What is a calcium silicate insulation board project report?
A calcium silicate insulation board project report is a detailed project report (DPR) for a plant that makes high-temperature insulation board from lime, silica and fibres in steam autoclaves. It sets out the process, machinery, raw materials, market, project cost, financing, five-year projections, DSCR and break-even.
Promoters use it to size the plant and raise a term loan; banks and investors use it to judge whether the plant can repay and earn a fair return.
Also known as: project report on calcium silicate insulation board, calcium silicate insulation board business plan, calcium silicate board plant feasibility report, xonotlite insulation board DPR.
Calcium silicate insulation board manufacturing plant cost in India
Our sample report models a plant making 68 cubic metres of board a day, or 22,440 cubic metres a year at full capacity over 330 working days. It starts at 60% utilisation and reaches 80% in Year 5, selling at ₹18,600 per cubic metre ex-factory.
Plant and machinery is about half the project cost, because autoclaves, the filter press line and the boiler are large pressure equipment. The lowest DSCR, 1.81, comes in Year 2, when full loan instalments begin.
| Land and site development | 142.68 |
|---|---|
| Building and civil works | 582.14 |
| Plant and machinery | 1,065.60 |
| Other fixed assets | 93.45 |
| Contingencies | 82.39 |
| Preliminary and pre-operative | 49.16 |
| Working capital margin | 98.34 |
| Total | 2,113.76 |
| Promoter's contribution (25%) | 528.44 |
|---|---|
| Term loan from bank (75%) | 1,585.32 |
| Cash credit limit (separate) | 295.03 |
| Total project cost | 2,113.76 |
Term loan at 10.5% with a 6-month moratorium and 72 monthly instalments. All figures are illustrative.
Calcium silicate insulation board manufacturing process
The board is made by a hydrothermal reaction: lime and silica combine under steam pressure to form calcium silicate crystals that hold the fibres together. Drying alone can take days, and the autoclave cycle sets the pace of the whole plant.
- Lime slaking
Quicklime is slaked with hot water into a reactive milk of lime; soft-burnt lime with low grit slakes faster and reacts more fully.
- Silica grinding
Quartz is wet ground in a ball mill to a fine flour, because coarse silica stays unreacted and weakens the board.
- Slurry preparation
Lime, silica, wollastonite and opened-up fibres are mixed in agitated reactors at a lime to silica molar ratio close to 1:1.
- Filter pressing
The slurry is pressed in moulds to drain water and fix the board thickness and density, typically a few hundred kilograms per cubic metre.
- Autoclaving
Green boards are cured in saturated steam at about 12–15 bar, the conditions used in our sample, so xonotlite crystals form.
- Drying
Boards lose most of their weight as free water in heated chambers; drying too fast causes cracks and warping.
- Finishing and testing
Boards are cut and sanded to size, then tested for density, flexural and compressive strength, linear shrinkage and thermal conductivity.
Which grade of calcium silicate board should the plant make?
The crystal formed in the autoclave decides how hot the board can run. That choice fixes the autoclave pressure, cycle time and silica quality, so it has to be settled before machinery is ordered.
| Point of difference | Tobermorite grade | Xonotlite grade |
|---|---|---|
| Typical service limit | About 650 °C | Around 1,000 °C; IS 9428:2024 covers insulation up to 950 °C |
| Autoclave conditions | Lower steam pressure, shorter cycle | Higher pressure and a longer cycle, so more steam per cubic metre |
| Silica quality | Tolerates some alumina in the mix | Low-alumina quartz; aluminium in the mix blocks xonotlite formation |
| Main buyers | Pipe and equipment insulation at moderate temperatures | Back-up insulation in furnaces, kilns, preheaters and hot ducts |
| Price and margin | Lower price, wider competition | Higher price, stricter testing and buyer approval |
Not the same as building board: calcium silicate ceiling and partition sheets are a different, denser product made on a different line. Many reports online mix the two, which gives wrong prices, capacities and buyers.
Raw materials for calcium silicate insulation board
Raw materials are 26.3% of sales in our sample, a modest share because steam, power and labour weigh heavily in this product. Reinforcing fibres, not lime, are the largest item, so fibre price and supply security matter most.
| Raw material | Share of cost | Year 3 (₹ lakh) |
|---|---|---|
| Quicklime | 30% | 230.60 |
| Quartz silica flour | 22% | 169.11 |
| Reinforcing fibres (cellulose and glass) | 32% | 245.98 |
| Wollastonite | 8% | 61.49 |
| Dispersants and process additives | 8% | 61.49 |
| Total | 100% | 768.67 |
Lime reactivity and silica fineness should be tested on every lot; a bad lot shows up only after autoclaving, when boards fail strength tests.
Machinery for a calcium silicate insulation board plant
The autoclaves are the costliest item in our sample, and their volume and cycle time set the plant's real output. The filter press line is the second largest item.
| Machine | What it does | Sample cost (₹ lakh) |
|---|---|---|
| Lime slaker and wet ball mill | Slakes lime and grinds quartz to flour | 127.88 |
| Slurry reactors with agitators | Mix and pre-react the slurry | 127.87 |
| Hydraulic filter press forming line | Presses slurry into boards of set density | 213.12 |
| Autoclaves with rail trolleys | Steam-cure boards to form crystals | 234.43 |
| Steam boiler and condensate system | Supplies autoclave steam, recovers condensate | 127.87 |
| Drying chambers | Remove free water slowly | 106.56 |
| Cutting, sanding and machining line | Sizes boards and makes cut shapes | 74.59 |
| Quality control laboratory | Tests density, strength, shrinkage, conductivity | 53.28 |
| Total plant and machinery | 1,065.60 | |
Costs are the sample report's estimates. Get current quotations, including boiler and autoclave inspection charges, before you finalise.
Power, steam and manpower for the plant
Power and fuel cost ₹479.86 lakh in Year 3 of our sample, 16.4% of sales and the second largest cost after raw materials. Most of it is boiler fuel for autoclave steam and heat for the drying chambers, so condensate recovery and dryer insulation pay back directly.
The plant runs shifts around the autoclaves and employs 156 people in the sample.
| Category | Number | Monthly wage (₹) | Year 1 cost (₹ lakh) |
|---|---|---|---|
| Management, supervision and administration | 23 | 29,000 | 80.04 |
| Skilled workers and operators | 55 | 18,500 | 122.10 |
| Semi-skilled and unskilled workers | 78 | 12,000 | 112.32 |
| Total | 156 | 314.46 |
Wages in the sample rise by 5% a year. Plan skilled operators for the boiler, autoclaves and filter press on every shift.
Licences, boiler registration and BIS standard
| Business registration | Udyam registration where the unit qualifies, and GST registration |
|---|---|
| Pollution board consent | Consent to establish and operate from the State Pollution Control Board. Ceramics and refractories using less than 12 tonnes of coal a day are listed in the Orange category under CPCB criteria; the state board confirms the category |
| Boiler registration | Under the Boilers Act, 2025, in force since 1 May 2025, a boiler must be registered and hold a certificate for use before it runs; the certificate is valid for up to 12 months |
| Product standard | IS 9428:2024, preformed calcium silicate insulation for temperatures up to 950 °C (second revision, replacing IS 9428:1993) |
| Factory licence | Registration and licence under the factory law of your state, with approval of the plant layout |
| Fire safety | Fire NOC from the local fire authority, where the state requires it for the building and fuel store |
Requirements differ by state. Checked as of October 2026; confirm with the authorities before applying.
Who buys calcium silicate insulation board?
Demand comes from heavy industry. Steel, aluminium, cement, glass, refinery and power plants use the board behind refractory linings and on hot pipes, ducts and flues. Orders follow new capacity and the shutdown and relining calendar of existing plants, so sales come in lumps rather than every month.
Much of the volume moves through insulation and refractory contractors, who buy against a project specification and expect credit. Our sample allows 45 days of credit to buyers.
- Steel and aluminium plants
- Cement plants, for preheaters and cyclones
- Refineries and petrochemical units
- Thermal insulation and refractory contractors
- Glass and ceramic kiln builders
- Power plants and boiler makers
Where a domestic plant wins: during a shutdown, buyers need cut sizes and pipe sections within days. A plant that holds stock and machines shapes to drawing can compete with imported board on delivery, not only on price.
Mistakes that weaken a calcium silicate board project report
- Setting capacity from the filter press
The press can form more boards than the autoclaves can cure. Output must be worked out from autoclave volume, loading and cycle time.
- Using building board prices or volumes
Ceiling and partition sheet data is sold per square metre to a different market; insulation board is priced per cubic metre and grade.
- Ignoring silica chemistry
Alumina-bearing silica stops xonotlite forming, so a high-temperature grade fails shrinkage tests. The report should name the silica source and its analysis.
- No allowance for drying rejects
Cracked and warped boards are scrapped after the costliest steps. Saleable output must allow for them.
- Short working capital for lumpy orders
Shutdown orders arrive together and contractors pay late. Stock and debtor days need a realistic cash credit limit.
How NPCS helps you plan a calcium silicate insulation board plant
- Grade and capacityChoose tobermorite or xonotlite grades, densities and an autoclave plan that suit your buyers and budget.
- Technology and machineryCompare process routes and suppliers for the filter press, autoclaves and boiler, with quotations.
- Bank-ready project reportProjections, DSCR, sensitivity to fibre and fuel prices, and working capital in your lender's format.
- Approvals and layoutPlant layout, steam and power load, and the list of boiler, pollution and factory approvals for your state.
NPCS's published client list includes 2 assignments on calcium silicate insulation board and 31 across ceramics, glass and refractories. NPCS, led by founder Ajay Kumar Gupta, has prepared project reports since 1994.
What's inside the calcium silicate insulation board sample report
- Introduction
- Uses and applications
- Market potential
- Manufacturing process
- Raw materials
- Plant and machinery
- Land, building and utilities
- Manpower
- Licences and approvals
- Project cost and means of finance
- Working capital
- Projected profitability
- Cash flow statement
- Projected balance sheet
- Depreciation
- Term loan repayment
- Debt service coverage
- Break-even analysis
- Financial ratios
- Key assumptions
- Conclusion
- Monthly loan repayment schedule
19 pages, five-year projections, illustrative figures.
Open sample reportFree sample or a report for your project?
| What you get | Free sample | NPCS report for your project |
|---|---|---|
| Capacity and location | Typical unit | Your capacity, site and state |
| Figures | Illustrative | Built on current prices and quotations |
| Machinery suppliers and quotations | No | Yes |
| Market survey for your region | No | Yes |
| Bank or scheme format (PMEGP, term loan) | No | Yes |
| Use for a loan application | No | Yes |
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Calcium Silicate Insulation Board project report: frequently asked questions
How much does it cost to set up a calcium silicate insulation board plant?
A plant making 40–80 cubic metres of board a day needs roughly ₹15–28 crore, including land, building, autoclaves and working capital margin. This range is indicative. Our sample report models a 68 cubic metre per day plant at ₹2,113.76 lakh, with plant and machinery at ₹1,065.60 lakh. Your own report works out the cost for your capacity, grade and site.
What raw materials are used to make calcium silicate insulation board?
The board is made from quicklime and finely ground quartz silica, reinforced with cellulose and glass fibres, with wollastonite and small amounts of dispersants. In our sample report, reinforcing fibres are the largest item at 32% of raw material cost, followed by quicklime at 30% and silica flour at 22%. Silica must be low in alumina for a high-temperature grade.
Which machines are needed for a calcium silicate board plant?
You need a lime slaker and wet ball mill, slurry reactors with agitators, a hydraulic filter press forming line, steam autoclaves with rail trolleys, a steam boiler, drying chambers, a cutting and sanding line and a testing laboratory. In our sample report the autoclaves are the costliest item at ₹234.43 lakh, followed by the filter press line at ₹213.12 lakh.
Is calcium silicate insulation board manufacturing profitable?
In our illustrative sample, a 68 cubic metre per day plant earns an 18% return on investment in Year 3, breaks even at about 44% of capacity and pays back in about 4 years, with an average DSCR of 2.05. Real results depend on fibre and lime prices, steam cost, rejection rates in drying and how quickly plant buyers pay.
How is insulation board different from calcium silicate building board?
Insulation board is a light, autoclaved block made by filter pressing, used behind refractory linings and on hot equipment. Building board is a thinner, denser sheet for ceilings, partitions and wall linings, made on a different forming line and sold through building material channels. The two need different plants, so a project report must say clearly which one it covers.
Which BIS standard applies to calcium silicate insulation board?
IS 9428:2024 is the Indian specification for preformed calcium silicate insulation for temperatures up to 950 °C. It is the second revision and replaced IS 9428:1993. Buyers may name it in tenders, so the plant laboratory should be equipped to test density, strength, shrinkage and thermal conductivity against it. Check the BIS portal for whether certification is compulsory before you start.
Is the calcium silicate insulation board project report PDF free, and can I use it for a loan?
The sample report PDF is free to view and download. It is illustrative: it shows the format and depth of an NPCS report, but its figures are representative and not based on a real project, so it should not be submitted to a bank. For a loan, NPCS prepares a report on your own capacity, product grade, location and lender format.
Sources and references
- IS 9428:2024, Preformed calcium silicate insulation (for temperature up to 950 °C), specificationBureau of Indian Standards, checked Oct 2026
- The Boilers Act, 2025 (Act No. 12 of 2025)India Code, Ministry of Law and Justice, checked Oct 2026
- Notification on the date the Boilers Act, 2025 comes into force (S.O. 1943(E))Inspectorate of Factories and Boilers, Government of Goa, checked Oct 2026
- Categorisation of industrial sectors under Orange as per CPCB criteriaState Pollution Control Board, Odisha, checked Oct 2026
The NPCS project team, led by Ajay Kumar Gupta
This page and its sample report are prepared and reviewed by the NPCS project team, which has written techno-economic feasibility studies and detailed project reports since 1994.
Ajay Kumar Gupta founded Niir Project Consultancy Services (NPCS) and leads the organisation. With 40 years of experience in MSME project consulting, he has built the team that has delivered more than 28,000 project reports for clients worldwide, helping entrepreneurs plan and finance profitable manufacturing businesses.
- Published
- Last updated
- Next review
- Oct 2027
- Reviewed by
- NPCS project team
This page is reviewed every 12 months, or sooner when scheme limits, GST rates, BIS rules or pollution categories change. The sample report is illustrative: its figures are generated from industry-typical ratios for a unit of this size, checked so every statement balances, and are not taken from any client project.