Industry Overview
Fly ash bricks are manufactured using fly ash, a finely divided industrial by-product generated from thermal power plants that burn pulverized coal. During combustion, the ash is carried by flue gases and collected using electrical or mechanical precipitators. As a pozzolanic material, fly ash reacts with lime over time to form cementitious compounds, making it a suitable raw material for a variety of construction applications, including brick manufacturing.
India's thermal power sector produces significant quantities of fly ash every year, creating challenges related to disposal, land utilization, and environmental pollution. Converting this industrial waste into construction materials provides an effective means of resource utilization while reducing the burden on dumping grounds. Over the past two to three decades, several advanced countries have successfully adopted fly ash in a wide range of construction products. In India, however, its application has traditionally been limited, with greater use in hydraulic structures and comparatively less emphasis on diversified applications such as road construction, soil stabilization, precast products, and bricks.
Research, development, and experimental construction have demonstrated that fly ash can be used successfully in building materials with several technical advantages. Despite these findings, the construction industry has been relatively slow to adopt fly ash bricks on a large scale. Nevertheless, increasing awareness of sustainable construction practices and efficient utilization of industrial by-products continues to support the growing importance of fly ash-based building materials.
Cost Estimation
| Particular | Value |
|---|---|
| Plant Capacity | 6000 Nos/Day |
| Land & Building | Owned |
| Plant & Machinery | Rs. 29.10 Lac |
| Working Capital for 1 Month | Rs. 14.18 Lac |
| Total Capital Investment | Rs. 45.28 Lac |
| Rate of Return | 40% |
| Break Even Point | 73% |
Content Index
- 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
- 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)
Frequently Asked Questions
Fly ash bricks are construction bricks manufactured using fly ash as a primary raw material. Fly ash is a finely divided residue collected from thermal power plants after pulverized coal is burned. Because it is a pozzolanic material, it reacts with lime over time to form cementitious compounds that provide strength and durability. These bricks offer an effective way to utilize industrial waste while producing building materials suitable for a variety of civil engineering applications.
Fly ash is used because it is a valuable pozzolanic material that can improve the performance of construction products. Its utilization helps reduce the environmental burden associated with fly ash disposal while converting an industrial by-product into a useful resource. When combined with suitable binders such as lime, it develops cementitious properties that make it appropriate for manufacturing durable building bricks.
The primary raw materials are fly ash, lime, water, and stain chemicals as listed in the report. Depending on the manufacturing process and specifications, materials such as sand, bottom ash, and approved additives may also be incorporated. The selection and quality of these materials play an important role in achieving the required physical characteristics and performance of the finished bricks.
Fly ash bricks are manufactured through a sequence of material preparation, mixing, pressing, and curing. The report describes stages including grinding and mixing, pressing, removal and stacking for curing or autoclaving, and the autoclaving process where applicable. Proper control of these manufacturing steps helps produce bricks with consistent dimensions and desirable physical properties.
Fly ash bricks are manufactured in accordance with relevant B.I.S. specifications wherever applicable. The report covers requirements relating to raw materials, dimensions and tolerances, compressive strength, water absorption, efflorescence, sampling, conformity criteria, and lime classifications. Following these specifications helps ensure product quality and consistency for construction use.
Fly ash bricks support sustainable construction by utilizing industrial waste that would otherwise require large disposal areas. Their production promotes resource conservation and helps reduce environmental issues associated with fly ash dumping. By converting waste into useful building materials, they contribute to more efficient material utilization while supporting environmentally responsible construction practices.
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