Manufacturing report on Fly ash brick

2. INTRODUCTION TO FLYASH AND FLYASH BRICKSINTRODUCTION TO FLYASH AND FLYASH BRICKS
Fly ash is a fine, glass-like powder recovered from gases created by coal-fired electric power generation. Flash material is
solidified while suspended in the exhaust gases and is collected by electrostatic precipitators or filter bags. Since the particles
solidify while suspended in the exhaust gases, fly ash particles are generally spherical in shape and range in size from 0.5 μm to
100 μm. They consist mostly of silicon dioxide (SiO2), aluminium oxide (Al2O3) and iron oxide (Fe2O3).
Flyash Bricks is a building material, specifically masonry units, containing fly ash and water, compressed at 28 MPa (272
atm) and cured for 24 hours in a 66 °C steam bath, then toughened with an air entrainment agent.

3. 1] To provide and promote business and services that strengthens the brick manufacturing sector for the ultimate benefit of its
customers and society.
2] To be in the forefront of creating awareness about environment, & to be the largest player in the field of fly-ash brick
production.
3] Nearly 73% of India’s total installed power generation capacity is thermal, of which coal-based generation is 90% – the
remaining comprising diesel, wind, gas, and steam. The 85 utility thermal power stations, besides the several captive power plants,
use bituminous and sub-bituminous coal and produce large quantities of fly ash. High ash content (30%–50%) contributes to these
large volumes of fly ash

4. 1] The country consumes about 180 billion tonnes bricks, exhausting approximately 340 billion
tonnes of clay every year and about 5000 acres of top soil land is made unfertile for a long
period.
2] The government is seriously concerned over soil erosion for production of massive quantities
of bricks, in the background of enormous housing needs.
3] The excellent engineering property and durability of fly ash brick enlarges its scope for
application in building construction and development of infrastructure, construction of
pavements, dams, tanks, under water works, canal lining and irrigation work etc.
4] Enormous quantities of fly ash is available in and around thermal power stations in all the
states.
5] The demand of bricks could be met by establishing small units near thermal Power stations
and to meet the local demand with less transportation costs.
MARKET DEMANDMARKET DEMAND

5. IMAGES OF BUILDINGS, MALLS, INFRASTRUCTURESIMAGES OF BUILDINGS, MALLS, INFRASTRUCTURES

6. GEOGRAPHICAL LOCATIONGEOGRAPHICAL LOCATION
For setting up a fly ash brick industry
these factors should be adhered:-
Land requirement - at least 1.5 acre of
land is required to set up a plant
Factory location – fly ash generally is
found near thermal power plant. Thus
setting up an industry within 60 -70 km
radius nearby a thermal power plant is an
advantage.
Availability of water – ample amount of
water is required for running this industry
Environmental issues – setting up a
factory nearby a residential township or
any other manufacturing industry is
prohibited, as it generates huge dust and
smoke and pollutes the air.

7. 1] FLY ASH 2] GYPSUM LIME
3] LIME 4] SAND

8. Procurement Of Raw Material
And Sand From Pits,Rivers,Seas etc.And Sand From Pits,Rivers,Seas etc.

9. PROPORTIONING OF RAW MATERIAL
Fly ash: 55-60%
Sand: 20-25%
Sludge Lime: 15-20%
Gypsum: 5%
1] NORMAL METHOD
Fly ash: 60-65%
Sand: 18-27%
Sludge Lime: 8-12%
Gypsum: 5%
2] PROFITABLE METHOD

10.  Manufacturing Process

11. PRODUCT SPECIFICATIONS:-
230 x 100 x 75 mm 230 x 150 x 80 mm
1] Flyash brick size details:- [ 4 inches ] [ 6 inches ]
230 x 100 x 100 mm 230 x 150 x 100 mm
2] Compressive strength:- 75-150 kg/cm2
3] Water Absorption:- 8-12% 4] Efflorescence:- Nil
5] Density:- 1700 kg/m3
230 x 100 x 75 mm [ weight about 4.75 – 5 kg approx ]
6] Weight:-
230 x 150 x 75 mm [ weight about 2.75 – 3 kg approx ]
7] Load bearing capacity:- More than 25% as compare to clay bricks.
8] Composition:- Cement, Thermal station flyash, Crushed sand / stone dust and chemicals
9] Drying shrinkage:- Maximum average drying test shrinkage 0.035 – 0.04%
10] Brick colour:- Gray / Dark gray

12. COST COMPARISION OF HOLLOW BLOCK
MASONARY WITH CLAY BRICK MASONARY
DESCRIPTION NORMAL
CONCRETE
BRICK
METHOD
FLYASH
BRICK
METHOD
SAVINGS /
EXCESS
1
2
3
4
CEMENT MORTAR
LABOUR
PLASTER
COST OF THE PRODUCT
10.35
21.45
27.00
55.96
6.56
14.84
20.66
56.90
3.79
6.61
6.34
0.94
TOTAL SAVING PER SQ.FT. ₹15.80
ALL UNITS PER SQUARE FEET₹
COST COMPARISION OF HOLLOW BLOCK MASONARY WITH
CLAY BRICK MASONARY

14. (A)LAND &
BUILDING
DESCRIPTION AMOUNT Rs
1 Land Lease
hold
30,000
2 Building (60 x
40 = 2400 Sq.
feet.)
2,00,000
3 Overhead water
tank
40,000
TOTAL 2,70,000
FIXED CAPITAL

15. (b)Machinery and Equipment DESCRIPTION QTY RATE AMOUNT
1 Automatic Fly ash Brick making
machine hydraulic operated with
all accessories and fitting with
18HP Motor
1 12,00,00
0
12,00,00
0
2 Pan Mixture 500 KG Capacity
with 7.5 HP Motor
1 2,50,000 2,50,000
3
Belt Conveyor with necessary
fittings and 2 HP Motor
1 50,000 50,000
TOTAL 15,00,000
VAT 4 % 60,000
GRANT TOTAL 15,60,000
Erecting and Electrification Charges 22,000
TOTAL 1,58,2000

16. (a)Raw
Material Per
Month: Rs.
S.N
DESCRIPTION QTY RATE AMOUNT
1 Fly ash 400 Mt 200 80,000
2 Gypsum Lime 80 2,00
0
1,60,000
3 Lime 100 1,20
0
120,000
4 Sand 35 800 28,000
TOTAL 3,88,000
RECURRING EXPENDITURE (PER MONTH):

17. (b) Salaries & Wages
Per Month : Rs. S.No
DESIGNATIO
N
NO SALARY Amount
1 Production
Manager
1 -- Self
2 Un skilled
workers
15 3500 52500
3 Office
assistant
1 4,000 4,000
4 Watch man 1 3,500 3,500
Total 18 60,000

18. (c)Utilities Per Month
: Rs. S.N
DESCRIPTION AMOUNT
1 Power 35 HP 3916
Units@ Rs.5 per Unit
19,583
2 Water 1,000
TOTAL 20,583
(d)Other Expenses Per
Month : Rs. S.N
DESCRIPTION AMOUNT
2 Postage and stationery 1,000
3 Repairs and maintenance 2,000
4 Travelling and
transportation
3,000
5 Insurance 1,000
6 Telephone 2,000
TOTAL 9,000

19. WORKING CAPITAL
ASSESSMENT
DESCRIPTION AMOUNT
1 Raw Material
(Required for one
week)
90,534
2 Work in progress
(Required for one
month)
1,09,583
3 Finished Good
(Required for 5 days)
1,05,917
4 Bill receivable
(Required for two
weeks)
2,06,900
TOTAL 512,934

20. TOTAL PROJECT COST
a. Land Lease hold:- 30,000₹
b. Building:- 2,00,000₹
c. Plant & Machinery:- 15,82,000₹
d. Raw materials:- 3,88,000₹
e. Salaries and Wages:- 60,000₹
f. Utilities:- 20,583₹
g. Other:- 9,000₹
h. Working Capital:- 5,12,934₹

21. DOCUMENTS REQURIED FOR SMALL SCALE INDUSTRY
1] Clearance from the municipal corporation
2] State pollution control board clearance
3] Sanction from the electricity board
4] Ownership/tenancy rights of the premises where unit is located
5] Copy of partnership deed/Memorandum of articles of association in case
of a private limited company
6] Sale bill of product manufactured
7] Sale bill of each end product
8] Purchase bill of each raw material
9] Purchase bill of machinery installed
10] BIS/QC certificate if applicable
11] An affidavit giving status of the unit, machinery installed,
power requirement, etc.

22. Step 1: Provisional SSI Registration
To obtain SSI registration the business must first apply for Provisional SSI Registration
Certificate (PRC). Provisional Registration Certificate is given when the unit is in a pre –
operative period and helps the SSI unit obtain term loans and working capital from financial
institutions/banks under priority sector lending.
Step 2: Start the Business
Start the business with the provisional SSI registration certificate. Commence activity or
production.
Step 3: Permanent SSI Registration
Once the business commences production or activity, the business can apply for and obtain
permanent SSI registration. Obtaining permanent SSI registration will help the business
obtain the following benefits.

23.  Comparison Between
Normal Clay Bricks And Fly Ash Bricks
NORMAL CLAY BRICK
FLYASH BRICK
Varying colour as per
soil
Uniform pleasing colour like
cement
Uneven shape as hand
made
Uniform in shape and smooth in
finish
Lightly bonded Dense composition
Plastering required No plastering required
Heavier in weight Lighter in weight
Compressive strength
is around
35 Kg/cm2
Compressive strength is around
100
Kg/cm2
More porous Less porous
Thermal conductivity
1.25 – 1.35 W/m2 ºC
Thermal conductivity 0.90-1.05
W/m2 ºC

24.  Characteristics of Fly Ash Bricks
 The standard size of the brick is 230mmx110mmx70mm.
 The bricks are manufactured and tested as per IS 12894-2002.
 Fly ash bricks are sound, compact and uniform in shape, size and colour.
Smooth rectangular faces of the bricks are accompanied with sharp and
square corners.
 They are free from visible cracks, warpage, flaws and organic matter.
 Economical & environment friendly.
 28% lighter than ordinary clay bricks.
 Compressive strength: 7.5N/mm2 on an average.

25.  Technical Advantages
 Energy Efficient
 Fire resistant
 Sound Resistant
 Structurally sound
 Strong • Durable • Versatile
 Safe • Secure • Robust
 Economical
 Less wastage and breakages
 It can reduce 10% of water consumption.
 Reduce dead load on total Building Structure
 Compression strength improves by more than 15 %.
 Less mortar consumption in masonry & saving in plastering cost.
 Uniformly in shape and size.

26. A] STRENGTHS:-
1) Cost Advantage
2) Unlike metals or organic materials flyash can withstand the onslaught of natural forces.
3) Flyash brick industry is an labour intensive industry. It has the potential to generate
employment.
B] WEAKNESSES:-
1) Flyash industry is an highly messy job with an immerse dusty working environment.
2) Due to lack of modern technologies and machineries to check pollution, flyash
Industry does not posses that eagerness in common man eyes.
C] OPPURTUNITIES:-
1) Flyash industry has now replaced brick in infrastructure development
2) Flyash is an good raw material for bricks. Thus it can substitute brick during
construction.
D] THREATS:-
1) Number of workers willing to work in flyash industry is decreasing day by day due to
health concerns
2) Availability of flyash is scarce.

27. ADVERTISEMENT OF PRODUCT
1) Email Marketing
2) Land Your Business in the Press
3) Pinterest
4) Facebook Shop Section
5) Uncrate
6) Blogger Outreach
7) Instagram

28. CONCLUSION
1]Fly ash utilization in the country has remained less than 30% during the past 5 years
and it might take several years to reach the final goal of cent percent utilization.
2]It is estimated at present nearly 160 million ton fly ash is produced every year, out of
which hardly 40-50 % is used in all possible applications.
3]To utilize such a huge quantity of ash, we have to take necessary actions from
government side and from nongovernment side for utilisation point of view.
Manufacturing of flyash bricks is a safe method for disposing flyash.