Fly ash is fine ash produced by coal-fired power plants that is collected from flue gases. Fly ash bricks are made primarily from fly ash using a process that mixes fly ash with additives like lime and cement. These bricks have advantages over traditional clay bricks like being lighter, stronger, and having better insulation. Government regulations require construction near power plants to use a certain percentage of fly ash in bricks to encourage its use and reduce waste.

1. Industry Newsletter
‘FLY ASH’ is the extremely fine ash ‘flying’ along with flue gases
which is trapped in electro-static precipitators (ESP) and is col-
lected. It is also called Pulverized Coal Ash (PCA).
Fly Ash Bricks are made by using fly ash as a main raw material.
The strength of the fly ash bricks can be engineered by varying
compositions. Equipment used can be manual or mechanised.
Mechanised machines deploy hydraulic compaction to produce
a variety of bricks and can be operated through electric or diesel
power.
Fly Ash Bricks
Clay Bricks - Traditional
Clay bricks are made by burning a block made of
clay in a kiln.
Fly Ash Bricks - Modern
Fly Ash Bricks are made by Pulverised ash brick
(PAB) technology. It is the process of converting
industrial waste materials i.e. fly ash into quality
building materials. At present, the technology is
used for converting thermal power plant waste
into quality bricks.
PAB technology uses dry ash (fly ash collected
from ESP or silos of thermal power plants), filler
materials (usually coarse sand or stone crusher
dust) and additives (lime, gypsum or cement).
Clay Brick
Varying colour as per soil
Uneven shape as hand
made
Lightly bonded
Plastering required
Heavier in weight
Compressive strength is
around 35 Kg/Cm2
More porous
Thermal conductivity
1.25 – 1.35 W/m2 ºC
Water absorption 20-25%
Fly Ash Brick
Uniform pleasing colour like
cement
Uniform in shape and
smooth in finish
Dense composition
No plastering required
Lighter in weight
Compressive strength is
around 100 Kg/Cm2
Less porous
Thermal conductivity
0.90-1.05 W/m2 ºC
Water absorption 6-12%
Technology Advantages

2. The Ministry of Environment and Forests issued directives for proper utilization of fly ash discharged from coal or lignite-
based thermal power plants. The notification was supported by the High Court of Delhi.
Within a radius of 100 km from coal or lignite based thermal power plants, no person shall manufacture clay bricks,
tiles or blocks (for use in construction activities) without mixing at least 25% of ash with soil on weight basis.
Every thermal power plant shall make available ash, for at least ten years without any payment or any other consid
eration for the purpose of manufacturing ash-based products.
Every construction agency engaged in the construction of buildings within a radius of 100 km from thermal
power plants shall use fly ash bricks in construction projects. It shall be the responsibility of the construction
agencies (either undertaking the construction or approving the design or both) to ensure compliance.
Quality Control and Standards:
The Bureau of Indian Standards (BIS) has formulated and published for maintaining quality of the Fly ash Brick and for testing
purpose.
IS 12894:1990 Specification for Fly Ash Lime Bricks
• Emaar MGF (DDA Common Wealth Games)
• IJM (MCD Civic Center Minto Road)
• Globe Civil Projects Pvt. Ltd.
500 Bedded GTB Hospital
Karkardooma Court Lawyers Chambers
Jawahar Lal Nehru Stadium
Geeta Colony Engineering Collage
• Ajay Enterprises Pvt. Ltd. (EROS GROUP)
Kenwood Tower
Brentwood Towers
Rosewood City
Royal Retreet-I
• Mahindra Lifespace Developers Ltd. (Housing Project)
• Jyoti Swarup Mittal (IIT Girls & Boys Hostels Delhi)
• R.S Sharma Construction Company Pvt. Ltd. (DDA)
• Makhijani Constructions (PWD Kamla Market Police Station)
Some Projects/Builders
using Fly Ash Bricks
Government Regulation
• Emaar MGF (DDA Common Wealth Games)
• IJM (MCD Civic Center Minto Road)
• Globe Civil Projects Pvt. Ltd.
500 Bedded GTB Hospital
Karkardooma Court Lawyers Chambers
Jawahar Lal Nehru Stadium
Geeta Colony Engineering Collage
• Ajay Enterprises Pvt. Ltd. (EROS GROUP)
Kenwood Tower
Brentwood Towers
Rosewood City
Royal Retreet-I
• Mahindra Lifespace Developers Ltd. (Housing Project)
• Jyoti Swarup Mittal (IIT Girls & Boys Hostels Delhi)
• R.S Sharma Construction Company Pvt. Ltd. (DDA)
• Makhijani Constructions (PWD Kamla Market Police Station)

3. Pressing in Moulding
Machine
Grinding &
Mixing
Fly-ash
Storage
Lime
Storage
Curing/
Autoclaving
coolingWater
Storage
Stain &
other
chemicals
Storing
The Manufacture of Flyash-Sand-Lime Brick
Removal & Stacking
for curing/autoclaving

4. • Screw feeders
• Bucket Elevator
• Double Shaft Mixers
• Hydraulic Press
• Autoclave
• Boiler
• Pulverizer
• AHP Machines, Maharashtra
• Jayem Manufacturing Co., Uttar Pradesh
• Expo Hydra Tech India (P) Ltd, Tamil Nadu
• Orbit Intelligent Engineering, Gujarat
• JVP Equipments, Tamil Nadu
• Sand Plast (India) Limited, Delhi
• Puzolana Green Bricks, Delhi
• Shirke Brick Industries, Maharashtra
• Brickwell, Andhra Pradesh
• Sri Vaari Bricks - Group of Lakshmi&Co, Tamil Nadu
• Sarvodaya Brick Industries, Andhra Pradesh
• Buildmat Bricks & Tiles Co. Limited, West Bengal
• Shree Balaji Flyash Bricks Pvt. Ltd., Haryana
• Jagdamba Flyash Bricks Industries, Bihar
• Eco Bricks Industries, Delhi
• Lokanath Fly Ash Bricks, Odisha
Major Plant Equipment
and Machinery
Some Machine Manufacturers
Some Fly Ash Brick
Manufacturers
For understanding the challenges and issues in the Fly ash brick industry, our research analyst conducted the telephonic
interview with some of the major builders and fly ash brick manufacturers etc
Survey Outcomes
Awareness - As per the survey findings, most of the builders or manufacturers have limited knowledge about
fly ash bricks, their advantages etc. Even some of them are not aware that such kind of bricks exists in the
market.
Familiarity - Most of the builders client are not familiar about the fly ash bricks and its advantage leading to its
acceptance over clay bricks.
Availability - Fly ash bricks are readily available in the near-by areas of thermal power plants or industries having
fly ash as their wastage product. While in other areas, supply is limited with respect to demand.
Prices - Fly ash bricks cost is higher due to their bigger size compared to the normal bricks and also the
transportation cost is additional.
Difference in Size - Fly Ash Bricks are manufactured in somewhat bigger size than the normal clay bricks as only
modular size can be produced.
Weak Mechanical Bonding – Fly Ash bricks require less amount of plastering material for their bonding,
therefore limiting their mechanical bonding strength.
Market Survey

5. Fly Ash Bricks future prospects seem quite bright as most of the major real estate players are using fly ash bricks in
their projects. Moreover, incentives and subsidies from government will encourage further growth. However, the
industry needs to overcome its present challenges and issues for fast track growth in future.
Future Prospects
For Setting up Flys Ash Brick Enterprises
• Credit Guarantee Fund Scheme for Micro & Small Enterprises (CGMSE)
• Credit Linked Capital Subsidy Scheme (CLCSS)
• Prime Minister’s Employment Generation Program (PMEGP)
• Khadi and Village Industries Commission (KVIC)
Carbon Credits
World Bank issued Letter of Intent for the purchase of 800,000 tons of carbon credits from fly ash brick technology and
block industry @ US$ 5/ton of CO2eq. This has helped to promote the new method by enabling entrepreneurs to earn
carbon credit revenues. So far, the project has enabled 108 fly ash brick plants to earn about INR 14.5 Crore.
Other
Various state governments are providing land, building and sales tax etc to encourage projects based on fly ash bricks.
Subsidies and Benefits