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Project Report on Manufacturing and Supplying of Fly Ash Bricks

1. Introduction
Fly Ash bricks are made of fly ash, lime, gypsum and sand. These can be extensively used in
all building constructional activities similar to that of common burnt clay bricks. The fly ash
bricks are comparatively lighter in weight and stronger than common clay bricks. Since fly
ash is being accumulated as waste material in large quantity near thermal power plants and
creating serious environmental pollution problems, its utilisation as main raw material in the
manufacture of bricks will not only create ample opportunities for its proper and useful
disposal but also help in environmental pollution control to a greater extent in the
surrounding areas of power plants. In view of superior quality and eco-friendly nature, and
government support the demand for Fly Ash Bricks has picked up..
It is proposed to set up a unit for manufacturing and supplying of fly ash bricks in various
sizes viz. 4", 6", 8" inches. These bricks can be used in building constructional activities
instead of common burnt clay bricks. These bricks are lighter in weight and stronger than
common burnt clay bricks.
2. Market Demand
The country consumes about 180 billion tonnes bricks, exhausting approximately 340 billion
tonnes of clay every year and about 5000 acres of top soil land is made unfertile for a long
period. The Government is seriously concerned over soil erosion for production of massive
quantities of bricks, in the background of enormous housing needs.
The excellent engineering property and durability of fly ash brick enlarges its scope for
application in building construction and development of infrastructure, construction of
pavements, dams, tanks, under water works, canal lining and irrigation work etc. Enormous
quantities of fly ash are available in and around thermal power stations in all the states. The
demand of bricks could be met by establishing small units near thermal power stations and to
meet the local demand with less transportation costs.
3. Location Advantages
The proposed Unit is to be situated at SF.NO:____________, _________ Village,
__________ Taluk, Coimbatore District, Tamil Nadu. The connectivity details are tabulated
below:
Distance
Destinations
in KMs
Coimbatore Railway Station

Destinations

Distance
in KMs

Coimbatore Airport
Coimbatore Bus stand
______ Thermal Power Plant
The location of the proposed unit is well placed in terms of Road, Railway and Airport
connectivity.
4. Capacity
The proposed installed capacity of the unit is 20,000 bricks per day.
5. Plant & Machinery
The Promoter is in the process of finalizing the suppliers for the purchase of machineries
such as _______. The cost of plant and machinery is estimated at Rs.20.21 lakhs, which
appears to be reasonable considering the features, technology and make.
5.1

Necessity of Multiple Block Machine (CI 320)


Considering the merits and limitations of various technology machines and also to meet the
environmental pollution related stipulations, CI 320 machine is the suitable option for the
proposed unit based on the following reasons:
a) Moulding of multiple products by replacing of moulds in the same machine,
b) Production quantity is more,
c) Good finished bricks (Unique shape)
d) Achieve good compressive strength,
e) Smooth & even surface,
f) Joints become strong,
g) Strength is consistent,
h) Low energy consumption and eco-friendly

5.2

Parts of Semi Automatic Multi Block Machine (CI 320 model):The above machine includes hydraulic compressing system, semi auto hydraulic control
panel, material hopper, hydraulic material feeder with auto vibrator, vibrating gear box with
motor, pallet conveyor, green brick conveyor, belt conveyor, pan mixer with hopper, face
feeding machine, blade pigment with one fly ash brick mould / Cement brick mould of size
(230*110*75 mm).

6. Raw Materials

The required raw materials are fly ash, lime, gypsum and sand. The promoter has already
identified list of suppliers from Coimbatore, ____________ for supply of raw materials. As
such, no difficulty is envisaged in sourcing the required quantity of raw materials.
7. Manufacturing Process
Fly ash (70%) Lime (10%) Gypsum (5%) and sand (15%) are manually feed into a pan mixer
where water is added to the required proportion for homogeneous mixing. The proportion of
raw material may vary depending upon quality of raw materials. After mixing, the mixture
are allowed to belt conveyor through feed in to automatic brick making machine were the
bricks are pressed automatically. Than the bricks are placed on wooden pallets and kept as it
is for two days thereafter transported to open area where they are water cured for 15 -20 days.
The bricks are sorted and tested before dispatch.
The process flow chart is given below:
FlyAsh

Gypsym

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 (15-20 days)
Drying (one or two days)
Sorting and Testing
Dispatch

8. Quality Specifications:
IS: 12894:1990 Specification for Fly Ash Lime bricks.

8.1

Maintaining quality of product and testing purpose. IS :12894 : 2002.


IS:13757:1976 Specification for Burnt clay fly ash building Bricks.
IS:4137:1989 Specification for calcium silicate bricks.
IS:3102:1976 Classification of burnt clay solid bricks.

For production of good quality fly ash bricks the quality of Fly Ash should be as
follows:
Moisture content of fly ash should not exceed 5%.
Visual appearance of fly ash should be of light steel grey or smoky grey colour.
Unburnt carbon content in the fly ash be around 5%.

9. Ministry notification
The Ministry of Environment and Forests (through its notification published in the Gazette
of India, Part II, Section 3, sub section (ii), vide S.O. 763(E) dated 14th September,
1999) issued directives for proper utilisation of fly ash discharged from coal or lignitebased thermal power plants. The importance for restricting the excavation of top soil for
manufacture of bricks and promoting the utilisation of fly ash in the manufacture of building
materials and in construction activity was recognised. It was notified that within a radius of
100 km from a coal or lignite-based thermal power plant, all brick making units must
compulsorily utilise 25% of fly ash (by weight) This notification was supported by the High
Court of Delhi in its order dated 25th August, 1999 in Centre for Public Interest Litigation,
Delhi v/s Union of India (CWP No. 2145/99).

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