Detailed Project Report (DPR) on

Fly ash Bricks

Prepared by :

JEGAN M
UDHAYAM ECO FRIENDLY BRICKS
NO 11,SATTAIYAPPAR SANNATHI,
NAGAPATTINAM – 611 001.
MOBILE :96000 35855
EMAIL:[email protected]
1. INTRODUCTION :
Pulverized fuel ash commonly known as fly ash is a useful by-product
from thermal power stations using pulverized coal as fuel and has considerable
pozzolonic activity. This national resource has been gainfully utilized for
manufacture of pulverized fuel ash-lime bricks as a supplement to common
burnt clay buildings bricks leading to conservation of natural resources and
improvement in environment quality.

Pulverized fuel ash-lime bricks are obtained from materials consisting of

pulverized fuel ash in major quantity, lime and an accelerator acting as a
catalyst. Pulverized fuel ash-lime bricks are generally manufactured by
intergrading blending various raw materials are then moulded into bricks and
subjected to curing cycles at different temperatures and pressures. On occasion
as and when required, crushed bottom fuel ash or sand is also used in the
composition of the raw material. Crushed bottom fuel ash or sand is also used in
the composition as a coarser material to control water absorption in the final
product. Pulverized fuel ash reacts with lime in presence of moisture from a
calcium hydrate which is a binder material. Thus pulverized fuel ash – lime in
presence of moisture form a calcium – silicate hydrate which is binder material.
Thus pulverized fuel ash – lime brick is a chemically ended bricks.

These bricks are suitable for use in masonry construction just like common burnt
clay bricks. Production of pulverized fuel ash-lime bricks has already started in
the country and it is expected that this standard would encourage production
and use on mass scale. This stand lays down the essential requirements of
pulverized fuel ash bricks so as to achieve uniformity in the manufacture of such
bricks.

The Proposed unit will be started by me and I have acquired EM Part I from the
District Industries Centre, Nagapattinam, And also obtained all the statuary
requirements to run the firm without any technical and managerial problems.
2. MARKET DEMAND

180 billion tones of common burnt clay bricks are consumed annually
approximately 340 billion tones of clay- about 5000 acres of top layer of soil dug
out for bricks manufacture, soil erosion, emission from coal burning or fire
woods which causes deforestation are the serious problems posed by brick
industry. The above problems can be reduced some extent by using fly ash
bricks in dwelling units.

Conventional brick-making is becoming difficult because of non availability of

labour, pollution control norms are becoming stringent by the day, The quality of
handmade bricks is extremely poor. They display poor dimensional accuracy
with variations up to +/ - 10 mm; poor compressive strength of not more than 35
kg/sq cm and high breakage during transportation up to 15 per cent; and high
porosity, making them unsuitable for exposed brick facades. There is high
consumption of cement mortar owing to irregular shape and clay cannot be
excavated from agricultural fields.

At present There is even Single unit is engaged in our Nagapattinam District.

And there will be scope to start the New units, Thus marketing of these product
are well shinning.

3 Company Introduction

M/S UDHAYAM ECO FRIENDLY BRICKS is a company that intends to set

up a production and distribution of high quality “Fly Ash” bricks. The company is
owned by Mr. JEGAN and is registered as a proprietorship firm with the District
Industries Centre, NAGAPATTINAM. The firm registration number is ………….
Owner has also applied for No Objection Certificate (NOC) toestablish the unit to
the State Pollution Control Board. It will be granted once the technology is
finalized. Owner has also applied to NEYVELI LIGNITE CORPORATION(NLC)
neyveli for free availability of fly ash to his manufacturing unit. In principle
consent of the same.
Product description

The fly ash brick to be produced and sold is a relatively new but well established
building material in the construction sector. It is made from a mix of fly ash and
sand stabilized by either cement or lime depending on the availability. The fly
ash is available free of charge within a radius of 130-140 km from Neyveli
Lignite Corporation (NLC).

With the increased generation of fly ash in the country Ministry of Environment
and Forests, Government of India has made it mandatory to use fly ash products
in both public and private construction within a radius of 100 km from a thermal
power plant throughout the country. This has resulted in a high demand of fly
ash bricks and other products for use in construction. Since no coal is required
to produce the brick, thus the entire production process is environment friendly
compared to the highly polluting burnt clay brick production process.

The Fly Ash Brick Production Technology

What is fly Ash?

Fly ash is one of the residues generated in the combustion of coal. 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. Fly ash material solidifies while
suspended in the exhaust gases and is collected by electrostatic precipitators or
filter bags. Since the particles solidify while suspended in the exhaust gases, fly
ash particles are generally spherical in shape and range in size from 0.5 μm
to 100 μm.

What are fly ash bricks?

Fly ash bricks are made up of fly ash, sand, lime and gypsum. In these bricks fly
ash is used as primary filler and sand is added as secondary filler. Lime and
gypsum is used as binder whichhelps in holding all the raw material together.

Why fly ash bricks?

In India, coal being the principal source of electricity, the problem of fly ash
disposal and utilization has assumed enormous proportion as the annual
production of fly ash in India has surpassed 150 million tones. Its increasing
accumulation every year, causes severe environmental and health hazards
around the thermal power plants. Fly ash is a versatile material and its
pozzolanic properties, permit its use in various construction applications.

Advantages of fly ash bricks

 Compact construction & Consistent quality

 Better thermal insulation properties
 Availability throughout the year.
 Better shape & finish
 Rationalization of Mortar with optional need of Plaster
 With ageing the strength of the bricks goes on increasing as lime is used in bricks.
 Absorb less water and also seepage is less.
 Saving the natural resource and environment
 More resistant to salinity and water.
 More lighten than conventional bricks

Technology
Fly ash brick (FAB) technology is a process of converting industrial waste
materials into quality building materials. At present, the technology is well
established in converting thermal power plant waste into quality bricks.

FAB technology uses dry ash (fly ash collected from ESP or silos of thermal
power plants)filler materials (usually coarse sand) and additives (lime, gypsum
or cement). Various technologies exist of commercial service providers.
Essentially they use the same process but at different machines and mix
designs. The present technology to be used has been developed based on
scientific analysis and understanding of the waste materials; fly ash and lime
with optimum utilization of sand and gypsum or cement. The desired strength of
fly ash bricks can be engineered by varying compositions.

Equipment and machineries

The requisite machinery and production system are designed to achieve the
desired level of production and will be procured from M/S SHREE
ENGINEERING offers technology packages with daily production capacity of
10000 bricks. The SHREE ENGINEERING is suited for daily production of
10000. M/S UDHAYAM ECO FRIENDLY BRICKS will procure and use the
M/S SHREE ENGINEERING technology of the following
Marketing Plan

Market Segmentation and Positioning

Brick is a commodity product purchased by a broad section of consumers. Fly

ash bricks will be of a superior finish and shape, and M/S UDHAYAM ECO
FRIENDLY BRICKS will target the upper segment of the market.

These buyers tend to be less price-sensitive and are also likely to be more
conscious of quality.

The company's principal target segments will be:

 Builders of High value private Residences

 Contractors executing large projects

Marketing Mix

Product

M/S UDHAYAM ECO FRIENDLY BRICKS will initially produce and sell bricks
of one type/quality only. However, the possibility of introducing brick tiles and
Paver Blocks will also be looked into in the later years. The following features of
M/S UDHAYAM ECO FRIENDLY BRICKS will be instrumental in attracting
customers

Uniformity in shape and size of the bricks, this will mean that the Fly Ash
bricks will consume less cement
 Strength of the bricks will be as per IS Codes and those specified by
construction agencies

Bricks will be produced in an environmentally friendly facility.

Pricing strategy
The Fly Ash brick will be of a superior shape, size and finish compared to other
products in the market. Being also CLEAN and GREEN, Fly Ash bricks will enjoy
a premium of around 10%. Despite this fact, M/S UDHAYAM ECO FRIENDLY
BRICKS will initially price its product at Rs. 5.50/piece compared to the
prevalent price of Rs. 6/piece. This penetrating pricing strategy will enable Fly
Ash to rapidly acquire market-share and help it gain acceptability in the market.

Distribution strategy
Logistics and distribution arrangements will play a key role in success. In order
to ensure control over the market and to gauge customer feedback, M/S
UDHAYAM ECO FRIENDLY BRICKS will handle the distribution aspect itself.
Owner will be entering into contract with tractor and truck owners into
transportation of finished goods to the customers on priority basis with a
guarantee ofreduced damage as possible.

Promotional strategy
The company will sell its products under its own brand name. The
communications and selling efforts will project 'quality' as the key attribute of the
brand.There will be two aspects to the promotion of Fly Ash bricks produced by
M/S UDHAYAM ECO FRIENDLY BRICKS. The planned Sales Office will act
as a point of contact with the market, retail customers will be serviced from this
location. A second element of the promotional strategy will be personal selling to
large institutional buyers. Initially the Owner will mainly handle this task. Later he
will also appoint two Sales Representatives. These sales representatives will
mainly focus on retail sales and smaller projects. The agents will be retained on
a commission basis only; the commission rate initially is planned at
0.20paisa/piece on the ex-factory price.
PROCESS FLOW CHART

Fly Ash Cement/Lime Sand

↓ ↓ ↓
---------------------------------------------------
Weighing
↓
Pan Mixer
↓
Conveyor
↓
Fly Ash Brick Making Machine
(Hydraulic Power Press)
↓
Transported To Wooden Racks
↓
Kept as it is for two days for setting
↓
Water Curing
(7 to 10 days)
↓
Drying
(one or two days)
 ↓
Sorting and Testing
↓
Dispatch

S.NO Name of the Machine No of machines H.P Connected

1 Automatic Fly Ash Brick 1 12

2 Pan Mixer7.5 +7.5 2 15

3 Belt Conveyor 1 2

4 Other electrical fittings/ 6

lighting etc

Electrical HP Details
FINANCIAL ASPECTS

(A) Land & Buildings

S.NO DESCRIPTION AMOUNT IN RS

1. Land 2 Acres @ 25,00,000.00

Prathabaramapuram Village

2. 120 X 60 Shed For Machinaries 4,50,000.00

3. Machinaries Area Construction 2,50,000.00

4. SG MIX for Utility Area 4,50,000.00

5. Fencing 3,00,000.00
6. Labour Sheds,Toilets 1,50,000.00

Total
41,00,000.00