Cover Image
close this bookBasics of Concrete Roofing Elements (SKAT)
View the document(introduction...)
View the documentIntroduction
View the documentWhat is MCR and FCR?
View the documentUsing MCR and FCR elements
View the documentProducing MCR and FCR elements
View the documentMCR and FCR for organizations
View the documentMCR and FCR for private entrepreneurs
View the documentHow to start MCR and FCR
View the documentMarketing
View the documentManagement
View the documentProfessional training
View the documentRaw materials
View the documentWorkshop and site
View the documentEquipment
View the documentRoof design
View the documentTiles, sheets and semi-sheets
View the documentWhat does it cost?
View the documentAddresses
View the documentLiterature
View the documentThe roofing advisory service (RAS) at SKAT

What does it cost?

The workshop

The typical cost structure of an MCR or FCR workshop in a Third World Country looks as follows:


The cost structure includes amortization and interest for: equipment, building and land, know-how transfer and working capital.

The capital investment for an electrical vibrating table with 200 moulds is around US$ 4.000. Adding working capital, costs for site and building, the investment is between US$7.000 and US$ 12.000.

Tiles made per week

1.000

2.000

5.000

10.000

Value of annual turnover (US$)

12.000

24.000

60.000

120.000

Number of production lines

1

2

5

10

Workforce (Direct Labour)

3

5

12

24

Minimum covered space required





for workshop area (sq.m)

25

50

200

400

Minimum external yard area





needed ( sq.m)

40

80

200

350

Ex-works value of equipment





to be supplied (US$)

4.000

8.000

19.000

38.000

Approximate investment costs at different scales of output (in the year 1989 ). To these costs you will have to add the investment for the building, fencing, water supply, etc. as well as the working capital.


Synoptic view of cost factors in a MCR and FCR project

A square metre of tiles

Once a workshop is installed, Fibre Concrete sheets or tiles can be produced in most countries at a cost between 2 and 4 US$ per sq.m. This includes costs for raw materials, labour, depreciation, profit and interest for initial investment.

A competitive material

Analysis of field-experience allows the following statement: Compared with other roofing methods, a fibre concrete roof including roof structure can be built at 2/3 to 3/4 of the cost of a similar roof covered with Asbestos-Cement. There is no apparent difference in the costs of the roof structure whether concrete roofing tiles or sheets are used.

The most serious competitor

Galvanized Iron Sheets are the most serious competitor to MCR and FCR. However, this is only apparent: Galvanized Iron Sheets have usually a lower life expectancy and the roof substructure needed is the same as for MCR/ FCR if made properly. However, these quality arguments often do not count for buyers with low income, and the correct roof substructure is in most cases neglected.

The conclusion is that in comparison to Asbestos Sheets MCR and FCR are “as good but cheaper” and that in comparison to Galvanized Iron Sheets MCR and FCR “are better in quality and in the medium run as cheap”.