricks, due
to its superiority and easy availability compared to that
51
of bricks. It is interesting to note that a good number of
cement plants are situated in areas identified as having
soils unsuitable for making good bricks. In such areas,
the proximity of the cement plant ensures regular supply
of cement to the units manufacturing these blocks. Also
the quality of the burnt bricks available in these areas
being poor the concrete blocks can compete as a
suitable walling material.
The estimate on production and demand for burnt
clay bricks show that the demand and supply gap will
persist for years to come. Also even though housing
activity is more intense around union centers the brick-
manufacturing unit are pushed away for urban areas due
to scarcity of suitable and resulting in shortage leading
to high prices in certain urban areas in particular,
Shimoga.
The substitution of brick by hollow concrete blocks
has been cosseted due to inconsistent capacity of
conventional bricks are savings in material viz. steel and
52
cement on an account of use of cement hollow concrete
blocks. This saving in cement at the construction site is
on an account of lesser thickness of plastering required
on the wall constructed of hollow concrete blocks. There
is also saving in steel due to lighter weight of the hollow
concrete blocks as compared the conventional burnt
bricks, which results in reduction in loading on the
columns and beans in a framed structure. The resultant
overall savings will be of the order of 30% to 40% in the
masonry and hence preferred in the construction of
buildings. There is an additional desirable quality of
hollow concrete blocks i.e. heats insulation. This
property is accomplished on account of air packets I the
cavities of the hollow concrete blocks which act as the
isolations.
On the basis of the market data collected from the
experts in the field it was found that about 1.60 lakhs of
hollow concrete blocks are required every month for
construction activity in and around Shimoga.
53
This primarily includes demand arising from the
commercial sector like office structure and business
shops.
Market information reveals that hollow concrete block
utilization by residential individual houses is less.
Presently hollow concrete blocks are being used
effectively for the construction of factory sheds,
compound walls, multi-storied buildings and very little
household construction. How ever due to increased
shortage and poor quality of bricks the demand from the
household sector is also on the increase.
Presently there are about five manufacturers of
hollow concrete blocks in Shimoga district. In addition to
this three other manufacturers will be shortly setting up
plants in the near future. The present installed capacity
is 5 lakhs of hollow concrete blocks per annum. Taking
into account the fact that the manual machines run at
40% efficiency.
54
The demand being 1-lakh hollow blocks per month, it
is clear that there exits a gap between supply and
demand. The proposed unit could function to fill this gap
partially to certain extent.
Marketing and Distribution
Presently, there are as such no middlemen in the
distribution process. The contractors place the order
directly to the manufacturers and the delivery is made
directly to the site. It should be noted that there is no
competition growing in Shimoga and no necessity to do
some marketing to push the product I the market. One
important aspect of hollow concrete blocks is that the
public contractors have gradually accepted the concept.
Market Arrangements: -
As mentioned earlier, the construction activity of
residential and commercial buildings are increasing day
by day on account of non-availability of local bricks or
good quality bricks in and around Shimoga.
55
The sudden spurt in construction activity coupled
with the preferential acceptability of hollow concrete
blocks over bricks has created a gap in demand and
supply. Hence there is good scope for the unit.
The proprietor has good public relations and contacts
with many of the leading civil engineers, builders and
contractors in and around Shimoga an hence no problem
is envisaged in marketing hollow concrete blocks.
The proprietor intends selling hollow concrete blocks
at Rs.13.00for 8”*8”*16” 11.00 for 6”*8”*16”Rs.11.00
per block of 4”*8”*16” size which is lesser than the price
of market leader thus gaining customer preference for
this product.
It is proposed to appoint an experienced sales officer
on commission basis whose duty is to travel extensively
to procure orders for the unit.
The proprietor has also planned to offer an attractive
package of incentives to the contractors, which will
56
motivate them to place their orders with the proposed
unit.
Demand and Supply of Hollow concrete Blocks during last four years:
year
Particulars
2005 2004 2003 2002
Production 1,42,458 1,38,250
1,39,352
1,25,500
Demand 1,50,000 1,00,000
1,20,500
1,05,000
57
Chapter -6
Analysis of Survey Findings
58
Analysis of Survey Findings
Today as we all very well known “ Consumer is the
King”. In the market, he is the judge and the final
decider for the product to purchase or not. Because he is
the final consumer satisfaction should be ultimate aim of
the producer and the marketer consumer interest should
be taken into consideration while taking decisions.
However it ids clear that consumer is the one and all for
all the area.
The total number of Blocks user is interview by this
survey the result is more than 87 respondents were
selected on a random basis in different areas. It was
observed that Hollow Concrete Blocks was famous
enough with masses and most of them posses Hollow
Concrete Blocks competition mainly from Molded
Bricks , Burnt Bricks, and other kind of Bricks
59
1. Table showing respondents occupation
Occupation No. of respondents Percentage
s
Government
servants
46 53
Businessmen 27 31
Agriculturist 04 05
Others 10 11
Total 87 100
Analysis: From the above table it is clear that number
of respondents from the side of government servants
and then the businessmen occupies the second place in
the respondents area.
60
Graph showing respondents occupation
61
2. Table showing Income group
Income No. Of
Respondents
Percentage
Below – 5000 25 32
5000 – 10000 30 40
10000 – 25000 15 19
Above - 25000 7 9
Total 87 100
Analysis: The above clearly and numerically suggest that
maximum number of persons from the second groups
only.
62
Graph showing Income group
63
3. Table showing type of bricks used
Type of bricks No of
respondents
Percentage
Bricks 33 38
Hollow Concrete Blocks 44 51
Unburnt Bricks 03 3
Solid Concrete Blocks 07 8
Total 87 100
Analysis: From the survey it is clear that maximum
number of respondents used the Hollow Concrete Blocks
only and then the Bricks occupies the second place in
the table.
64
Graph showing type of bricks used
65
4. Table showing reasons for buying Hollow Concrete Blocks
Reasons No.of Respondents Percentages
Less in price 55 63
Quality Others 12 14
Uniformity in size
of blocks
9 10
Others 11 13
Total 87 100
Analysis: Maximum respondents prefer only less in price.
From the above table it is clear that the second higher
group will be quality respondents.
66
Graph showing reasons for buying Hollow
Concrete Blocks
67
5. Table showing the Special feature for buying
Athani Concrete Blocks
Special feature No.of Respondents Percentages
Low price 27 31
High performance 33 38
High quality 20 23
Others 07 8
Total 87 100
Analysis: From the above table it is clear that the
customer of the above firm identified the performance of
the firm as compared to other quality.
68
Graph showing the Special feature for buying
Athani Concrete Blocks
69
6. Table showing on what basis or what made to
buy Athani Concrete Blocks
Factor No. of respondents Percentage
Goodwill of the
company
09 10
Service provided
by the company
45 53
Price 16 18
Service quality 10 11
Other factors 07 8
total 87 100
Analysis: Maximum respondents came buy the Blocks
on the basis of service provided by the Athani Concrete
Blocks.
70
Graph showing on what basis or what made to buy
Athani Concrete Blocks
71
7. The table showing satisfaction about Athani
Concrete Blocks
Particulars No.of
respondents
Percentage
Satisfactory 69
Not Satisfactory 18
Total 87 100
Analysis:The maximum numbers of respondents are
satisfied with service provided by the Athani Concrete
Blocks.
72
The Graph showing satisfaction about Athani
Concrete Blocks
73
Chapter – 7
SUMMARY, SUGGESTIONS AND CONCLUSION
74
SUMMARY, SUGGESTIONS AND CONCLUSION
Summary:
The survey has been conducted to different kinds of
sectors.
Customer according to them occupation monthly
income types of bricks reasons, factors influence to
purchase, advantages and satisfaction.
In occupation sector there are many types of
respondents like government servant Business and
others.
As per survey has been conducts government servant
are majority of respondents of 45% and next to him
businessmen, agriculture, other respectively
30%,15%, 10%.
As per survey of monthly income the people majority
are will as to buy the bricks are who earn income from
5000-10000 means 60%of respondents
As per survey on the types of bricks used in people
75
In that hollow concrete bricks are commonly used by
all that is 65%of respondents and reaming 35%is
other.
I studied about willingness of people to buy the Hollow
concrete bricks.
The most common attitude of human being are
concentration on price factor same in the case of
Hollow bricks 55%of despondence of on price factor
because it is tower in price.
As per survey of publicity the people were current
know about Athani Association by the held of
engineers [i.e 45%] and reaming were came to know
from advertisements, friends, goodwill, others.
At lost advantages of bricks advantage in the people
set good and strong quality of bricks, which gives long
life to buildings and secondary factor of low price.
If we see throughout out the table of survey on an
average the people who gave positive response
towards Hollow bricks is 80% and they are satisfied
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and remaining are unsatisfied because of some
reason may be transport, price, advertisement ect.
Suggestion
It ha to maintain to supply the concrete blocks as
early as possible door delivery
It has to make mere advertisement to Know the
firm’s popularity
It is to be made easily available to the poor class
with low price as far as possible
Blocks should be readily available in large numbers
and blocks should be made available by door
delivery
Smaller width blocks could be more useful for walls
By reducing the quantity of dust and increasing in
quantity of cement helps the blocks in better
strength and also useful for load bearing walls.
77
To rise the portion of ingredients and thus helps to
use for multi storied buildings
It needs vast publicity to show and demonstrate the
work at size, so that, common people can use this
It should maintain uniform size and specifications
The manufacturer of Hollow Concrete Blocks. Experts
in the field engineers, technician, and traders can be
asked to gather for symposiums. The different
aspect of improving the quality, strength,
marketability, and popularity of Hollow Concrete
Blocks can be discussed so that it could be
competitor for the traditional burnt bricks.
Conclusion
I hereby conclude by saying that Hollow Concrete
Blocks will be ultimate in construction technology in the
near future and construction without it will be inevitable.
It has been a great experience to work with the
proprietor of Athani Concrete Blocks. I have really
enjoyed doing this project. Thank you one and all.
78
Annexes
Questionnaire
Bibliography
79
Questionnaire
Dear Sir or Madam:
I am a student of Sahyadri arts and Commercrce
collage Shimoga-577203 studying in final year BBM for
the academic year 2008-09 for the partial fulfillment of
my course. I am conducting the survey on the
Marketing Of Hollow Concrete Blocks -a case study
of Athani Concrete Blocks, Shimoga and preparation of
project report. Therefore I request you to spend for me a
few minutes to answer the question in the questionnaire.
Thanking you,
Yours faithfully,
SIDDESHA.N.C1. Name :
2. Address :
80
3. Occupation :
Government Servant [ ]
Businessman [ ]
Agriculturist [ ]
Others [ ]
4. Monthly Income
Below – 5000 [ ]
05000 – 10000 [ ]
10000 – 25000 [ ]
Above 25000 [ ]
5. Have you ever involved in construction of any
premises?
Yes [ ] No [ ]
6. If yes, what type of Bricks you have used?
Burnt Bricks [ ]
Unburnt Bricks [ ]
Hollow Concrete Blocks [ ]
Solid Blocks [ ]
Others Please Mention -------
81
7. Have you ever used Hollow Concrete Blocks?
Yes [ ] No [ ]
8. If yes, which of the following factor you consider while
purchases Hollow Concrete Blocks?
Less in price [ ]
Quality Others [ ]
Uniformity in size[ ]
Others [ ]
9. What are the advantages and disadvantages you found in the bricks?
Advantages DisadvantagesUniformity in sizeStrengthMore savings Less Labour intensive Others
Difficult repaid More weightOthers
10. How do you come to know about Hollow concrete Blocks?
Advertisements [ ]
Friends [ ]
Engineers [ ]
Others [ ]
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11. In case you are planning to buy a Hollow Concrete
Blocks, which company would you prefer first?
12. Have you ever heard of Athani Concrete Blocks
Yes [ ] No [ ]
13. If yes, how did you come to know about it?
Advertisement [ ]
Goodwill of Company [ ]
Engineers [ ]
Friends [ ]
Others [ ]
14. Which of the following factor you consider while
purchasing Athani Concrete Blocks?
Goodwill of the company [ ]
Service provided by the company [ ]
Price [ ]
Good quality [ ]
Others [ ]
83
15. Do you find any advantages in using Athani
Concrete Blocks ?
Yes [ ] No [ ]
16. If yes, what are the advantages you found
Low price High [ ]
Performance [ ]
High quality [ ]
17. If no, disadvantages are ?
High price [ ]
Bad service [ ]
Other, Please mention [ ]
18. Was the service provided by Athani Concrete Blocks
satisfactory
Yes [ ] No [ ]
19. If yes, Satisfactory level after using Athani Concrete
Blocks
Very high High Low Very lowCost of servicePrice levelSpeed of servicequality
84
20. Would you recommend your friends/relatives to
purchase Athani Concrete Blocks, concrete Blocks?
Yes [ ] No [ ]
21. Suggestion for Improvement of Athani Concrete
Blocks, Blocks
---------------------------------------------------------------
Place:
Date:
Signature
85
Bibliography
Marketing Management - Phillip Kotler Marketing Management - Sherleker Human Resource Management - B.S. Raman
Journals
1. Inside Outside – a magazine2. Architectural Design3. Building Materials
86