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How to start producing aerated concrete: business plan, financial calculations. Business idea: production of aerated concrete blocks Business plan for the production of aerated concrete

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Concept summary

To open a shop for the production of gas blocks, an example of a business plan of which is presented in this material, you must first decide which legal form of business will be optimal for this undertaking. Due to the fact that the scale of gas block production will be relatively modest, then register a company with limited liability at least not rational. Best Option- Individual entrepreneur on a simplified taxation system. The tax rate in the simplified tax system is relatively acceptable and amounts to 15% (income minus expenses). A pleasant feature of individual entrepreneurs on the simplified tax system is tax returns, which are filled out in no time even by a person who is far from the accounting profession.

As for the classification of this business according to OKVED, you should choose such codes as:

23.61 Manufacture of concrete products for use in construction.
23.61.1 "Production of finished building products from concrete, cement and artificial stone."
23.61.2 "Production of prefabricated building structures from concrete, cement and artificial stone."

As for raw materials for the production of aerated concrete blocks, the following components are used:

Ordinary clean water.
Quality Portland cement.
Various fillers.
hardening catalysts.
Caustic soda.
Gasifier.

At the initial stage of the business, the search for bona fide suppliers of raw materials should be the top priority for the entrepreneur.

How much to invest in opening

It was determined above that the initial costs for opening a shop for the production of gas blocks will amount to 500 thousand rubles. For what purpose these funds will be used is described in the following table:

Note: equipment for the production workshop, the cost of which is 200 thousand rubles, will allow the production of up to 10 cubic meters of aerated concrete in one work shift. Subsequently, the production line can be upgraded to increase output finished products.

Marketing plan

Here is an approximate “outline” of a marketing plan, the timely execution of the points of which will significantly increase the chances of a business to reach an acceptable level of profitability:

Establishing contacts with construction organizations and organization retail with private individuals.
Periodic placement of advertising modules in the print media of the region.
Creation of a business card site with minimal information about the products of the production workshop.
Accommodation advertising banners in the busiest places in the city.

Most likely, in the first six months, the shop for the production of gas blocks will operate at no more than 80% of its potential "capacity". The daily output will be at the level of 8 cubic meters of gas blocks. The cost of selling one cubic meter of aerated concrete blocks is approximately 3,500 rubles (this figure varies slightly in different regions). Accordingly, with 23 working days per month, the shop will bring its owner 644,000 "dirty" income. In a year, the amount of income will be about 7,728,000 rubles.

Production plan

To accommodate a workshop for the production of gas blocks, you need to rent a relatively small room, with an area of about 50 square meters. meters. It must be well ventilated and heated, and must comply with all necessary requirements fire safety. When preparing the premises for the launch of the production of gas blocks, special attention should be paid to checking the condition of the electrical wiring and plumbing. It is better to store ready-made aerated concrete blocks not in the workshop, but on the street under a tarpaulin canopy.

The most optimal schedule for the production of gas blocks is given below:

Monday-Friday from 08:00 to 20:00.
Saturday and Sunday are scheduled maintenance days for equipment or days off.

The list of employees of the aerated concrete production shop, as well as their approximate amounts wages are shown in the following table:

№	Job title	Number of people	Salary, rub.	Monthly payment fund, rub.	Payment per year, rub.
1	Production technologist	1	25 000	25 000	300 000
2	production line worker	2	20 000	40 000	480 000
3	Loader	2	15 000	30 000	360 000
TOTAL					1 140 000

Calculations of income and expenses

In this section, you can see the calculations of the current financial costs for ensuring the stable functioning of the production workshop, as well as calculations of the possible profit from this type of business. The first table is an overview running costs workshops for the production of aerated concrete blocks.

The profitability of a gas block production plant opened in a small Russian city is calculated in the following table:

The calculations show that the gas block production business can bring an extremely good annual income to its owner. Even despite the location of production in a provincial Russian city, the potential net annual profit could be almost four million rubles. Accordingly, the monthly net income from the work of the shop for the production of aerated concrete blocks will be more than 300,000 rubles. The profitability of a small private workshop for the production of concrete gas blocks is around 50%, and this is an extremely high value. With the rapid establishment of distribution channels for products, the initial investment in the organization of this production will pay off in about two to three months.

Possible risks

Opening a gas block production workshop is a business that involves some risks, which, however, will not be so great if you initially think over the development strategy to the smallest detail. The most likely risk factors include the following:

Increase in prices for public utilities and, consequently, an increase in the cost of production.
Decline in sales associated with a decrease in demand for aerated concrete blocks due to the unstable economic situation in the construction industry in the region.
The emergence of new building materials on the market, which in their properties and price are superior to the "classic" aerated concrete blocks.
An increase in the level of competition in the construction sector of the region, which may lead to forced dumping of prices for the products of the shop for the production of aerated concrete blocks.

In conclusion, I would like to note that if there are stable distribution channels and supplies of raw materials, the threat of any of the above “extraordinary” situations can be leveled without serious negative consequences for business development.

Aerated concrete is a building material. An artificially created stone with spherical air pores. Beginning entrepreneurs think about creating a business, which includes the creation and implementation of a product. But first you need to draw up a business project for the production of aerated concrete.

In our time this project enjoys in great demand. Aspiring entrepreneurs are interested in how to launch this project to create quality material. It is attractive in that the payback period is short, because many people use this type of stone during construction. Aerated concrete parameters: 10 * 30 * 60 cm and 20 * 30 * 60 cm. It has a large number of positive qualities:

unpretentiousness to the base of the house, high strength, low weight;
retains heat well, does not let in cold, protects from external noise;
easy to lay, allows you to quickly erect a structure;
easy to handle desired shape material;
environmentally friendly material;
earthquake resistant;
fire-resistant stone, with high fire safety.

Therefore, consumers choose this product. The product contains the following components:

cement;
sand (quartz is perfect);
blowing agent (it can be: aluminum powder, paste, lime, ash, gypsum).

Stages of organization

Determine how large your enterprise will be, what type of products you will produce. There are two types of material production:

autoclave;
non-autoclave.

In order to produce aerated concrete according to method 1, it is necessary to harden it in an autoclave with steam. To make material according to method 2, it is necessary to dry aerated concrete using heating.

What you need:

rented or private premises;
line for the production of gas blocks from scratch;
workers.

From the data on how much production will be and what type of material is suitable, you can determine the area of \u200b\u200bthe room, the amount of equipment and the number of employees.

If you plan to produce up to 30 meters of cubic blocks per day, work an 8-hour shift, a room of 70 square meters will be enough for you. In the manufacture of 100 - 150 cubic meters, working around the clock, an area of \u200b\u200babout 600 square meters will be required. It is necessary to have warehouses for storing products, although it is allowed to leave the blocks in the open.

To produce 1 cubic meter of blocks you need:

With such data, it turns out that the cost is 1,500 thousand. It turns out that the minimum price for 1 cubic meter is 2,500 thousand.

Business plan for the production of aerated concrete blocks:

registration of an organization - from 7 to 10 days;
finding rental premises- a month before the start of the enterprise;
purchase of equipment - two weeks before the opening;
installation of equipment and connection - before the start of activities;
purchase of the necessary raw materials - a week before the start;
recruitment of employees - before the start;
Start production process- after registration paperwork;
finding buyers, establishing sales - from the moment the work on the project begins;
material sales;
stock creation.

Finding Clients

Pleases manufacturers and buyers with the fact that the building material is suitable for any climatic zones. It is commonly used when constructing buildings:

low-rise residential premises;
industrial;
agrarian;
administrative;
social.

The product is in demand both among large organizations involved in construction, and among individuals who have the right to build.

You can sell goods to construction trade warehouses, markets. Distribute price catalogs to stores. Send business proposals to developers. Publish ads for private clients.

Necessary equipment

If you have a small organization with a small capital investment, use non-autoclave aerated concrete equipment (drying of the manufactured blocks is carried out naturally). In this case, you will need molds for pouring and a professional mixer.

If an autoclave discovery occurs with a more powerful production line, you will need an autoclave in addition to the usual fixtures (for the purpose of increased heat treatment). Also required:

vibrating sieve;
compressor;
dispenser;
cutting devices;
conveyor line.
steam generator;

A vibrating sieve is needed for sifting sand. The dispenser precisely determines the amount of the required components. The steam generator provides steam for the processing of aerated concrete blocks.

With such a set, the production speed will increase, but a larger amount of money will be required to open.

Based on a capacity of 60 cubic meters daily, the cost of the minimum set is 790,000 rubles. The price of delivery, VAT of installation, adjustment and connection of equipment to utilities is not taken into account.

Costs and profits

You will spend three months on starting a business, you should think about opening in early spring. The amount of your investment during this period will be 4,378,000 rubles.

Costs in rubles:

All this is required to start a business. Every month you will spend certain amounts in rubles:

It turns out about 1,100,000 rubles every month.

Profitability per high level. Payback period from 4 months to a year.

Possible income level

Income depends on productivity. You can have 3 predictable development options: pessimistic, realistic, optimistic.

With option 1 (download capacity - 30%), your proceeds are 331,200 rubles per month:

Option 2 (download capacity - 60%) assumes an income of 662,400 rubles per month:

Efficiency is up to you. Also influenced by the factor that the demand for this product is seasonal. It is advisable to start production during this period and have time to sell all the goods.

Registration and registration of business

You need to register your organization in the form of "IP" or "LLC". It is necessary to draw up a business plan for production, analyze the situation on the market, and identify competitors. Here step-by-step instruction:

Enterprise resume;
Marketing project;
Organizational plan;
Financial plan;
Risk analysis.

If you understand that you cannot deal with all the subtleties in the registration process, we advise you to contact specialists.

Costs and payback period

You will need to invest about 5 and a half million in the project. With an average capacity of aerated concrete production (30 - 60% of the potential), the payback period for your production will take from 7 to 12 months from the start of the production line. It is possible that this period will be reduced, with the condition that the implementation of the material reaches 90%.

Disadvantages and advantages of this business.

The positives are:

demanded goods, the demand for which is constantly growing;
low production costs;
high profitability, short payback period;
not a very large amount of initial capital is required;

The flaws are seen in the following:

increasing and serious competition in this market;
demand for goods is seasonal;
the need for storage facilities;
You need to constantly attract new customers.

Each region has its own specifics. When opening a production, be based on data from your region.

Useful video

First, get to know the market. It is advisable to find buyers in advance, this will save you from the fact that the finished product will be idle.

Organize your venture in the spring so that by the time construction usually begins, the vases have a stock of finished product.

If you are going to produce non-autoclaved concrete up to 10 meters of cubic material daily, then you will spend about 200,000 thousand on equipment, if from 25 - 30 cubic meters, then about 450,000 thousand, if 75 - 150 cubic meters, then from 2,000,000 thousand . Decide how much product you can sell in your area. From this data, decide how much to produce.

It is profitable to create an organization for the production of aerated concrete. A novice entrepreneur needs to expand their knowledge in this area. Follow all the instructions of the business plan before opening a business. With the right organization of the project, success awaits you!

How to start producing aerated concrete: a business plan, financial calculations

5 (100%) votes: 1

Staff
Sales
Taxation system
Permissions to open

How to organize a mini production of aerated concrete in the current realities, and is it even worth climbing into this niche in the current competition, because a small enterprise will not be able to “survive” at the same prices for its products as the flagships of this niche, and a large one requires huge investments. Let's try to understand this issue.

How to start an aerated concrete business

To organize a business, you will need to rent a room. Its area, of course, depends on the scale of production, and it can vary from 70 sq. m. up to 600 sq. m. m. If average cost 1 sq. m. per month is about 100 rubles in Russia, then the cost of rent will be from 7 thousand rubles. up to 60 thousand rubles A warehouse for storing aerated concrete is optional, as it is not whimsical and can be stored on the street.

What equipment to choose for the production of aerated concrete

You can purchase equipment for the production of aerated concrete yourself, or you can contact companies that will offer you ready-made lines plus training in production technology. The equipment includes: molds where aerated concrete is poured, an electronic water dispenser, a dispenser unit for bulk materials, a mass cutting device, an activator mixer and a slurry mixer. The performance of various ready-made lines can be different from 10 to 150 cubic meters. m per day. So their cost will be different, about 90 thousand rubles. and higher.

Raw materials used in the production of aerated concrete

One of the main issues in the production of aerated concrete is raw materials and their suppliers. The components in the manufacture are:

water, in the amount - 250-300 liters per 1 m3 of aerated concrete, temperature 40-60 gr.
Portland cement, in the amount - 260-320 kg per 1 m3 of aerated concrete.
fillers, in the amount of 250-350 kg per 1 m3 of aerated concrete, river or quarry sand can be used as it,
curing accelerator,
caustic soda
blowing agent, in the amount of 0.5-0.7 kg per 1 m3 of aerated concrete, it is aluminum powder.

Your task is to find profitable suppliers raw materials in your area.

Manufacturing technology of aerated concrete blocks

The production of aerated concrete blocks includes the following technological algorithm:

form preparation,
preparation of aerated concrete mortar,
array filling,
cutting aerated concrete massif,
heat treatment,
disassembly of the array into separate blocks.

Staff

Not only the area of the required premises and the volume of raw materials, but also the number of jobs depends on the volume of production. With minimal volumes, you can do without hiring workers, the entrepreneur himself can handle it, but if you want production larger scale, without hiring staff is indispensable (from 2 to 10 employees). You should think about a two-shift work day. As for wages, it is equal to 100-200 rubles per 1 cubic meter. m. of manufactured products. This is somewhere around 20-30 thousand rubles. per month.

Sales

After the production of products, the question of its implementation arises. You can sell finished products construction firms, private developers, there are single clients. It is only necessary to advertise your production: in newspapers, at construction markets, when leaving the city, near cottage settlements under construction, etc.

How much can you earn in the manufacture of aerated concrete blocks

What profit can the production of aerated concrete bring? Let's give brief economic indicators.

The cost of 1 cu. meters of aerated concrete will be about 1500 rubles. It consists of the cost of cement (250 kg - 1000 rubles), sand (300 kg - 180 rubles), aluminum powder and chemical additives (150 rubles), wages and overheads (150 rubles). In Russia, aerated concrete sold for at least 2500 rubles. for 1 cubic meter. Accordingly, your minimum profit will be 1000 rubles. and more. The advantage of this business is that it does not require large working capital, since from the time of purchase of raw materials to the sale of finished products, no more than 2-3 days can pass.

How much money do you need to invest to start a business

The cost of creating a production facility for the production of aerated concrete will amount to 30,000-85,000 rubles, depending on the capacity of the produced concrete, (capacity 12 - 50 cubic meters per shift). The cost of molds for the production of blocks is 30,000-40,000 rubles (1 cubic meter of mixture is poured into 1 mold).

Total: 60,000-125,000 rubles.
You will also need consumables (per 1 cubic meter)
Powder aluminum, 500 gr. 105 rub. for 1 kg.
Sand 300-350 rubles. for 1 cu. meter (1.3 tons).
Cement 100 kg. 380 rub.

The cost of producing aerated concrete blocks is insignificant: 520 rubles. for 1 cu. m. The profitability of the production of aerated concrete in all regions is high.

Which OKVED to indicate when registering a business for the production of aerated concrete

OKVED 26.61 - production of concrete products for use in construction; OKVED 23.69 - production of other products from plaster, concrete or cement. If planned wholesale aerated concrete, then you must specify OKVED 46.73.6 - wholesale of other building materials and products.

What documents are needed to open

It is necessary to register a business entity: most often it is individual entrepreneur. If it is planned to sell materials through large companies, then it is recommended to register a limited liability company. Prepared documents are submitted to state authorities or to multifunctional centers public services(MFC). It is also necessary to register with the Pension Fund, Social and Medical Insurance Fund. For settlements with legal entities you need to open a bank account.

Taxation system

To conduct this business, it is better to choose a simplified taxation system, the simplified tax system - “Income minus expenses”, since in the production of blocks there is constant flow on raw materials. The only requirement in this system of taxation is proof of expenses. The tax will be from 5% to 15%.

Permissions to open

To open the production of aerated concrete, a business license is not required. But you need to get permission from Rospotrebnadzor. To do this, you must provide the following documents:

constituent and registration documents;
premises lease agreement;
copies of documents for equipment.

In addition, it is necessary to obtain permission from the fire department, the sanitary and epidemiological service, and environmentalists. The lease agreement for the premises must be drawn up for a long period.

DIY productionaerated concreteand foam concrete.

In the construction process, two types of concrete blocks are used - foam concrete and aerated concrete. The release of load-bearing walls is associated with the manufacture of durable aerated concrete, since such blocks bear the main load of the entire structure of the structure. Cheaper foam concrete blocks, the cost of which is 20-25% lower, are used to install non-bearing bulkheads and partitions. From this we can draw the corresponding conclusion that the production of both types of blocks is equally expedient.

One block made of cellular concrete can replace 30 pieces of bricks, so it has a mass of less than 30 kg. It should be borne in mind that aerated concrete blocks, which are light in weight and easily processed, make it possible to build houses without the use of special equipment, that is, lifting installations, tower cranes, etc.

Due to these properties, aerated concrete can be one of the most commonly used materials in the construction of low-rise housing, as well as country houses, private buildings, etc. The popularity of this material is confirmed by the growth dynamics of its production and sales volumes.

Equipment for the production ofaerated concrete.

It should be noted that on this moment domestic enterprises do not develop solutions related to an automated production process with a low cost of non-autoclaved types of aerated concrete, and imported suppliers offer very expensive ones.

In order to release blocks of aerated concrete in a semi-automatic way, which will have a productivity of 12-21 m3 / day, the “aerated concrete” installations used should ensure the presence of:

1. Installations "aerated concrete" with a certain capacity;
2. Vibrating sieve with a mesh of 3 mm;
3. Cassette metal molds used for the production of block products of a fixed size 600x300x200 mm;
4. Petrochemistry, which involves the use of:
a) a complex chemical additive - a gas-forming agent;
b) the choice of hardening accelerator;
5. Additional equipment, as well as chemistry:
a) hydraulic trolleys - 1-2 pcs. (up to 2 tons);
b) substances for lubricating and washing forms;
c) multi-tube dispensers for cement and sand supply (one for cement and one for sand), or separately for cement and sand, two for each installation.

The price is about 18,000 rubles.

Production technologyaerated concrete.

The production of aerated concrete is associated with a very simple technology, which includes several main steps.

The main part of technology.

This group of cellular concrete is characterized by the presence of a cellular structure. The low volumetric weight of cellular concrete is ensured by the presence of bubbles filled with gas and occupying up to 85% of the total volume of the product.

For cooking concrete mix lime, water, quartz sand and cement are used, which are mixed using an aerated concrete mixer. Stirring takes 4-5 minutes, after which it is necessary to add a little aqueous suspension of aluminum powder to the prepared mixture, which can react with lime. As a result, this reaction occurs with the formation of hydrogen, which fills numerous pores or bubbles of the raw mass, having a size of 0.5-2 mm, which evenly penetrate the entire porous material.

After the suspension with aluminum paste is added, the mixture is quickly poured into prepared metal containers, where the process of swelling of the concrete mass should take place. These chemical reactions can be accelerated by vibration loads, which also help the entire mass of the semi-finished product to set and harden faster. After the aerated concrete reaches the required stage of initial hardening, using wire strings, irregularities are cut off from the surface of the solid mixture. After that, the remaining mass is cut into blocks of equal size. The resulting aerated concrete blocks are subjected to heat treatment using an autoclave. After that, the blocks are calibrated with a special milling device.

Autoclaving aerated concrete.

Autoclaving is used to improve the properties of aerated concrete. Formed as well as cut blocks of aerated concrete are placed in autoclave chambers, where for 12 hours under conditions of high pressure (12 kg / cm²) using saturated water vapor, the blocks are processed with a set temperature level of 190 ° C.

The autoclave process makes aerated concrete more durable, which allows for less shrinkage, as well as providing a more uniform structure in the blocks. This type of aerated concrete, like autoclaved, is widely used in many areas of construction due to its sound and heat insulating properties. The level of thermal conductivity of such aerated concrete is 0.09-0.18 W/(m.°C). This thermal conductivity of autoclaved aerated concrete products, when used taking into account Russian climatic conditions, allows the construction of single-row walls that have a thickness of 375-400 mm. In this case, the use of additional heaters is not required.

aerated concrete can also be produced by the non-autoclave method.

If the production of aerated concrete is carried out by a non-autoclave method, then its mass hardens when natural conditions are created. This type production will not require the use of modern high-tech equipment, since it can be produced independently and at home, but its strength will be minimal.
Non-autoclaved types of aerated concrete have a shrinkage of 3-5 mm / m during operation, and autoclave 0.3-0.5 mm / m. Autoclaved aerated concrete has a strength of 28-40 kgf / m², and non-autoclaved - 10-12 kgf / m².

The release of conventional aerated concrete is carried out more rarely than autoclaved. It can also be made at home, since there is no need to buy sophisticated equipment in this case.

Material costs for launching a mini-factory for productionaerated concreteand foam concrete.

In order to open a joint production of foam concrete and aerated concrete, some investments may be required, the calculation of which is presented below.

The mini-plant itself for the production of these types of concrete can have a cost of 105,600 - 283,800 rubles, which depends on the capacity or volume of production of concrete products, which will be 10 - 30 cubic meters. m per shift. For the purpose of producing ordinary aerated concrete - from 29,800 to 85,000 rubles, with a capacity of 12 - 50 cubic meters. m in one shift.

For the manufacture of foam concrete, a foam generator will be needed, costing 27,800 rubles, as well as a compressor - 37,800 rubles. In addition, the mini-factory will use a peristaltic pump, which costs 57,700 rubles.

In the production process, molds for concrete mass will be used, having different sizes - 28,000-40,000 rubles. At the same time, 1 cubic meter of the mixture can be pumped into 1 mold, and if the plant's capacity is 10 cubic meters / m, then 10 molds will be needed.

Total: cost minimum investment will amount to 538,700 rubles, and the maximum - 1,332,100 rubles.
A foam block of 1 cubic meter will cost 3,000 rubles.
Zazoblok in 1 cu. m - about 3,600 rubles.
Price Supplies per 1 cu. m will be:
1. Foam concentrate - 75 rubles per 1 kg - for foam concrete;
2. Aluminum powder (500 gram package) - 105 rubles per 1 kg - for aerated concrete;
3. Sand (300 kg) - 350 rubles per cubic meter - 1.3 tons;
4. Cement (100 kg) - 2 bags at a price of 189 rubles.
It can be seen from the calculation data that the material costs are insignificant - about 540 rubles per 1 cubic meter for foam concrete, or 520 rubles per 1 cubic meter for aerated concrete.

Expenses and income.

The aerated concrete production process is very profitable. The cost of 1 cubic meter will be 1,800 rubles, and the retail price will be 2,500 rubles. Therefore, when producing and selling 250 cubic meters / m of block products per month, the level net income will be 175,000 rubles. At the same time, the payback period of investments will be 1-2 years.

During the seasonal construction works between May and October, the demand for aerated concrete blocks is at its highest as private construction is intensified. Preparatory work related to the start-up of production should fall on the off-season. The presence of small stocks of concrete products during this period in warehouses will be useful, in this regard, it is better to start production from March-April. A quick return on capital investment will be ensured if these conditions are met, which will accelerate the receipt of profit in the form of cash.

If there is a private business not in a rented, but in its own premises, production costs will be minimal. For the manufacture of 1 m3 of concrete, it will take about 2-3 hours. Within one working day, it will be realistic to produce 2-5 m3 of products, and outside help will not be required. If the productivity is 1-2 m3 per day, then all equipment costs can be recouped in a month. When setting up a regular production process of 3-5 m3 per day, one person can make a profit of up to $ 3,000 every month, while the correct construction of the sales market is important. Since the sale of products will affect the profitability of this business.

You can use various ways of advertising, they are all useful, for example, advertise in local newspapers, hand out business cards, place ads on the street, etc. In addition, you should immediately offer ways to deliver products to customers, which will also lead to successful implementation blocks. By signing a contract for the provision transport services you can get discounts later. Any developer will be pleased with the timely delivery of concrete blocks, and he will not even know where they are produced.

Video mini do-it-yourself production of aerated concrete and foam concrete: