The document discusses the concept and manufacturing processes of clay fly ash bricks, including the benefits of using fly ash from thermal power plants to alleviate topsoil depletion. It highlights the current high usage of coal for power generation in India and outlines the specifications and standards for brick quality and dimensions. Key advantages of fly ash bricks include reduced waste, lower costs, and improved efficiency in brick production.

1. Rishabh Lala
Dual Degree
RGPV, Bhopal
CLAY FLY ASH BRICK

2. CONCEPT
CURRENT SCENARIO
BENEFITS
CODE SPECIFICATIONS
WAYS OF MAKING
DIMENSIONING
OUTLINE

3.  Fly ash brick + Local Soil - BURNT TOGETHER
 KEY POINTS 
 Manufacturing is similar to conventional Clay Bricks
Manufacturing
 Modifies the drying behavior of bricks
 MANUFACTURING 
 I – Soil is layered
 II – Required Quantity of Fly ash is layed
 III –Manual Mixing in their dry form
 IV –Put them in wooden moulds
 V – Moulded Bricks are then air Dried
CONCEPT

8.  The bricks we currently use are made up of a specific quality
of Top Soil (Approximately 10,000 Hectares of Top Soil is lost
every year for Brick Manufacturing).
 If the top soil consumption carries on at the same pace, very
soon, we will not have enough soil for cultivation.
 Also, the thermal power plants and the industrial units using
coal as a fuel have no use with the Fly Ash left after the
combustion and they need to dump it some where.
CURRENT SCENARIO

9.  Nearly 73% of India’s total installed power generation
capacity is thermal, of which coal based generation is 90%,
the remaining comprising of diesel and gas.
 The 85 utility thermal power plants, besides the 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

10.  a) REQUIRES LESS DRYING AREA;
 B) SAVING IN SPACE OF FLOOR AREA;
 C) ECONOMY IN COST OF BRICK MASONRY
 D) SAVING IN LABOUR COST;
 E) LESS LOSSES DURING HANDLING
 F) LESS CONSUMPTION OF MORTAR.:
BENEFITS

11.  Classes or Burnt Clay-Fly Ash Bricks IS 13757 (1993)
CODE SPECIFICATIONS

12.  Hand Moulded
 Hand-moulded bricks of 90 mm or 70 mm
 height shall be moulded with a frog 10 to 20 mm deep on one of
its flat sides;
 Machine Moulded
 Have smooth Surface and Sharp Corners
 The Fly Ash :
 Shall conform to grade 1 or grade 2 as per IS 3812 : 1981.
WAYS OF MAKING

13. DIMENSIONS
 STANDARD SIZES :

14.  WATER ABSORPTION :
IS 3495 ( Part 2 ) : 1992
In Cold water for 24 hours
Not more than 20% by weight of Brick
For Class higher than 12.5, maximum water
absorption is 15 % by weight of Brick
 Compressive Strength Test:
The 95% of the lot should satisfy the compressive
strength tests
TESTS