C. B. M. Engineering

Radaur, Yamunanagar, Haryana

• Fly Ash : Key ingredient for manufacturing CLC blocks is fly ash. Most of the CLC companies in India use fly ash to manufacture CLC blocks. Fly ash is mixed with water to form Fly Ash slurry. The slurry is then mixed with Cement to form a proper homogeneous mixture suitable enough to add Foam. Silo is recommended for storage of Fly-Ash due to large quantities being required.
• Cement : 53-grade Ordinary Portland cement (OPC) from reputed manufacturer is required for manufacturing CLC blocks. Cement supplied by mini plants is not recommended due to drastic variations in quality over different batches. The Strength of the block produced depends largely on the quality and quantity of cement used. Cement is usually stored in silos or can be stored in bags itself.
• Foam : Foam is the main accounting factor in production of CLC Blocks. The density of the blocks produced depends upon the quantity of foam induced in the mixture. Foam is generated with the help of Foam generator. Foam is produced by mixing the Foaming Chemical in water. The solution is then sucked through the foam generator which then generates suitable amount of Foam.
• Water : Water is required in all stages of manufacture of CLC Blocks right from the slurry mixture formation to final Curing of the blocks produced.

• The lower densities of 400 600 kg/m³ are ideal for thermal insulation applications. This range is also used in laying sound insulating layer over structural slabs of intermediate floors in high-class hotels and institution buildings to minimise transmission of noise between lower and upper floors. It can also be used as a filling in depressions in bathrooms or other floors due to up-stand beams etc. It makes a far superior alternative to the commonly used Glass wool, wood-wool etc.
• The medium density range 800-1000 kg/m³ is utilized for making pre-cast blocks for non-load-bearing walling masonry in framed structures. The size of blocks for the party/external walls may be 500x250x200 mm and the internal partition blocks may be 500x250x100 mm nominal size, although any desired size as per requirements, may be produced.
• The high density range from 1200kg/m³ is structural grade material utilized for:-(a) In-situ casting of structural (load-bearing) walls and roofs of low rise individual or group housing schemes.(b) Manufacture of reinforced structural cladding or partitioning panels.(c) Making pre-cast blocks (500x250x200/100 mm) for load- bearing walling masonry for low rise buildings.

• Lightweight : CLC Blocks are about 50% lighter than clay bricks of equivalent size. This translates into less dead weight of buildings and allows entire structure to be lighter therefore reducing amount of steel and concrete used in structural components like beams, columns and roof/floor slabs
• Ease of Working : CLC Blocks are very easy to work with and can be cut as well as drilled accurately reducing the amount of waste generated.
• Single product solution : Buildings constructed with CLC Blocks do not require separate insulation products reducing construction cost, energy footprint and environmental impact of buildings.
• Environmental Friendly : Manufacturing of CLC Blocks does not have high energy requirements. Since CLC Blocks are made from fly ash an industrial waste product generated by thermal power plants, it offers a low cost and sustainable solution for today and tomorrow. CLC Blocks are a requisite for green building.
• Increase in Strength : CLC Blocks gain strength over time due to water curing properties and thus have Longer Life. Buildings constructed with CLC Blocks do not require routine repairs that are required for buildings using clay bricks.
• Thermal Insulation : CLC Blocks offers excellent thermal insulation. This reduces recurring cost of energy required for heating and cooling. Better thermal insulation also allows usage of smaller capacities Air-Conditioner than required conventionally.
• Shorter Project Duration : Buildings can be built with CLC Blocks 50% faster compared to clay bricks. This translates to lower project completion times benefiting project developers.
• Fire Resistance : Due to high fire resistance offered by CLC Blocks, structure made from CLC Blocks have higher rate of survivability in case of fire.
• Sound Insulation : Sound absorption properties of CLC Blocks make it ideal material for reducing ambient noise. CLC Blocks is well-suited for establishments like hospitals and offices situated in noisy areas.

• Preparing a mixture of slurry of Cement, Sand, Fly Ash, Foam and Water.
• Pouring the mixture into a form or mould of the intended concrete product.
• Curing the poured mixture.
• De-moulding the concrete product.
• Utilizing the concrete product.

• Steam Curing Plant : Steam Curing Plants are usually suitable for Higher Production Capacity plant and include Set up of Boiler, Steam Chamber, Silos, Cutting Machines etc. Such plants require heavy initial investment but result in less labour, fast curing, more production.
• Water Curing Plant : These Plants are generally suitable for Small & Medium capacity plants and can be started with a very small investment.

Comparison of CLC Blocks & Red Clay Bricks