CONTENTS Chapter 1 Introduction •
Introduction
•
Objective of the Study
•
Scope of the study
•
Methodology
•
Limitation
Chapter 2 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
Chapter 3 Firm Profile – Asma Traders •
•
History of Factory Nature of Factory
•
The Regular Manpower Working
•
Organization Chart
•
Manpower recruitment
1
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
Chapter 5 Market Potential •
Demand And supply
•
Marketing and Distribution
•
Market Arrangement
Chapter 6 Data Analysis and Interpretation
Chapter – 7 Findings, Suggestions and Conclusion
Annexure •
Questionnaire
•
Bibliography
2
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
Chapter 5 Market Potential •
Demand And supply
•
Marketing and Distribution
•
Market Arrangement
Chapter 6 Data Analysis and Interpretation
Chapter – 7 Findings, Suggestions and Conclusion
Annexure •
Questionnaire
•
Bibliography
2
Chapter 1 INTRODUCTION
Introduction
Objective of the Study
Scope of the study
Methodology
Limitation
3
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 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.
4
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.
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, userfriendly aspects.
5
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.
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 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
7
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.
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 ↓
8
Stacking for curing ↓ Dispatch of finished goods
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 beds and the transportation cost will be minimum and ten the cost of sand is Rs. 5 per cft.
9
(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
Annual requirements of raw materials and consumables at 100% capacity utilization:
Sl.No. 1 2 3
Materials Quantity Portland 9330 bags cement Sand Granite
58,135cft 69,695cft
Price 135/bag
Total 12,59,550
5/cft 12/cft
2,90,675 8,36,340
Total
23,86,565
aggregate Other
10
consumable 1% Total
11
at
23,865 24,10,430
Total requirement of concrete at 100% capacity utilization: No. Of blocks: - 3,82,500(per year)
Sl.No .
1 2
Block size
Quantit Concrete y
8”*8”*16 6”*8”*16
1,46,000 73,000
Total
requirement
requirement
per block cft
of
0.36767 0.25246
cft 53,679.82 18,429.5
concrete
8 3
4”*8”*16
73,00
0.16828
0 4
Other blocks
solid
12,284.4 4
73,00 0
0.16828
12,284.4 4
12
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
(3) Size: - 4”*8”*16 (22mm shell thickness)
13
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
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-
14
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
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
15
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.
Sl.No. 1 2 3
Size per block
Weight
8”*8”*16” 6”*8”*16” 4”*8”*16”
block 23kgs 18kgs 18kgs
16
per Rate per block Rs.13.00 Rs.11.00 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 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.
17
(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. (13)
Depreciation on plant and machinery is taken at 13.57%.
18
CHAPTER - 3 FIRM PROFILE – ASMA TRADERS •
History of Factory
•
Nature of Factory
•
The Regular Manpower Working
•
Organization Chart
•
Manpower recruitment
19
FIRM PROFILE History and nature of Factory History of Factory Asma Traders is situated in Uragadur, Opp. Sri Ram Petrol
Bunk, Byepass road, Simoga 577 203. Established in the year 2006, 12th May. Name of the Proprietor is Mohammed Rafiq. 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.
Nature of Factory: -
The Asma Traders 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 Asma Traders manufactures more than 36,72,000 blocks per year.
20
Asma Traders cover (1) Shimoga district, (2) Chickmagalure,
The sizes of concrete blocks manufactured by Asma Traders 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) (f) Supervisor and technicians The
minimum
area
(Platform)
50”*100”
21
required
is
–
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
22
Manpower recruitment: Following are the labors – Supervisory and personnel requirements for the unit
Sl.No
Labors-supervisory
.
Number of
Total Rs./month
workers 1
3,500
1
Supervisor @
2
3500/month Machine Operator @
2
2,400
3
1,200/month Mixer Operator @
1
1,200
4
1,200/month Semi skilled operator for moldings machine and
1
1,000
mixer (sandy) @ 5
1,000/month Unskilled workers •
Molding machine
2
1,800
•
Mixer
2
1,800
•
Batching
8
7,200
•
Curing
3
2,700
•
Handling
4
3,600
Each at Rs. 900/month Total
24
23
25,200
The following were the major activities in the implementation of this manufacturing unitCost of the project and means of finance (Rupees in lakhs)
I. Land II. Plant and Machinery
Own
(a) Machinery (b) Rain and Moulds
1.93
(c) Mixer
0.35
(d) Electrification
0.45
(e) Generator (20Kva)
1.50 5.85
III. Vehicle IV. Civil works (a) Godown for cement store
0.50
(b) Platform for pressing
2.50
(c) Water supply for curing V. Bore well VI. Deposits with telephone VII. Preliminary and pre operative
0.055 0.70 0.04 0.20
Expenses VIII. Interest during implementation IX. Contingencies @ 5% on office
0.20 0.24
And Machinery X. Working capital XI. M/s on fixed deposits Total cost of the project Proprietors investment – 25% Bank Loan – 75% = 15.91
24
5.08 1.13 21.22 05.31
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,
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
25
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 annexThe working capital margin is based on 1-month requirement of raw material like Portland cement and 2 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.
26
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
27
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 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.
28
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 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 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:
29
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.
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
30
(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.
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
31
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: -
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 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
32
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.
33
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, •
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,
34
•
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 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,
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,
35
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.
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.
36
Chapter – 5 MARKET POTENTIAL
Demand And supply Marketing and Distribution Market Arrangement
37
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.
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 85, 00 corers of bricks by 2010. 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 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.
38
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 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 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
39
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. 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.
40
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 nonavailability of local bricks or good quality bricks in and around Shimoga.
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.
41
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 motivate them to place their orders with the proposed unit. Demand and Supply of Hollow concrete Blocks during last four years:
year
2010
2009
2008
2007
Particulars Production
2,42,458
2,38,250
1,39,352
1,25,500
Demand
2,50,000
2,00,000
1,20,500
1,05,000
42
Chapter -6 Data Analysis and Interpretation
43
Data Analysis and Interpretation
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
44
1. Table showing respondents occupation
Occupation Government servants Businessmen Agriculturist Others Total
No. of respondents 46 27 04 10 87
Percentages 53 31 05 11 100
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.
45
Graph showing respondents occupation
Agriculturist 5%
Others 11%
Government ser vants 53%
Businessmen 31%
46
2. Table showing Income group Income Below – 5000 5000 – 10000 10000 – 25000 Above - 25000 Total
No. Of Respondents 25 30 15 7 87
Percentage 32 40 19 9 100
Analysis: The above clearly and numerically suggest that maximum
number of persons from the second groups only.
Graph showing Income group
30
30 25
25
20 15
15
10
7
5
0 Below – 5000
5000 – 10000
10000 – 25000
47
Above - 25000
3. Table showing type of bricks used
Type of bricks
No of respondents 33 44 03 07 87
Bricks Hollow Concrete Blocks Unburnt Bricks Solid Concrete Blocks Total Analysis:
Percentage 38 51 3 8 100
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.
48
Graph showing type of bricks used
44
45 40
33
35 30 25 20 15 7
10
3
5 0 Bricks
Hollow Concrete Blocks
Unburnt Bric ks
49
Solid Concrete Blocks
4. Table showing reasons for buying Hollow Concrete Blocks
Reasons No.of Respondents Less in price 55 Quality Others 12 Uniformity in size of 9
Percentages 63 14 10
blocks 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.
50
Graph showing reasons for buying Hollow Concrete Blocks
13% 10%
14%
63%
Less in price Quality Others Uniformity in size of blocks Others
51
5. Table showing the Special feature for buying Asma Traders Concrete Blocks
Special feature Low price High performance High quality Others Total Analysis:
No.of Respondents 27 33 20 07 87
Percentages 31 38 23 8 100
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.
52
Graph showing the Special feature for buying Asma Traders Concrete Blocks
33
35
30
27
25 20
20
15 7
10
5
0 Lowprice
Highperformance
High quality
53
Others
6. Table showing on what basis or what made to buy Asma Traders Concrete Blocks
Factor Goodwill
of
No. of respondents the 09
Percentage 10
company Serv Servic icee prov provid ided ed by
45
53
the company Price Service quality Other factors total
16 10 07 87
18 11 8 100
Analysis:
Maximum respondents respondents came buy the Blocks on the basis
of service provided by the Asma Traders Concrete Blocks.
54
Graph showing on what basis or what made to buy Asma Traders Concrete Blocks
45
45 40 35 30 25 20
16
15 10
9
7
10 5 0 Go odwill of the company
Service provided by the company
P rice
55
Ser Service quality
Oth Other fact factor ors s
7. The table showing satisfaction about Asma Traders Concrete Blocks
Particulars Satisfactory Not Satisfactory Total Analysis:
No.of respondents 69 18 87
Percentage
100
The maximum numbers of respondents are satisfied with
service provided by the Asma Traders Concrete Blocks.
56
The Graph showing satisfaction about Asma Traders Concrete Blocks
Not Satisfactory 21%
Satisfactory 79%
57
Chapter – 7
FINDINGS, SUGGESTIONS AND CONCLUSION
58
SUGGESTIONS AND CONCLUSION
Findings:
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
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 Asma Traders Association by the held of engineers [i.e 45%] and
59
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 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.
To rise the portion of ingredients and thus helps to use for multi storied buildings
60
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 Asma Traders I have really enjoyed doing this project. Thank you one and all.
61
Annexes
Questionnaire
Bibliography
62
Questionnaire
Dear Sir or Madam I am a student of Sahyadri arts and Commercrce collage Shimoga, studying in final year BBM for the partial fulfillment of my course. I am conducting the survey on the Marketing of Hollow Concrete Blocks -a case study of Asma Traders Uragadur, Shimoga
and preparation of project report. Therefore I request you to spend for me a few minutes to answer the question in the questionnaire.
Your’s Syed Khadeer 1. Name
:
2. Address
:
3. Occupation
:
Government Servant
[ ]
Businessman
[ ]
Agriculturist
[ ]
Others
[ ]
4. Monthly Income Below – 5000
[ ]
05000 – 10000
[ ]
10000 – 25000
[ ]
Above 25000
[ ]
63
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 -------
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 Uniformity in size
Disadvantages Difficult repaid
Strength
More weight
More savings
Others
Less Labour intensive Others
10.How do you come to know about Hollow concrete Blocks? Advertisements
[ ]
64
Friends
[ ]
Engineers
[ ]
Others
[ ]
11.In case you are planning to buy a Hollow Concrete Blocks, which company would you prefer first? 12. Have you ever heard of Asma Traders
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 Asma
Traders ? Goodwill of the company
[ ]
Service provided by the company
[ ]
Price
[ ]
Good quality
[ ]
Others
[ ]
15. Do you find any advantages in using Asma Traders?
Yes
[ ]
No
[ ]
16.If yes, what are the advantages you found Low price High
[ ]
65
Performance
[ ]
High quality
[ ]
17.If no, disadvantages are ? High price
[ ]
Bad service [ ] Other, Please mention [ ] 18. Was the service provided by Asma Traders Concrete Blocks
satisfactory Yes
[ ]
No
[ ]
19. If yes, Satisfactory level after using Asma Traders Concrete Blocks
Very high Cost
High
Low
Very low
of
service Price level Speed of service quality
20. Would you recommend your
friends/relatives to purchase Asma
Traders Concrete Blocks, concrete Blocks? Yes
[ ]
No
[ ]
21. Suggestion for Improvement of Asma Traders Concrete Blocks,
Blocks --------------------------------------------------------------Place: Date:
66
Signature
67
