Fly Ash Bricks

Fly ash bricks are hi-tech well-improved quality bricks used for construction of brick masonry structures. They are used as replacement for normal clay bricks and have better properties than it.

Fly ash bricks competitive in comparison to the conventional clay bricks and provide enormous indirect benefits. The utilization of fly ash bricks results  in conservation of natural resources as well as protection of environment.

Composition

Fly Ash or Cement Brick
  • Fly Ash – 60 To 80 %
  • Sand Or Stone Dust – 20 To 25 %
  • Cement ( OPC ) – 7 To 10 %
  • Water
Fal-G Brick
  • Fly Ash – 60 To 80 %
  • Sand Or Stone Dust – 10 To 20 %
  • Lime – 10 To 20 %
  • Gypsum – 5 To 10 %
  • Water

Sources of Raw Material

Fly Ash

In India Most Of The Power Plants Are Coal Based. These Power Stations Generate Nearly 40 Million Tons Of Fly Ash Annually. 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

Cement

OPC Cement Stands For ‘Ordinary Portland Cement. It Is The Most Widely And Commonly Used Variant Type Of Cement In The World. OPC Cement Is Manufactured By Adding Limestone And Other Raw Argillaceous, Calcareous Materials And Gypsum Materials Like Argillaceous, Calcareous And Gypsum

Stone Dust or Quarry Dust

Quarry Dust Is A Byproduct Of The Crushing Process Which Is A Concentrated Material To Use As Aggregates For Concreting Purpose, Especially As Fine Aggregates. In Quarrying Activities, The Rock Has Been Crushed Into Various Sizes; During The Process The Dust Generated Is Called Stone Dust Or Quarry Dust And It Is Formed As Waste.

Types & Size of Fly Ash Bricks

  • 10 X 4 ½ X 3 Inch
  • 9 X 6 X 3 Inch
  • 9 X 4 X 3 Inch
  • Size As Per Local Requirements
  • Interlocking Bricks
  • Pavers For Road, Petrol Pump, Foot Path, Garden & Others

Tests Are Applied to Bricks

Compressive Strength Test

 The Compressive Strength Of Fly Ash Brick Is Three Times Greater Than The Normal Clay Brick. The Minimum Compressive Strength Of Clay Brick Is 3.5 N/Mm².So As The Fly Ash Brick Has Compressive Strength Of 10-12 N/Mm². Bricks To Be Used For Different Works Should Not Have Compressive Strength Less Than As Mentioned Above. The Universal Testing Machine Is Used For Testing The Compressive Strength Of Bricks.

Water Absorption Test

 Fly Ash Bricks Should Not Absorb Water More Than 12%. The Bricks To Be Tested Should Be Dried In An Oven At A Temperature Of 105 To 1150 C Till Attains Constant Weight Cool The Bricks To Room Temperature And Weight (W1). Immerse Completely Dried And Weighed W1 Brick In Clean Water For 24 Hrs At A Temperature Of 27±20 0C. Remove The Bricks And Wipe Out Any Traces Of Water And Weigh Immediately (W2).

Efflorescence

Efflorescence Is The Usual Terms For Deposit Of Soluble Salts, Formed In Or Near The Surface Of A Porous Material, As A Result Of Evaporation Of Water In Which They Have Been Dissolved.

Drying Shrinkage

The Average Drying Shrinkage Of The Bricks When Tested By The Method, Being The Average Of Three To Five Bricks, Shall Not Exceed 0.15 Percent.

Advantages of Using Fly Ash Bricks

  • Fly Ash Bricks Are Very Suitable For Multi-Floored Buildings.
  • Fly Ash Bricks Absorb Less Heat And Considering The Indian Climate, It Makes It Better When Compared To Clay
  • From The Cost Front, It Requires Less Mortar During Construction. Further, The Machine That We Provide Requires Less Labor Too. Our Machines Are Made Keeping In Mind The Costs Associated With Water Wastage And Raw Material Wastage Too. You Hence Save In The Breakage Front, The Plaster And Jointing Front And Curing And Labor Front. So Our Fly Ash Brick Machines Reduce The Overall
  • The Compressive Strength Is Very High And They Are Less Porous. They Absorb Less Water And Saves Cost There, As
  • It Is Environmentally Friendly And Hence Allows Your Business To Take A Step Towards Sustainable Development. Our Machines Are Green Machines Too, That Promote Environmental Protection And Conservation. Production Of Fly Ash Bricks Requires No Fossil Fuel And Hence Does Not Lead To The Emission Of Greenhouse
  • Production Of Clay Bricks Damages The Top-Soil And This Is Prevented In The Manufacturing Process Of Fly Ash Bricks. There Is No Pollution Or Environmental Damage, As A Result Of Which It Has Been Put Into The White Category Of
  • Fly Ash Bricks Are Stronger, More Uniform And Denser As Compared To Clay Bricks. While Their Mortar Consumption Is Low, Their Wastage Is Only About Less Than 1% As Against That Of Clay
  • Due To Lower Water Penetration Seepage Of Water Through Bricks Is Considerably
  • Gypsum Plaster Can Be Directly Applied On These Fly Ash Bricks Without A Backing Coat Of Lime
  • Fly Ash Bricks Have High Fire
  • Its Provide Good Thermal
  • The Pozzolanic Reaction In Between Lime And Fly Ash Will Significantly Generate Less Heat And Thus, Prevents Thermal

These Are Some Advantages Of Using Fly Ash Bricks That Is Making Major Construction Houses, And For That Matter, Even The Government, Move Towards It.

Flowchart Showing the Manufacture of Fly Ash Brick

Benefits of Fly Ash Bricks for Environment

The Increase In Greenhouse Gases, Out Of Which CO2 Is One Of The Major Constituents, Increases The Global Warming Year After Year, Causing Drought And Floods. The Total CO2 Emissions Globally Account For 24,960 Million Tons At 1990 Levels. Cement And Building Materials Industry Is One Of The Major Contributors.

The CO2 Emission Is About Ninety Million Tons Out Of Cement And Forty-Nine Million Tons Out Of Clay Bricks Production In India. As Per The Ongoing Practices In India, Each Million Clay Bricks Consume About 200 Tons Of Coal (Or Any Other Fuel With Equal Quantity Of Thermal Values) And Emit Around 270 Tons Of CO2.

Fly Ash Bricks Production In Energy-Free Route Saves The Emissions Totally, Befitting The Project To Qualify Under Clean Development Mechanism (CDM), As Envisaged By Kyoto Protocol Towards The Welfare Of Mother Earth.

Comparison of Clay Bricks & Fly Ash Bricks

 

Properties

Red Bricks/Clay Bricks

 

Fly Ash Bricks

 

Remarks

 

Density

 

1600-1750 Kg/M3

 

1700-1850 Kg/M3

Higher Load Bearing

 

Compressive Strength

 

30-35 Kg/Cm2

 

90-100 Kg/Cm2

Higher Load Bearing

 

Absorption

 

15-35%

 

10-14%

Less Dampness

 

Dimensional Stability

 

Very Low Tolerance

 

High Tolerance

Saving In Mortar Up To 25%

 

Wastage During Transit

 

Up To 10%

 

Less Than 1%

Saving In Cost Up To 9%

 

Mortar And Plastering

Thickness Varies On The Both Sides Of Wall.

Due To Bricks Are Not In Size.

 

Even On Both Sides Due To Bricks Are In Size.

 

Saving In Mortar & Plaster Up To 40%

Sound Insulation Normal Better

Difference Between Fly Ash & Red Brick