Micro Concrete- ROOF
Content
Micro-concrete Roofing Tiles ousing is the basic need of every human
being. Central Government as well as State Governments are keen to provide
housing to everyone and especially to weaker sections of the society. The cost of housing construction is increasing day by day due to rising cost of building materials. The government sponsored agencies and individuals are looking towards low-cost building materials without compromising with the quality. Research and development organizations of the country have developed low-cost building components for walling and roofing which enable one to build improved houses at comparatively cheaper cost. Price of corrugated G.I. sheets used for roofing, is continually increasing while its use doesnot provide thermal comfort in a tropical country like India. Use of Asbestos-cement sheets is being discouraged due to health hazards associated with asbestos fibre. MCR (micro concrete roofing) technology meets the growing demand for high quality roofing. MCR tiles are cost effective and extremely versatile roofing material. MCR tiles can be used on steel and wooden under structure to make attractive roofs on residences, farmhouses, and pavilions.
Advantages MCR tiles have several advantages: 1. These are water and fire proof proof 2. These are eco-friendly
verandahs
3. Cheap in cost 4. Utilises waste (stonedust)
Process of manufacturing 1. Step I •
Selection of raw material
•
Cement (43 grade)
•
Stonedust (fine)
•
Aggregate (<6mm)
•
Water
2. Step II Mix preperation: The above raw materials are mixed in the following ratio: Cement: Stonedust: Aggregate: Water 1: 1.5 : 1.5 : 0.5 (by weight) 3. Step III Mix vibration: The prepared mix is put on a polythene sheets and placed over vibration table for about 45 sec. a nail is inserted in the rib for holes. 4. Step IV Moulding and stock curing: The polythene sheet is then carefully placed on the plastic moulds for getting a uniform shape. The moulds are then stacked one above the other in a set of 25 for next 24 hr. 5. Step V Demoulding and water curing: The tiles are then demoulded and seperated from the plastic sheets. The nails are also taken out and edges sharpened for better finishing. Then the tiles are kept in the curing tank for another 7 days.
6. Step VI Strength and quality testing: After the tiles are taken out from the tank these are stored for next 21 days in open or shed. Tiles from the stock are taken at random for testing in accordance with standard specifications. Then the tiles are ready for sale.
Product Specifications Clear length
488 mm
Length after overlap
400 mm
Clear width
240 mm
Width after overlap
200 mm
Thickness
8mm/ 100mm
Corrugation depth
50mm
Normal weight
2.25-2.60 kg
Purlin spacing
400 mm
Load bearing capacity
80/100 kg
For covering 10 sq. m. (100 sq. K) roof area 130 tiles are required.
Operating Parameters •
Capacity: 200 tiles/day
•
Machine/equipment:
•
TARA-MCR Machine: 1
Moulds (PAN): 200
Alignment tool: 200
Bend test equipment: 1
Power requirement: 5 units/ day, single phase 1 KW electric connection would be sufficient.
•
Other requirement: water 100 l./ day
•
Raw material
Cement: 2 bags/day
Sand/stone dust: 4 qt./day
•
Packaging: No special packaging is required
•
Manpower requirement for production: 4
Techno-economics a) Land and building with auxiliaris, 300 Sq. ft. covered area: Rs. 1,00,000 b) Machinery and equipment: Rs. 1,00,000 c) Working Capital: Rs. 2,00,000 d) % Profit: 30 per cent Selling price per tile: Rs. 12.00 M/s Development Alternatives a NGO of repute has developed the technology and machine for manufacturer of MCR tiles. M/s D. A. Orchha District Tikamgarh near Jhabua. Entrepreneurs can contact state rural engineering services for supply of tiles.
M. S. Virdi Ex-Director, CSIR, Bhopal. H-15, Sterling Castles, Hoshangabad Road, Bhopal. E-mail: [email protected] Note: The author may have used various references in the preparation of t his article. For further details please contact him/her. Disclaimer: Articles & information in the e-zine Science Tech Entrepreneur contain views expressed by individual authors or are taken from various sources Science Tech Entrepreneur does not own any responsibility for their authenticity.
being. Central Government as well as State Governments are keen to provide
housing to everyone and especially to weaker sections of the society. The cost of housing construction is increasing day by day due to rising cost of building materials. The government sponsored agencies and individuals are looking towards low-cost building materials without compromising with the quality. Research and development organizations of the country have developed low-cost building components for walling and roofing which enable one to build improved houses at comparatively cheaper cost. Price of corrugated G.I. sheets used for roofing, is continually increasing while its use doesnot provide thermal comfort in a tropical country like India. Use of Asbestos-cement sheets is being discouraged due to health hazards associated with asbestos fibre. MCR (micro concrete roofing) technology meets the growing demand for high quality roofing. MCR tiles are cost effective and extremely versatile roofing material. MCR tiles can be used on steel and wooden under structure to make attractive roofs on residences, farmhouses, and pavilions.
Advantages MCR tiles have several advantages: 1. These are water and fire proof proof 2. These are eco-friendly
verandahs
3. Cheap in cost 4. Utilises waste (stonedust)
Process of manufacturing 1. Step I •
Selection of raw material
•
Cement (43 grade)
•
Stonedust (fine)
•
Aggregate (<6mm)
•
Water
2. Step II Mix preperation: The above raw materials are mixed in the following ratio: Cement: Stonedust: Aggregate: Water 1: 1.5 : 1.5 : 0.5 (by weight) 3. Step III Mix vibration: The prepared mix is put on a polythene sheets and placed over vibration table for about 45 sec. a nail is inserted in the rib for holes. 4. Step IV Moulding and stock curing: The polythene sheet is then carefully placed on the plastic moulds for getting a uniform shape. The moulds are then stacked one above the other in a set of 25 for next 24 hr. 5. Step V Demoulding and water curing: The tiles are then demoulded and seperated from the plastic sheets. The nails are also taken out and edges sharpened for better finishing. Then the tiles are kept in the curing tank for another 7 days.
6. Step VI Strength and quality testing: After the tiles are taken out from the tank these are stored for next 21 days in open or shed. Tiles from the stock are taken at random for testing in accordance with standard specifications. Then the tiles are ready for sale.
Product Specifications Clear length
488 mm
Length after overlap
400 mm
Clear width
240 mm
Width after overlap
200 mm
Thickness
8mm/ 100mm
Corrugation depth
50mm
Normal weight
2.25-2.60 kg
Purlin spacing
400 mm
Load bearing capacity
80/100 kg
For covering 10 sq. m. (100 sq. K) roof area 130 tiles are required.
Operating Parameters •
Capacity: 200 tiles/day
•
Machine/equipment:
•
TARA-MCR Machine: 1
Moulds (PAN): 200
Alignment tool: 200
Bend test equipment: 1
Power requirement: 5 units/ day, single phase 1 KW electric connection would be sufficient.
•
Other requirement: water 100 l./ day
•
Raw material
Cement: 2 bags/day
Sand/stone dust: 4 qt./day
•
Packaging: No special packaging is required
•
Manpower requirement for production: 4
Techno-economics a) Land and building with auxiliaris, 300 Sq. ft. covered area: Rs. 1,00,000 b) Machinery and equipment: Rs. 1,00,000 c) Working Capital: Rs. 2,00,000 d) % Profit: 30 per cent Selling price per tile: Rs. 12.00 M/s Development Alternatives a NGO of repute has developed the technology and machine for manufacturer of MCR tiles. M/s D. A. Orchha District Tikamgarh near Jhabua. Entrepreneurs can contact state rural engineering services for supply of tiles.
M. S. Virdi Ex-Director, CSIR, Bhopal. H-15, Sterling Castles, Hoshangabad Road, Bhopal. E-mail: [email protected] Note: The author may have used various references in the preparation of t his article. For further details please contact him/her. Disclaimer: Articles & information in the e-zine Science Tech Entrepreneur contain views expressed by individual authors or are taken from various sources Science Tech Entrepreneur does not own any responsibility for their authenticity.
