SSM 35 Paver Plant in Karachi – One Million Pavers Monthly Near Bahria Town Karachi (2018 Installation)
Introduction – Karachi’s Giant Step Toward In‑House Paver Manufacturing
Karachi is Pakistan’s largest and most dynamic construction market. From high‑rise towers to sprawling housing schemes, the demand for quality interlocking pavers (tuff tiles) is insatiable. By 2018, with projects like Bahria Town Karachi and numerous commercial developments, the need for a reliable, high‑volume paver plant became critical.
Enter Silver Steel Mills. We supplied, installed, and commissioned a fully automatic SSM 35 block making plant configured specifically for paver (tuff tile) production. Located near Bahria Town Karachi, this plant has been producing one million pavers per month – a benchmark for the city’s construction industry.
This article documents the complete story: why Karachi needed such a plant, the machine specifications, daily output, and how Silver Steel Mills turned a challenge into a success.
Project Overview – Karachi’s Mega Paver Plant (2018)
| Parameter | Detail |
|---|---|
| Project Location | Near Bahria Town Karachi (industrial zone, off M‑9 motorway) |
| Client Type | Private construction materials company (serving Bahria Town, DHA Karachi, and other developers) |
| Installation Year | 2018 |
| Machine Model | SSM 35 (Fully Automatic Paver/Tuff Tile Plant) |
| Plant Area | 10 kanals (approx. 54,000 sq. ft.) |
| Production Capacity | 1,000,000 pavers per month (approx. 33,333 pavers daily) |
| Key Components | Batching plant, 2 mixer machines, conveyor belt, automatic stacker |
| Primary Products | Interlocking tuff tiles (50‑60 mm) for roads, footpaths, parking areas |
Why near Bahria Town? Bahria Town Karachi is one of Asia’s largest housing schemes. The client wanted to be within 5 km of the project to ensure just‑in‑time delivery of pavers for roads, walkways, and commercial plazas.
The Challenge – Karachi’s Paver Quality & Supply Gap
Before 2018, most developers in Karachi relied on:
Imported pavers from China and UAE (expensive, long lead times)
Local small‑scale plants (low production, inconsistent quality, frequent breakdowns)
Key problems:
Quality variation – Pavers would crack within months under heavy vehicle traffic.
Supply shortages – One large housing scheme could empty the stock of three small plants.
High logistics cost – Transporting pavers from Lahore or Gujranwala added 25‑30% to the final price.
The solution was a high‑capacity, local, and reliable paver plant – exactly what Silver Steel Mills delivered.
The SSM 35 Plant – Complete Configuration for One Million Pavers Monthly
The plant is built around the SSM 35 block machine, but configured specifically for paver production. It includes a full batching plant, two mixers, conveyor belts, and an automatic stacker – all integrated into a single production line.
1. Main Block Machine (SSM 35 – Paver Configuration)
| Feature | Specification |
|---|---|
| Operation System | Auto pallet + double trolley system |
| Cycle Time | 20‑30 seconds |
| Hydraulic Pressure | 300 tons (from 30 HP pump) |
| Vibration | Dual 20 HP motors (under‑bed + shaft vibrator) |
| Total Power | 131 HP (including auxiliaries) |
| Product Height | 50 mm – 200 mm |
| Pallet Size | 889 × 1219 × 38 mm |
2. Batching Plant (Digital, 0.75 m³)
Aggregate bins: 8 hoppers with electric discharge gates.
Weighing system: 4 digital load cells (Taiwan/imported).
Cement silo: 100 ton (separately erected).
Water & admixture weighing integrated.
3. Two Mixer Machines (Dual‑Line Production)
| Mixer | Capacity | Role |
|---|---|---|
| First Mixer (Main) | 0.75 m³ (750 litres) | Base concrete for high‑volume paver production |
| Second Mixer | 0.50 m³ (500 litres) | Coloured top layer (for decorative pavers) |
Both mixers are planetary type with hardened blades and separate motors (30 HP + 20 HP). They discharge into a common conveyor system.
4. Conveyor Belt System
3 weighing conveyors – move aggregates from hoppers to mixers.
2 transport conveyors – deliver fresh concrete from mixers to the block machine hopper.
Heavy‑duty rubber belts with cleats to prevent spillage.
5. Automatic Stacker
Pallet stacker & destacker – automatically stacks finished pallets and feeds empty ones.
Stacker power : 10 HP (hydraulic lift + pusher).
Capacity : Handles up to 20 pallets per stack.
This fully automatic stacking eliminates manual handling, reduces breakage, and allows continuous operation.
6. Control System
Digital weighing panel (SSM make) for batching.
Separate hydraulic operating system (imported from Taiwan) for the block machine.
Electrical panel with PLC (for main machine) and push‑button controls.
Production Reality – One Million Pavers Monthly
The plant operates in two shifts (16 hours/day). Actual output achieved since 2018:
| Period | Production |
|---|---|
| Daily | 33,000 – 35,000 pavers (50 mm thick) |
| Monthly (25 working days) | 825,000 – 875,000 pavers (consistently) |
| Peak month (with overtime) | 1,000,000+ pavers |
“We’ve never missed a single delivery to Bahria Town or DHA. The SSM 35 plant gives us the throughput of three small plants combined, with better quality.”
– Plant Manager, Karachi Paver Industries
The pavers are used for:
Internal roads in Bahria Town Karachi (Phase 1‑4)
Footpaths & commercial plazas in DHA City Karachi
Parking areas for Gulshan‑e‑Maymar and other cooperative societies
Industrial zones near Port Qasim
Quality – Why Karachi Developers Trust These Pavers
Independent lab tests (conducted by Bahria Town’s quality assurance team) show:
| Property | Result | Requirement |
|---|---|---|
| Compressive strength | 4,800 – 5,200 PSI | > 4,000 PSI for heavy traffic |
| Water absorption | < 5% | < 7% acceptable |
| Abrasion resistance | < 2 mm wear | < 3 mm |
| Dimensional tolerance | ± 1 mm | ± 2 mm acceptable |
The dual vibration + high hydraulic pressure of the SSM 35 ensures dense, non‑porous pavers that resist cracking even under container truck traffic.
Silver Steel Mills’ Role – Turnkey Installation & Training (2018)
Silver Steel Mills provided complete end‑to‑end service:
Site layout & foundation design – Based on the 10‑kanal area, we positioned the batching plant, mixers, and machine for optimal material flow.
Erection & commissioning – Our team of 4 technicians assembled the entire line in 25 days.
Calibration – Load cells, hydraulic pressure, and vibration frequency were fine‑tuned for paver production.
Operator training – Two local operators (and four helpers) were trained for 2 weeks on machine operation, mould change, and preventive maintenance.
After‑sales support – 3 months free service, with spare parts stocked at our Gujranwala factory.
Client’s responsibilities (fulfilled) :
Civil foundation (bricks, concrete, anchor bolts)
Electricity supply (200 kVA transformer)
800 litres hydraulic oil + 50 litres gear oil
Water supply & pump
Accommodation & meals for technicians
Loader (2 ton) and forklift
Financial Impact – How the Client Achieved ROI in 6 Months
Before the SSM 35 plant, the client purchased pavers from suppliers at an average cost of PKR 135 per square foot (including transport). Their in‑house production cost:
Raw material (cement, crush, sand): PKR 55 per sq. ft.
Labour & electricity: PKR 10 per sq. ft.
Total in‑house cost: PKR 65 per sq. ft.
Monthly production (1,000,000 pavers = approx. 60,000 sq. ft.)
Revenue (if sold at market rate) : 60,000 × 135 = PKR 81 lakh
Cost : 60,000 × 65 = PKR 39 lakh
Gross margin : PKR 42 lakh per month
Machine investment (2018) : Approximately PKR 1.5 crore (SSM 35 + batching + mixers + stacker + moulds + pallets).
Return on Investment : < 4 months.
“We paid off the plant in less than half a year. Now it’s pure profit, and we dominate the paver market in Karachi’s southern region.”
– Owner, Karachi Paver Industries
Why This Plant Remains Relevant in 2025
Seven years after installation, the SSM 35 plant at Bahria Town Karachi continues to run 16 hours a day. Silver Steel Mills has supplied replacement wear parts (blades, liners, hydraulic seals) promptly, ensuring minimal downtime. The plant has produced over 70 million pavers to date – enough to pave thousands of kilometres of roads.
Conclusion – Your Karachi Paver Plant Partner
Karachi’s construction market demands high volume, high quality, and local supply. The SSM 35 paver plant near Bahria Town Karachi is proof that Silver Steel Mills can deliver – and has delivered – a solution that meets all three.
Are you a developer or contractor in Karachi, Hyderabad, or Sukkur? Do you need a reliable source of high‑strength pavers (tuff tiles) or want to set up your own captive plant?
Silver Steel Mills offers complete turnkey block & paver plants (SSM 15 to SSM 50), with batching, mixing, conveying, and stacking systems. We provide design, manufacturing, installation, training, and after‑sales support – all from Pakistan.