MICRO CONCRETE ROOFING

TECHNOLOGY

TECHKNOW ENVIRONMENTAL AND SUSTAINABLE SOLUTIONS

PVT. LTD.
E-61 (First Floor ), Bali Nagar
New Delhi 110 015
Ph : 011 25153139 Fax : 011 45552803
www.techknow-india.com

INTRODUCTION
In India there is an acute shortage of locally available cheap roofing materials. Homebuilders
particularly the poor are in dire need of cost-effective materials to build their homes with. In
addition, mass rural housing programmes supported by Central and State Governments are
increasingly looking at low-cost building techniques. In urban slums, development authorities
involved in up gradation are offering schemes for replacement of roof primarily to ensure
protection against rain, to enable proper electricity connections and protect families against
fires. Conventionally available materials do not offer acceptable solutions. Prices of
corrugated G.I. sheets are continuously escalating, and their use in not preferred because of
thermal discomfort. Use of cement sheets is not recommended because of health hazards
associated with asbestos. The cost of fired clay tiles is increasing rapidly due to rising costs
of clay and energy used for firing.
The strategy to transfer MCR technology revolves around the establishment of microenterprises in rural areas. The measurable indicators used for assessment are: easy and
wide access to affordable roofing, increased employment opportunities, improved resource
utilization and positive environmental impact. After successfully setting up rural
entrepreneurs, tapping the urban market is undertaken. Techknow India now plays the role
of a Technology Support Service provider to entrepreneurs and technical consulting
organizations, offer equipment, training, after-sales service and technical assistance.

ADVANTAGES
The main advantages of MCR tiles roofing are:

They can be produced locally on site wherever availability of cement can be ensured.

The technology is adaptable to any scale of production including 4 persons and

production units using one vibrating table.

Compared to fired-clay tiles, MCR tiles require less timber for support structure thus
reducing cost of roofing system.

Thermal and acoustic performance is superior to that of GI sheets and on par with
cement sheets.

Skills for production and installation can be easily acquired by skilled workers and
masons.

MCR tiles are reusable and easy to replace.

High durability of that of concrete

Can be coloured to users preference

No noise during rains; reduce heat gain

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EQUIPMENTS
The production kit includes:
Vibrating table operated by electric motor (220 v; single phase; HP; 2800 r.p.m.)
Tile moulds made of High Impact Polystyrene (HIPS), mounted on wooden frames.

PRODUCTION PROCESS
The mix of cement, sand, aggregate and water is vibrated for about 45 seconds and then
transferred on to a High Impact Polystyrene moulds to give MCR tiles their unique profile.
The MCR mix consists of 1 part cement, 2 parts of graded sand, and 1 part of stone grit,
smaller than 6 mm in size. The mix requires a water-cement ratio between 0.45 and 0.5.
After initial setting for 24 hours, they are water cured for 7 days. This results in great strength
and durability of MCR tiles.

RAW MATERIALS
For 8 hrs shift / day
Cement 300 kgs (3 bags approx.)
Aggregate 300 kgs
Sand 600 kgs

PRODUCTION
For 8 hrs shift / day
200 Tiles

AREA REQUIRED
1. Covered Area (Machine + Store + Cement Store) 600 sq.ft.
2. Open Area for curing tank 200 sq.ft.
3. Drying Area 800 1000 sq.ft.
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APPLICATIONS
A variety of roof designs for farm and country houses, bungalows, verandahs and pavilions
are possible with MCR tiles. They have also been used on industrial sheds, workshops and
restaurants. MCR tiles allow total creative freedom to designers, architects and engineers to
create a variety of roof forms.

BUILDING WITH MCR TILES

MCR roofs are constructed in a conventional manner using rafters and purlins made from
wood or steel. Rafters are according to the shape and size of the roof. The purlins are
welded / placing at a distance of 40 cm from each other. MCR tiles are secured by tying
them to purlins with G.I. wire. The angle of roof slope should be at least 22. Greater
inclination of up to 30 is preferred for more aesthetic appeal and high rainfall area.
Standard architectural details for gable and hipped roof ridges, eaves, side overhangs and
valleys can be used for MCR roofs. MCR tiles are also an excellent cladding material for
sloping RCC slabs. They act as an effective damp proofing layer and enhance the aesthetic
appeal of the buildings. The tiles can be fixed to the slabs with cement mortar.

PROJECT PROFILE
Technical Details of MCR tileProduct Specifications

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Clear length

480 mm

Length after overlap

400 mm

Clear width

240 mm

Width after overlap

200 mm

Thickness

8 mm/10 mm

Corrugation depth

50 mm

Nominal weight

2.25 kg/2.6 kg

Purlin spacing

400 mm

Load bearing capacity

80/100 kg

Installed Capacity

5250 tiles / month

A. Fixed Capital

Amount in Rs.

Machinery
Water Arrangement
( Motor) + Curing Tank
(14X102) + Pipes
Commissioning and training
Total
B. Working Capital

1,90,000.00
10,000.00
15,000.00
2,15,000.00
Amount in Rs.

Workshed on rent
Raw material / month
Cement 74 bags @ 300
Sand 210 cft @ 15
Aggregate 100 cft @ 50

1200.00

SubTotal

22,200.00
3,150.00
5,000.00
31,550.00

Skilled @ 4000 p.m. - 1

Semi skilled @ 3500 p.m. - 1
Unskilled @ 3000 p.m. - 2
SubTotal

4,000.00
3,500.00
6,000.00
13,500.00

Wages (4 laborers)

6,000.00

Supervision and marketing cost

Power
Overhead expenses
Interest on Working capital @16%
Total

500.00
1,000.00
8,408.00
60,958.00

Production /pm
Less 4% breakage and rejection
Net Production/pm

5250 tiles
210 tiles
5040 tiles

Production Cost per tile

Selling price /tile Rs.
Mark-up /tile Rs.
Break even period

Rs. 12/- (Approx.)

Rs.17/- (Approx.)
Rs.5/15 months

Total Investment ( Fixed Capital + Working capital for 2 months )

Tiles Production / annum 60,480
Profit / Tile (without colouring) Rs. 5.00
Total Income Rs. 3,02,400
Expenses / pm Rs. 60,958.00
Income / pm Rs. 85,680.00
Profit Rs. 24,722.00

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- Rs. 3,36,916

MICRO CONCRETE ROOFING TILES

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APPLICATION OF MCR

MEETING POINT

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