Fly ash bricks

1. JAVID IQBAL SODAGAR
DGM
ELECTRICAL
Husien sugar mills ltd
Jaran wala

2. In the sugar industry, sugarcane bagasse is more related as the by-product in sugarcane mills. After the
sugarcane is pressed to remove sucrose or known as table sugar, the residue is called as sugarcane
bagasse which contains highly fibrous residue. After the sucrose removal, the bags is generated and its
accumulation presents as a waste problem for the sugar industry.
The sugarcane bagasse consists of approximately 50% of cellulose, 25% of hemicelluloses and 25%
of lignin. Each ton of sugarcane generates approximately 28% of bagasse (at a moisture content of
50%) and 0.62% of residual ash. The residue after combustion presents a chemical composition
dominates by silicon dioxide (SiO2). In spite of being a material of hard degradation and that presents
few nutrients, the ash is used on the farms as a fertilizer in the sugarcane harvests . Due to limited
availability of natural resources and rapid urbanization, there is a shortfall of conventional building
construction materials. Therefore, study has been conducted by many researchers on the use of
agricultural waste as partial construction materials either cement, sand or aggregate
Sugarcane bagasse fly ash

3. ➢Introduction
➢Types of fly ash bricks
➢Raw materials required
➢Manufacturing Process
➢Advantages and Disadvantages
➢Conclusion

4. ➢Fly ash bricks are constructed at least partially from the residue of burnt coal & sugar mills bagasse
residue. The resulting fly ash can take a number of different forms. Some kinds of fly ash require a
cementing agent, such as quicklime or Portland-cement.
➢ Other types contain a large enough percentage of lime that they are self setting, requiring only
the addition of water to be turned into fly ash bricks..
INTRODUCTION
➢• We are introducing the business of manufacturing Fly Ash Bricks with a view point of
eliminating
➢Fly Ash as an Environment Pollutant which provides huge benefit to organization as well as to
environment
➢• Fly-Ash Bricks are an environment friendly
➢• These bricks are three times stronger than conventional bricks with consistent strength.
➢• The major advantage of Fly ash bricks over conventional handmade clay bricks is, these
are made from thermal waste and it is eco friendly.
➢• It's very economical / cost effective, low wastage while transporting and handling.

5. ❑Types of fly ash bricks
1-FAL-G (fly ash-lime-gypsum) Bricks:
Fly ash-lime-gypsum bricks/blocks
technology has been developed
successfully by many countries
Fal-G bricks are made of a mixture of fly ash-lime gypsum or fly ash-cement-gypsum. In either
combination, Fal-G is a hydraulic cement, which means it sets and hardens in the presence of moisture,
on the lines of ordinary Portland cement, gaining strength progressively over ageing.
Features:
• Faster construction
• Less mortar consumption
• Most suitable for boundary walls
• Plastering not required
• Decorative, like stone masonry
• Ash content 26%

6. ❑ Clay-Fly ash Bricks
Clay-Fly ash bricks
❖ Manufacturing process of clay fly ash bricks by manual
or extrusion process involves mixing of fly ash (60 %)
with clay of moderate plasticity.
❖ The green bricks are dried under ambient atmospheric
conditions or in shed to equilibrium moisture level of
below 3 percent.
❖ Dried bricks are fired in traditional brick kilns at 1000º ±
30º C with a soaking period of 5 – 7 hours at maturing
temperature.
❖ This technology has great potential to reduce not only
precious top soil and consumption of coal in making
clay bricks, but also requires minimum charges in
conventional existing set up at kiln sites and not very
much susceptible to quality of ash.

7. ❑Fly ash – Sand lime
Bricks
Fly ash – Sand lime Bricks
❖This processes involves
homogeneous mixing of raw
materials (generally fly ash, sand
and lime), moulding of bricks and
then curing of the green bricks.
❖ In presence of moisture, fly ash reacts with
lime at ordinary temperature and forms a
compound possessing cementatious
properties. After reactions between lime and
fly ash, calcium silicate hydrates are
produced which are responsible for the
high strength of the compound.

8. ❑Cold Bonded Lightweight Fly ash
Bricks, Blocks and Tiles
✓ The material can be produced in a variety of
building blocks, bricks and tiles, depending on
local markets and regulations. Keraton consists of
cheap and ubiquitous raw materials such as fly ash
and / or other waste materials.
✓ These materials are mixed and a cold bonding agent
is added. The mixed raw material is cast in moulds,
after which the moulds are processed in a microwave
oven for transportation to the building site.
✓ The products can be applied as a lightweight material in the house
building industry and utility building A surface treatment or coating
for coloring is possible

9. ❑ Flux Bonded Fly ash Bricks
Blocks and Tiles
✓ For making of this type of blocks fly ash is mixed with less than 10 %
plastic clay and a few additives and tiles, bricks or blocks are pressed.
These shapes are fired in the range of 900ºC to 1000ºC to make the final
product. More than 85% of fly ash is used in the process.
✓ The process is similar to the one in the conventional tile industry
✓ The process is based on the formation of low melting fluxes at the firing
temperature, which partly react with the fly ash and form a high
temperature reactive glass binder phase

10. ❑ Raw Materials Required
The following are the RAW MATERIALS required for making of FLY ASH
bricks
➢Lime
➢Gypsum
➢Stone dust
➢Sand
➢Water

11. ❑Procurement Of Raw Material
And
Sand From Pits,Rivers,Seas etc.

12. ❑ Manufacturing Process

13. ❑ Brick Making Machine
o The machine consist the following
parts
➢Brick making machine.
➢Vibrator, hydraulic power pack
motor and Control panel
➢Pan mixing machine with gear
box and motor
➢Belt conveyer system
➢Hydraulic pallot trolley
FULLY AUTOMATIC FLY ASH BRICK MAKING MACHINE

14. ➢Manufacturing of fly ash bricks is done by Two Methods
as follows
Normal Method
62% FLY
ASH
8% LIME
5% GYPSU
M
25% SAND OR
QUARRY DUST

15. Profitable Method
20% FLY ASH
15% LIME
5% GYPSUM
60% SAND OR
QUARRY DUST

16. Fly Ash, Gypsum, Lime, Sand
↓ ↓ ↓ ↓
Weighing
↓
Pan Mixer
↓
Conveyor
↓
Fly Ash Brick Making Machine
(Hydraulic (or) Power Press)
Transported To Wooden Racks
↓
Kept as it is
for two days for setting
↓
Water Curing
(7 to 20 days)
↓
Drying
(one or two days)
↓
Sorting and Testing
↓
Dispatch
❑ Flow Chart Diagram pf Manufacturing of Fly ash
Bricks

17. ❑ 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
Water absorption 20-25% Water absorption 6-12%

20. ❑ 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.
✓ Water absorption <8%.

21. ❑ Advantages of fly ash
bricks
✓ Appearance and Structural Capability
✓ Toxicity and Breath-ability
✓ Sustainability
✓ Buildability, availability and cost
✓ DIMENSIONAL ACCURACY.
✓ Applicability
✓ Thermal properties
✓ Sound insulation
✓ Durability and moisture resistance
❖Fly ash bricks has numerous advantages are as follows
✓MINIMUM BREAKAGE/WASTAGE DURING

22. ❑ Technical Advantages
✓ Energy Efficient
✓ Fire resistant
✓ Sound Resistant
✓ Structurally sound
✓ Strong • Durable • Versatile
✓ Safe • Secure • Robust
✓ Economical

23. ❑ Other Advantages
✓ 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.

24. ❑ Disadvantages
× Manufacturing process involves strong health hazard for the labors.
× Its disposal require large quantities of land, water, and energy, its fine
particles.
× Fly ash is one of the numerous substances that cause air, water and soil
pollution.
× FA contains trace amounts of toxic metals (U, Th, Cr, Pb, Hg, Cd etc.), which
may have negative effect on human health and on plants.

25. ❑ Technical Specifications230 x 100 x 75 mm 230 x 150 x 80 mm
(1) Fly Ash Brick Size Details : [4 Inches ] [ 6 Inches ]
230 x 100 x 100 mm 230 x 150 x 100 mm
(2) Compressive Strength : 75 to 150 kg/cm2
(3) Water Absorption : 8-12 %
(4) Efflorescence : Nil
(5) Density : 1700 Kg/m3
230x100x75 mm ( Weight about 4.75 to 5.00 kgs.approx )
(6) Weight :
230x150x75 mm ( Weight about 2.75 to 3.00 kgs.approx )
(7) Load Bearing Capacity : More than 25% as compare to clay bricks
(8) Composition : Cement, Thermal Station Fly Ash ,Crushed Sand / Stone Dust And
Chemicals
(9) Drying Shrinkage : Maximum Average drying test shrinkage 0.035-0.04 %
(10) Brick Colour : Gray / Dark gray

27. CONCLUSION
• The bricks which currently most of us are
aware is made up of the soil of specific quality,
but due to which earth erosion takes place and
we waste natural resources.
• This job is too laborious and involves cost.
• Natural seasons affect the quality and cost.
• This bricks creates environmental pollution.

28. 3D Layout – Fully Automatic Plant