Complete Guide to Setting Up a 500m³/Day Precast Concrete Factory.

 

Complete Guide to Setting Up a 500m³/Day Precast Concrete Factory.

For set up a precast concrete factory with a daily production capacity of 500m³. Below is a tentative detailed breakdown of the requirements:

1. Required Machinery and Equipment

A. Main Machines:

• Batching Plant – 60-100m³/hour capacity

• Molds & Formwork – For different precast products

• Hydraulic Table Vibrator – For better concrete compaction

• Overhead Crane / Gantry Crane – For lifting and transporting heavy precast elements

• Material Handling Equipment: 

• Forklifts

• Trolleys and Conveyor Belts

• Concrete Pump

• Curing Chamber – Steam curing or water curing

• Reinforcement Processing Machines: 

• Stirrup Bender

• Bar Cutting & Bending Machine

• Automatic Mixer Truck / Dumper – For raw material transportation

• Cement & Aggregate Storage Silos

• Water Treatment & Recycling System

B. Additional Equipment:

• Vibrating Tables – For smaller precast products

• Air Compressor – For equipment cleaning and mold release

• Tools & Welding Machines – For finishing and repairs

• Mold Release Agents & Other Chemicals

• Curing Tanks & Heating System – For faster drying

• Quality Control Lab Setup

2. Required Materials

• Cement – OPC 53 grade or PPC

• Sand – Washed M-sand or natural sand

• Aggregates – 10mm, 20mm sizes

• Steel Reinforcement – TMT bars, steel fiber, etc.

• Admixtures: 

• Plasticizers

• Superplasticizers

• Setting Time Controllers

• Air Entraining Agents

• Water – Potable quality

• Chemical Hardeners & Sealants

• Rubber / Steel / FRP Molds – As per production requirements

• Fiber Materials – Glass fiber, synthetic fiber

3. Required Manpower

A. Technical Staff:

• Plant Manager – 1

• Planning manager - 1

• Planning Engineer - 2-3

• Production Engineers – 3-4

• Mechanical Engineers – 2

• Electrical Engineer – 2

• Quality Control Officers – 4-6

B. Machine Operators:

• Batching Plant Operator – 3

• Crane Operator – 4

• Concrete Mixer Operator – 2

• Molding & Casting Workers – 30-40

• Vibration & Finishing Workers – 15-20

• Curing & Storage Staff – 10-15

• Welder & Fitter – 25-30

• Steel Fitter & cutting bending opt.– 20-30

• Helpers & Laborers – 50-60

C. Other Staff:

• Supervisors – 5-6

• Accountant & Admin Staff – 2-3

• Safety Officer – 2

Total Staff Required: 200-250 people (depending on workload)

4. Time Required for Factory Setup

The time required to build and start production in the factory depends on various factors.

• Plant Design & Approvals – 15-30 days

• Site Preparation & Civil Works – 2-3 months

• Machinery Installation & Commissioning – 1-2 months

• Trial Run & Training – 15-30 days

Total Estimated Time: 5-6 months

5. Land Requirement

For a 500m³/day precast plant, the following land is required:

• Production Hall – 4000-5000 sq. meters

• Storage Area (Cement, Aggregates, Steel) – 3000 sq. meters

• Curing Yard & Finishing Section – 2000-3000 sq. meters

• Office, Laboratory, Workshop & Utilities – 1500 sq. meters

• Loading / Unloading Area – 1500-3000 sq. meters

Total Land Required: 15,000-20,000 sq. meters.

6. Estimated tentative Cost of Setting Up the Precast Factory

The total cost of setting up the factory will depend on machinery, infrastructure, and operational expenses.

A. Machinery & Equipment:

• Batching Plant – ₹1.5-2 crore

• Cranes & Molds – ₹1-1.5 crore

• Other Machinery – ₹50 lakh - 1 crore

Total Machinery Cost: ₹3-4.5 crore

B. Infrastructure:

• Civil Works – ₹2-3 crore

• Curing Yard – ₹50 lakh - 1 crore

• Storage & Utilities – ₹50 lakh

Total Infrastructure Cost: ₹3-4 crore

C. Working Capital & Other Expenses:

• Raw Materials – ₹50 lakh - 1 crore

• Labor & Staff Salaries – ₹30-50 lakh (for 6 months)

• Approvals & Licenses – ₹10-20 lakh

• Other Expenses – ₹20-30 lakh

Total Estimated Cost: ₹8-12 crore

Conclusion

Setting up a 500m³/day precast concrete factory requires proper planning, investment, and skilled manpower.

Note: Above the calculation and valuations are tentative. These are might be reduced an

d increased depends on project design, factory location, Machinery, equipments and materials price's.