BRICKS FROM FLY ASH

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Bricks may be made from a no. of different kinds of material, but they must usually possess (can be capable of developing) a certain amount of plasticity. fly ash is one of them. Fly-ash is an industrial waste of thermal power stations using pulverised coal. it is finely divided residue, resulting from the combustion of pulverised coal in the boiler, which is transported by the flue gases and subsequently collected by means of electrical or mechanical precipitators.

There are about 40 major thermal power plants in India which produces about 15 million tones of fly ash every year. Such enormous quantities need huge dumping grounds, and create pollution problems.

Fly ash being a puzzolanie material forms cementations products in conjunction with time and thus find use in civil Engineering Works. In advanced countries fly ash has been used in variety of product during the last 2-3 decades. Whereas in this country a very limited use of fly ash has been made in hydraulic structures. However, very little has been done on the diversified use of lips fly ash viz. in road construction soil slabbing precast block etc.

Even though research and development and suprimental construction has shown that fly-ash can be used with considerable advantages in building construction, the construction industry has still not taken to the use of fly ash to any large extent. The reasons asisigned for this may be.

1. Unawareness of the usefulness of fly ash in conjuction with lime, cement or bricks in the various civil engineering works.

2. Unavailability of ready mix lime fly ash mixture of standard quality.

There is considerable lack of awareness and appreciation about the possibility of use of fly ash in partial replacement of cement to the extent of 15 to 20% without affecting in any way the strength of the structure adversely or producing any other detrimental affect. This report is intended to give the essential technical information and data regarding the use of in building construction and the process and feasibility of making lime fly ash mix which can be used in variety of works.
Flyash lime bricks are chemically bonded bricks manufactured by utilising 80-82% of fly ash, which is a major waste bye-product of pulverised coal fired in Thermal Power Stations, 9-10% of lime, 9-10% of sand and 0.2% of Chemical accelerator (Covered by Central Fuel Research Institute, Dhanbad’s patent). The process know-how has been developed by Central Fuel Research Institute, Dhanbad and marketed through National Research Development Corporation, 20-22, Zamroodpur Community Centre, Kailash Colony Extension, New Delhi – 110 048.

For manufacturing flyash lime bricks no firing is needed. Curing in steam for predetermined period is employed to enable the bricks to gain desired strength. Thus, flyash lime bricks satisfy the basic parameters of building units, moreover the bricks are also suitable for the construction of building in coastal areas where normal red clay burnt bricks are found to be affected.

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Description

INTRODUCTION
VARIOUS SPECIAL FEATURES OF FLYASH LIME BRICKS ARE AS FOLLOWS
FLY ASH LIME BRICKS – SPECIFICATION
USES AND APPLICATIONS
ADVANTAGES OF FLYASH SAND LIME BRICKS:
PROPERTIES & CHARACTERISTICS
CHARACTERISTICS OF FLYASH-SAND-LIME BRICKS:
ADVANTAGES OF FLYASH-SAND LIME BRICKS OVER CLAY-BRICKS:
PROPERTIES OF BURNT CLAY FLASH BRICKS:
CLAY-FLYASH BURNT BRICKS:
ADVANTAGES OF CLAY FLY ASH BRICKS:
B.I.S. SPECIFICATION
RAW MATERIAL
1. FLY ASH
2. LIME
3. WATER
4. STAIN CHEMICALS
PROPERTIES & CHARACTERISTICS OF RAW MATERIALS USED
PROPERTIES OF FLY ASH:
PHYSICAL PROPERTIES OF FLY ASHES:
CHEMICAL PROPERTIES OF FLY ASH FROM DIFFERENT THERMAL
POWER STATIONS IN INDIA
COMPARISION PROPERTIES WITH ISI:
CHEMICAL REQUIREMENTS
PHYSICAL REQUIREMENTS
B.I.S. SPECIFICATION FOR LIME:
CLASS A:-
CLASS B:-
CLASS C:-
CLASS D:-
CLASS E:-
CHEMICAL REQUIREMENT:
FLY ASH LIME BRICKS – SPECIFICATIONS:
GENERAL REQUIREMENTS:
DIMENSIONS AND TOLERANCES:
MATERIALS:
FLY ASH:
BOTTOM ASH:
SAND:
LIME:
ADDITIVES:
PHYSICAL CHARACTERISTICS:
COMPRESSIVE STRENGTH:
DRYING SHRINKAGE:
EFFLORESCENCE TEST:
WATER ABSORPTION:
SAMPLING AND CRITERIA FOR CONFORMITY:
TABLE : CLASSES OF BURNT CLAY-FLY ASH BRICKS
GENERAL QUALITY
IMENSIONS AND TOLERANCES:
TOLERANCES:
PHYSICAL REQUIREMENTS:
COMPRESSIVE STRENGTH:
WATER ABSORPTION:
EFFLORESCENCE:
MARKET OVERVIEW OF FLY ASH BRICKS
CURRENT FLY ASH DISPOSAL PRACTICES AND EFFECTS
FLY ASH – A RESOURCE
GOVERNMENT INITIATIVES
PRESENT MANUFACTURERS/SUPPLIERS OF BRICKS FROM FLYASH
VARIOUS FLY-ASH BRICK COMPOSITIONS
FLYASH SAND-LIME BRICKS: (AS PER CBRI)
BURNT CLAY-FLY ASH BRICKS: (AS PER CBRI)
FLY ASH SAND-LIME BRICKS: (AS PER CENTRAL FUEL RESEARCH
INSTITUTE, DHANBAD)
FLY ASH BRICK COMPOSITION : (AS PER ISWAR B. VISAKHAPATNAM)
ANOTHER FLY ASH LIME BRICKS COMPOSITION:
OTHER FLY ASH SAND LIME BRICK COMPOSITION:
SAND-LIME BRICKS COMPOSITION: (AS PER CBRI)
PROCESS OF MANUFACTURE
1. GRINDING & MIXING :
2. PRESSING :
3. REMOVAL & STACKING FOR CURING/AUTOCLAVING :
AUTOCLAVING :
PROCESS FLOW DIAGRAM FOR THE MANUFACTURE OF FLY-ASH-
SAND-LIME BRICK (AS PER CBRI)
CERTAIN FEATURES
BRICK COMPOSITION:
MAJOR COMPONENTS:
ALIENT TECHNICAL FEATURES:
ENVIRONMENTAL ASPECTS:
MAJOR PLANT EQUIPMENT & MACHINERY:
AS PER TRADITIONAL BRICK PRODUCTION –
TECHNOLOGY PACKAGE:
RED SOILS:-
ADMIXTURE:-
MARINE SOILS:-
MANUFACTURE OF PROCESS OF FLY ASH BRICK
PROCESS OF MANUFACTURE OF SAND-LIME BRICKS
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF FLY ASH
SUPPLIERS OF LIME
SUPPLIERS OF GYPSUM
SUPPLIERS OF MACHINERY FOR BRICK MAKING FROM FLY ASH

APPENDIX – A:

01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)

Additional information

Plant Capacity

9000 Nos/Day
Land & Building

(15000 sq.ft.)
Plant & Machinery

US$ 21429
Rate of Return

33%
Break Even Point

66%

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