For investors

Definitions

HSLWC (abbr. high-strength lightweight concrete) is kind of concrete which has highest strength characteristics and lowest average density. The high-strength lightweight concretes is called concretes with specific strength Rsp more than 25 MPa.

Specific strength (Rsp) is ratio of compressive strength Rcom to relative density of the material (ratio of concrete average density to the true density of water).

Open panel
  • Registration

The business goal of project High-strength lightweight concrete is creating of factory to manufacture the products made of lightweight concrete with high strength for construction of the residential and public buildings as well to participate in the participatory construction using developed technology.

The finished products of our project is:

  1. Reinforced concrete products (or mixed concrete) is made of high-strength lightweight concrete for special building design. These products are intended for corporate clients (organizations) exercising prefabricated or monolithic construction of houses, offices and other buildings;
  2. Residential or public rooms (real estate) which was builded by participatory construction using HSLWC products.

Required investment

Two directions is worked to achieve our business objectives: modernization of existing plant and creating of new plant. Calculation of planed investments and model of development is presented for each direction.

Upgrade the plant

For first direction we need a plant-partner which has own areas, equipments and infrastructure for production of precast concrete.

No Stage Works Time Cost, $
1 Stage 1 Modernization of production equipment, purchase the missing components and assemblies 8-14 months 115-285 thousands
2 Stage 2.1 Design and construction of the object using the designs of high-strength lightweight concrete 6-7 months 30 thousands
Stage 2.2 Development of technical specifications and other documentations for release of finished goods 6-12 months 30 thousands
3 Stage 3 Сommissioning and release of "pilot" products 4-6 months 30 thousands
4 Stage 4 Manufacturing of high-strength lightweight concrete and fractional real estate construction including working capital for production (purchase of materials, salaries, etc.) 12-18 months 1.85-2.29 millions
5 Stage 5 Increase of production volumes and development of technology, patenting 3-5 years 285-345 thousands
6 Stage 6 Creating the own plot for the production of hollow filler 8-12 months 145-200 thousands

In conditions of limited capital to organize the site for development and implementation of civil works it is appropriate to attract a partner-builder, having land, equipment and the necessary licenses for construction activities. The participation in share building (due to products made ​​of concrete) require increased working capital. Based on this start of the project will require the $635 000-$920,000 or $3,210,000 for 3.5 years, excluding working capital for the production of products and in view of these costs, respectively. In this case, the total return on the project will come in 2,5 years.

Build the plant

It is obvious that such a direction requires significant investment, individual design and calculation work for the organization of construction, logistics and operation of the new plant. The model of development of such Business will focus on high-tech production of high quality products, so steps of adaptation technologies and modernization of equipment is minimized:

No Stage Works Time Cost, $
1 Stage1

Design and construction of the plant for the production of high-strength lightweight concrete products

1-2 years 20-28.5 millions
2 Stage 2.1 Design and construction of the object using the designs of high-strength lightweight concrete 6-7 months 30 thousands
Stage 2.2 Development of technical specifications and other documentations for release of finished goods 6-12 months 30 thousands
3 Stage 3 Сommissioning and release of "pilot" products 4-6 months 30 thousands
4 Stage 4 Manufacturing of high-strength lightweight concrete according to project 12-18 months  
working capital for production (purchase of materials, salaries, etc.) 1.43-1.72 millions
perform basic types of work on the construction of the object 4.29-5.72 millions
5 Stage 5 Increase of production volumes and development of technology, patenting 3-5 years 285-345 thousands
6 Stage 6 Creating the own plot for the production of hollow filler 8-12 months 145-200 thousands

Thus, the start of the project in this direction will require an investment of $36.5 million for 5 years. The calculation shows that the first building which will built of high-strength lightweight concrete, will increase income more than 20% than the same area building of the traditional heavy concrete. At the same time for payback of investment is required 7,5 years.

Competitive advantages

Technological advantage developed high-strength lightweight concrete is a universal combination of low average density and high strength. HSLWCs outperform global analogues in these indicators by 15-40% and have additional positive qualities that are not achievable for traditional lightweight and/or heavy concrete.

The advantage for the market is the high efficiency of high-strength lightweight concrete due to a set of special properties that allows to reduce the cost by 2-2.5 times in the zero cycle, increase the number of floors of buildings, reduce the cost shipping and installation work, save in the course of operation of the building. Ultimately it reduces the cost of erected real estate  by 30-40%.

Market size

По данным Федеральной службы государственной статистики объем производства тяжелого бетона за 2011 г. составил 24,7 млн.м3, где 46% - произведено в Москве, Московской области, Санкт-Петербурге и Краснодарском крае. В 2012 году рост рынка составил более 30% и достиг 32,1 млн.м3. Потенциальный рынок для производств железобетонных изделий из высокопрочного легкого бетона или модернизация существующих предприятий позволит занять до 10% общего рынка бетона, что к 2020 году может составлять до 1,5-2,2 млн.м3 в год. При этом реально доступный объемом производства для одного завода по выпуску ЖБИ является 200...350 тыс.м3 в год.

При ориентировании таких производств на жилищное строительство (ввод общей площади жилых домов за 2012 г. – 20,25 млн.м2), общий объем рынка которого к 2015 году составит более 25 млн.м2, использование технологии высокопрочного легкого бетона позволит увеличить его на 1,2...1,5 млн.м2 дополнительно при сохранении темпов роста экономики. В случае использования 100% мощности завода на нужды собственных строительных объектов общая площадь возведенного жилья составит до 800 тыс.м2, при реализации которого по цене 25 тыс. руб./м2 оборот составит до 20 млрд.руб.

Economic efficiency of high-strength lightweight concretes

Снижение материалоемкости и уменьшение массы строительных конструкций без потери их несущей способности и других эксплуатационных свойств является одним из основных факторов повышения эффективности строительства. По оценкам специалистов, применение легкого бетона в 1,5–2,5 раза снижает материальные затраты по сравнению с обычным тяжелым бетоном того же самого класса прочности.

Расчеты показывают, что применение высокопрочных легких бетонов в качестве конструкционного материала при строительстве многоэтажных зданий позволяет снизить общий вес более чем на 40% по сравнению с аналогичной конструкцией из тяжелого бетона или увеличить этажность на 20…25%. В первом случае обеспечивается снижение требований к основаниям и фундаментам, сокращение их материалоемкости (почти вдвое сокращается стоимость работ на нулевом цикле). Во втором – увеличивается общая площадь здания на единицу площади земли, а следовательно, сокращается удельную стоимость 1 м2 квартиры или офиса (до 30%).

Высокопрочный легкий бетон обладает преимуществами при строительстве ответственных сооружений, мостов, эстакад и большепролетных элементов конструкций. Сочетая высокую прочность и малый вес изделия из такого бетона могут иметь большие геометрические размеры будь то балка, ферма или ригель.

Кроме того, высокопрочные легкие бетоны за счет меньшей теплопроводности сокращают энергопотребление при эксплуатации зданий. Изделия из бетона с низким удельным весом способствуют экономии на транспортных, погрузочно-разгрузочных и других накладных расходах при строительстве.

Для области специального строительства расчет экономическую эффективности необходимо осуществлять для конкретной области отдельно.

Works are alreade made

We completed some works in our project to 01 June 2014:

  • The method for calculation and designing the composition of HSLWC that allows to select the recipe of individual kind of reinforced concrete products is developed;
  • Significant volume of scientific results for controlling of prescription and technological factors is obtained that allows to get a desired structure and properties of high-strength lightweight concrete;
  • The technology of the preparation of HSLWC with average density 1300-1500 kg/m3 and compressive strength more than 70 MPa is developed;
  • A patent for an invention is obtained;
  • Industrial testing of HSLWC technology was implemented at the plant of reinforced concrete products January 2013;
  • Own funds to research and survey works for our project is $35 500;
  • Raised investments by grants from 01 June 2012 is $26 000 (in 2 years).

Risks

The main component which lowers the density of the concrete are hollow glass or ceramic microspheres. Increase volume of consumption of microspheres due to their using for the preparation of the developed concrete may encourage producers to increase in production volumes (to meet demand), or increase in the cost of the hollow filler. The creation of own shop for the production of micro filler ($140 000-200 000$ ) will solve this problem. It will increase the production of concrete, reduce its costs and get rid of the dependence on the supplier, but will require increased capital investment in the initial stage of the project.

Navigation menu

Industrial experience

Industrial experience of production of the High-strength lightweight concrete
Industrial experience of production of the High-strength lightweight concrete
Industrial experience of production of the High-strength lightweight concrete
Industrial experience of production of the High-strength lightweight concrete
Industrial experience of production of the High-strength lightweight concrete

Patent

Patent RU №2515450 - High-strength lightweight concrete

Protection of the rights

All information from this website is only for familiarization. These does not can to use without written consent by authors. Intellectual property is protected by a patent for an invention RU №2515450 C1 High-strength lightweight concrete (MPK C04B28/00, C04B111/20) from 11.10.2012. Copyright is FGBOU VPO Moscow State University of Civil Engineering.

S5 Box

Login

Register

*
*
*
*
*
*

Fields marked with an asterisk (*) are required.