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Investment, Manufacturing Cost & Return on Investment of Boundary Wall / Compound Wall with
Worlds latest Concrete Extrusion Technology duly reinforced with Carbon steel wires.
Investment in project: -Rs. 28 Lakhs all-inclusive except for land, which is considered on Rent. Land required about 1-Acre, having length to width ratio of 4:1. Power 35KW.
Imported Machinery Rs. 18 Lakhs: - from China Approx. Landed price Mumbai with Import duty, only if complete set is purchased i.e. Boundary wall Panel Extrusion M/c Size 50 x
300mm x 2 -1 set & Supporting 'H' Column M/c size 150 x 150mm x 2 1 set, other Supporting machinery: - Concrete Mixer 17.5 CBM on stand with platform (with single horizontal
shaft mixer having discharging gate installed Bottom of mixer, so that concrete falls directly into tray of manual cart)+ Stressing m/c -1 set + Manual Feeding Cart for concrete mix
delivery 2 Nos. + Slab Cutting m/c (for Panels & Column) 1 Nos. + Wire Coil Dispensing stand -3 set + Lifting & Shifting Trolley for shifting Extrusion M/c -1 Nos.) &
Balance 10 lakhs is cost towards, consultancy by Ace Associate detail given below, Civil Work for making well-leveled long line Concrete Platform for 10 Lane (Which is similar to
making concrete road) of size 80 meter x 10 meter for Extrusion of wall panels slab etc. + Civil cost for Abutment + Steel Flats to be grouted on Floor for Guiding Extrusion M/c & Cost
of Land Development to set-up plant.
Panels & columns are Extruded with extrusion M/c & other supporting M/cs on a Well-leveled long line concrete platform without the need of any Mold or Formwork. Process is 5 times
faster & less curing time then convention casting process. Needs only 6 labors. Panels have Hollow cores hence less in weight by keeping same strength. 100% margin compared to
Market Price. Can make Toilet block unit under Swachh Bharat Abhiyan. Vision of Shri Narendra Modi Honable Prime Minister
Additionally manufacture other Extruded concrete products like heavy duty Boundary Wall Panels & Supporting H column, manufacture Light Load Slabs with additional
reinforcement for Affordable housing, Mezzanine floor, Factory walls, Fencing wall, Panels for Toilet blocks, Beam, Column, Lintel, Fencing post, T Beam, Purlin Etc. with respective
Extrusion m/c & its size on the same concrete platform & above Supporting machinery.
Complete Manufacturing Cost for Extrusion of Boundary Wall Panel 50 X 300 mm 7 feet long- Weight 9.5 kgs / sq. feet Panel Column
& Column 150 x 150 mm9 feet long & weight is 13.5kgs/ running feet: - Rs / Sq. Rs /
Concrete Mix contents: - Cement + Sand + Aggregate. Density 2400 kgs / Cbm feet Run Ft
Cost of M25 Concrete is used for Boundary wall Panel. Size 50 x 300mm. Weight 9.5kgs / Sq. feet & Supporting 'H' Column size 150 x 150mm &weight is
13.5kgs/feet approx. Cost of Raw Material:-Cement Rs. 5,500 / Ton, Sand - 600/Ton (Rs. 22 CFT), Cost of Aggregate Rs. 450 /Ton (Rs.21 CFT). 12.00 16.50
Total CBM cost of M25 Concrete is Rs. 2,950. There by cost of Panel Rs. 12 per Running feet & Column Rs.16.50 per Running Ft.
Reinforcement by Carbon Steel Wire of 3mm Dia. Boundary Wall panel has 4 Nos.& Cost is Rs. 4.40 / Running feet &Supporting H column has 7 Nos. & cost is
4.40 7.60
Rs. 7.50 per Running feet. Rate considered of carbon steel wire is @ Rs. 65 / Kgs.
Cost of 6 Nos. of Labor for 10 hrs. / Shift. Skilled Labor to run machine @ Rs. 11,000 / Month. 5 helpers @Rs.9,000 / Month. With all calculation Labor cost for
0.90 0.20
Boundary Wall panel is Rs. 1.00 per Running feet & H Column is Rs. 0.25 per Running feet. Considered 300 days working with all benefits & 95% efficiency.
Cost of Cutting of Slab. Average length of panel 7 ft & H Column is 8 ft & the cost of wear & tear of blade per cut is approx. Rs 1.83/- for panel & Rs 1.83/- H
0.25 0.25
Column. Hence cutting Cost per Running Feet for panel is Rs. 0.25/- & H Column is Rs. 0.25/-.
Cost of Local Power / D.G. Set (35KW) & Water (1,000 liter /day) for Slab & Column is Rs. 0.90 per running feet out of which 85% of expenses are loaded on
0.80 0.10
Panel i.e. Rs.0.80 according to the production & 15% is loaded on Column i.e. Rs. 0.10.
Cost of Repair & Maintenance: - 15% of the plant cost is considered as annual cost of maintenance for Replacement of Wear & Tear parts & labor for Repair.
(Plant cost Rs. 15 lac) To this we have also added Cost of Storage, Handling, and Packaging & Misc. Expenses. Total cost for Panel & Column Is Rs. 0.66 per 0.45 0.10
running feet. Loading 85% on Panel & 15% on Column i.e. 0.45/- + 0.10/-
Cost of Rejection: - 2% of Panel & Column cost is considered towards Rejection, Wastage, Breakage, rejection & shortage in Incoming Raw Material Etc. For
0.20 0.50
Panel are 0.20/- Running feet & of Supporting H Column are 0.50/- Running feet.
Rent cost for 1 acre Land: - @ Rs. 50,000 /Acre / Month per Running Ft of Panel & Supporting column. (In case of own Land, Add this amount to your profit.)
0.80 0.20
Total Rent Rs. 1.00 per running feet out of which 85% of expenses are loaded on Panel & 15% is loaded on Column i.e. 0.80 + 0.20/-
Amortizing & Depreciation cost on Plant & Machinery for 60 months for Panel & Supporting column per Running Feet of
0.70 0.30
Total cost of Amortizing & depreciation is Rs. 1.00/- out of which 85% of expenses are on Panel & 15% is on Column. i.e.0.70 + 0.30
Interest Cost on 28 Lakhs @ 15% per Annum for Panel & Supporting column per Running feet.
0.50 0.25
Total cost is Rs. 0.75 out of which 85% of expenses are loaded on Panel & 15% is loaded on Column. i.e. i.e.0.50 + 0.25
A). If Cost per Ton of Cement 5500, Sand 600 (Rs. 22CFT), Aggregate 450 (Rs.21CFT) than Mfgr. Cost of Panel & Column per Running feet 21 26
While considering Variation in Cost of Raw Material across India we have worked out Cost for Panel & Column accordingly
B). If Cost per Ton of Cement 4800, Sand 425 (Rs. 16 CFT), Aggregate 525 (Rs. 24 CFT) than Mfgr. Cost of Panel & Column per Running feet 20 24
C). If Cost per Ton of Cement 6000, Sand 670 (Rs. 25 CFT), Aggregate 850 (Rs. 40 CFT) than Mfgr. Cost of Panel & Column per Running feet 24 30
D). If Cost per Ton of Cement 6000, Sand 560 (Rs. 21 CFT), Aggregate 410 (Rs. 19 CFT) than Mfgr. Cost of Panel & Column per Running feet 22 27
E). If Cost per Ton of Cement 4500, Sand 1200 (Rs. 45 CFT), Aggregate950 (Rs. 42 CFT) than Mfgr. Cost of Panel & Column per Running feet 24 30
Panel of 7 feet with 4 wires of 3mm is (Rs.22 Avg. cost x 7feet) Rs. 154/- & Column of 8 feet with7 wires of 3mm is (Rs. 28Avg. cost x 8feet) Rs. 224

Case A: - Panel in Rs Case B: - Panel in Rs Case C: -Supporting Column in Rs Case D: - Supporting Column in Rs
Sale price - Mfg. cost = Profit (%) 350 154 = 196 (56%) 225 - 154 = 71 (32%) 540 224= 316(58 %) Rs.480 224= 256 (53%)

For making boundary wall with 6 Nos. Panels of 7 feet long (6nos x 7 feet= 42 sq. feet) + 1no of Supporting H Column of 8 ft height (4 x 8ft ht =2 Sq. feet) Total = 44 Sq ft.
Sales price for Making wall with 6 panels for height of wall of 6 ft is Rs. 350 /panel x 6nos.= Rs.2,100 +1 Pc of Supporting Column@ Rs. 540 /pc.
So Total Sale price for making Boundary Wall is 2,100 + 540 = 2,640 / 44 sq. feet = 60 / Sq. ft with 6 ft height. Or 2640 / 7.4 = Rs.356 Running feet.
Manufacturing Cost for Making wall with 6 panels for height of wall of 6 feet is Rs. 154 / panel x 6nos = Rs.924 + 1 Pc of Supporting Column Rs. 224 /pc.
So Total cost of wall is Rs. 924 for panels + 224 column = 1148 / 44 Sq. ft = Rs.26 per Sq. feet with 6 ft height or 1148/ 7.4 = Rs.155 Running feet.
Profit refer above calculation (Rs. 2100 -924= 1,176)+ (Rs. 540- 224= 316)so 1176 + 316= 1492/44 Sq. ft = Rs.34 Sq. ft is Profit with 6 ft height or 201 Running feet.
Return on Investment / Break-even
a). If your selling price is Rs 60/- per Sq. ft than your Return on investment of Rs. 28 Lakhs will be by sale of 82,350 Sq. feet OR 14,000 running feet of wall.(with 6 feet height Wall)
b). If you selling price is Rs 50/- per Sq. ft your Return on investment of Rs. 28 Lakhs will be by sale of 1,16,700 Sq. feet OR 20,000 running feet of wall.(with 6 feet height Wall)
c). If your selling price is Rs. 350/- per Running ft than your Return on investment of Rs. 28 Lakhs will be by sale of 15,000 Running feet. (With 6 feet height Wall)
d). If your selling price is Rs. 300/- per Running ft than your Return on investment of Rs. 28 Lakhs will be by sale of 20,000 Running feet. (With 6 feet height Wall)
Please note: You also earn on installation of boundary wall i.e. mini. of Rs. 4 / sq. ft or Rs. 30 / Running ft of 6 ft high wall. This is not considered in above.

Assumptions, Consideration & Conclusion for above Manufacturing Cost Analysis: -

Please note if you make double the size of concrete bed your production will be double with same machinery, but need to add 3 people & cost will reduce to another 15%.
1). Plant set-up - In a 4 5 weeks. Open to sky. Slabs Extruded are Naturally Cured under our hot & humid climate.
2). Start with lowest investment initially, than upgrade the plant to highest capacity.
3). At a time 2 Cast per Lane is Extruded of Boundary Wall Panels for 11 days in a month & 2 days for Supporting 'H' Column by Extrusion m/c.
4). Production time consumed for extruding slab on 80-mtr long platform is less than 1.15 hour & slab cutting about 5 minutes per cut.
st Nd rd
5). Production Cycle for extrusion of slab: - say 1 day Extrude slabs on all 7 Lanes for Boundary wall panels& on 2 day Cut, Lift & Clean and start casting on 3 day. Go on repeating
this for total 13 days& alternate days cut, lift & clean. 2 days cast supporting Column (to match the quantity of Panel & column).
6). So total 15 days extrusion production & balance days Cut, Lifted & Cleaned.
7). Extrusion Ratio of Panel to Supporting Column is 85% : 15%.
8) Total production per month for Boundary Wall panels on (260 feet long) 80 meter less wastage 4 mtr = 76 mtr long casting bed x 7lane x 2 cast per lane x 11days (11days cut lift &
clean)x efficiency 95% = 11,120 Running meteri.e36,470Sq feet.
9). Total production per month for Supporting 'H' Column on 80 meter less wastage 4 mtr = 76 mtr long casting bed x 7lane x 2 cast per lane x 2 days (2 days cut lift & clean)x efficiency
95% = 1968 Running meter i.e. 6,450 Running feet. Production per Year for 300 working days = 1,33,000 Sq. mtr with 6 lane casting bed.
10) Zero Slump Concrete is used for Extrusion of above. Where Water Cement ration is just 0.3%.
11). Extruder needs to be fed continuously with concrete hence we advice good Cylindrical Mixer & not Drum mixer. (Optional For High volume of Production you require Cement Silo &
Batching & Dosing plant with Wheel loader.)
12). You are required to do your working before you make investment, as we will not be responsible for above calculation in what so ever is the case.

M/S ACE ASSOCIATE - Mumbai| Mobile No. +91 99209 90902 | Email aceassociate@hotmail.com| www.indiaprecast.com
 We Offer Most Economical and Simple Smart Solutions for Precast Construction Industry
Comparison & Advantages of Boundary wall with Concrete Extrusion Process V/S Conventional casting in mold Process.
Boundary Wall Panels & Columns are Manufactured By worlds Latest Concrete Extrusion Technology duly reinforced with Carbon steel wires.

Boundary Wall manufacturing by Boundary Wall manufacturing by

No
Worlds Latest technology of Concrete Extrusion Process. Conventional casting in mold Process.
1 Investment: - Boundary wall Panel Extrusion M/c Size 50 x 300mm x 2 -1 set & Supporting Investment in steel Moulds used for Casting Process @ Rs. 65/kg for Panel mould
'H' Column M/c size 150 x 150mm x 2 1 set, other Supporting machinery: - Concrete =255 Nos. of 7 Ft. & Column mould 42 Nos. of 8 feet. Total Investment in Molds +
Mixer 17.5 CBM on stand with platform (with single horizontal shaft mixer having Drum mixture + Stressing m/c + feeding Bucket+ Grinder for Cutting wires + Trolley +
discharging gate installed Bottom of mixer, so that concrete falls directly into tray of manual Land development is Rs 20 lacs.
cart) + Stressing m/c -1 set + Manual Feeding Cart for concrete mix delivery 2 Nos. +
Slab Cutting m/c (for Panels & Column) 1 Nos. + Wire Coil Dispensing stand -3 set +
Lifting & Shifting Trolley for shifting Extrusion M/c -1 Nos. (Landed price Mumbai with
Import duty only if complete set is purchased)+ Consultancy &Cost of land Development for
setting plant isRs.10 lakhs.
Total Investment Rs. 20 lakhs.
Total Investment Rs. 28 lakhs.
2 Profit Margin - minimum 40% compared to molded process. Profit Margin is less compared to extrusion process.
3 Technology - Latest & Fastest. Technology - Very Old & Absolute.
4 Return on Investment- within 4 months. Return on Investment- Minimum 12 months.
5 5 times faster being m/c production, Very easy & simple to manufacture. Slow & Tedious being manual production.
6 Panel Weight of 7 feet is just 66.5 kgs being Hollow with same strength. Panel Weight of 7 feet is just 73.5 Kgs with same strength.
7 Supporting H column Weight of 8 ft is just 108 kgs with same strength. Supporting H column Weight of 8 feet is just 116 kgs.
8 Labors requirement only 6 Nos. Labors requirement minimum 20 Nos. + Supervisor.
9 Molds are not used, No limitation in production. Molds used & highly labor oriented, hence Limitation in production.
10 Curing Time Very less as dry concrete is used. Cement Water ratio 0.3%. Curing time Very high as wet concrete is used.
11 Day & Night production possible by increasing 4 labors. Day & Night production not possible as molding cycle is of 24 hours.
12 Expansion -Using present set-up & supporting m/c it is cheap & easy. Expansion -Using present set-up & supporting m/c it is very difficult.
13 Transportation cost is affordable for long distance as there is high margin Transportation cost is not affordable for all above limitation.
14 Stocks- Low. Cut length from slab as per order & no wastage. Stocks- High. Requires Mold of differ. length or cut from stock & waste
15 Hole in center of column while Extruding to fix steel angle & Barbed wire. Hole not possible for fix steel angle & Barbed wire.
16 Water - free of salt required for production is very less. Water - free of salt required for production is More.
17 Monsoon it is Not difficult to manufacturing, just stop when it rains. Monsoon it is Very difficult to manufacture most plant are closed.
18 Panel Size 50 x 300mm x 7 ft. long weighs only 9.5 Kgs. / ft. Panel size 50 x 300 mm x 7 ft. long weighs 10.28 Kgs. / ft.
For making Wall of 6 feet Height and 7 feet long:- No of Panels on 7 feet required are 6 For making Wall of 6 feet Height and 7 feet long:-
Nos. i.e. 66.5x 6 = 399kgs No of Panels on 7 feet required are 6 Nos. i.e. 71.96 x 6 = 432 kgs
H Column of 8 feet long (13.5kgs) 1no is 13.5 x 8 = 108kgs H Column of 8 feet long (13.5kgs) 1no is 14.5 x 8 = 116 kgs
Total square feet are44 & Total weight Approx. 507 Kgs. Total square feet are 44 & Total weight Approx. 548 Kgs.
Saving in weight - 40 kgs in just 44 Sq. ft. More Weight 40 Kgs. In just 44 Sq. Feet.
19 Production is with only 6 Labor no supervisor. Production is with 20 labor plus supervisors.
1). Production Per Month of Panels is 5200 Nos. (36,470 running feet / 7). 2). 1). Production Per Month of Panels is 3200 Nos. 2). Production Per year =
Production Per year = 62,500 Nos. Average Production by 1 Labor is 38 Panels / Day 38,400 Nos. Average Production by 1 Labor is 6.5 Panels / Day
3). Cost per Panel is Rs. 154/- (Rs 22 per Sq feet) 3). Cost per Panel is Rs. 210/- (Rs. 30 per Sq feet)
4). Supporting 'H' Column Run only 24 days in a year to produce 9600 Nos. 4). Supporting 'H' Column Run only 150 days in a year to produce 6300 Nos.
To match Quantity to production with above panel production with only 6 labors. To match Quantity to production with above panel production with only 20 labors.
5). Cost of Column is Rs. 224/- (Rs 28 per running feet) 5). Cost of Column is Rs. 304/- with 20 labors. (Rs 38 per running feet)
6). Saving by Extrusion process is Rs. 56/- per panel & Rs. 80/- per Column. 6). Rs. 40 extra compared to extrusion process per panel & No saving in
column.
20 Installation / erecting of column: - By Portable Hydraulic earth Drilling Machine. Installation / erecting of column: - Manually by labors.
Using our Hydraulic Drilling M/c., The cost of Installation goes down drastically. Installation cost of Wall: - Labor Rs. 6 + Material at Site Rs. 6.
The Labor cost of drilling is Rs.3/- & Cement with other Material for fixing / holding Column Total Rs. 12/- with manual labor.
is only Rs.3/- Total Rs 6/-. With this Hydraulic Drill m/c you can drill 150 holes in a day.
Material Cost per Sq. Ft. of Boundary Wall - Rs. 26/- by Extrusion Process. Material Cost per Sq. Ft. of Wall Rs. 36/- by Mould Process.
Total Saving per Sq. ft on wall material is Rs. 10/- & Installation cost is Rs 6/- Hence it is costly & more dependent on labor.

Additional Information:-
There are 3 types of Boundary Wall Panels: - Light-duty Panel: Easy to lift by 2 persons for installation, Medium duty & Heavy-duty Panel: Need crane for installation.
Boundary wall panel can be made by Extrusion M/c & its supporting Machinery in Thickness of 50, 75, 90, 100 & 120mm having Width of 300, 500 & 600mm & Length can be cut as
per requirement without any wastage from long slab.
Supporting H Column are made by Extrusion M/c & Supporting Machinery in Size 150 x 150mm, 180 X 220 mm with inter-changeable inserts to suit panel thickness of 50 /75 mm &
Size 180 X 280mm with inter-changeable inserts to suit panel thickness of 90 / 100 thick with through & through Hole in the center for fixing M.S. Angle with Barbed wires for further
extension on height.
Given below is Manufacturing Cost & Weight of various thicknesses of Panels.
(Also given details for its Supporting H column / Beam / fencing Pillar to make Boundary wall)
1a). Light weight Panels used for Boundary Wall or for making Toilet block. (By Extrusion M/c for panel. Size 50 x 300mm x 2 having 20 mm Dia. 5 cores, with 4 nos. of 3mm Dia.
reinforcement.) Panels from this m/c also has Multiple uses for making Toilet Blocks, Sheds, Garden curbing etc. Cost of 1 no of wire per Running feet is Re.1/-. Weight of panel being
hollow is.9.5 kgs / Sq ft. & Approx. Cost of panel Rs. 22 / Sq feet.
1b). Supporting H column (Beam / fencing Pillar) for fitting above panel to make Boundary Wall. (By Extrusion M/c for column. Size 150 x150mm x 2 having 25 mm Dia. core, with 8
nos. of 3mm Dia. reinforcement.) Cost of 1 no of wire per Running feet is Re. 1/-. Weight of Column is 13.5 kgs. / Running ft. Approx. Cost of H column is Rs. 26 / Running ft.
2a). Medium weight Panels used for Toilet blocks or for making Boundary Walls. (By Extrusion M/c for panel. Size 75 x 600mm x 2 having 42 mm Dia. 8 cores, with 8 nos. of 3mm
Dia. reinforcement.) Panels from this m/c also have multiple uses for making Partition Walls, Light load slabs for affordable housing etc. Cost of wire per Running feet is Re.1/-. Weight
of panel being hollow is 12.5 kgs / Sq. ft. Approx. Cost of panel is Rs 28 / Sq. feet.
2b). Supporting H column (Beam / fencing Pillar) for fitting above panel to make Boundary Wall. (By Extrusion M/c for column Size 180 x 220mm x 2 having 30 mm Dia. core, with 8
nos. of 3mm Dia. reinforcement.) Cost of wire per Running feet is Re. 1/- Weight 24 kgs. / Running ft. Approx. Cost of H column is Rs 55 / Running ft.
3a). Heavy weight Panels are used for making Partition Walls / Making Toilet blocks or Heavy duty Boundary Wall. (By Auger / Screw type Extrusion M/c for better finish of
panel. Size 90 x 600mm x 1 having 58 mm Dia. 7 cores, with 8 nos. of 3mm Dia. reinforcement.) Panels from this m/c also have multiple uses for making Partition Walls, Light load
slabs for affordable housing etc. Cost of wire per Running feet is Re. 1/-. Weight of panel being hollow is 13 kgs. / Sq. ft. Approx. Cost of panel is Rs 36 / Sq. feet.
3b). Supporting H column (Beam / fencing Pillar) for fitting above panel to make Boundary Wall. (By Extrusion M/c for column Size 180 x 280mm x 2 having 35 mm Dia. core, with 8
nos. of 3mm Dia. reinforcement.) Cost of wire per Running feet is Re. 1/- Weight 31 kgs. / Running ft. Approx. Cost of H column is Rs. 65 / Running ft.
Medium & Heavy duty Concrete Panels with proper reinforcement & topping coat of concrete can be used for making Roof & floor for affordable housing / Mezzanine floor / Making
Partition wall for Hotels, Bathrooms, Kitchens, Bedrooms, Offices etc. plus Factory walls, Fencing wall, Heavy-duty Boundary wall etc.
Portable Hydraulic Earth Drilling Machine: We also supply Portable Hydraulic Drilling m/c for Drilling Holes/ bores, for Quick Installation of Poles. The m/c is Road Towable & having
272cc petrol engine. 1 man can operate the m/c for Drilling bore effortless & install column. Work done will be super fast and Accurate plus you save Labor by more than 75% & Material
by 50%, which is used at site for column installation. Drills 15- holes / hour of 10 or 12 diameter & 2 feet to 5 feet deep. The same m/c has Multi-purpose use to Drill hole for installing
Vineyard pillars / Tree plantation or to remove soil for Testing etc.
M/S ACE ASSOCIATE - Mumbai| Mobile No. +91 99209 90902 | Email aceassociate@hotmail.com| www.indiaprecast.com