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Manufacturing Process of Fly ash Bricks

Composition

Fly ash bricks are a type of building material made primarily from fly ash, a byproduct of coal combustion in thermal plants. Fly ash bricks are manufactured at Raebareli plant, combining the same with other materials like sand or stone dust, lime, and gypsum. The manufacturing capacity of our plant is 3000 bricks per day. These bricks offer several advantages over traditional clay bricks and are becoming increasingly popular in the construction industry due to their environmental benefits and cost-effectiveness.

Here’s a simplified overview of the manufacturing process

Composition:

Fly Ash: The main ingredient, which constitutes about 60-70% of the brick. Fly ash is a fine powder that results from burning pulverized coal in power plants.

Sand/Stone Dust: Added to improve the texture and strength of the bricks.

Cement/Lime: Used as a binding agent to hold the ingredients together.

Gypsum: Sometimes added to enhance the setting properties of the bricks.

Water: Used to mix and form the bricks.

Preparation of Mixture

Mixing: Fly ash, sand/stone dust, cement/lime, and gypsum are thoroughly mixed with water to form a uniform paste.

Molding:

  • The mixed material is then transferred to a brick molding machine.
  • In the molding machine, the mixture is poured into the molds of desired sizes and shapes.
  • The molds are then vibrated or pressed to compact the mixture and remove any air voids, ensuring a dense and uniform brick.

Curing:

  • The molded bricks are then cured in a curing yard for a specific period. Curing can be done either by natural curing (air drying) or by steam curing, depending on the manufacturing process and requirements.
  • Curing helps in the hydration of lime and gypsum, which enhances the strength and durability of the bricks.

Drying: After curing, the bricks are dried in the sun or in a drying chamber to remove excess moisture. This step is essential to prevent cracking during transportation and handling.

Testing: Random samples of the bricks are tested for compressive strength, water absorption, density, and other properties to ensure they meet quality standards. Once the bricks pass the quality tests, they are packed and prepared for distribution to construction sites or retailers.

Advantages of Fly Ash Bricks

1. Environmental Benefits: 

  • Waste Utilization: Fly ash bricks utilize waste material from coal power plants, reducing the need for disposal in landfills and minimizing environmental pollution.
  • Reduced Carbon Footprint: The production process emits less CO2 compared to traditional clay brick manufacturing, which involves firing in kilns.

2. Structural Benefits:

  • Strength and Durability: Fly ash bricks are known for their high strength and durability. They have a uniform size and shape, which makes them easier to use in construction.
  • Thermal Insulation: These bricks provide good thermal insulation, contributing to energy efficiency in buildings.
  • Sound Insulation: They also offer better sound insulation properties compared to clay bricks.

3. Economic Benefits:

  • Cost-Effective: The manufacturing process is less expensive, and the raw materials are often cheaper than those used in traditional brick making.
  • Reduced Construction Costs: The uniform size and shape of fly ash bricks reduce mortar consumption during construction, leading to savings in overall construction costs.

Applications

  • Residential buildings
  • Commercial buildings
  • Industrial structures
  • Road construction
  • Pavements and pathways