Fly Ash Brick S. A.

Salaka
PROJECT REPORT ON
FLY ASH BRICK
BY MISS S.A. SALAKA
16
th
August, 2014
Page 0
Fly Ash Brick S. A. Salaka
C!t"!ts
S#. N. P$%t&'u#$%s P$g" N.
1 Introduction 2
2 Objective 3
3 Process of Manufacture 3
4 Types of Machine use for the production of Fly Ash ric!s 4
" ifurcations of #a$ %aterials 4
& Procedure for procure%ent of Fly Ash "
'
#e(uire%ents of )tatutory Approvals before co%%ence%ent of
business
"
* +o%parison bet$een Fly Ash ric! and +lay ric! "
, +onclusion &
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Fly Ash Brick S. A. Salaka
1. I!t%(u't&!)
The $ord -ric!. defined as in the O/ford 0ictionary as a -ba!ed clay used for
buildin1 $alls2 houses and other buildin1s3 Fly ash bric! is a buildin1 %aterial2
specifically %asonry unit2 containin1 fly ash and $ater3 The %anufacturin1 %ethod
saves ener1y reduces %ercury pollution cost appro/i%ately 245 less than traditional
clay bric! %anufacturin13 urnt bric!s are and $ill be the %ost popular buildin1
%aterial in India despite the availability of alternate %aterial choices3 The Indian bric!
industry is lar1e second only to +hina in ter%s of production3 6o$ever it is hi1hly
unor1ani7ed and co%prised of s%all scale production units3 Authori7ed units ran1e
of over 1442444 $ith an e(ual a%ount of unauthori7ed units3 6o$ever no definite
fi1ure can be esti%ated since no study has yet been conducted on the sa%e3 ric!
units are 1enerally or1ani7ed in clusters spread across rural and peri8urban areas in
the country3 As stated in 9nited :ations 0evelop%ent Pro1ra%%e;s <=reen ric!s;2
244,2 an esti%ated 144 billion bric!s are produced each year in order to %atch the
annual 1ro$th in the construction sector.
Fly Ash ric!s are %achine %ade bric!s %anufactured by hydraulic or vibratory
press3 Fly ash based buildin1 products are %anufactured by usin1 Major percenta1e
of fly ash 1enerated fro% Ther%al Po$er stations and plants li!e >i? :TP+2 Fara!!a2
>ii? @ola1hat Ther%al Po$er )tation2 >iii? 0)P2 0ur1apur3 >>iv? :AA+O2 Orissa >v?
#)P2 #our!ela2 etc3 and %any Paper Mills 2 Alu%iniu% Industries2 $ho uses oiler B
captive po$er plant produces bul! (uantity of Fly Ash in the Castern #e1ion of our
country3 Other ra$ %aterials used alon1 $ith Fly Ash are li%e and 1ypsu%3 Fly Ash
ric! are popular out of all buildin1 products can be %anufactured $ith lo$
invest%ent in co%parison to urned +lay bric!s3 At present Fly Ash ric! buildin1
technolo1y is %uch popular in of Odisha $ho has accepted this eco8friendly
technolo1y bein1 inspired and encoura1es by the =ovt3 authority and pro%otional
a1encies li!e Fly Ash Mission2 I#C0A2 and different Cnviron%ental Pro1ra%%e of
)tate =ovt3 Fly Ash ric!s do not lose stren1th unduly even upon soc!ed in $ater
continuously3 6ence plasterin1 is optional rather than necessity3 Dell cured Fly Ash
ric!s absorb 48125 $ater only3 On account of less $ater absorption2 rationalisation
of plasterin1 and %ortar2 a finished Fly Ash ric! $all is li1hter and cheaper in
co%parison to finished clay bric! $all3
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Fly Ash Brick S. A. Salaka
2. O*+"'t&,"s)
The %ain objectives are to protect the environ%ent fro% un$anted pollutions and
conservation of valuable resources of nature3 Fly ash if not %ana1ed $ell2 %ay pose
environ%ental challen1es3 It is ideal for use in %anufacture of ce%ent2 concrete2
concrete products2 cellular concrete products2 bric!sEbloc!sE tiles etc3 as $ell as for
construction of roads2 e%ban!%ents2 da%s2 dy!es or for any other construction
activity3 Thus fly ash can be considered as a -resource. and not a $aste3
In our Industrial visit to Fly Ash ric! Industry on dated 1&
th
Au1ust2 24142 $e have to
find out the cost and benefit co%parison bet$een Fly Ash ric! and +lay ric!
productions and their uses by different sta!eholders3
-. P%'"ss . M$!u.$'tu%")
Fly ash2 li%e sand and 1ypsu% are %anually fed into a %achine $here $ater is
added in the re(uired proportion for inti%ate %i/in13 The proportion of the ra$
%aterial is 1enerally in the ratio 44 5 of fly ash 1"5 of li%e2 35 of =ypsu%2 445 of
sand2 and 35 of ce%ent2 dependin1 upon the (uality of ra$ %aterials3 After %i/in12
the %i/ture is shifted to the hydraulicE%echanical presses3 If $e use 1ypsu% in the
%i/ture it $ill hold $ater up to 1" days but clay bric! hold up to 283 days3 The Fly
Ash bric!s are carried on $ooden pellets to the open area $here they are dried and
$ater cured for 21 days3 The bric!s are tested and sorted before dispatch3
The current Fly Ash Industry uses %easure unit is 124 @1 per +enti%etre E )(uare
Feet but the standard approved by the =overn%ent is *4 @13 per +enti%etreE )(uare
Feet3 De can find standardi7ation only in Fly Ash ric!s not in +lay ric!s3
Accordin1 to the current Fly Ash Industry to start a ne$ Fly Ash ric! industry the
%ini%u% re(uire%ent of land is 2 Acres3
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Fly Ash Brick S. A. Salaka
4.T/0"s . M$'h&!"s us" &! th" 0%(u't&! . F#/ Ash B%&'1s)
There are t$o types of Fly Ash ric! %achines operated by the current Fly Ash
ric!s Industry as enu%erated belo$
P$%t&'u#$%s Rt$%/ T/0" M$'h&!" St$t&!"%/ T/0" M$'h&!"
C$0$'&t/ . M$'h&!" * 6rs32 &2444 nu%bers of ric! * 6rs2 1"2444 nu%ber of ric!s
Produce 3 bric!s at a ti%e Produce 14814 ric!s at a ti%e
P2"% C!su30t&! ` *42444 per %onth `*42444 per %onth
B%$!( :on8randed randed
I!,"st3"!t
Cst ` 34 Aa!h ` 3" Aa!h
R$2 M$t"%&$# ` "4 Aac!h ` "4 Aa!h
Oth"%s `14 Aa!h `14 Aa!h
4,"%!3"!t
Su*s&(&"s
=overn%ent provides subsidy of
345 on `14 Aa!h to =eneral
cate1ory and 445 on `14 Aa!h to
)TE)+3
=overn%ent provides subsidy of
345 on `14 Aa!h to =en3 cate1ory
and 445 on `14 Aa!h to )TE)+3
T%$!s0%t$t&!
14F"F3 ` 43&4 ` 43&4
,F4F3 ` 43"4 ` 43"4
*F4F3 ` 4344 ` 4344
L$*u%s 13 workmen 9 workmen
5. B&.u%'$t&!s . R$2 3$t"%&$#s 6&! t"%3s . 'st *"!".&t7 us"( &! th"
0%(u't&! 60"% 3!th7 . F#/ Ash B%&'1s $%" "!u3"%$t"( *"#2)
P$%t&'u#$%s Tt$# R"8u&%"3"!t P"% 9!&t A3u!t &! `
Production 4 Aa!h 9nits
)and 242444 @1 `4334 `&2444
Fly Ash 242444 @1 `43'" `1"2444
=ypsu% 142444 @1 `23"4 `2"2444
+e%ent "4@1 `1"344 `344
Ai%e 3 @1 `2.67 `8
The Fly Ash ric!s industry visited by us2 produces three volu%e di%ension of bric!2
are as follo$s
T/0"s S&:" P%&'" P"% 9!&t
+ate1ory I 14F"F3 Inch `"344
+ate1ory II ,F4F3 Inch `4344
+ate1ory III *F4F3 Inch `33"4
6. P%'"(u%" .% 0%'u%"3"!t . F#/ Ash.
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Fly Ash Brick S. A. Salaka
In our )tate there are three sources fro% $here2 $e can procure the Fly Ash2 are
enu%erated belo$F
Talcher
:TP+
:AA+O
De have to %a!e an application to the above%entioned Gendors in a prescribed
%anner for the procure%ent of ra$ %aterial3
;. R"8u&%"3"!ts . St$tut%/ A00%,$#s *".%" '33"!'"3"!t . *us&!"ss.
There are certain approvals $hich are %andatory before the establish%ent of the
industry2 the follo$in1 authority should approve the project and 1ive the no objection
certificate to start these !inds of industries3 The follo$in1 authorities are enu%erated
belo$F
0istrict Industrial +entre
Pollution +ontrol oard
<. C30$%&s! *"t2""! F#/ Ash B%&'1 $!( C#$/ B%&'1
P$%t&'u#$%s F#/ Ash B%&'1 C#$/ B%&'1
Dhether it is approved and pro%oted by
1overn%ent or notH
Ies :o
)tandardi7e in si7e Ies :o
+ost savin1s Ies :o
#e(uire%ent of Fire durin1 production :o Ies
)tren1th and durability Much %ore than +lay ric!
=. C!'#us&!)
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Fly Ash Brick S. A. Salaka
Dith the pace of chan1in1 technolo1ies and scarcity of natural resources the Indian
ric! Industry should opt for the ne$ technolo1y and 1ift of science throu1h $hich2 it
can %eet all the re(uire%ents of its sta!eholders3 =ro$in1 population and
urbanisation needs2 forced to the bric! industries to produce bric!s in a lar1er
(uantity $hile lo$erin1 the cost2 i%provise the standards are also a pri%e objective3
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