FLY ASH BRICKS PROJECTS

FLY ASH BRICKS PROJECT

A Eco-friendly Bricks

Introduction

Fly ash is a fine, glass-like powder recovered from gases created by coal-fired electric power generation. Fly ash material is solidified while suspended in the exhaust gases and is collected by electrostatic precipitators or filter bags. Since the particles solidify while suspended in the exhaust gases, flyash particles are generally spherical in shape and range in size from 0.5 µm to 100 µm. They consist mostly of silicon dioxide (SiO2), aluminum oxide (Al2O3) and iron oxide (Fe2O3).

History of fly ash utilization Fly ash concrete was first used in the U.S. in 1929 for the Hoover Dam, where engineers found that it allowed for less total cement. It is now used across the world.

Properties Fly Ash is • Fine powder in grey color • Having no virtual odour • Non – Toxic • Non – Flammable • Non - Explosive

Fly ash does not have any adverse health effects, however when the exposure to fly ash is more than the recommended limits, the necessary protective equipment for respiratory / eye / hand / skin protection to be used.

Raw MaterialFly Ash Bricks can be produced by various types of recipes depending onavailable Raw Materials. Mainly adopted recipes are as following:-

•FAL-G Bricks:

• Fly Ash: 60-80 %

•Lime: 10-20 %

•Gypsum: 5-10 %

•Sand: 10-15 %

• Fly Ash-Cement Bricks:

• Fly Ash: 60-80 %

• Sand: 20-25 %

• Cement: 8-10 %

Process of Manufacture• Raw materials like Fly Ash, lime sand and gypsum or Fly Ash, Cement & Sand are manually fed into a pan mixer where water is added in the required proportion for intimate mixing. The proportion of the raw material is generally in the ratio 60-80% of fly ash, 20-25% sand and 8-10% Cement OR 60-80% of fly ash 10-20% lime, 10% Gypsum and 10% sand, depending upon the quality of raw materials.

• After mixing, the mixture is shifted to the hydraulic/mechanical presses. The bricks are carried on wooden pellets to the open area where they are dried and water cured for 21 days. The bricks are tested and sorted before dispatch.

• Curing is done by spray water on the dried bricks. Bricks are then covered, bricks develop themselves.

INSPECTION AND QUALITY CONTROL

The Bureau of Indian Standards has formulated and published the specifications for maintaining quality of product and testing purpose. IS : 12894 :2002. Compressive strength achievable: 60-250 Kg/c m .S q. Water absorption: 5 – 12 %; Density: 1.5 gm/cc Co-efficient of softening (depending upon water consistency factor) Unlike conventional clay bricks fly ash bricks have high affinity to cement mortar though it has smooth surface, due to the crystal growth between brick and the cement mortar the joint will become stronger and in due course of time it will become monolithic and the strength will be consistent.

POLLUTION CONTROL• The technology adopted for making fly ash bricks is eco-friendly. It does not require steaming or auto-calving as the bricks are cured by water only. Since firing process is avoided. There are no emissions and no effluent is discharged. Facial masks and dust control equipment may be provided to the employees to avoid dust pollution more over all the raw materials are kept under covered by polythene sheet to avoid air pollution.

• Workmen working with Fly Ash and at the mixing area are to be provided with protective equipment like dust masks and safety goggles.

Market Demand180 billion tones of common burnt clay bricks are consumed annually approximately 340 billion tones of clay- about 5000 acres of top layer of soil dug out for bricks manufacture, soil erosion, emission from coal burning or fire woods which causes deforestation are the serious problems posed by brick industry. The above problems can be reduced some extent by using fly ash bricks in dwelling units. There is good demand for fly ash bricks . The awareness among the people is required and also same time the government has to give some special incentives for these type of activities . The technologies are eco friendly , Reduces solid waste and dust in the nature. Compared to hallow brick and clay brick the cost is reasonable . Technology for construction of wall with out cement between the brick has been developed by GODWIN industries , Auto Nagar, Guntur. Construction of wall with these bricks is very easy and cost effective . Technology is indeginiously available.

The need of the hour is to find wealth from wastage and eco- friendly technologies for our progress and prosperity. With the rise in population and increase in constructional activities considering the improvement in the standard of living the demand for building bricks is increasing day by day.

•Building of Fly Ash .

BASIS AND PRESUMPTION • The unit will work 300 working days in a year on two shifts basis

and will be able to utilize its full capacity utilization after one year of regular production. However, the efficiency of capacity utilization has been considered as 80%.

• Labour and wages will be as per the prescribed minimum wages.

• The rate of interest for both the fixed and working capital has been considered as 17%.

• Margin money of around 25% of the project cost has to be arranged by the entrepreneur.

• Operative period of the project has been considered as 10 years considering technology obsolescence rate and period of repayment of loan.

• the cost of land, construction cost, cost of machinery and equipment, etc. has been considered as per the prevailing market rate and as per quotation of machinery obtained.

FINANCIAL ASPECTS

1 Land: 0.5 acre 1,50,000

2 Building/Shed : Work Shed: 100 Sq. Mtr. @ Rs. 1500/ Per Sq. Mtr. 1,50,000

3 Office & Store: 20 Sq. Mtr. @ Rs.2500/- Per Sq. Mtr. 50,000

4 Tube well with over head tank, pipe line and other civil 60,000 construction including Boundary and Gate etc.

4,10,000

Our Purchase Order

Resources

• 1 Truck Stone dust - 1000ft x Rs. 36 Approx =Rs 36,000/-

• 1 Truck Fly Ash – 1 ton. x Rs.600 =Rs. 600 22 ton x Rs. 600 = Rs. 13200/-

• O.P.C Cement – 1 Bag x Rs. 260 = Rs260/-

• Labor - Per Brick x Rs. 0.40 = 0.40 paisa

Conclusion• Fly Ash thus holds a vast potential for improving the modern day concrete when it comes to quality in the long term. In spite of being an industrial waste, it can improve durability and reduce heat of hydration.

• The prospect of fly ash still being underused even today. Thus keeping in mind about environmental concerns and its indispensability as a mineral admixture, the values of fly ash should be effectively garnered .