SSM 35 Block Making Machine in Islamabad – Real Case Study: Gulberg Greens Plaza & Apartments (2019 Installation)

Introduction – A Game‑Changing Block Plant in the Heart of Islamabad

In 2019, when the prestigious Gulberg Greens housing scheme was rapidly expanding, the developers faced a critical challenge: ensuring a steady, high‑quality, and cost‑effective supply of concrete blocks for their Plaza & Apartments project. Buying blocks from multiple local suppliers led to inconsistent quality, frequent delays, and inflated costs.

The solution was bold: set up their own captive block manufacturing plant right inside the 8‑kanal project site. After evaluating several manufacturers, they chose Silver Steel Mills to supply, install, and commission a fully automatic SSM 35 block making machine – a decision that transformed their construction efficiency.

Today, this plant produces 35,000 blocks daily and has saved the client millions of rupees. This article shares the complete story, technical specifications, real production data, and the exact role Silver Steel Mills played.

 

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Project Overview – Gulberg Greens, Islamabad

Note: The plant was installed and commissioned by Silver Steel Mills’ team, including complete training for local operators.

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Why the Client Moved from Outsourcing to In‑House Production

Before 2019, the developer purchased blocks from several kilns around Rawalpindi/Islamabad. Problems included:

• Quality variance – Blocks from different suppliers had different strength and size.

• Supply chain delays – Trucks often arrived late, halting construction.

• High cost – Transport and middleman margins added 20‑30% to block prices.

• Wastage – Many blocks cracked during loading/unloading.

By investing in their own SSM 35 plant, they gained:

• Full control over quality – Every block meets their exact mix design.

• Uninterrupted supply – Blocks available 24/7, right at the site.

• 40‑50% cost saving compared to purchased blocks.

• Ability to produce different sizes by changing moulds (hollow, solid, pavers).

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The SSM 35 Plant – Complete Configuration (As Installed at Gulberg Greens)

The plant includes not just the block machine but a complete batching, mixing, and conveying system. Below are the exact components delivered by Silver Steel Mills:

1. Main Block Making Machine (SSM 35)

• Operation: Fully automatic with auto pallet and double trolley system.

• Production rate: 80‑100 pallets per hour.

• Moulding cycle: 20‑30 seconds per cycle.

• Hydraulic system: 30 HP pump, 800 litres oil capacity (provided by client).

• Vibration system: Dual vibration – under‑bed vibration + shaft vibrator (40 HP total).

• Product height range: 50 mm to 200 mm.

2. Batching Plant (0.75 m³ Digital Weighing System)

• Capacity: 0.75 cubic meters per batch.

• Aggregate storage: 8 hoppers with electric discharge gates.

• Weighing system: Digital load cells (4 units) for cement, sand, crush, and water.

• Cement silo: 100 ton (separately supplied).

3. Two Mixers (Different Capacities)

• Both mixers are planetary type with hardened blades and separate motors (10 kW + 30 kW).

• Discharge via electric motor and pneumatic jack.

4. Conveyor System

• 3 weighing conveyors – Transfer material from hoppers to mixer.

• 2 transport conveyors – Move mixed concrete to block machine hopper.

• Total conveyor power: 11 HP.

5. Automatic Stacker & Pallets

• Stacker power: 5+3+2 = 10 HP.

• Wooden pallet size: 889 × 1219 × 38 mm.

• Pallet quantity: 1,000 wooden pallets supplied initially.

6. Moulds (Dies)

• Rectangle paver mould (60 mm)

• I‑section hollow block mould (80 mm)

• Standard brick mould

• Curb stone mould (12″×14″)

Extra moulds were supplied as per client requirement.

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Daily Production Reality – 35,000 Blocks

The plant operates in two shifts (16 hours/day). With an experienced operator (trained by Silver Steel Mills) and 4‑5 labourers, the actual output is:

“We consistently achieve 35,000 blocks a day. The digital batching system ensures every batch has the right cement content. Our masons love the uniform size – plastering is much faster now.”
– Site Engineer, Gulberg Greens Plaza & Apartments

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The Role of Silver Steel Mills – Installation, Training, and Support

Silver Steel Mills didn’t just supply the machine – we provided end‑to‑end service:

1. Site layout & foundation design – Advised on anchor bolt placement and concrete footings (civil work done by client).

2. Machine erection – Our technicians assembled the entire plant (block machine, batching system, mixers, conveyors, stacker).

3. Commissioning – First trial runs and calibration of digital weighing system.

4. Operator training – Two client operators were trained for 2 weeks on all aspects (operation, maintenance, troubleshooting).

5. After‑sales support – 3 months free service, with spare parts available from our Gujranwala factory.

Client’s responsibilities (fulfilled as per agreement):

• Foundation civil work (bricks, cement, crush, anchor bolts)

• Electricity supply (131 HP total load, provided via dedicated transformer)

• 800 litres hydraulic oil + gear oil

• Water supply for mixers and chiller

• Accommodation & meals for our technicians

• Loader (2 ton) and forklift for material handling

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Why This SSM 35 Plant Stands Out (Technical Strengths)

Heavy Hydraulic System

The 30 HP pump generates up to 300 tons of pressing force, ensuring blocks are fully compacted without voids.

Dual Vibration – The Secret to Strong Blocks

• Under‑bed vibration (20 HP × 2) – Shakes the entire mould box at high frequency.

• Shaft vibrator – Additional vibration through the mould core.

Result: Blocks achieve 4500‑5000 PSI compressive strength – far above the building code’s 3000 PSI requirement.

Digital Batching (0.75 m³)

Load cells automatically weigh each material, and the PLC (or digital panel) allows storing up to 100 recipes. The operator simply selects “Hollow Block M15” and the plant does the rest.

Two Mixers for Flexibility

• The 0.25 m³ small mixer is used for coloured pavers or fly‑ash bricks (small batches).

• The 0.75 m³ main mixer handles the high‑volume hollow block production.

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Financial Impact – How the Client Saved Millions

Before installing the plant, the developer purchased blocks at around PKR 45 per block (including transport). Their in‑house cost (raw material + labour + electricity) is approximately PKR 28 per block.

• Daily saving : 35,000 blocks × (45 – 28) = PKR 5,95,000 per day.

• Monthly saving (25 days) : ~PKR 1.49 crore.

• Plant investment (including SSM 35, batching, mixers, conveyors, moulds, pallets) : ~PKR 1.5 crore.

Return on Investment (ROI) : Less than 2 months.

“We recovered the entire plant cost in under 60 days. Now it’s pure profit – and we never worry about block availability.”
– Project Director, Gulberg Greens

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Visual Proof – Site Photos Available

Real photographs of the SSM 35 plant at Gulberg Greens are available, showing:

• The 8‑kanal plant layout.

• Two mixers (0.25 & 0.75 m³) and the batching system.

• Conveyor belts feeding the block machine.

• Automatic stacker with wooden pallets.

• Finished block stacks ready for curing.

(Photos can be provided upon request or embedded on your website to enhance trust.)

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Conclusion – A Benchmark Installation for Islamabad’s Construction Industry

The SSM 35 block making machine at Gulberg Greens Plaza & Apartments is a perfect example of how in‑house block production can slash costs, boost quality, and accelerate project timelines. The installation (2019) is still running flawlessly, producing 35,000 blocks daily, and has become a model for other housing schemes in Islamabad/Rawalpindi.

Silver Steel Mills is proud to have been the partner in this success. Our turnkey approach – from design and manufacturing to installation, training, and after‑sales support – ensures our clients achieve maximum productivity with minimum downtime.

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Are You Planning a Similar Project?

Whether you are developing a housing society, a commercial plaza, or a large infrastructure project, a captive block making plant can be your best investment. We offer complete SSM series plants (15, 18, 24, 28, 35, 50) with batching, mixing, and stacking systems tailored to your production needs.

 

 

 

 

Pakistan ke real estate aur construction sector mein aaj kal modern design, behtareen quality aur kam lagat (low cost) mein kaam mukammal karna sab se bada challenge hai. Jab baat ho Islamabad ki sab se premium locations jaise Gulberg Greens ki, jahan high-rise plazas, luxury apartments aur modern commercial offices tezi se tameer ho rahe hain, toh wahan standard bricks ke bajaye high-strength concrete blocks aur interlocking pavers ki demand bohot zyada barh jati hai.

Isi zaroorat ko dekhte huye, Silver Steel Mills (SSM) ne Year 2019 mein Gulberg Greens Islamabad ke ek bade plaza, apartment aur offices project ke liye apni flagship SSB 35 Automatic Block Making Machine aur Digital Batching Plant ki mukammal manufacturing, installation aur commissioning ka kaam kamyabi se sar-anjaam diya.

Yeh mukammal case study aapko batayegi ke kaise ek bade commercial contractor ne apni tameerati lagat ko kam karne ke liye SSM ki heavy-duty machinery par bharosa kiya.

Project Background: Own Manufacturing Se Low-Cost Ka Khwab

Gulberg Greens Islamabad mein plaza aur residential apartments ki tameerati sargarmiyon ke liye market se mahnge daamon mein blocks kharidna contractor ke liye sasta sauda nahi tha. Client ne pehle koi manual block production nahi ki thi, balki unhone directly ek naya aur modern step uthaya.

• Main Objective: Commercial plaza aur apartment structures ke liye khud (Own Manufacturing) ke zariye high-quality aur low-cost concrete blocks taiyar karna.

• Project Location: Gulberg Greens, Islamabad (Commercial Plaza & Apartments Site).

• Plant Setup Area: Yeh poora automatic plant 8 Kanal ke bahi-wasee (spacious) area par lagaya gaya, jahan raw material storage, mixing unit, curing yard aur stacking area ko behtareen planning se optimize kiya gaya.

Technical Specifications: SSM 35 Plant Ka Mukammal Skeleton

Gulberg Greens ka yeh project koi aam setup nahi tha, is liye isme heavy compaction aur zero failure rate wali machinery integrate ki gayi. SSM 35 Block Making Machine ke saath mukammal auto-pallet aur double trolley system lagaya gaya, jo high hydraulic pressure aur strong under-bed vibration force (shaft vibrator) ke saath kaam karta hai. Is wajah se har block aur paver bina kisi cracks ya air pockets ke behtareen density ke saath nikalta hai.

Is fully automated plant ki mazeed technical details neeche darj hain:

1. Dual Mixer & Digital Batching System

Concrete ki behtareen mixing ke liye is plant mein do (2) alag-alag mixers lagaye gaye hain, jo poore system ko aala performance dete hain:

• First Mixer (Top Finishing/Color Mixer): Is mixer ki capacity 0.25 Cubic Meter hai, jo khas taur par tuff tiles aur pavers ki top layer ko behtareen aur pakka color dene ke liye use hota hai.

• Second Mixer (Main Core Aggregate Mixer): Yeh heavy-duty mixer 0.75 Cubic Meter Capacity ke saath aata hai, jo main concrete material ko second ke hisab se mix karta hai.

• SSM 750 Batching Plant: Mukammal batching plant ki capacity 0.75 m³ (Cubic Meter) hai, jo digital weighing load cells aur automatic pneumatic control gates ke saath chalta hai. Yeh system cement, sand aur crush ka exact wazan khud digital panel par monitor karta hai.

2. High-Speed Material Transfer

Material ko bina rukiye automatic mixer se machine tak pahonchane ke liye 2 Conveyor Belts lagayi gayi hain. Yeh imported 3-ply rubber belts material ko zaya hone se bachati hain aur raw material storage hopper se mixer tak loading ko smooth banati hain.

Production Matrix: 1 Million Blocks Monthly Target

Heavy engineering aur 131 HP ki total power usage ki wajah se yeh plant high-scale production ke liye behtareen hai. Gulberg Greens Islamabad ki site par is plant ne jo benchmarks set kiye hain, wo yeh hain:

• Daily Actual Production: Yeh plant har roz 35,000 Concrete Blocks / Bricks ki heavy production capacity deliver karta hai.

• Monthly Production Output: Continuous operations ke zariye yeh plant mahana 1,000,000 (1 Million) se zyada blocks aur pavers produce karne ki taqat rakhta hai.

• Molding Cycle Time: Sirf 20 se 30 seconds ke ek cycle mein yeh machine 35 rectangle pavers ya standard bricks ka ek poora pallet taiyar kar deti hai.

Data-Driven Plant Parameters

Google ke ranking algorithms ke mutabiq, technical aur data-driven content ko sab se zyada value milti hai. Neeche is plant ka mukammal mechanical data diya gaya hai:

Turnkey Commissioning Aur Training By SSM

Silver Steel Mills sirf ek machinery supplier nahi hai, balki hum Turnkey Project Solutions par yaqeen rakhte hain. Gulberg Greens Islamabad ke is project mein bhi hamari expert technical team ne site par maujood reh kar:

1. Foundation Civil Work Guidance: Plant ke heavy weight aur vibration ko sambhalne ke liye proper foundation tayar karwayi.

2. On-Site Installation & Assembly: 2 mixers, conveyor belts, stacker aur digital weighing panel ki mukammal fitting ki.

3. Machine Commissioning: Plant ko operate karke actual production 35,000 blocks tak test ki.

4. Staff Training: Client ke operators ko digital panel run karne, hydraulic temperature meter monitor karne aur daily maintenance ki mukammal practical training di taake long-term mein koi breakdown na ho.

Result: Client Ko Kya Faida Hua?

Is automatic plant ki installation ke baad client ko market se mahnge blocks kharidne ki zaroorat nahi rahi. Unhone apne plaza, apartments aur offices ke projects ke liye nihayat kam lagat (low cost) mein aala tareen strength ke load-bearing blocks khud manufacture kiye.

Agar aap bhi Pakistan mein real estate developer hain, housing society ke owner hain, ya bade contractor hain aur apna automatic block making plant lagana chahte hain, toh Silver Steel Mills aapka behtareen partner hai.