Atul Polytechnic

A Report on
“Fly ash Bricks’’

Submitted By.:
Name Enrollment No
Vinodkumar Dodiyar 166640306011
Maulik Bhavsar 166640306505
Roshan Tabiyad 166640306046
Sumit Chaudhari 136640306008

Diploma III, semester – 5

(civil Branch)

(1) Mr. Rahul Panchal (2) Mr. Apoorva Patel

(Faculty Guide)

Mrs. Abhigna Patel

(Head Of Depatment)
 Abstract

 Fly Ash bricks can be extensively used in all building constructional

activities similar to that of common burnt clay bricks.
 The fly ash bricks are comparatively lighter in weight and stronger than
common clay bricks.
 Since fly ash is being accumulated as waste material in large quantity near
thermal power plants and creating serious environmental pollution problems,
its utilization as main raw material in the manufacture of bricks will not only
create ample opportunities for its proper and useful disposal but also help in
environmental pollution control to a greater extent in the surrounding areas of
power plants.
 Also 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.
 And also in this project various laboratory experiments were carried out on fly
ash bricks samples.
 Some of them are
 Compressive Strength Test
 Water Absorption Test
 Introduction
 Production of burnt clay bricks requires
consumption of coal leading to green house gases
emissions.
 The primary raw material used for bricks is the
soil, causing land degradation as well as
economic loss due to diversion of land.
 Fly Ash bricks can be extensively used in all
building constructional activities similar to that of common burnt clay bricks.
 The fly Ash bricks comparatively lighter in weight and stronger than common
clay bricks.
 . Since fly ash is being accumulated as waste material in large quantity near
thermal power plants and creating serious environmental pollution problems, its
utilization as main raw material in the manufacture of bricks will not only create
ample opportunities for its proper and useful disposal but also help in
environmental pollution control to a greater extent in the surrounding areas
of power plants.
 In view of superior quality and eco-friendly nature, and government support the
demand for Fly Ash Bricks has picked up.
 Also 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.
 Bricks made of fly ash can be broadly classified into following groups –
 Clay Fly Ash Bricks
 Fly Ash Lime Bricks
 Mud Fly Ash Bricks
 Fal-G Technology
 Fly ash- lime-gypsum (FaL-G) is not a brand name but it is duct name, christened
to the mix for easy identification of its ingredients.

 FaL-G technology is based on the principles namely, that fly ash lime pozzolanic
reaction does not need external heat under tropical temperature condition, and
strength of fly ash- lime mixtures can be greatly augmented in the presence of
gypsum.

 FaL-G technology was developed by institute of solid waste research and

ecological balance, Vishakhapatnam.

 Fly ash lime mix in different proportions, is mixed in pre- determined

proportions with calcined gypsum which produces FaL-G having strong binding
properties and can be used as cement.
 Raw Materials
 FLY ASH :
 Pulverized fuel ash commonly known as fly ash shall conform to Grade 1
or Grade 2 of IS 3812.
 The proportion of the Fly ash is generally in the ratio 60-80%,
depending upon the quality of raw materials.

 SAND/STONE DUST :
 Deleterious materials, such as clay and silt in sand, shall preferably
be less than 5 percent. About 10 to 20% may used.
 Bottom ash used as replacement of sand shall not have more than 12
percent loss on ignition when tested according to IS 1727.

 LIME :
 Quick Lime or hydrated lime or both can be mixed in the composition.
Lime should have minimum 40% CaO content.

 GYPSUM :
 Hydrated calcium sulphates are called gypsum. (CaSO42H2O). Gypsum
should have minimum 35% purity and 5 to 15% may be used.
 Manufature Process

 Fly ash, lime, sand and gypsum are manually fed into a pan mixer where water is
added in the required proportion for intimate mixing.
 The proportion of the raw material is generally in the ratio 60-80% of fly
ash 10-20% lime, 10% Gypsum and 10% sand, depending upon the quality of raw
materials.
 The materials are mixed in pan mixture. After mixing, the mixture is conveyed
through belt conveyor to the hydraulic/mechanical presses. The homogenised
mortar taken out of roller mixer is put into the mould boxes. Depending on the type
of machine, the product is compacted under vibration / hydraulic compression etc.

 The green bricks are dried up under sun from 24 to 48 hours, depending
whether lime route or cement route; the dried up bricks are stacked and
subjected for water spray curing once or twice a day, for 7-21 days, depending on
ambience. The bricks are tested and sorted before despatch.
Flow Sheet for the manufacture of FaL- G bricks
 Advantages of Fly Ash Bricks
I. Appearance
 These bricks have a pleasing colour like cement, are uniform in shape
and smooth in finish, also, they require no plastering for building
work. The bricks are of dense composition, uniformly shaped
with/without a frog, free from visible cracks, warp- age, organic
matter, pebbles and nodules of free lime. They are lighter in weight
than ordinary clay bricks and less porous too.

II. Structural Capability

 These bricks can provide advantages being available in several load-
bearing grades, savings in mortar plastering, and giving smart looking
brickwork. High compressive strength eliminates breakages/wastages
during transport and handling, the cracking of plaster is reduced due
to lower thickness of joints and plaster and basic material of the bricks,
which is more compatible with cement mortar. Due to its comparable
density the bricks do not cause any extra load for design of
structures and provides better resistance for earthquake loads due to
panel action with high strength bricks.
III. Theremal Power Properties
 Thermal conductivity is 0.90-1.05 W/m2 ºC (20-30% less than
those of concrete blocks). These bricks do not absorb heat; they
reflect heat and gives maximum light reflection without glare.

IV. Sound insulation

 It provides an acceptable degree of sound insulation.

V. Durability and moisture resistance

 These blocks are highly durable, after proper pointing of joints,
the bricks can be directly painted in dry distemper and cement
paints, without the backing coating of plaster. Rectangular faced with
sharp corners, solid, compact and uniformly Water absorption is 6-
12% as against 20-25% for handmade clay bricks, reducing dampness
of the walls.

VI. Toxicity and Breath-ability:

 There are no definite studies on the toxic fume emissions or the indoor
air quality of structures built with fly ash bricks, though claims of
radioactive emissions by these blocs have been made at some scientific
forums.
VI. Fire and vermin resistance
 Fly ash bricks have a good fire rating. It has no problems of
vermin attacks or infestation.

VII. Sustainability
 Fly ash is one of the numerous substances that cause air, water
and soil pollution, disrupt ecological cycles and set off
environmental hazards. It‘s also contains trace amounts of toxic
metals – silica, aluminium, iron oxides, calcium, magnesium,
arsenic, mercury, and cadmium, which may have negative effect
on human health and plants.

VIII. Buildability, availability and cost

 The blocks have an easy workability and high compressive
strength eliminates breakages/wastage during handling giving a neat
finish, with lower thickness of joints and plaster. The construction
technique remains the same as regular bricks ensuring easy change of
material, without requiring additional training for the masons. Though
these bricks are abundantly available closer to thermal power
plants all over the country for obvious reasons, finding dealers in all
major cities and towns wouldn‘t be a problem.
IX. Applicability
 The blocks being available in several load bearing grades are suitable
for use: -
Load bearing external walls, in low and medium size structures.
Non - load bearing internal walls in low and medium size structures.
Non - load bearing internal or external walls in high-rise buildings.
Fly Ash Bricks Clay Bricks

Uniform pleasing color like Varying color as per soil.

cement.
Uniform in shape and smooth and Uneven shape as hand made.
smooth in shape.
Dense composition Lightly bonded

No plastering required Plastering required

Lighter in weight Heavier in weight

Compressive strength is around 35 Compressive strength is around

kg/cm2 100 kg / cm2
Thermal conductivity 0.90-1.05 Thermal conductivity 1.25-1.35
w/m2 c w/m2 c
 Testing of Fly Ash Bricks
1. Measurement of Bricks

Total Measurement for 10 Bricks Mean Measurement for single

Dimensions brick (mm)
(mm)

Length, L 2370 237

Width, W 1150 115
Height, H 790 79
2. Determination of water absorption

 APPARATUS
 A sensitive balance capable of weighing within 0.1 percent of the
mass of the specimen and a ventilated oven.

 PRECONDITIONING
 Dry the specimen in a ventilated oven at a temperature of 105 to 115 °C
till it attains substantially constant mass. Cool the specimen to room
temperature and obtain its weight (M1). Specimen warm to touch shall
not be used for the purpose

 PROCEDURE
Immerse completely dried specimen in clean water at a temperature of
27 ± 2 °C for 24 hours.
Remove the specimen and wipe out any traces of water with a damp cloth
and weigh the specimen. Complete the weighing 3 minutes after the
specimen has been removed from water (M2). Water absorption, percent
by mass, after 24-hour immersion in cold water is given by the following
formula:
 [(M2-M1)÷(M1)] × 100
 Weight (dry) Weight (wet, % of water
Sample
gm after 24 hr) gm absorption
A 2679 3202 19.53
B 2666 3218 20.07
C 2675 3182 18.95
D 2683 3187 18.78
E 2672 3179 18.97
Average 19.26

 From the result average % of water absorption is 19.26 %.

3. Determination of compressive strength test of fly
ash bricks

 APPARATUS
 Compression testing machine, measuring tape or scale, surface grinder,
plywood sheets.

 PROCEDURE
i. Remove unevenness observed in the bed faces to provide two
smooth and parallel faces by grinding.
ii. Immerse the sample in water at room temperature for 24 hours.
iii. Prepare cement mortar (1:1) and fill the frog and all void in bed
faces with it.
iv. Store the sample prepared in (iii) under damp jute bag for 3 days in
clean water.
v. Remove and wipe out a trace of moisture.
vi. Measure the area of two horizontal faces.

 Testing
i. Place the specimen with flat faces horizontal and mortar filled
 facing upwards between two plywood sheets and centre
carefully between plates of testing machine.
ii. facing upwards between two plywood sheets and centre
carefully between plates of testing machine.

 Calculation

 Compressive strength = (N/mm²)

 observation table

Dimension of fly ash bricks Avg. area Max Compres

sample
of bed load at sive
Length (mm) Width (mm)
Height surface failure strength
(mm)
(mm2) (kn) (n/mm2)
A 230 100 78 23000 118 5.153
B 228 100 80 22800 104 4.582
C 228 100 76 22800 132 5.815
D 230 102 78 23000 127 5.546
E 230 100 80 23000 138 6.026
5.425(app
Average rox 54.25
kgf/cm2)

From the result average compressive strength is 5.425 N/mm2 (approx 54.25
kg/cm2)which is higher than normal clay bricks.
 Conclusion
Fly ash utilization in the country has remained less than 30% during the past 5
years and it might take several years to reach the final goal of cent percent
utilization. It is estimated at present nearly 160 million ton fly ash is produced
every year, out of which hardly 40-50 % is used in all possible applications.

To utilize such a huge quantity of ash, we have to take necessary actions
from government side and from nongovernment side for utilisation point of view.

Based on the results for the experiments done on Fly ash lime brick,

Compressive strength = 54.25 kg/cm2

% Water absorption = 19.26 %

Fly ash bricks have many advantages like -

 Light weight

 Economical

 Environmental friendly

 Saving of fertile land, pure water

 More compressive strength

 Use of wastage etc.

 Reference
1. N. Bhanumathidas and N.Kalidas, ‗Fly ash: The resource for
construction industry‘, April 2003 ,The Indian Concrete Journal, PP. 997-1004

2. N. Bhanumathidas and N. Kalidas, INSWAREB, ‗Sustainable

Development through use of Fly Ash‘, Keynote Paper presented at National Seminar
on Building Materials & Technology for Sustainable Development; Ahmadabad: Jan
2005