Presentation On Fly-Ash brick

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Submitted by: Savita Malik 7th semester 1 Page

What is Flyas brick?

Fly ash brick (FAB) specifically masonry units, is a building material,

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Raw material for Fly ash brick

The raw materials for fly ash brick are: fly ash, sand/stone dust, lime, gypsum and cement. Fly ash bricks are lighter than clay bricks. Assorted fly ash bricks of different colors made at ET. (The bricks have natural color of low-carbon fly ash; the dark ones have natural color of high-carbon fly ash; the red ones are made with 1 to 2% of commercially available red colored pigments.

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Raw material for Fly ash brick

COMPOSITION: The important compositions of fly ash bricks are as follows; FLY ASH CEMENT SAND WATER

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SOURCES OF FLY ASH:

72% of Indias power plants are coal based. 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. In all the power plants and industries, they separate the fly ash by using the cyclone converter. This fly ash is then used as a raw material for manufacture of bricks.

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

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Manufacturing:
It contains Class C fly ash and water. Compressed at 4,000 psi. Cured for 24 hours in a 150 F (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 "selfcementing". The manufacturing method saves energy, reduces mercury pollution, and costs 20% less than traditional clay brick manufacturing.

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Manufacturing:
The fly ash brick is nothing but a slow setting pozzalona cement mix. The process is same as making cement in cement factories whereas the clay and limestone are burnt with coal and gypsum. And it is mixed and ground to cement. In fly ash mix also the fly ash, which is burnt clay particles (oxides of clay) obtained from burning coal, which contains clay from the mines. When hydrated lime powder, gypsum are mixed and ground in a pan, the mixture gives a slow setting pozzalona cement. While the mix is pressed at low pressure at low moisture content in hydraulic machine, which is specially designed to give high pressure load at a slow rate, in the order of 350kg/square inch. At this of rate of pressure and with holding the pressure for a desired time gives ultimate strength to fly ash bricks.
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Manufacturing Plant of Fly ash brick

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Manufacturing Plant of Fly ash brick

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Fly Ash Bricks - Technical Specifications

(1) Fly Ash Brick Size Details :
Size [4 Inches ] :- 230 x 100 x 75 mm 230 x 100 x 100 mm Size [6 Inches ] :- 230 x 150 x 80 mm 230 x 150 x 100 mm Can be available in other suitable sizes depending on the quantity.

(2) Compressive Strength :

Avg. 7.5 N / Sq.mm. ( As against 3.5 N/Sq. mm for handmade clay bricks )

(3) Water Absorption :

8-12 % ( As against 20 to 25% for clay bricks )

(4) Efflorescence :
Nil

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(5) Density :
1700 Kg/m3

(6) Weight:
230x100x75 mm ( Weight about 4.75 to 5.00 kgs.approx ) 230x150x75 mm ( Weight about 2.75 to 3.00 kgs.approx )

(7) Composition : (i) Cement : Best Quality OPC 53 Grade Cement /

Gypsum Powder,Lime Powder (ii) Thermal Station Fly Ash (iii) Crushed Sand / Stone Dust (iv) Chemicals

(8) Thermal Conductivity :

0.90 1.05 W/m2 0 C ( 0.75 0.90 K cal/m2 hr 0C )

(9) Drying Shrinkage :

Maximum Average drying test shrinkage 0.035-0.04 %

(10) Brick Colour :Gray / Dark Gray

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PROCESSED FLY ASH PLASTER INSTENT SUNLA.: Coverage 300 sqft. Area covered in 40 Kg. bag. Coating Super smooth bright coating. Life Long lasting self life due to Pozzolonic properties. Thermal Insulation good thermal insulating properties. Sound absorption very good sound absorption properties. Packing Available in temper proof 40 Kg & 17 Kg. packs only. Eco-Friendly Totally envoirmental eco friendly product. Utilization use 1.5 Thapi cement in one patty of sunala. Perfectly blended mixture to obtain uni-grade surface. Economically improved & tested

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Quality Checking Process :

Monitoring and improvement of achieve continual improvement of the quality management system & they are dried and water cured for 14 days. The bricks are tested and sorted before dispatch.

Inspection and quality control: the bureau of Indian standards has formulated and published the specification for maintaining quality of product and testing purpose. IS: . Compressive strength achievable:Avg. 7.5 N / Sq.mm ( As against 3.5 N/Sq. mm for handmade clay bricks ) Water absorption: 8-12%; density- 1700 Kg/m3. co-efficient of softening (depending upon water consistency factor) unlike conventional clay bricks fly ash bricks have high affinity to cement mortar the joint will become stronger and in due course of time it will become monolithic and strength will be consistent.

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ADVANTAGES: 1.compressive strength is more than conventional clay bricks 2.More resistant to salinity and water than conventional bricks 3.More lighten than conventional bricks 4.Uniform in shape & size and more durable as strength increases with passage of time 5.Less mortar consumption in masonry & saving in plastering cost.

DISADVANTAGES: 1. Mechanical bonding strength is weak. But this can be rectified by adding marble waste. 2. Limitation of size. Only modular size can be produced. Large size will have more breakages.

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Price of fly ash brick :

The prices of fly ash bricks are likely to increase by 20-25 paise per brick because of the hike in cement prices. Each fly ash brick used to cost Rs 1.50-Rs 2.00 a year ago. But the manufacturers were forced to raise its price to Rs 2-Rs 3 each recently. In view of rising cement prices .

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