Concrete products manufacturing ManualConcrete Products PlantProposal

IntroductionConcrete products plant is a plant that can produce all kinds of molded concrete that includes flooring, paving , retaining walls and building products Concrete products also includes non automatic products like Reinforced precast walls Bulk curbstones Hardstone tiles.Fully automatic products includes CMUs interlock squared interlock Hexagonal and behaton interlocks bond beams solid bricks CurbstonesA concrete products plant includes patching plant, block machine and stacking machine.There are a lot of manufacturer for concrete products plants but the best manufacturer is the German manufacturer of block machines FRIMA GmbH, which will be the scope of this proposal.Concrete products are very appealing products with a very wide variety of products and very few manufacturers in Egypt thats why the market is very big, opened and wide, for a new company the market share will be very big as what will be shown in the section of market research.

Cost analysis:The total initial cost consists of three phases1. Construction & Equipments2. Operation3. Other Expenses----------------------------------------------------------------------------------------------------------------------------------------------------------------1. Constructions Land : the best location for the plant is near to raw material sources like cement, aggregates and sand in order to decrease raw material costs we should consider also the customers locations like ports like adabia and , industrial zones like suez canal improvements and new industrial zones and commercial resorts and construction sites like resorts located in Ain sokhna sharm el skeikh and hurgada, so I suggest that the plants better location is in either Suez in the industrial zone or in Cairo.The complete area for the plants machinery is about 1500 m2, and the recommended storing area is about from 8000m2 to 9000m2.The building for the plant must be app. 30 x 50 x 10h m. The Plant machinery :The recommended plant is Frima HP 1200 with 2 filling devices this plant includes 2 mixers & 2 bucket conveyors with 2 filling devicesThe price of a HP1200 with one filling device is app. 1.75 Mio EURBut the recommended we have to add 2nd filling device and mixing- and batching with two mixers. The price of complete HP1200 with face mix is app. 1.92 Mio EUR. Additionally a rack system is required. A rack system for 2 shift operation must have a capacity from more than 4.000 pieces pallets and costs app. 280.000 EUR (German made)For 2 shift operation you need app. 4.000 pieces pallets. You can use wood, plastic or steel pallets. The wood pallets are good, but the lifetime is limited. (app. 50,00 EUR each)Plastic pallets are ok and the lifetime is good (app. 120,00 EUR each) RecommendedSteel pallets are good and have a very good life time, but heavy. (App. 150,00 EUR each)

And here is the detailed price list for the machinaery costsFRIMA HP1200, 2 filling, complete with mixing- and batching (2 mixers)

1.920.000,00 EUR

Installation and commissioningIncluded

rack system250.000,00 EUR

4.000 pieces plastic pallets480.000,00 EUR

Local steel work200.000,00 EUR

5 paver moulds + 5 block moulds135.000,00 EUR

Transport to Egypt150.000,00 EUR

Total app. 3.135.000,00 EUR

There are alot of alternatives and solutions from frima GmbH and here is the complete budget offer from frima

Concrete products plant proposal5/1/2014Page 6 of 10

Introduction

Budget - offer for FRIMA E500, P650, FRIMA HP1200 and FRIMA HP1400 plant incl. mixing- and batching plant

E500 1 fillingE500 2 fillingP650 1 fillingP650 2 fillingHP1200 1 fillingHP1200 2 fillingHP1400 1 fillingHP1400 2 filling

semi automaticfully automatic

max pallet size1200 x 550 mm1400 x 670 mm1400 x 1200 mm1400 x 1400 mm

Capacity/8 hour product.

8"-blocks (40 x 20 x 20hcm)6.300 pieces6.300 pieces11.500 pieces11.500 pieces25.000 pieces25.000 pieces30.000 pieces30.000 pieces

pavers without facemix700 m700 m1.250 m1.2500 m2.600 m2.600 m3.200 m3.200 m

pavers with facemixnone500 mnone950 mnone2.000 mnone2.500 m

kerbstone - singlemix (higher mixer capacity required)1.180 lm1.180 lm2.650 lm2650 lm4.420 lm4.420 lm5.300 lm5.300 lm

Complete block- and paver plant 295.000,00 320.000,00 877.010,00 EUR942.350,00 EUR1.347.480,00 EUR1.439.150,00 EUR1.422.940,00 EUR1.520.380,00 EUR

- with wetside

- with drysidewithout cuber

- with finger car group none - done by forklift

- with control system + hydraulic

- with safety device

complete mixing- and batching plant

for E500 1 fillingfor E500 2 fillingfor P650 1 fillingfor P650 2 fillingfor HP1200 1 fillingfor HP1200 2 fillingfor HP1400 1 fillingfor HP1400 2 filling

with only basemixer276.380,00 EUR383.510,00 EUR411.470,00 EUR190.000,00

with base facemixer395.590,00 EUR477.440,00 EUR535.970,00 EURno separate facemixer

Complete FRIMA plant485.000,00 510.000,00 1.153.390,00 EUR1.337.940,00 EUR1.730.990,00 EUR1.916.590,00 EUR1.834.410,00 EUR2.151.270,00 EUR

installation + commisioningincluded - with support from customer

transportnot included - ex works Emden acc. Incoterms 2010

civil work and simple steel workMade by customer - FRIMA will support with drawings/sketches

moulds, pallets, racks and other accessoriesnot included - can be delivered by FRIMA or by other suppliernot included racksystem not required

terms of payment30% downpayment, 60% by delivery, 10% after 3 months against performance guarantee, covered by L/C

Time of delivery4 - 6 months after recipe of down payment ex works Emden

2. Operation Equipments:That are used for operations are 1 Loader & 1 Forklift the prices for these equipments varied if its rented or plants property.If rented the 1 working day for loader is 150 L.E and the same to the fork lift, the recommended is that we start with rented equipments the decide whether to buy new or used equipments.A compression machine is needed for performing tests on final products; the recommended is ELE compression machine which may cost up to 10.000 EURO. ManpowerThe total workers and labors for the plant is about1. 10 Labors for sorting and cleaning.2. 3 operators, 1 for every line.3. 3 technicians mechanical and electrical4. Loader and forklifts operators5. Lab technician.6. Store keeper7. Administrator8. AccountantLabors can cost 1500 L.E/monthOperators can cost 1700 L.E/monthTechnicians can cost 1800 L.E/month