The document summarizes a presentation on Project FAB-1, which studied the market potential for fly ash bricks (FAB) in Nagpur, Wardha, and Chandrapur districts of India. It describes the project approach, findings from interviewing FAB manufacturers and end users, challenges faced in data collection, and limitations of the study. The main findings were that demand for FAB fell after 2012, manufacturers now face difficulties in sales due to negative perceptions of FAB, and alternative building materials like AAC blocks are more popular than FAB.

1. PRESENTATION ON PROJECT FAB-1

2.  INTRODUCTION ABOUT JOURNEY
 PROJECTS UNDERTAKEN
 ABOUT FAB
 APPROACH FOR FAB
 CHALLENGES DURING THE PROJECT
 FINDINGS
 LIMITATIONS DURING PROJECT

3.  Started on 15th January 2016.
 Got selected and told to do the internship at Nagpur.
 Connected with Mitra sir for further Guidelines.
 Arrived at Nagpur on 1st May 2016.
 Introductory session on 2nd May 2016.
 Started working on projects from 3rd May 2016.

4.  JCB-CTA,CSMM for JCB India-50 interviews.
 Edge-Pureit Audit-5 shops.
 Khushi-CSMM for John Deere-6 interviews.
 JSW steel, customer feedback-6 interviews.
 FAB-I-35 interviews.
 SSI-India, dealer rating for JD power-12 interviews.

5.  Started working on 20th of May 2016.
 The project has the main objective to understand the
market potential of Fly ash bricks and the expectation of
manufacturers regarding the brick manufacturing
machines.
 There are 2 types of respondents
1.Fly Ash brick manufacturers.
2.End customers of Fly ash bricks.-builders, government
contractors,architects,CA
 The region for the study was Nagpur cluster including
Nagpur,Wardha and chandrapur districts in perticular.

6.  The sample size for Nagpur was 15 for each type of
respondent.
 For Wardha it was 7 per type of respondents.
 For Chandrapur it was 8 per type of respondents.
 We have conducted interviews for both manufacturer
and end user respondents.

7.  Fly ash brick is a building material mainly containing
Fly ash which is a waste generated from various power
plants
 The brick is described as Self cementing brick.
 The manufacturing method saves energy, reduces
mercury pollution and costs 20% less than traditional
clay bricks
 These bricks are considered to be replacement for
traditional bricks along with CLC(cellular lightweight
concrete) blocks and ultra light AAC (autoclaved
aerated concrete) blocks.

8. Material Mass
Fly ash 45%
Sand/stone dust 30%
Lime sludge 10%
Cement 10%
Gypsum 5%
Total 100%

9.  Same number of bricks will cover more area than clay bricks.
 High fire insulation.
 No breakage during transport.
 Uniform size-mortar reduction by 50 %.
 Does not require soaking in water for 24 hours, only sprinkling
is enough.
 Best example of waste Management.

10.  Mechanical strength is low.
 Limitations of size-only modular size can be
produced. Large size have more breakage.
 Can be manufactured only in those areas where
fly ash is easily available as its the main
material in the production.

14.  To get information about the leading fly ash brick
manufacturers in the cluster.
 Take their response and get further respondent details
from them-Snowball sampling.
 To get the information about the customers of FAB
from the manufacturers which comes under the end
user segment of our project.

15.  Initial thought
1. Since the industry is local we thought that we’ll get
the respondent information easily.
2. Also we thought people will be really interested to
give their expectation for the client’s new machine.
3. Builder and other end users will not be having any
issue in sharing information abut the client.
4. Since the information is general getting references
from the respondents will not be an issue

16.  Practical scenario
1. Manufacturer were not ready to give any
information without knowing the client name.
2. No any manufacturer was ready to share name of its
customers.
3. The industry is on downward spree so many
manufacturers have stopped producing FAB.
4. Due to slowdown real estate industry builders were
neither accessible to us nor they were interested to
share any information.

17.  Our final approach
1. Managed to convince manufacturers by telling them
that the study is for government report.
2. Took the help of questions in the questionnaire.
3. Told them about getting their references from others
and how others have contributed into the study.
4. Took more contacts from the DIC office .

18.  For Manufacturers
 Many plants were established during the period of
2008 to 2012 as the demand was high in those days.
3
9
6
0
2
4
6
8
10
2004-2008 2008-2012 2012-2016
no. Of new plants
no. Of new plants

19. 2
12
1
3
0
2
4
6
8
10
12
14
supporting red
bricks business
increasing FAB
demand
government
encouragement
in line with
education and
business
Reason for entering FAB business

20. 12
6
0
0 5 10 15
will improve
will remain same
will deplete
Availability of raw material
12
6
0
0 5 10 15
will improve
will remain same
will deplete
Availability of raw
material in future

21. 0
2
4
6
8
10
12
2000-4000 4000-8000 8000 and above
Average FAB production per day

22.  Almost all plants have machines mainly purchased
from companies in Coimbatore and Gujrat.
 Machine manufacturers like engineering enterprise,
Reva engineering holds great reputation here.
 Few small scale manufacturers have self built
machine.
 Manufacturers from Butibori MIDC have customised
machines which can be threat to big machine
manufacturers and our client.

23.  But suddenly the demand has fallen leading to the halt
of many FAB production units.
 Only 1-2 manufacturers are getting subsidies an that
too in the form of tax exemption of 10%.
 No special subsidy as such.
 The manufacturers are facing challenges in selling
FAB due to bad perception of people towards FAB.
 Red brick is still considered better over FAB.
 Manufacturers are no more interested in the
production of FAB.

24.  For end users
1. FAB has been mainly used by the builders as it is cheaper
than red clay bricks.
2. Government contractors have been ordered to use only fly ash
bricks as they are environment friendly.
3. AAC blocks and other ultra light concrete blocks are more
famous than FAB when it comes to replacement of red bricks.
4. Household end users and normal people have extremely bad
perception about FAB like over heating , rigid-cannot make
holes, doesn’t hold plaster.

25.  Name of the client was unknown
 Unable to fetch more information regarding machines
 Respondents were not aware about market research
studies
 Non co-operative and suspicious attitude of manufacturers
and builders
 Conversion ratio of contacts to respondents was poor 0.3.
 Snowball sampling failed
 Respondents didn’t give the factual information about
subsidies and the finance in the business.