Pmegp Flyash Bricks Project Report 4-24 PDF

A Green Eco friendly Project
KHADI & VILLAGE INDUSTRIES COMMISSION (KVIC )
PROJECT REPORT FOR
Automatic Fly Ash Bricks & Blocks Unit

UNDER
Prime Minister'
s Employment Generation Programme (PMEGP)
(SUBSIDY UPTO 35% OFPROJECT COST)
Preparation Date
th
9 , February, 2015
Project Report Version: 001:006
Project Name
Project Address
Name of the PROMOTOR
Prepared by
N.Gangadhar Reddy
Project Consultant,
www.Indiablockmachine.com
Prepared by www.indiablockmachine.com Email-info@indiablockmachine.com

1. Project at a Glance
1 Product Details : Bricks & Blocks
Type : Fly Ash-Lime-Gypsum (FAL-G) Based
NIC Product Code : 320901009
BIS Code : IS: 12894 : 2002
2. Assumptions
The following assumptions have been made while preparing this Project Report.
a. Land required mentioned is approximate. 75% of land required is for storage of

Finished Products.
b. The project can be started at a smaller land , if there is a good management
practice of marketing as per the prevailing orders. This helps holding a slim stock.
c. Fly to be provided free of cost by power plants. Only transportation to be

arraigned by Project. All raw material prices assumed is landing price at project
site.
d. The Unit aims for optimal fly ash utilization.
e. Production is estimated at moderate capacity, 1 shifts a day. for ratios analysis
f. 300 working days is considered in a year during the first year.
g. Boundary wall to be constructed from trail production bricks of Unit.
h. Sale price at site is estimated as per existing market Price.
i. Bricks of all sizes will be manufactured according to the market requirement,

though mainly 230mm x 110mm x 70mm are the major concentration area.
j. IT IS ASSUMED THAT THE PROJECT IS DONE THROUGH KVIC’S

PMEGP SCHEAME.
k. THE INTREST AMOUNT ON PMEGP PART IS ADJUSTED FROM THE

INTREST CHARGABLE ON LOAN AMOUNT.

3. Introduction
FAL-G is not a brand name, but a product name like Ordinary Portland Cement
(OPC). This name is given for easy identification of its ingredients. FAL-G stands for Fly-
Ash-Lime-Gypsum. In recent days, Lime-Gypsum is being replaced by OPC cement as it is
cheap and also quick setting. The process itself is concept development based on a cement
theory called “Crystallo-Mineral Combination or setting behavior” in technical jargon. In a
recent development it was found that use of OPC in many places is not only economical but
also it provides quick setting, faster curing, improved strength, and overall better quality (
including strength)
Fly-Ash, an indispensable by-product of Thermal Power Plants, is an environmental

threat across the globe. Power plants are facing an ever increasing challenge disposal of this
polluting agent. This unit is proposed to manufacture FAL-G Bricks & Blocks by consuming
the Fly-Ash as one of the prime raw material. Secondly, it also helps environment by saving
the invaluable top soil by not using them in brick making like conventional brick making.
Thirdly, they need no burning, thus further enhancing their Eco-Friendly Brand. This is the
reason these bricks are also referred as Eco Bricks or popularly Green Bricks, (though the
color is gray).
Fly-Ash Bricks and Blocks are largely used in various constructions, such as load
bearing and pillar structure Buildings, Boundary walls, Roads, Culverts, Pavements, and
wherever conventional bricks can be used. The general Fly ash bricks fall in the strength zone
of 60-250 Kg/Cm2, thus is much stronger then conventional Bricks. These bricks gain
strength over a period of time up to 2 years, where as the conventional bricks tend to lose
strength over a period of time. Because of this strength, the same mix can be also be used to
make the Paver Blocks in the same casting machine with interchanging the moulds.
These green bricks can attain very regular and uniform shapes. As no burning is
involved, so the shape also remains unchanged. As a result, the final Brick work with these
green bricks consumes less mortar to build, less mortar to plaster. Further, the FAL-G being
artificial cement itself, it forms a more uniform bond with cement, giving almost a
homogeneous structure. Not only this, even exposed brickwork (without plastering) is a good
durable structure. So people prefer to leave the Green Bricks Brickworks in garages,
boundary walls etc. un-plastered.
4. Advantages of using Fly- Ash Bricks.

The advantages are as follows
1. Environmental friendly : Consumes Fly ash
2. Environmental friendly : Saves invaluable top soil
3. Environmental friendly: needs no burning/backing.

4. Strength: Higher Strength Bricks.
5. Uniform Shape: Easier and faster Brick working.
6. Uniform Shape: Less Mortar in Brick work.
7. Uniform Shape: Less Mortar in Plaster.
8. Artificial Cement: Gains strength over time.
9. Artificial Cement: Walls can be left exposed/un plastered.
10. Better heat & sound insulation compared to red Bricks
11. Far Lesser brakeage during handling & transportation.
12. Better Vibration resistance compared to red Bricks
5. Market
Shelter is third skin, according to a German Concept, which implies it’s importance
next to human Skin and Clothing. This also shows the attachment of human race to this
fundamental requirement.
Building Material accounts for major component of the construction cost. Depending
on the location they can contribute to 60 - 70 % of the cost of construction. With the ever
increasing population, the demand for housing increases. This directly creates demand for
this prime commodity of building.
Add to the above fact the area under discussion and its surrounding area is undergoing
a major infrastructure revolution. As Residential, Commercial, IT companies, and
Industrial establishments are coming in, we can conclude that the Bricks unit will prosper
and flourish in this environment.
There is a central government gadget notification mandating government departments

and CPWD to use 100% Fly Ash Bricks in their all constructions- directly of through
contractors. This factor will help the marketability of this product immensely.
Fly Ash policy of the Government also mandates that 20% of Fly ash Generated by a
power plant must be given free of cost to SME sector on a priority basis.

6. Carbon Credits Estimates
FAL-G Bricks have already qualified as a CDM projects in India for earning
Carbon Credits since January 2004. But as the conventional FAL-G Bricks Units are very
small in size, having a daily production of 3000 to 6000 Bricks per day, thus CDM
Project for this industry has been designed as a bundled approach. Already two bundles of
FAL-G: CDM projects have been registered and the third bundle is under process of
registration. The first bundles have already received their first trench of payment in
August-2007.
This Unit, unlike the above said units is a high capacity Bricks Production Plant.
Its production capacity is around 20 times higher than conventional units discussed as
above. Thus this plant can be individually treated as a Single CDM project as well.
Generally, the existing FAL-G:CDM project estimates a saving of 350 Tons of

Carbon Credits for every Million of Bricks. Thus the Present Project of 24,000,000 will
have an annual Carbon Credits Generation of Approximately 8400 CERs. In present day
market it stands around EURO 17 per CER. ( data as on 2012-June )
POST SCRIPT ON CDM STATUS AS ON DATE
The CDM projects which are aimed to get carbon credits or CERS
have been on hold post Dec-2012 scenario, as all the participating nations
need to decide on a newer framework. All the environmentalists are very
much hopeful that the newer version of the CDM framework will be more
beneficial to the Green ventures like this project.
For latest updates on CDM and its resumption and its onward
registration, please check www.unfccc.org.

7. Raw Materials, Sources and Availability.
Fly-Ash:
A lot has been said about this raw material in this Project Profile itself. But
this Raw material is freely available in Thermal Power plants. There are no taxes on this item
whatsoever. Transportation charges are only to be attended by the entrepreneur.
However, the proposed Unit will get Fly Ash from locally available Thrmal
Powerplants, which is having best quality fly ash not only in the country, but also in the
whole world
Lime/OPC:
Lime used in this process is known as Hydrated Lime, which can be obtained
by Calcining Brunt Lime. One KG of Brunt Lime gives 2.2 Kgs of Hydrated Lime after
Calcining. Brunt Lime can be obtained from Kuddur, Andhra Predesh where Lime Kilns and
High Quality Brunt Lime are pettily available. Alternativily Hydrated lime is available as an
industrial by-product of Paper Mills
This Project however aims to utilize OPC cement as a substitute for Lime. It
will give faster strength to the bricks, besides giving improved consistent quality. It also
ensures a better cost effectiveness for the same. Using OPC will be a standardized practice
compared to Lime, as, unlike OPC, Lime quality changes widely across suppliers and across
seasons. The other prime advantages of using OPC (compared to Lime) is it’s easy
availability locally through nationwide Retail Network of Cement Companies.
Gypsm:
This too is an industrial waste. This is available at Fertilizer Plant as in

industrial wastes
Sand / Crusher Dust.
Sand is used as an economizer and to increase the strength of bricks to some

extant. Sand is procured locally. Crusher dust can also be successfully used in place of sand.

8. Process
The Process of manufacture is simple and suitable to start. A mix of Fly Ash, Cement,
Gypsum and Sand/Crusher Dust are automatically weigh batched in a batching plant.
1. Loading of Raw materials- Materials are loaded onto PAN MIXTURE. There is a
provision to fit a BATCHING PLANT in future and loading can be done by the Mini
Loader
2. Automatic Batching – In case a batching plant is fitted, The Raw materials are
automatically weighed as per the preset weights by means of Load cells and its
control circuit.
At present, the loading is done by volumetric proportions directly into PAN mixture
3. Mixing - From the batching plant the mixture hopper pulls the materials and then the
mix is blended homogenously and intimately in a semi wet form in a Twin shaft
mixture.
4. Carrying to Brick machine - The mix is carried to the casting machine by means of
conveyer belt.
5. Automatic Brick Making- there are a series of operations which is achieved by

automatic PLC system. Pallet is pulled into the Machine. The mix is then collected
fed into the machine moulds.. Automatic PLC controlled Vibration and hydraulic
pressure is given for a while and bricks are cast on the pallets. The dual application of
Pressure and vibration ( in a patent pending micro-sequence application ) ensures
perfect compaction with best quality of bricks
6. Automatic Stacking – The machine has a provision to fit a stacker in future. The
pallets along with the freshly cast bricks are rolled on a roller platform to the pallet
stacker. The Pallet stacker stacks the pallets along with the bricks automatically and
the
7. Brick shifting– in the absence of a stacker, the bricks are rolled into the specially
provided trolley and they are shifted to the drying yard.
If a stacker is present, then the stack is removed by Manual Hydraulic traulley or a
mini forklift
8. Curing - Soon after the initial setting of one day, the Blocks/ Bricks are stacked for
curing in layers. The layers are stacked in a way to enable water and air to go all
around, to ensure proper curing and drying. The curing process is continued for 7
days. The blocks are allowed to normally dry for a day. Now they are ready for
dispatch.
Alternatively, the blocks/bricks can be steam cured for 8 hours or mist cured for 24
hours immediately after production, and made ready for dispatch immediately.
9. Dispatch - the cured bricks can be dispatched to market. The fnal strength of bricks
will be around 80 to 120 Kg/Cm2 , water absorption of 6 to 10% and around 1.5 to 1.7
Gms/CC Density.

9. Process Flow Chart.

Crusher Main
Fly Ash Dust/ OPC/lime Gypsm Raw Materials
Sand
From 20% 60to 5 % OPC 6% Gypsum 1%

to 70% Or Quantity
Lime 10%
PAN MIXTURE Water
Bricks Casting on Machine
Stacking and drying Under Shade/ under plastic

Sheets
Water Curing For 7 Days
Dry for 24 Hours and Eco-Bricks Ready for Sale

10. Quality Control.
For Production of good Quality Fly Ash Bricks, The following precautions must be
taken.
1. Moisture Content in Fly Ash should not be more than 5%
2. The color of Fly Ash should be either Light Steel or Smoke Gray.
3. It should never contain un-burnt Carbon by not more than 5%
4. Phospho Gypsum should better be made acid free by washing, if it is acidic
5. Special emphasis should be given to curing.
6. Proper stacking and layering can greatly enhance the quality of Bricks & Blocks.
7. Fresh Laid bricks to be protected from rain showers by Polythene Sheets.
8. Fresh Laid bricks to be protected direct heavy sun drying by Polythene Sheets.
9. Controlled drying under PVC covers of Fresh Laid bricks is advisable.
10. Stacks should not be allowed to fully dry at any time (within first 6 days).
11. Pollution Control Needs



There are no solid or liquid effluents out of this plant.

The unit is a Green unit as it consumes Fly-ash, saves fertile top soil and earns CER
Workman working in the Bricks production Unit to be provided with protective
equipments like dust masks, safety goggles, Gum Boots, Gloves etc.
12. Energy Conservation needs

The management has to be vigilant in ensuring higher productivity by the optimal
utilization of man and machine hours. Periodic checks on working stages, functioning of
machinery, their preventive maintenance and timely repairs will help in energy conservation.

13. Statutory clearances needed

The following is a list of regulatory or statutory clearances needed for this project. The State
to State requirement may vary. Please check your state industrial law.
DIC (District Industry Center) is the Best place to check for the following requirements.
Many DICs provide a single window system to facilitate the clearance of all documents in
one go
A. The following clearances must be required before setting up of this plant

a. MSME-1 certificate from District Industries center
b. NOC or Consent to Establish ( For Air and Water ) from Pollution control Board
c. Sales tax/VAT, entry tax, CST registration from state sales tax department
d. Land conversion ( to non-agriculture ) from revenue department
B. The following clearances will be required after setting up of this plant

a. MSME-2 certificate from District Industries center
b. NOC or Consent to Operate ( For Air and Water ) from Pollution control Board
C. The following clearances/registrations may be needed for the operation of the plant.
Please check your state laws
a. NOC from local authorities/Sarpanch/local government body
b. ESI for Employees’ insurance.
c. PF with provident fund department
d. Inspector of factories for factory approval.
14. Project Time Line

The Project gestation period is approximately 3 months as per the following schedule.
Day-0 : Booking of Order and advance Payment

Day-25: Machine ready by China companies
Day-30: Balance payment and machine loading at china factory
Day-35: Ship bound to India port.
Day 40: Sending of plant staff/operator for training to Bhubaneswar
Day 55: Ship reaches India port
Day 65: Custom clearances and Machines reaching Client site
Day 65: work shed electrical connection and panel, water connection ready at site
Day 70: Installation engineers reach site
Day 80: Trail production start
Day 90: Commercial production Start.

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Pmegp Flyash Bricks Project Report 4-24 PDF

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A Green Eco friendly Project

KHADI & VILLAGE INDUSTRIES COMMISSION (KVIC )

PROJECT REPORT FOR

Automatic Fly Ash Bricks & Blocks Unit

Name of the PROMOTOR

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a. Land required mentioned is approximate. 75% of land required is for storage of

c. Fly to be provided free of cost by power plants. Only transportation to be

d. The Unit aims for optimal fly ash utilization.

e. Production is estimated at moderate capacity, 1 shifts a day. for ratios analysis

f. 300 working days is considered in a year during the first year.

g. Boundary wall to be constructed from trail production bricks of Unit.

h. Sale price at site is estimated as per existing market Price.

i. Bricks of all sizes will be manufactured according to the market requirement,

j. IT IS ASSUMED THAT THE PROJECT IS DONE THROUGH KVIC’S

k. THE INTREST AMOUNT ON PMEGP PART IS ADJUSTED FROM THE

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Fly-Ash, an indispensable by-product of Thermal Power Plants, is an environmental

4. Advantages of using Fly- Ash Bricks.

1. Environmental friendly : Consumes Fly ash

2. Environmental friendly : Saves invaluable top soil

3. Environmental friendly: needs no burning/backing.

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4. Strength: Higher Strength Bricks.

5. Uniform Shape: Easier and faster Brick working.

6. Uniform Shape: Less Mortar in Brick work.

7. Uniform Shape: Less Mortar in Plaster.

8. Artificial Cement: Gains strength over time.

9. Artificial Cement: Walls can be left exposed/un plastered.

10. Better heat & sound insulation compared to red Bricks

11. Far Lesser brakeage during handling & transportation.

12. Better Vibration resistance compared to red Bricks

There is a central government gadget notification mandating government departments

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6. Carbon Credits Estimates

Generally, the existing FAL-G:CDM project estimates a saving of 350 Tons of

POST SCRIPT ON CDM STATUS AS ON DATE

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7. Raw Materials, Sources and Availability.

This too is an industrial waste. This is available at Fertilizer Plant as in

Sand / Crusher Dust.

Sand is used as an economizer and to increase the strength of bricks to some

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5. Automatic Brick Making- there are a series of operations which is achieved by

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9. Process Flow Chart.

From 20% 60to 5 % OPC 6% Gypsum 1%

PAN MIXTURE Water

Bricks Casting on Machine

Stacking and drying Under Shade/ under plastic

Water Curing For 7 Days

Dry for 24 Hours and Eco-Bricks Ready for Sale

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10. Quality Control.

1. Moisture Content in Fly Ash should not be more than 5%

3. It should never contain un-burnt Carbon by not more than 5%

4. Phospho Gypsum should better be made acid free by washing, if it is acidic

5. Special emphasis should be given to curing.

7. Fresh Laid bricks to be protected from rain showers by Polythene Sheets.

9. Controlled drying under PVC covers of Fresh Laid bricks is advisable.

11. Pollution Control Needs

12. Energy Conservation needs

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