Artificial Sand - A Viable

Alternative
An Alternate to River Sand in Concrete and
Construction Industry
Manufacturing Plant, Detailed Project Report, Profile,
Business Plan, Industry Trends, Market Research, Survey,
Manufacturing Process, Machinery, Raw Materials,
Feasibility Study, Investment Opportunities, Cost and
Revenue, Plant Economics, Production Schedule, Working
Capital Requirement, Plant Layout, Process Flow Sheet,
Cost of Project, Projected Balance Sheets, Profitability
Ratios, Break Even Analysis

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Introduction

The artificial sand produced by proper machines

can be a better substitute to river sand. The sand
should be sharp, clean and course. The grains
should be of durable material. The grain sizes
must be such that it should give minimum voids.
The presence of clay and silt retards the setting of
the cement and makes the mortar weaker and the
walls or the slab leaks and holds dampness.

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 The sand in the mortar does not add any strength but
it is used as an adulterant for economy and with the
same it prevents the shrinkage and cracking of
mortar in setting. The sand must be of proper
gradation (it should have particles from 150 microns
to 4.75 mm in proper proportion) When fine particles
are in proper proportion, the sand will have less
voids. The cement required will be less when there
will be less void in sand. Such sand will be more
economical.

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 Manufactured or Artificial Sand V/s Natural or River sand

The Civil engineers, Architects, Builders, and Contractors

agree that the river sand, which is available today, is
deficient in many respect. It does content very high silt fine
particles (as in case of Filter sand).

Presence of other impurities such as coal, bones, shells, mica

and silt etc makes it inferior for the use in cement concrete.
The decay of these materials, due to weathering effect,
shortens the life of the concrete.

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 Now-a-days, the Government have put ban on
lifting sand from River bed.

Transportation of sand damages the roads.

Removing sand from river bed impact the

environment, as water table goes deeper &
ultimately dry.

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 General Requirements of Manufactured
Sand/Artificial Sand
All the sand particles should have higher crushing strength.
The surface texture of the particles should be smooth.
The edges of the particles should be grounded.
The ratio of fines below 600 microns in sand should not be
less than 30%.
There should not be any organic impurities
Silt in sand should not be more than 2%, for crushed sand.
In manufactured sand the permissible limit of fines below
75 microns shall not exceed 15%.

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 Sand is a naturally occurring granular material composed of
finely divided rock and mineral particles. The composition
of sand is highly variable, depending on the local rock
sources and conditions, but the most common constituent
of sand in inland continental settings and non tropical
coastal settings is silica (silicon dioxide, or SiO2), usually in
the form of quartz. Sand is generally mixed with cement and
water form concrete. These sand particles should be hard
and inert with respect to cement. In the construction
industry commonly used artificial sand to compound
concrete.

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 Use of artificial sand concrete density, anti
permeability, antifreeze performance is good,
other physical and mechanical performance and
long term durability all can reach the design
requirements of operation. Artificial sand
preparation is especially suitable for high strength
grade of concrete, the high performance concrete
and pumping concrete.

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 Applications

Sand has its applications in various fields. In agriculture

sandy soils are ideal for crops such as watermelons, peaches,
and peanuts and their excellent drainage characteristics
make them suitable for intensive dairy farming. In aquaria it
makes a low cost aquarium base material which some believe
is better than gravel for home use. Manufacturing plants add
sand to a mixture of clay and other materials for
manufacturing bricks. Coarse sand makes up as much as
75% of cob. Sand is mixed with cement and sometimes lime
to be used in masonry construction.

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 Sand is often a principal component of this
critical construction material. Sand is the
principal component in common glass. Mixing
sand with paint produces a textured finish for
walls and ceilings or non slip floor surfaces.
Sand is also used as sand bags, these protect
against floods and gunfire. Media filters use
sand for filtering water.

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 Global demand
Due to the increase of population & living standards, the
demand for this product is multiplying in every year. Present
supply of production is meeting only about 20% of the
demand if all the crusher units of the state start
manufacturing machine made sand as an additional venture
then also it could meet only about 50- 60% of the
requirement. At present the existing sand manufacturers are
producing sand like materials form granite stone and people
are facing difficulties while plastering work.

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 The demand of river sand will roll and will bring back the
smiles on the faces of both the environmentalists and
the industries. Because there is abundant of natural sand
because of the heavy demand in the growing
construction activities in nowadays society, the artificial
sand production line the sand produce field has a popular
and a welcome position.

The demand of sand in the market is immense and

therefore its market position is splendid. Hence it is an
excellent field to venture.

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 Reasons for buying the report:

• This report helps you to identify a profitable project for

investing or diversifying into by throwing light to crucial areas

like industry size, market potential of the product and reasons

for investing in the product

• This report provides vital information on the product like it’s

characteristics and segmentation

• This report helps you market and place the product correctly

by identifying the target customer group of the product

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 • This report helps you understand the viability of the project

by disclosing details like machinery required, project costs and

snapshot of other project financials

• The report provides a glimpse of government regulations

applicable on the industry

• The report provides forecasts of key parameters which helps

to anticipate the industry performance and make sound

business decisions

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 Our Approach:

• Our research reports broadly cover Indian markets, present

analysis, outlook and forecast for a period of five years.

• The market forecasts are developed on the basis of secondary

research and are cross-validated through interactions with the

industry players

• We use reliable sources of information and databases. And

information from such sources is processed by us and included

in the report

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Scope of the Report

The report titled “Market Survey cum Detailed Techno Economic

Feasibility Report on Artificial Sand from Stones and Waste Metals”
provides an insight into the Artificial Sand from Stones and Waste
Metals market in India with focus on uses and applications,
Manufacturing Process, Process Flow Sheets, Plant Layout of Artificial
Sand project. The report assesses the market sizing and growth of the
Indian Artificial Sand Industry. While expanding a current business or
while venturing into new business, entrepreneurs are often faced with
the dilemma of zeroing in on a suitable product/line. And before
diversifying/venturing into any product, they wish to study the
following aspects of the identified product:

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 • Good Present/Future Demand
• Export-Import Market Potential
• Raw Material & Manpower Availability
• Project Costs and Payback Period

We at NPCS, through our reliable expertise in the project

consultancy and market research field, have demystified the
situation by putting forward the emerging business opportunity
in the Artificial Sand sector in India along with its business
prospects. Through this report we have identified Artificial Sand
project as a lucrative investment avenue.

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PROJECT AT A GLANCE

Capacity: 720000MT/Annum
Plant and Machinery: 595 Lakhs
Cost of the project: 1066 Lakhs
Rate of return: 44%
BEP: 51%

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Major Queries/Questions Answered in the Report?

1. What is Artificial Sand industry ?

2. How has the Artificial Sand industry performed so

far and how will it perform in the coming years ?

3. What is the Project Feasibility of a Artificial Sand

Plant ?

4. What are the requirements of Working Capital for

setting up a Artificial Sand plant ?

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5. What is the structure of the Artificial Sand
Business and who are the key/major players ?

6. What is the total project cost for setting up

Artificial Sand plant ?

7. What are the operating costs for setting up a

Artificial Sand plant ?

8. What are the machinery and equipment

requirements for setting up a Artificial Sand
plant ?

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9. Who are the Suppliers and Manufacturers of
Plant & Machinery for setting up a Artificial
Sand plant ?

10. What are the requirements of raw material

for setting up a Artificial Sand plant ?

11. Who are the Suppliers and Manufacturers of

Raw materials for setting up a Artificial Sand
plant ?

12. What is the Manufacturing Process and

Formulations of a Artificial Sand plant ?

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13. What is the total size of land required for setting
up Artificial Sand plant ?

14. What will be the income and expenditures for

Artificial Sand plant ?

15. What are the Projected Balance Sheets of Artificial

Sand plant ?

16. What are the requirement of utilities and

overheads for setting up Artificial Sand plant?

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17. What is the Built up Area Requirement and cost
for setting up a Artificial Sand Business?

18. What are the Personnel (Manpower)

Requirements for setting up a Artificial Sand
Business?

19. What are Statistics of Import & Export for

Artificial Sand?

20. What is the time required to break-even?

21.What is the Break-Even Analysis of a Artificial

Sand plant?

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22.What are the Project financials of Artificial Sand
plant?

23. What are the Profitability Ratios of a Artificial

Sand plant?

24. What is the Sensitivity Analysis-Price/Volume

of a Artificial Sand plant?

25. What are the Projected Pay-Back Period and

IRR of a Artificial Sand plant?

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26. What is the Process Flow Sheet Diagram of a
Artificial Sand project?

27. What are the Market Opportunities for

setting up a Artificial Sand plant?

28. What is the Market Study and Assessment for

setting up a Artificial Sand plant?

29. What is the Plant Layout for setting up a Artificial

Sand Business?

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Table of Contents
of the
Project Report

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1. PROJECT LOCATION
1.1. District Profile & Geotechnical Site Characterization
1.1.1. General
1.1.2. Map
1.1.3. Physical Characteristics
1.1.4. Climate
1.1.5. Transportation and Communications
1.1.6. Economy & Industries
1.1.7. Major Industries

2. INTRODUCTION

3. COMPOSITION OF SAND

4. USES & APPLICATIONS

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5. PROPERTIES

6. STANDARD SPECIFICATION FOR FINE AGGREGATES

7. ARTIFICIAL SAND
7.1. Comparison of River sand and Artificial sand in
Concrete design

8. IMPORTANCE OF THE SHAPE OF PARTICLES IN FINE

AGGREGATES

9. BUREAU OF INDIAN STANDARD SPECIFICATIONS &

REQUIREMENTS
9.1. Quality Control and Standards

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10. MARKET SURVEY
10.1. Crushed sand to replace river sand

11. RAW MATERIAL DETAILS

12. MANUFACTURING PROCESS

12.1. Plant & Machinery Required
12.2. Raw Material Required
12.3. Process

13. PROCESS FLOW DIAGRAM

13.1. Less Than 40 Mm Sand Making Process Flow Diagram
13.2. Larger Than 40 Mm Sand Making Process Flow Diagram
13.3. Process Flow Diagram

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14. MACHINERY DETAILS

15. SUPPLIERS OF PLANT & MACHINERY

16. RAW MATERIAL SUPPLIERS

17. PLANT LAYOUT

18. MACHINERY PHOTOGRAPHS

19. QUOTATION OF PLANT, MACHINERY AND

EQUIPMENTS FROM SUPPLIER

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 Project Financials
• Project at a Glance Annexure

• Assumptions for Profitability workings ………………………..1

• Plant Economics…………………………………………………..2
• Production Schedule………………………………………………3
• Land & Building……………………………………………….……4
Factory Land & Building
Site Development Expenses

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 • Plant & Machinery……………………………………………..……..5
Indigenous Machineries
Other Machineries (Miscellaneous, Laboratory etc.)

• Other Fixed Assets………………………………………..........….......6

Furniture & Fixtures
Pre-operative and Preliminary Expenses
Technical Knowhow
Provision of Contingencies

• Working Capital Requirement Per Month……………………….…7

Raw Material
Packing Material
Lab & ETP Chemical Cost
Consumable Store

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 • Overheads Required Per Month and Per Annum………….…….…8
Utilities & Overheads (Power, Water and Fuel Expenses etc.)
Royalty and Other Charges
Selling and Distribution Expenses

• Salary and Wages …………………………………………....…………..9

• Turnover Per Annum ……………………………………………........…10

• Share Capital………………………………………………………….....11
Equity Capital
Preference Share Capital

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 • Annexure 1 :: Cost of Project and Means of Finance

• Annexure 2 :: Profitability and Net Cash Accruals

 Revenue/Income/Realisation
 Expenses/Cost of Products/Services/Items
 Gross Profit
 Financial Charges
 Total Cost of Sales
 Net Profit After Taxes
 Net Cash Accruals

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 • Annexure 3 :: Assessment of Working Capital
requirements

 Current Assets
 Gross Working Capital
 Current Liabilities
 Net Working Capital
 Working Note for Calculation of Work-in-
process

• Annexure 4 :: Sources and Disposition of Funds

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 • Annexure 5 :: Projected Balance Sheets

 ROI (Average of Fixed Assets)

 RONW (Average of Share Capital)
 ROI (Average of Total Assets)

• Annexure 6 :: Profitability Ratios

 D.S.C.R
 Earnings Per Share (EPS)
 Debt Equity Ratio

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 • Annexure 7 :: Break-Even Analysis

 Variable Cost & Expenses

 Semi-Variable/Semi-Fixed Expenses
 Profit Volume Ratio (PVR)
 Fixed Expenses / Cost
 B.E.P

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 • Annexure 8 to 11 :: Sensitivity Analysis-Price/Volume

 Resultant N.P.B.T
 Resultant D.S.C.R
 Resultant PV Ratio
 Resultant DER
 Resultant ROI
 Resultant BEP

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 • Annexure 12 :: Shareholding Pattern and Stake Status
 Equity Capital
 Preference Share Capital
• Annexure 13 :: Quantitative Details-Output/Sales/Stocks
 Determined Capacity P.A of Products/Services
 Achievable Efficiency/Yield % of
Products/Services/Items
 Net Usable Load/Capacity of Products/Services/Items
 Expected Sales/ Revenue/ Income of Products/
Services/ Items

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 • Annexure 14 :: Product wise Domestic Sales
Realisation

• Annexure 15 :: Total Raw Material Cost

• Annexure 16 :: Raw Material Cost per unit

• Annexure 17 :: Total Lab & ETP Chemical Cost

• Annexure 18 :: Consumables, Store etc.

• Annexure 19 :: Packing Material Cost

• Annexure 20 :: Packing Material Cost Per Unit

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 • Annexure 21 :: Employees Expenses

• Annexure 22 :: Fuel Expenses

• Annexure 23 :: Power/Electricity Expenses

• Annexure 24 :: Royalty & Other Charges

• Annexure 25 :: Repairs & Maintenance

Expenses

• Annexure 26 :: Other Manufacturing Expenses

• Annexure 27 :: Administration Expenses

• Annexure 28 :: Selling Expenses

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 • Annexure 29 :: Depreciation Charges – as per Books
(Total)
• Annexure 30 :: Depreciation Charges – as per Books (P
& M)
• Annexure 31 :: Depreciation Charges - as per IT Act
WDV (Total)
• Annexure 32 :: Depreciation Charges - as per IT Act
WDV (P & M)
• Annexure 33 :: Interest and Repayment - Term Loans
• Annexure 34 :: Tax on Profits
• Annexure 35 :: Projected Pay-Back Period and IRR

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Niir Project Consultancy Services (NPCS)
can provide Detailed Project Report on
Artificial Sand from Stones and
Waste Metals
See more:
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http://goo.gl/OLULZL
http://goo.gl/CWqCk1

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