Small businesses contribute their lion's share to all areas of production. If we consider one type of activity as a whole, a good example would be mini-factories for the production of concrete in individual settlements. This area of production is in great demand due to the increased demand for individual and low-rise construction.
The industry has put on sale equipment designed for various daily volumes of concrete production. For small businesses, the conventional technology of preparing concrete in a concrete mixer is not suitable.
Concrete production capacity
Depending on the production equipment, any mini-plant is designed for a limited capacity for concrete production, so all equipment can be divided into categories.
Mobile concrete plants . American CEMEN TECH equipment is designed to prepare fresh concrete mortar directly on the consumer’s premises thanks to the development of a compact mobile plant on wheels.
This concrete manufacturing technology is a waste-free production. This product is of high quality. Delamination of the material and hardening during the preparation/delivery/unloading of the mixture are completely eliminated. Production can operate in three modes: around the clock; periodic, for regular customers; for the period of construction of complexes.
The following types of concrete can be produced in a mobile plant:
- traditional;
- color;
- with options for various additives;
- fiber-reinforced concrete and foam concrete.
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Stationary concrete plants. For small businesses, you can purchase enterprises with small production volumes, with a productivity of 20-25 m3 of concrete per hour. This will be a great purchase to get started in this industry. An automated control system allows us to fully maintain the entire technical process and produce high-quality raw materials. An ideal option would be plants of the BSU ST-30 SOLO type.
Search for sales channels for finished products
In the first 3–4 months after the launch of the plant, serious work will be done to find buyers for concrete. Possible product sales channels:
- developers;
- private individuals;
- farms.
Ready-mix concrete in the form of a dry mixture can be sold to wholesale construction bases and markets. Effective advertising methods include posting advertisements on paid and free boards on the Internet, creating a plant website that will present price lists for different grades of concrete and terms of cooperation, and advertisements in local media.
Ingredients and proportions for making concrete
The following factors guarantee high-quality production of material:
- ideal selection of components that determine the proportions of the composition of the prepared mixture;
- methods and conditions of preparation;
- transportation (rotary or stationary bins);
- concrete hardening time;
- resistance to climatic conditions.
The calculation of ingredients in percentage terms depends on the requirements for a specific brand of concrete being produced for sale to the customer, or for mass production.
The amount of aggregates in the solution is calculated taking into account the minimum use, then the prepared cement paste evenly fills the voids between the grains of added sand. Thus, reliable binding occurs between the components of the composition being prepared for sale.
Fillers: crushed stone or gravel, crushed or torn stone, waste from blast furnaces (slag), sand of various grain sizes.
The water ratio is calculated using a special formula; only a pure solution is used, without salt content. The use of sea water is prohibited.
The mobility of the concrete mixture can be changed by adjusting (increasing/decreasing) the composition of the cement paste.
The composition of concrete can be expressed as follows:
- ratio of mixed components by weight;
- measurement in units of volume.
Regardless of the choice of the type of laying components, the quality of the prepared construction mixture always corresponds to the required brand of product.
Equipment for making concrete
Concrete is prepared using equipment (concrete mixers) of periodic or cyclic action. It is necessary to observe proportions when making concrete in a concrete mixer.
With periodic mixing, gravitational mixing of the mixture occurs, or through a forced influence on the mixing of the embedded components.
The preparation time is determined by the mass of the materials laid, as well as the volume of the bunker in which the future cement is mixed.
The cooking process itself consists of the following stages:
- receiving and laying fillers;
- binder dosage;
- mixing ingredients;
- unloading the mixture from the bunker.
Ready-made concrete has a shelf life and delivery time to consumers.
With round-the-clock production, the plant has a number of additional services and equipment that provide the following functions:
- provision of necessary supplies of cement and binders;
- technological equipment to maintain a constant temperature of concrete (heating);
- fortification of additives;
- washing and sorting of fillers.
Only with such a coordinated approach to work can we ensure round-the-clock production operation.
Staff
For smooth production and business operations at the plant, the following minimum number of workers is required.
| Job title | Qty | Salary | Salary | Total | |
| Human | rub/month | rub/shift | Payroll | ||
| RBU operator | 1 | 30000 | 1363,6364 | 30000 | |
| Loader driver | 1 | 30000 | 1363,6364 | 30000 | |
| Repairman | 1 | 30000 | 1363,6364 | 30000 | |
| Dispatcher | 1 | 20000 | 909,09091 | 20000 | |
| Technologist | 1 | 10000 | 454,54545 | 10000 | |
| Director of operations | 1 | 40000 | 1818,1818 | 40000 | |
| Director | 1 | 20000 | 666,66667 | 20000 | |
| TOTAL | 7 | 180000 | 7272,7273 | 180000 | |
Let's make a table showing the costs of the wage fund.
| Total | Total | Total | |
| 1 year | 2 year | 3 year | |
| RBU operator | 210000 | 210000 | 210000 |
| Loader driver | 210000 | 210000 | 210000 |
| Repairman | 210000 | 210000 | 210000 |
| Dispatcher | 140000 | 140000 | 140000 |
| Technologist | 70000 | 70000 | 70000 |
| Director of operations | 280000 | 280000 | 280000 |
| Director | 220000 | 240000 | 240000 |
| TOTAL PAYROLL | 1340000 | 1360000 | 1360000 |
And on payroll taxes.
| Total | Total | Total | |
| 1 year | 2 year | 3 year | |
| RBU operator | 63000 | 63000 | 63000 |
| Loader driver | 63000 | 63000 | 63000 |
| Repairman | 63000 | 63000 | 63000 |
| Dispatcher | 42000 | 42000 | 42000 |
| Technologist | 21000 | 21000 | 21000 |
| Director of operations | 84000 | 84000 | 84000 |
| Director | 66000 | 72000 | 72000 |
| TOTAL PAYROLL | 402000 | 408000 | 408000 |
It was decided to engage an accounting company under a contract for accounting services.
The amount of financial costs for the purchase of raw materials for concrete
The most popular brand of concrete, the safest to start working with, is the M 250 and M 350 grades.
Cost calculation depends on the selected production technology. In our business plan, we made a calculation based on the M 250 grade, so based on the consumption of materials per 1 m3 of ready-made concrete, the following figures will be obtained:
- M 250: crushed stone – 1280 kg, cement – 320 kg, sand – 1280 kg, water – 205 liters
Materials are purchased from officially operating quarries in the city of Yekaterinburg and nearby cities that have the necessary certificates and strength test reports for their material, etc., the cost of the material includes delivery to our territory
The volume of material consumption per 1 m3 of the finished product will be 2000 rubles, water costs will be included in utility costs, because We do not purchase water, but get it from a well.
There are other associated costs - staff salaries, costs for work clothes and equipment for work, diesel fuel for the loader, payment for electricity and site rental. If all this is taken into account, then the production cost will increase to 2,250 rubles per 1 m3 of finished concrete. The next section of the business plan provides a detailed table of variable and fixed costs.
Types of concrete
For pouring foundations, as well as for the construction of monolithic buildings, plain or reinforced concrete is used, depending on the design load on the foundation. This process requires the production of forms for pouring concrete.
Heavy concrete is used in the construction of nuclear power plants, rooms in which they work with radioactive elements, or for the construction of shelters from the effects of nuclear weapons.
Terrazo is a technology for producing colored concrete. This option is used for finishing facades and basement floors of premises. The material is also used for laying on highways. It has high resistance to ultraviolet radiation, as well as to water and snow.
Prestressed concrete - the mixture contains reinforcement and steel, distributed in a certain way.
Fiber-reinforced concrete - characterized by the presence of fibrous filler. Used for patching concrete surfaces and applying top layers to concrete highways.
Washed concrete - used for arranging foundations and decorative borders. A distinctive feature of the technology for producing washed concrete is the use of setting time retarders for the laid mixture. The final touch to the work is to wash away the surface of the laid concrete with a stream of water.
Registering a business and choosing a tax system
In the business plan being developed, it is imperative to include the issue of registering a legal entity, in our case it will be a Limited Liability Company (LLC). This step is important for several reasons. The first is that in case of any unforeseen situations, the LLC is responsible only with its authorized capital. Secondly, any company or organization will agree to work with an organization of a similar form of ownership.
To organize and conduct the production in question, the OKVED code is determined: 26.63. The production of ready-mixed concrete requires the following standards (they must comply with established GOSTs):
- “Concrete. Methods for determining frost resistance" (10060.0-95);
- “Concrete. Squad selection rules" (27006-86);
- “Concrete. Rules for controlling compressive strength for monolithic structures" (18105 – 86).
- “Concrete mixtures. Test methods" (10181-2000);
- “The concrete is heavy and fine-grained. Technical conditions" (26633-91);
Let's move on to choosing a taxation system; in generally accepted practice, this is the general taxation system, the simplified tax system for annual revenues of less than 60 million rubles. To maintain accounting records for an enterprise, it is necessary to hire an accountant. The taxation system of the enterprise under consideration is the simplified tax system “income-expenses” 7%.
Special concrete production line
This is the name of equipment that has high productivity and is also equipped with the most advanced technology in the field of high-tech continuous concrete production.
The configuration of any line is selected depending on the type and volume of production, area of installation, and energy capabilities. This is usually a modular design that is assembled in a line.
Structurally, these can be structures of open, closed and semi-open types. The compactness of the lines allows for maximum use of space thanks to the multi-level design of the entire complex.
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The layout option can be selected from a set of equipment:
- pallet feeding mechanisms;
- molding machine;
- winding machine;
- warehouse for work pallets;
- racks, platforms and carts;
- automatic packaging machine for finished products;
- forklifts;
- transport carts;
- conveyor.
The production of concrete products is fully automated in compliance with all safety rules and regulations. The operation of most lines is controlled using computer programs, with full visualization of all stages of production.
Such lines can produce concrete blocks, floor slabs and other reinforced concrete products.
The cost of the line is high, but given its productivity, full payback will occur in 5 years, provided it is fully loaded, in compliance with all maintenance rules. Such products are always in high demand.
Optimal concrete mini-plants
Plant Hartmann Powermix 75
German quality never raises doubts about the performance of the equipment, so the Hartmann Powermix 75 mini-plant will be your reliable partner in the building mixtures market.
Technical parameters of the enterprise:
- productivity - 75 m3/h;
- mixer type – two-shaft;
- 4-chamber loading hopper for filler;
- equipped with two equivalent engines with a total power of 60 kW;
- presence of 10 At compressor;
- electronic weighing of concrete components at each load.
Compact equipment allows for uninterrupted operation of the plant.
Italian concrete mixing plants are excellent mobile devices that are not tied to a plot of land, because they are located on a movable mobile platform.
The plant is located on a two-axle trailer and can operate on any construction site. Concrete productivity ranges from 25 to 90 cubic meters/hour. For high-quality production of products, the following equipment is available: dispensers, moisture sensors for bulk mixtures, an automatic process control system.
Mobility is the main advantage of such an enterprise; during the construction season you can make a very good income, because high-quality fresh concrete is in great demand in individual suburban construction.
Budget options are factories from Chinese manufacturers. Here you can purchase creeks with the configuration of your choice. The affordable price allows you to start your own concrete production at minimal cost. You can buy such production complexes both for seasonal production (open-type plants) and all-season ones.
Thus, a short excursion into the world of preparing concrete and learning how to implement this idea will help budding entrepreneurs stay afloat in this difficult topic.
With the right approach to choosing equipment for preparing concrete mixtures or reinforced concrete products, you will open a profitable business.
