Artificial Sand - A Viable Alternative, An Alternate to River Sand in Concrete and Construction Industry, Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study, Investment Opportunities, Cost and Revenue, Plant Economics, Production Schedule, Working Capital Requirement, Plant Layout, Process Flow Sheet, Cost of Project, Projected Balance Sheets, Profitability Ratios, Break Even Analysis

The artificial sand produced by proper machines can be a better substitute to river sand. The sand should be sharp, clean and course. The grains should be of durable material. The grain sizes must be such that it should give minimum voids. The presence of clay and silt retards the setting of the cement and makes the mortar weaker and the walls or the slab leaks and holds dampness.

The sand in the mortar does not add any strength but it is used as an adulterant for economy and with the same it prevents the shrinkage and cracking of mortar in setting. The sand must be of proper gradation (it should have particles from 150 microns to 4.75 mm in proper proportion) When fine particles are in proper proportion, the sand will have less voids. The cement required will be less when there will be less void in sand. Such sand will be more economical.

Manufactured or Artificial Sand V/s Natural or River sand

The Civil engineers, Architects, Builders, and Contractors agree that the river sand, which is available today, is deficient in many respect. It does content very high silt fine particles (as in case of Filter sand).

Presence of other impurities such as coal, bones, shells, mica and silt etc makes it inferior for the use in cement concrete. The decay of these materials, due to weathering effect, shortens the life of the concrete.

Now-a-days, the Government have put ban on lifting sand from River bed.

Transportation of sand damages the roads.

Removing sand from river bed impact the environment, as water table goes deeper & ultimately dry.

 

General Requirements of Manufactured Sand/Artificial Sand

All the sand particles should have higher crushing strength.

The surface texture of the particles should be smooth.

The edges of the particles should be grounded.

The ratio of fines below 600 microns in sand should not be less than 30%.

There should not be any organic impurities

Silt in sand should not be more than 2%, for crushed sand.

In manufactured sand the permissible limit of fines below 75 microns shall not exceed 15%.

 

PRODUCT PROFILE

Sand is a naturally occurring granular material composed of finely divided rock and mineral particles. The composition of sand is highly variable, depending on the local rock sources and conditions, but the most common constituent of sand in inland continental settings and non tropical coastal settings is silica (silicon dioxide, or SiO2), usually in the form of quartz. Sand is generally mixed with cement and water form concrete. These sand particles should be hard and inert with respect to cement. In the construction industry commonly used artificial sand to compound concrete. Use of artificial sand concrete density, anti permeability, antifreeze performance is good, other physical and mechanical performance and long term durability all can reach the design requirements of operation. Artificial sand preparation is especially suitable for high strength grade of concrete, the high performance concrete and pumping concrete.

Applications

 Sand has its applications in various fields. In agriculture sandy soils are ideal for crops such as watermelons, peaches, and peanuts and their excellent drainage characteristics make them suitable for intensive dairy farming. In aquaria it makes a low cost aquarium base material which some believe is better than gravel for home use. Manufacturing plants add sand to a mixture of clay and other materials for manufacturing bricks. Coarse sand makes up as much as 75% of cob. Sand is mixed with cement and sometimes lime to be used in masonry construction. Sand is often a principal component of this critical construction material. Sand is the principal component in common glass. Mixing sand with paint produces a textured finish for walls and ceilings or non slip floor surfaces. Sand is also used as sand bags, these protect against floods and gunfire. Media filters use sand for filtering water.

 

Global demand

Due to the increase of population & living standards, the demand for this product is multiplying in every year. Present supply of production is meeting only about 20% of the demand if all the crusher units of the state start manufacturing machine made sand as an additional venture then also it could meet only about 50- 60% of the requirement. At present the existing sand manufacturers are producing sand like materials form granite stone and people are facing difficulties while plastering work. The demand of river sand will roll and will bring back the smiles on the faces of both the environmentalists and the industries. Because there is abundant of natural sand because of the heavy demand in the growing construction activities in nowadays society, the artificial sand production line the sand produce field has a popular and a welcome position.

The demand of sand in the market is immense and therefore its market position is splendid. Hence it is an excellent field to venture.

 

Table of Contents

 

1.       Project Location

1.1.    District Profile & Geotechnical Site Characterization

1.1.1.General

1.1.2.Map

1.1.3.Physical Characteristics

1.1.4.Climate

1.1.5.Transportation and Communications

1.1.6.Economy & Industries

1.1.7.Major Industries

2.       Introduction

3.       Composition of Sand

4.       Uses & Applications

5.       Properties

6.       Standard Specification for Fine Aggregates

7.       Artificial Sand

7.1.    Comparison of River sand and Artificial sand in Concrete design

8.       Importance of the Shape of Particles in Fine Aggregates

9.       Bureau of Indian Standard Specifications & Requirements

9.1.    Quality Control and Standards

10.   Market Survey

10.1.Crushed sand to replace river sand

11.   Raw Material Details

12.   Manufacturing Process

12.1.Plant & Machinery Required

12.2.Raw Material Required

12.3.Process

13.   PROCESS FLOW DIAGRAM

13.1.Less Than 40 Mm Sand Making Process Flow Diagram

13.2.Larger Than 40 Mm Sand Making Process Flow Diagram

13.3.Process Flow Diagram

14.   Machinery Details

15.   Suppliers of Plant & Machinery

16.   Raw Material Suppliers

17.   PLANT LAYOUT

18.   Machinery Photographs

19.   Quotation of Plant, Machinery and Equipments from Supplier

PROJECT FINANCIALS

·         Project at a Glance

Annexure

·         Assumptions for Profitability workings ….…………………………………………....................... 1

·         Plant Economics…………………………………………………………………………….................... 2

·         Production Schedule……………………………………………………………………….................... 3

·         Land & Building…………………………………………………………………………….................... 4

§  Factory Land & Building

§  Site Development Expenses

·         Plant & Machinery………………………………………………………………………….................... 5

§  Indigenous Machineries

§  Other Machineries (Miscellaneous, Laboratory etc.)

·         Other Fixed Assets………………………………………………………………………….................... 6

§  Furniture & Fixtures

§  Pre-operative and Preliminary Expenses

§  Technical Knowhow

§  Provision of Contingencies

·         Working Capital Requirement Per Month………………………………………………................. 7

§  Raw Material

§  Packing Material

§  Lab & ETP Chemical Cost

§  Consumable Store

·         Overheads Required Per Month and Per Annum ……………………………………................. .8

§  Utilities & Overheads (Power, Water and Fuel Expenses etc.)

§  Royalty and Other Charges

§  Selling and Distribution Expenses

·         Salary and Wages ……………………………………………………………………………................. 9

·         Turnover Per Annum ………………………………………………………………………................ 10

·         Share Capital…………………………………………………………………………………................ 11

§  Equity Capital

§  Preference Share Capital

 

•        Annexure 1            ::        Cost of Project and Means of Finance

•        Annexure 2            ::        Profitability and Net Cash Accruals

§  Revenue/Income/Realisation

§  Expenses/Cost of Products/Services/Items

§  Gross Profit

§  Financial Charges    

§  Total Cost of Sales

§  Net Profit After Taxes

§  Net Cash Accruals

 

•        Annexure 3            ::        Assessment of Working Capital requirements

§  Current Assets

§  Gross Working Capital

§  Current Liabilities

§  Net Working Capital

§  Working Note for Calculation of Work-in-process

 

•        Annexure 4            ::        Sources and Disposition of Funds

•        Annexure 5            ::        Projected Balance Sheets

§  ROI (Average of Fixed Assets)

§  RONW (Average of Share Capital)

§  ROI (Average of Total Assets)

 

•        Annexure 6            ::        Profitability ratios

§  D.S.C.R

§  Earnings Per Share (EPS)

§  Debt Equity Ratio

 

•        Annexure 7            ::        Break-Even Analysis

§  Variable Cost & Expenses

§  Semi-Variable/Semi-Fixed Expenses

§  Profit Volume Ratio (PVR)

§  Fixed Expenses / Cost 

§  B.E.P

 

•        Annexure 8 to 11   ::        Sensitivity Analysis-Price/Volume

§  Resultant N.P.B.T

§  Resultant D.S.C.R

§  Resultant PV Ratio

§  Resultant DER

§  Resultant ROI

§  Resultant BEP

 

•        Annexure 12          ::        Shareholding Pattern and Stake Status

§  Equity Capital

§  Preference Share Capital

 

•        Annexure 13          ::        Quantitative Details-Output/Sales/Stocks

§  Determined Capacity P.A of Products/Services

§  Achievable Efficiency/Yield % of Products/Services/Items 

§  Net Usable Load/Capacity of Products/Services/Items   

§  Expected Sales/ Revenue/ Income of Products/ Services/ Items   

 

•        Annexure 14          ::        Product wise domestic Sales Realisation

•        Annexure 15          ::        Total Raw Material Cost

•        Annexure 16          ::        Raw Material Cost per unit

•        Annexure 17          ::        Total Lab & ETP Chemical Cost

•        Annexure 18          ::        Consumables, Store etc.

•        Annexure 19          ::        Packing Material Cost

•        Annexure 20          ::        Packing Material Cost Per Unit

•        Annexure 21          ::        Employees Expenses

•        Annexure 22          ::        Fuel Expenses

•        Annexure 23          ::        Power/Electricity Expenses

•        Annexure 24          ::        Royalty & Other Charges

•        Annexure 25          ::        Repairs & Maintenance Expenses

•        Annexure 26          ::        Other Manufacturing Expenses

•        Annexure 27          ::        Administration Expenses

•        Annexure 28          ::        Selling Expenses

•        Annexure 29          ::        Depreciation Charges – as per Books (Total)

•        Annexure 30          ::        Depreciation Charges – as per Books (P & M)

•        Annexure 31          ::        Depreciation Charges - as per IT Act WDV (Total)

•        Annexure 32          ::        Depreciation Charges - as per IT Act WDV (P & M)

•        Annexure 33          ::        Interest and Repayment - Term Loans

•        Annexure 34          ::        Tax on Profits

•        Annexure 35          ::        Projected Pay-Back Period And IRR

 

 

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