Manufacturing Process – How We Make It | Igloo Building Materials Tiruchirappalli

01Step 01

Raw Material Procurement & Inspection

Only certified raw materials enter our facility. Cement (OPC 53 Grade), crushed aggregate (ISI marked), sand (river/M-sand), and steel fiber are checked for quality certificates and tested in-house before acceptance.

Cement: OPC 53 Grade (IS 269)

Aggregate: 10mm & 20mm nominal size

Steel Fiber: Hooked-end, 40kg/m³ dosage

Water: Potable quality, pH tested

Material Inspection Yard

02Step 02

Concrete Mix Design & Batching

Our in-house concrete technologist designs product-specific mix proportions. Computer-controlled weigh batching ensures exact material ratios are maintained batch-to-batch — eliminating human error in proportioning.

Mix design per IS 10262 methodology

Automated weigh batcher — ±0.5% accuracy

Water-cement ratio strictly controlled

Admixtures dosed per design specification

Weigh Batching Plant

03Step 03

Forced-Action Mixing

A planetary mixer homogenizes all ingredients including steel fibers to a uniform distribution. Proper mixing duration (minimum 90 seconds) ensures complete fiber dispersion without balling — critical for SFRC products.

Planetary pan mixer — 750 litre capacity

Mixing time: 90–120 seconds per batch

Slump test performed on every batch

Fiber distribution visual check

Planetary Mixer — 750L

04Step 04

Vibro-Compaction Moulding

Fresh concrete is placed into precision steel moulds and compacted using high-frequency vibration tables (50–60 Hz). This expels air voids, achieves maximum density, and ensures a smooth surface finish — all critical to final strength.

Vibration frequency: 50–60 Hz

Steel mould — ±1mm dimensional tolerance

Compaction time: 45–90 seconds per unit

Demoulding after 8–12 hours

Vibration Moulding Press

05Step 05

Water Curing & Maturation

Demoulded units are moved to the curing yard where they are continuously water-cured for a minimum 28 days. This hydration process develops concrete's full strength potential — ensuring every product dispatched has attained its target compressive strength.

Minimum 28 days water curing

Sprinkler system for uniform coverage

Cubes cast & tested at 7, 14, 28 days

Temperature monitored during curing

28-Day Curing Yard

06Step 06

Heat-Reflective Coating (Roof Tiles)

For Cool Roof Tiles, a specially formulated heat-reflective coating with SRI ≥ 78 is applied uniformly by spray-painting in a controlled environment. Each tile is checked for full surface coverage and uniformity before moving to QC.

Solar Reflectance Index (SRI) ≥ 78

UV-stabilised acrylic coating

Spray application — uniform 200 micron DFT

24-hour drying before QC inspection

Spray Coating Station

07Step 07

Quality Testing & Certification

Every batch undergoes comprehensive testing in our on-site laboratory and periodic third-party certification. Only units passing all tests receive the Igloo quality mark and dispatch authorization.

Compressive strength (IS 516)

Water absorption test (IS 2185)

Dimensional check — ±2mm tolerance

Visual inspection for surface defects

In-House QC Laboratory

08Step 08

Packaging & Dispatch

Passed units are palletized, wrapped, and labeled with batch number, production date, and test certificate reference. Our fleet of trucks ensures on-time delivery directly to project sites or dealer warehouses across Tamil Nadu.

Pallet stacking for damage-free transit

Batch certificate attached to each consignment

Same-day dispatch for orders placed before 12 PM

Pan-Tamil Nadu delivery network

Dispatch & Delivery Fleet

How We Make It

ISO-Certified Factory in Tiruchirappalli

Our Manufacturing Process

Quality is Not an Option

Standards We Comply With

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