Fly ash bricks are an environmentally friendly building material made from fly ash, a byproduct of coal combustion in thermal power plants. They provide benefits over traditional clay bricks such as higher strength, less water absorption, more uniform dimensions, and lower costs. The production of fly ash bricks helps reduce environmental pollution by utilizing a waste material that would otherwise require proper disposal. India's power plants generate around 40 million tons of fly ash annually, so fly ash bricks help address the problem of fly ash disposal while providing a competitive alternative building material.

1. Fly Ash Bricks
A useful & Environment friendly Building Product
Submitted
by:
Sheetal Verma

2. What is Fly Ash Brick?
• Fly ash bricks are hi-tech well-improved quality bricks used for construction of brick
masonry structures. They are used as replacement for normal clay bricks and has better
properties than it.
• Fly ash brick (FAB) containing class C or class F 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, the bricks last for more than 100 freeze-
thaw cycles. Owing to the high concentration of calcium oxide in class C fly ash, the brick
is described as "self-cementing".
• The manufacturing method saves energy, reduces mercury pollution, and costs 20% less
than traditional clay brick manufacturing.
• The utilization of fly ash bricks results in conservation of natural resources as well as
protection of environment.

3. • India’s power plants
• These power stations generate nearly 40 million tones of fly ash annually.
• Fly ash contains Co2 emitted from Thermal power plants, industries using coal as a fuel
emits unwanted ash and smoke from which fly ash is produced.
Sources of Fly Ash
Nature of Pollution Caused by Fly Ash
• Fly ash causes severe pollution of air and water, and its disposal gobbles up large tracts
of land
• Well-planned programs for proper management of fly ash are therefore being
undertaken to enhance the use of fly ash in various applications, so that our already
perilously imbalanced environment can be protected

4. Composition of Fly Ash Bricks
Fly ash : -
60%(mass)
Cement :-
10%(mass)
Sand :-
30%(mass)
Fly Ash
Brick

5. Comparison of Clay Bricks and Fly Ash Bricks
Properties Red Bricks/Clay
Bricks
Fly Ash Bricks Remarks
Density 1600-1750 kg/m3
1700-1850 kg/m3
Higher load bearing
Compressive strength 30-35 kg/cm2
90-100 kg/cm2
Higher load bearing
Absorption 15-25% 10-14% Less dampness
Dimensional stability Very low tolerance High tolerance
Saving in mortar up to
25%
Wastage during
transit
Up to 10% Less than 2% Saving in cost up to 8%
Plastering
Thickness vary on the
both sides of wall
Even on both sides
Saving in plaster up to
15%.

6. Examples of use of Fly Ash Bricks
 NTPC has manufactured more than 54 crores ash bricks in its various thermal
power stations
 NTPC Townships at Simhadri in Andhra Pradesh, Sipat in Chhattisgarh,
Faridabad in Haryana and Talchar – Kaniha in Orissa
 NTPC’s NETRA office building at Greater Noida
 IIT Delhi has utilized these bricks for their cafeteria and Management School
building
 Greater Noida Development Authority have used these bricks in office building
construction
 Large number of houses are being constructed with these bricks by private
parties, in various metro cities viz Pune, Vishakhapatnam etc.

7. Manufacturing Process Flow chart
Fly Ash Gypsum Lime Sand
Weighing
Fly Ash Brick Machine
(Hydraulic or Power Press)
Pan Mixer
Conveyor
Transported to Wooden Racks Kept as it is for 2 days for setting
Water Curing ( 7-10 days)
Drying (One or two days)
Sorting and testing
Dispatch

8. Market potential for Fly ash Bricks
 According to the notification from MoEF, Every construction agency engaged in
the construction of buildings within a radius of hundred kilometers (by road) from
a coal or lignite based thermal power plant shall use only fly ash based products
for construction.
 The construction industry contributes to about 10 % of the Gross Domestic
Product (GDP), registering an annual growth of about 9 %. Developing means
50% construction.
 In many areas where fly ash brick is available the Government has made it
compulsory to use only Fly Ash Bricks in any construction of Government
undertaking such as Western Coal Field, Maharashtra State Electric Board, PWD,
CPWD, Municipal Corporation

9. Demand for Fly ash
 Uniform in Shape and Smooth in Finish
 No Plastering Required
 Light in Weight
 Compressive strength is 100 kg/2cm
 Available in Different Size
 Cost of fly ash bricks is lower than clay bricks
 Fly ash bricks are of better quality and more eco-friendly

10. Whom do we sell ?
 Contractor
 Land developer
 Sarpanch
 Petrol Pumps

11. Pricing Strategy
 The pricing strategy adopted for Fly ash brick is Cost plus unit
 Cost Plus Unit – calculation of the cost involved and add up a mark up
 Cost Plus pricing calculation is based on where fixed percentage is added on
top of the cost to produce one unit of the product

12. Price Analysis
 Production of 1000 Bricks unit
 Cement – 3.5 bags @ Rs.260 Plus 28% GST ( O.P.C Cement)
 Sand 6cft = 1000 unit
 Fly ash bricks 6 cft
 Labour cost @ 0.5 paisa per piece
 Electricity price @ Rs.560
 Price per piece @ Rs.3-3.5
 Profit per piece 20% for Manufacture

13. Pricing
 Plant : M/S Jai Balajee Enterprises, Roulkela
 Year of establishment : 2010
 Production capacity: 180,000 bricks / per month
 Brick size: 9”x 4”x3”
 Brick weight: 3kg
 Brick Price: Rs. 3
 Man Power: 15

14. Pricing
 Plant: M/S Mahila Ash Industry,Chandrapur, Maharashtra
 Year of Establishment: 2006
 Production Capacity: 600 bricks/hour
 Brick Size: 9˝×4˝×3˝
 Brick weight: 3 kg
 Brick Price: Rs. 1.90/ brick
 Man Power: 30
 President: Smt. Shobha Prakash Tonga

15. SWOT ANALYSIS OF FLY ASH BRICKS
STRENGTH
• Fly ash bricks are 28% lighter than clay bricks.
• Unlike metals or organic materials fly ash can with stand the onslaught of natural
forces
• Fly ash bricks industry is an labour intensive industry. It has the potential for
generating employment.
• The bricks also have a very high tensile strength, which eliminates the chances of
their collapse during earthquake.
WEAKNESS
• Fly ash industry is an highly messy job with an immense dusty working
environment.
• Due to lack of modern technology and machineries to check pollutions, fly ash
industry does not possess that eagerness in common man eyes.

16. OPPURTUNITIES
• Fly ash industries has now replaced brick in infra-structures development.
• Raw material used for regular red brick is limited.
• Fly ash is an good raw for bricks. Thus it can substitute brick during
construction.
THREATS
• No of labours willing to work in fly ash factories are decreasing day by day due
to health concern.
• Long inhalations of fly ash causes silicosis, fibrosis of lungs, bronchitis etc.
• Availability of fly ash is scarce.
• Fly ash generates huge amount of pollution.

17. Payment Terms
 2 Months Credit is given to Real State , Land developers and Builders
 1 Month Credit is given to local contractors
 15 Day Credit is given to Sarpanch and Petrol Pumps

18. Thank You