Overall Customer experience

BLOGS

To become a first generation Entrepreneur.

How to Manufacture Fly Ash Brick

In simple words, Fly ash is one of the residues produced by coal combustion. Fly ash is generally captured from the chimneys of coal-fired power plants, and is one of two types of ash that jointly are known as coal ash; the other, bottom ash, is removed from the bottom of coal furnaces. While suspended in the exhaust gases, fly ash solidifies and is collected by electrostatic precipitators or filter bags.

Complete Guide For Starting a Fly Ash Brick Manufacturing Business in India-

Fly ash bricks are hi-tech well-improved quality bricks used for the construction of brick masonry structures. They are used as a replacement for regular clay bricks and have superior properties. Fly ash bricks are cost-competitive with traditional clay bricks and provide significant indirect benefits. The use of fly ash bricks results in the conservation of natural resources as well as environmental protection.
The construction industry accounts for about 10% of the GDP and is growing at a rate of about 9% per year. Clay-fired bricks are the foundation of the construction industry, which is worth approximately $70.8 billion. Although unorganized, India's brick sector is massive in size and scope. India is the world's second-largest brick producer (China has a 54% market share). It is constantly growing as a result of the rapid increase in demand for bricks in the infrastructure and housing industries.To meet this demand, more than 150,000 brick units employ more than 8 million people directly. During the Ninth Five-year Plan period (1997-2002), the annual demand of 170 million bricks per year was estimated to be generating revenues of over US$ 4.8 billion.
 

Question: Why are fly ash bricks used? 

In India, coal being the principal source of electricity, the problem of fly ash disposal and utilization has assumed an enormous proportion as the annual production of fly ash in India has surpassed 150 million tonnes. Its annual accumulation poses serious environmental and health risks in the vicinity of thermal power plants. Fly ash is a versatile material with pozzolanic properties that allow it to be used in a variety of construction applications.

The Characteristics of Fly Ash Pollution 

Fly ash causes severe pollution of air and water, and its disposal gobbles up large tracts of land. Well-planned programs for proper management of fly ash are therefore being undertaken to enhance the use of fly ash in various applications so that our already perilously imbalanced environment can be protected.

Fly Ash Bricks Project Report -  Buy Now

Uses of fly ash blocks - 

Fly ash blocks can be used in place of burned clay bricks. The application of fly ash blocks is almost the same as like burnt clay bricks. It can be used as masonry units in the following applications:

It can be used as masonry units in the following applications: 

  • Factories/Workshops 

  • Institutional Construction 

  • commercial enterprise. 

  • Frame structure

  • Compound boundary fence

Fly Ash Brick Manufacturing Business

 

Advantages 

  • Because of its lightweight, it reduces the dead load on structures (2.6 kg, dimension: 230 mm X 110 mm X 70 mm. 

  • A similar number of bricks will cover a larger area than clay bricks. 

  • High fire resistance 

  • Due to its high strength, practically no breakage during transport and use. 

  • Because of the uniform size of the bricks, the amount of mortar required for joints and plastering is reduced by nearly 50%. 

  • Water seepage through bricks is significantly reduced due to lower water penetration. 

  • Without a lime plaster backing coat, gypsum plaster can be applied directly to these bricks. 

  • These bricks do not require a 24-hour soak in water. A light sprinkling of water before use is sufficient.

Subsidy (PMEGP)

In the following technology there is a subsidy of around 30% given by the Govt. of India through KVIC and KVIB under the PMEGP scheme. To be eligible for the subsidy, please follow the guidelines and eligibility criteria as published from time to time. 

This scheme provides a subsidy on a loan taken out by an entrepreneur that is less than Rs.25 lakhs. Out of the total project cost (not exceeding Rs. 25 lakhs) entrepreneur contribution would be 10% of the overall capital invested. The total amount of funds (capital plus debt) cannot exceed Rs. 25 lakhs. The release of the subsidy grant on the overall funds would occur in the third year of the business's continuous operation.


Technology 

The process of converting industrial waste materials into high-quality building materials is known as fly ash brick (FAB) technology. At the moment, the technology for converting thermal power plant waste into high-quality bricks is well established. 

FAB technology makes use of dry ash (fly ash collected from ESP or thermal power plant silos), filler materials (typically coarse sand), and additives (lime, gypsum or cement). Various technologies exist of commercial service providers. They essentially use the same process, but at different machines and different designs. The current technology will be used based on scientific analysis and understanding of the waste materials; fly ash and lime, with optimal utilisation of sand and gypsum or cement. The desired strength of fly ash bricks can be engineered by varying compositions.

Conclusion:

Ash bricks are superior to clay bricks in every way. They are environment-friendly because the maximum constituent is ash and flies ash bricks have greater strength as compared to red bricks. We can choose to fly ash brick which is the best brick for home construction

Get Customized Project Report - https://www.iid.org.in/customize-bankable-report

 

Read Our Blog-https://www.iid.org.in/blogs/credit-linked-capital-subsidy-scheme-for-technology-upgradation

Frequently Asked Questions

Fly ash, a waste product from burning coal, is usually combined with sand or stone dust, cement, and water to make fly ash bricks. The main binding agent is fly ash, and the structural integrity of the brick is enhanced by the inclusion of sand or stone dust. Water helps to aid the mixing and curing process, while cement serves as a secondary binder.
 

Fly ash bricks differ from traditional clay bricks in their composition and environmental impact. Fly ash bricks are made from industrial waste, fly ash, which is abundant and reduces landfill usage. They require less energy for production and have better thermal insulation properties. Clay bricks, on the other hand, rely on clay soil and kiln firing, contributing to environmental degradation.

A slurry is made by combining fly ash, cement, sand, and water during the brick-making process. After that, this slurry is compacted, hardened, and poured into molds. The bricks are taken out of the molds and given time to dry after curing. They are an affordable and environmentally responsible option for building materials.
 

The first step in launching a fly ash brick company is to study market demand. Obtain the required licenses and permits, find an appropriate location, and make the necessary purchases of raw materials and equipment. Create a distribution network, set up production procedures, and draft a business plan. The success of this environmentally friendly business initiative depends on marketing and quality control.
 

A fly ash brick factory's initial costs in India can differ significantly based on a number of variables, including location, size, and equipment. Larger enterprises may require a significantly higher initial investment; on average, this ranges from 10 to 30 lakh Indian Rupees (INR). Land, equipment, labor, raw materials, and regulatory fees are all included in the costs.