A PROJECT REPORT

ON
FLYASH

In Partial Fulfillment for the Award of

Bachelor of Technology
Degree Of
Rajasthan Technical University, KOTA

2014-2015
Submitted by: -

ABHIJEET PARASHAR
RAVI PRAKASH SWAMI
BHARAT BHUSHAN PIPLIWAL

ACKNOWLEDGEMENT
We thank the Head of the Department of CIVIL ENGINEERING(CE),
Prof. Dr .D.K SHARMA for cooperating us for making this project.
Our special thanks go to the Principal, GRIET, Prof.
, for giving us such a wonderful opportunity to do this project.
Without these people, it wouldnt have been possible to do this project on
ROLE
OF FLY-ASH BRICKS IN CONSTRUCTION.

ABHIJEET PARASHAR
RAVI PRAKASH SWAMI
BHARAT BHUSHAN

ABSTRACT
Fly ash is a fused residue of clay minerals present in coal. The high
temperature
generated when coal burns in thermal power plants, transforms the clay
minerals in
coal powder into a variety of fused fine particles of mainly aluminium silicate
composition.

Pulverized fuel ash commonly known as fly ash. It is a useful

byproduct from thermal power stations using pulverized coal as fuel and has
considerable pozzolonic activity. This national resource has been gainfully
utilized for
manufacture of fly ash-lime bricks as a supplement to common burnt clay
buildings
bricks leading to the conservation of natural resources and improvement in
environment quality.
Fly ash-lime bricks are obtained from materials consisting of
pulverized fly ash in major quantity, lime and an accelerator acting as a
catalyst. Fly
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. Fly ash reacts with lime in presence of
moisture from
a calcium hydrate which is a binder material. Thus fly ash lime in presence
of
moisture form a calcium silicate hydrate which is binder material. Thus fly
ash
lime brick is a chemically ended bricks.
These bricks are suitable for use in masonry construction just
like
common burnt clay bricks.

CONTENTS
1. INTRODUCTION
1.1 General
1.2 Utilization of fly ash in cement and bricks
1.3 Fly ash production
1.4 scope and objectives
2. LITERATURE REVIEW
2.1 General
2.2 Characteristics of fly ash
2.2.1 Physical Properties Of Fly Ash
2.2.2 Chemical Compositions Of Fly Ash
2.2.3 Mineralogy of Fly Ash
2.2.4 Reactivity
2.3 Classification of Fly Ash
2.4 Fly Ash utilization

3. FLY ASH BUILDING BLOCKS/BRICKS

3.1 Raw Materials Required
3.1.1 Fly Ash (pulverized fuel ash)
3.1.2 Lime
3.1.3 Gypsum
3.1.4 Sand
3.1.5 Water
3.2 Types of Fly Ash Bricks
3.3 Market Demand
4. METHODOLOGY
4.1 Manufacturing process of bricks
4.2 Characteristics of Fly Ash Bricks
4.3 Technical Specifications
4.4 Comparison of normal clay bricks and Fly ash bricks
4.6 Fly Ash Brick Site Visit
4.7 Brick making machines
4.8 Advantages & Disadvantages
4.9 Uses
5. TEST RESULTS AND DISCUSSION
5.1 General
5.2 Test results
5.2.1 WATER ABSORBTION TEST
5.2.2 COMPRESSIVE STRENGTH TEST

6. CONCLUSION
7. BIBILOGRAPH

INTRODUCTION
1.1 GENERAL
Fly ash brick First invented in 2007.....
American civil engineer Henry liu announced the invention of a new type of
fly ash
brick in 2007. Liuss brick is compressed of at 4,ooo psi and cured for 24 hrs
in a
150 F(66 C) steam bath, then toughened with air entrainment agent , so
that it
lasts for more than 100freeze thaw cycles. Owing to high concentration of
calcium in
class c fly ash , the brick can be described as self cementing. Since method
contains
no clay and uses pressure instead of heat ,it saves energy, reduces mercury
pollution,
costs 20% less than traditional manufacturing techniques. This type of brick
is now
manufactured under license in USA.
Fly ash bricks are constructed at least partially from the residue of burnt
coal .

Depending on the type of coal that is burned, the resulting fly ash can take a
number
of different forms. Some kinds of fly ash require a cementing agent, such as
quicklime
or Portland cement . Other types contain a large enough percentage of lime
that they
are self setting, requiring only the addition of water to be turned into fly ash
bricks.
These bricks have been utilized in construction since the 1950s in some
parts of the
world, and in certain configurations are able to meet or exceed specifications
for clay
or cement bricks.
When coal is burned, one of the results is a fine powder known as fly ash.
While other
ashes might settle at the base of the furnace where the coal is being burned,
fly ash is
light and fine enough that flue gases often are able to carry it up through the
chimney.
In the past, this ash was typically allowed to escape into the atmosphere,
though in
many locations environmental regulations the fly ash must be captured for
safe
disposal or reuse. Since toxic materials like mercury and lead may be highly
concentrated in fly ash, this can lead to environmental or health concerns.

1.2

UTILISATION OF FLY ASH IN CEMENT AND BRICKS

It has been above 70 years to research and use fly ash. With its application,
the action
mechanism of fly ash had been recognized. During the initial stage, only its

pozzolanic activity is paid attention [ 8 and 9]. Many researchers devoted

themselves
to the research of the potential activity of fly ash and the hydration process
of fly ash
cement. With the deepening of the cognition for fly ash properties, some
people found
that the particles of fly ash have the morphology that is different to other
pozzolanic
materials. It is the unique particle morphology to make it have the ability
reducing
water, which other pozzolanic materials do not have [ 10, 11, 12 and 13 ].
and In 1981,
Yinji [ 15 ] and Danshen [ 16 ] summarized the previous research results and
put
forward the hypothesis of "fly ash effects." They considered that fly ash has
three
effects in concrete, i.e., morphological, activated and micro aggregate
effects. The
three effects are relative each other. This shows that the morphological
effect is the
important aspect of fly ash effects. 1.2
CEMENT AND BRICKS

UTILISATION

OF FLY ASH IN

It has been above 70 years to research and use fly ash. With its application,
the action
mechanism of fly ash had been recognized. During the initial stage, only its
pozzolanic activity is paid attention [ 8 and 9]. Many researchers devoted
themselves
to the research of the potential activity of fly ash and the hydration process
of fly ash
cement. With the deepening of the cognition for fly ash properties, some
people found
that the particles of fly ash have the morphology that is different to other
pozzolanic

materials. It is the unique particle morphology to make it have the ability

reducing
water, which other pozzolanic materials do not have [ 10, 11, 12 and 13 ].
and In 1981,
Yinji [ 15 ] and Danshen [ 16 ] summarized the previous research results and
put
forward the hypothesis of "fly ash effects." They considered that fly ash has
three
effects in concrete, i.e., morphological, activated and micro aggregate
effects.

1.3

Fly Ash Production

In each country utilization of fly ash depends on the local condition and has
much to
do with the fact that fly ash is multifunctional material and can be used for
various
purposes. In the building industry fly ash can be used in different ways for
different
products. In concrete fly ash can be used as partially replacement of cement
and/or
sand to enhance workability of fresh concrete, to reduce heat of hydration
and to
improve concrete impermeability and resistance to sulfate attack.
~ 10 ~
The properties of fly ash are varying depending on the coal kind and origin
and on the
power plant mode of operation. In certain uses some kind of beneficiation is
required,
either to improve its properties for the specific use or to achieve
homogeneity. In
concrete, fly ash can actually be used also "as is" when its properties fall
within

certain limits, but classification by particle size and/or control of the

unburned coal
greatly enhance the beneficial effects of the fly ash and of course its
commercial
value.
Utilization of fly ash ranged between 3-5% in the late 1980s and early 1990s.
There
was no large-scale concerted effort for promoting fly ash utilization.
Technologies
and research were
commercialization.

generally

isolated

with

little

emphasis

on

Although attempts were made to use of fly ash in manufacturing bricks,

cellular
concrete, prefab items, and cement as well as for reclamation of low lying
areas and
construction of roads, the desired impact could not be achieved.

Table 1 Fly ash production and utilization

S.N
O

ZONE NAME

FA
GENERATION

UTILIZATIONS

UTILIZATIONS

(Million tones)

(%)

(Million tones)
1.

SOUTHERN

13.5

0.8

2.

WESTERN

16.5

0.8

3.

EASTERN

10.21

2.94

28.8

4.

NORTHERN

15.5

TORAL
(ALL INDIA)

55.71

2.3

14.8

6.84

54.6

The minimum and maximum percentages of fly ash in PPC,

specified by IS 456, have risen from 10% to 15% and from 25% to 35%
respectively. The government of India has issued a notification that makes it
mandatory to use at least 25% ash in the manufacture of clay bricks, blocks, or
tiles
within a radius of 50 km from coal or lignite based thermal power plants.

1.4

SCOPE AND OBJECTIVE OF STUDY

The relationship of fly ash bricks to construction sector, in the context of fly
ash
generation by coal based thermal power plants.The present status of fly ash
brick
manufacture in India, availability of fly ash, and potential of utilization of fly
ash
bricks.
Status of fly ash brick technologies in India by way of research
work

being done by various institutions, and technologies being used for

manufacture of
these bricks.
Keeping in view, the technological status for fly ash brick manufacture,
assessment of
the technologies for its relevance and suitability, keeping in view material
inputs
required, energy requirements, costs, infrastructure requirements etc.
It may also be noted that various cements and mixes which can be made
using fly ash,
have the potential become raw materials for fly ash bricks and blocks of
various
specifications. Therefore, this aspect has also been discussed.Utilization of
fly ash can
result not only in reducing the magnitude of the environmental problems, but
it is also
to exploit fly ash as raw material for value added products (and conserve
traditional
materials), and for extraction of valuable materials.
Amongst many uses that fly ash can be put to, that in building materials is
particularly
suitable. It is also anticipated, that there would be considerable short-fall in
production of various building materials. According to a study, there would
be a large
short-fall in the production of bricks to the tune of 25 billion bricks on an
estimated
demand of 100 billion bricks per year in India by the turn of the century.

2.

LITERATURE REVIEW

2.1

GENERAL

Fly ashes from Vijayawada thermal power plants were used in the
experiments
of the present study. A brief review of literature about the physical and
chemical
properties; mineralogy and morphology behavior of fly ashes is presented.
Literatures
regarding concrete applications of fly ashes have been used in construction
are also
discussed.
Fly ash is produced from burning of pulverized coal in thermal
power
plants. The pulverized coal is fed into the boilers and burnt with the supply of
additional air. The temperature in the boiler exceeds 1600 C and the most of
the
mineral matter present in the coal are fused and altered physically and
chemically.
The resulting residue is called coal combustion by-products namely bottom
ash,
economizer ash, air pre-heater ash, and electrostatic precipitator ash (fly
ash). These
ashes are handled and disposed off separately owing to their differing
qualities by
mechanical, hydraulic and pneumatic conveying systems.
The quality of ash produced is dependent on various factors like source coal
and its
degree of pulverization, design of furnace, changes in coal supply, changes
in boiler
load, and firing condition. Because of this inherent variability of the material,
it is
necessary to study the characteristics and engineering behavior of fly ash in
detail

before its use in an application.

2.2

CHARACTERISTICS OF FLY ASH

As per ASTM C 618 1993[17], there are two classes of fly ash namely class
F and
class C. Class F fly ash is produced from burning anthracite or bituminous
coal and is
pozzolanic in nature and class C is obtained from lignite or sub-bituminous
coal.
Class C fly ash possesses both pozzolanic and self-hardening property.
Hence, it is
necessary to characterize the material scientifically to utilize it in different
applications.
2.2.1 Physical Properties Of Fly Ash
The specific gravity, loss on ignition
prominent
physical properties of fly ashes.
from 1.3 to

and specific surface area are the

The specific gravity of fly ash may vary

4.8 . The iron oxide content plays a decisive role in the specific gravity of the
material.
The specific gravity is more for fly ashes containing more iron oxide and vice
versa.
The presence of opaque spherical magnetite and hematite particles in
sufficient

quantity will increase the value of specific gravity to about 3.6 to 4.8. On the
other
hand, as the amount of quartz and mullite increases, the specific gravity
decreases.
However, coal particles with some minerallic impurities will have lower
specific
gravity in the range 1.3 to 1.6. The range of specific gravity of Canadian fly
ashes is
reported to be in the range of 1.91 to 2.94 and that of American fly ashes in
the range
of 2.14 to 2.69.
2.2.2 Chemical Compositions Of Fly Ash
The main chemical compounds of class F fly ash are silica, alumina and iron
oxide.
Other minor constituents include oxides of calcium, magnesium, titanium,
sulphur,
sodium and potassium. Class C fly ash contains relatively higher proportion
of
calcium oxide and lesser proportion of silica, alumina and iron oxide than
class F flyash.

2.2.4 Mineralogy of Fly Ash

Fly ash consists of both crystalline and amorphous phases. The crystalline
phases
could be quartz, mullite, silimanite, crystallite, cristobalite, sulphates of
iron,
magnetite etc. The amorphous phases could be of silica and silicates
predominantly of
aluminium but containing calcium, magnesium, and iron in varying
concentration
with and without traces of sodium and potassium.

The reactivity of fly ashes depends on the non crystalline or glass content in
it. The
chemical composition of the glass in the high calcium fly ash is different from
the low
calcium fly ash and hence the reactivity of both the ashes are different. The
high
calcium fly ashes are more reactive than low calcium fly ashes. Diamond
(1986)[20]
and Mehta (1998)[19] pointed out that the composition of glass in low
calcium fly
ashes is different from high calcium fly ashes. American fly ashes contained
magnetite and hematite in large proportions. The range of quantitative
measurement
in British fly ashes was quartz (1-6.5%); mullite (935%); magnetite and
hematite
(5% or less). For American fly ashes the proportions were quartz (0 - 4%);
mullite (0
16%); magnetite (030%); and hematite (18%). The glass proportions in
these fly
ashes were found to range from 50 to 90%.
The range of quantitative measurement
in British fly ashes was quartz (1-6.5%); mullite (935%); magnetite and
hematite
(5% or less). For American fly ashes the proportions were quartz (0 - 4%);
mullite (0
16%); magnetite (030%); and hematite (18%). The glass proportions in
these fly
ashes were found to range from 50 to 90%..

2.2.4.1

Reactivity

It is generally agreed that the glass or non-crystalline constituent of Class F

fly ash
goes into reaction with Ca(OH)2,which is added as lime or released from the
hydration of portland cement. However, there are many other factors that
influence
there activity and relative rates of hydration such as fineness, particle shape,
particle
size distribution. Fly ash is generally judged for its quality in terms of
strength
behaviour. This is studied for pozzolanic characteristics in two approaches;
lime
reactivity strength(LRS)
1981,accords

and

pozzolanic

activity

index

(PAI).

IS:3812-

two grades to fly ash based on LRS2. Grade I is identified with a minimum 4
MPa
LRS whereas fly ash with lower strength at 3 MPa is categorised as Grade II.
The
same code has also specified replacement compressive strength(PAI) at 80
percent as
another yardstick. The LRS given forthese grades generally does not
correlate with
pozzolanic activity index. It is observed that certain fly ashes registering low
LRS
prove better for PAI and certain other fly ashes recording good LRS have
shown
lower PAI. Hence to as certain the suitability of fly ash as supplement to
cement,the
reactivity study in terms of PAI is desirable.

2.3 CLASSIFICATION OF FLY ASH

FLY ASH: THE MODERN POZZOLON

Fly ash is comprised of the non-combustible mineral portion of coal

consumed in a
coal fueled power plant. Fly ash particles are glassy, spherical shaped ball
bearings
typically finer than cement particles that are collected from the
combustion airstream exiting the power plant.

There are two basic types of fly ash:

A) Class F
B) Class C.
Both types react in concrete in similar ways. Both Class F and Class C fly
ashes
undergo a pozzolanic reaction with the lime (calcium hydroxide) created by
the
hydration (chemical reaction) of cement and water, to create the same
binder (calcium
silicate hydrate) as cement. In addition, some Class C fly ashes may possess
enough
lime to be self- cementing, in addition to the pozzolanic reaction with lime
from
cement hydration.

2.4

FLY ASH UTILIZATION

Several factors have impeded fly ash utilization in India, while it is being
extensively
used globally. Coal-based thermal power stations have been operational for
more than
50 years but the concept of developing environment-friendly solutions for fly
ash
utilization is only about 15 years old. Overall fly ash utilization in India stands
at a
fairly low level of about 15 per cent of the quantity generated. Various
possibilities
for its use are under research.

Among numerous factors that

utilization, the chief factors are:

account

for

the

low

level

of

Poor understanding of the chemistry of fly ash and its derivatives for proper
end
Applications.
Absence of standards and specifications for fly ash products.
Lack of reliable quality assurance for fly ash products Poor public awareness
about
the products and their performance.

Fly ash from coal-fired thermal power stations is an excellent potential raw
material
for the manufacture of construction material like blended cement, fly ash
bricks, mosaic tiles,
blocks. It also has other, high volume applications and can be used for
paving roads,
building embankments, and mine fills.

3. FLY ASH BUILDING BLOCKS/BRICKS

3.1 General
Fly Ash bricks are alternative to burnt clay bricks in the construction sector in
India.
At this time India is witnessing a new phase in development. With rapid
economic

growth and high rate of urbanisation. Construction provides the direct means
for the
development,
settlements is

expansion,

improvement

and

maintenance

of

human

particular and economic growth in general. Construction activity accounts for

more
than 50% of the development outlays in India. Building construction costs
are
increasing at rates which are So per cent over inflation.

This is primarily due to the increase in the cost of basic building materials
like burnt
brick, steel, cement, timber, etc. As a result, the cost of construction using
conventional building materials and construction forms range from As.
40001- to As.
6000/- per sqm even for normal housing. Construction costs of this order is
beyond
the affordable capacity of the economically Weaker Section and Low Income
Group
and a large cross section of the Middle Income Groups, whose income levels
have not
increased commensurately. This has become all the more relevant in the
macro
context. due to the large volume of housing to be done in both rural and
urban areas
and the limited resource of building materials and finance available.
According to the projections for the Ninth Five Year Plan, there will be a
shortage of
6.6 million houses in urban areas and 12.76 million houses in the rural areas
at the end
of year 2001, inspite of all the Governmental efforts and resources.

3.1.1 Availability of Fly Ash

Total flyash generation in India from Thermal Power Plants is estimated at
aboot 60
million tonnes per year, which may increase to about 110 million tonnes per
year by
2010 AD. India utilize only 3-4% of the flyash generated as compared to
more than
40% utilisation in Europe, China and America etc. The Government has
indicated a
clear willingness to achieve 50% fIyash utilization by the turn of the century
at its
enlarged level of 90 million tonnes per annum. In India, from Rajasthan fly
ash will be
available from Kota Thermal Power Plant that is 15 years old.
It can also be obtained from the cities like Ahmadabad , Bikaner , Barmer etc.

3.2 Raw Materials Required

Fly Ash bricks are made of fly ash, lime, gypsum and sand stone and water .
These 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
pollutionproblems, its utilisation 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.

3.2.1 Fly Ash(pulverized fuel ash):

Flyash is a waste material from thermal power stations. About30 million

tonnes of
flyash is produced annually from as manyas 63 thermal power stations in the
country.
This very fine industrial waste not only causes environmental pollution
butalso poses
problem of disposal. The need for scientific andpollution free disposal of
flyash has
become a compelling necessity.

Large variations in thegrading of flyash from different thermal power plants,

nonavailability of flyash in dry form, absence of any organisedbuilding industry
in the
country, high initial investment insetting up flyash based building material
units,
nonavailabilityof indigenous plants and machinery for commercialproduction
of
building materials from flyash are amongthe major hurdles in the production
of
different building products from Indian flyash.

3.2.2 Lime
Lime is truly a versatile material in building construction projects. Lime can
be used
to prepare the construction site by stabilizing the soil or remediating
brownfield sites.
Lime can be used in the construction of masonry systems as a component of
mortar or
the masonry unit. Exterior (stucco) and interior plaster systems can also
contain lime.
Finally, the decorative finishes can be created with lime washes.

Lime provides benefits in the plastic and hardened state to mortars and
plasters. In the
plastic state, lime can enhance the workability and water retention of
plasters and
mortars. In the hardened state, lime products react with carbon dioxide to
regenerate
calcium carbonate or limestone. This is a slow, gradual process which
increases the
hardness of the finished surface and allows for the healing of hairline cracks
by a

process called autogenous healing. Since initial strength is needed in most

applications, additives such as gypsum, cement or pozzollans are mixed with
lime in
construction applications. Lime can react with pozzolanic materials in the
mortar or
plaster to produce a cement-like product.

CRUSHER DUST : 0 6 mm

3.2.3 Gypsum

Gypsum is a very soft sulfate mineral composed of calcium sulfate

dihydrate , with
the chemical formula CaSO 42H 2O . It is found in alabaster , a decorative
stone used
in Ancient Egypt . It is the second softest mineral on the Mohs scale of
mineral
hardness . It forms as an evaporite mineral and as a hydration product of
anhydrite .

Gypsum is a common mineral, with thick and extensive evaporite beds in

association
with sedimentary rocks . Deposits are known to occur in strata from as far
back as the Archaean eon . Gypsum is deposited from lake and sea water, as
well as in hot springs ,
from volcanic vapors, and sulfate solutions in veins . Hydrothermal anhydrite
in veins
is commonly hydrated to gypsum by groundwater in near-surface exposures.
It is
often associated with the minerals halite and sulfur .
Gypsum is also formed as a by-product of sulfide oxidation , amongst others
by pyrite
oxidation , when the sulfuric acid generated reacts with calcium carbonate .
Its
presence indicates oxidizing conditions. Under reducing conditions, the
sulfates it
contains can be reduced back to sulfide by sulfate reducing bacteria . Electric
power
stations burning coal with flue gas desulfurization produce large quantities of
gypsum

as a byproduct from the scrubbers. Calcium sulfate, commonly known as

natural
gypsum, is found in nature in different forms, mainly as the dihydrate (CaSO
4 2H 2O)
and anhydrite (CaSO 4). They are products of partial or total evaporation of
inland seas
and lakes. Both the dihydrate and the anhydrite occur in nature in a variety
of forms.
The origin of gypsum, its genesis, varieties and properties are discussed, and
the focus
is then on the most common binding material produced from it, plaster of
Paris ( hemihydrate), known in France as pltre de Paris, in the USA as calcined
gypsum,
and in Germany as Stuckgips. Details are given of the properties of gypsum
paste
(setting, expansion, and adhesion) and of hardened gypsum (strength, bulk
weight,
thermal expansion, volume and linear changes under humidity fluctuations,
moisture
absorption, paintability,
behaviour, and

corrosivity,

thermal

and

acoustic

insulation

fire resistance).

Natural River Sand was used which is locally available in Hyderabad region.
The
specific gravity was found 2.57. Fineness Modulus is also determined using
10mm to
150 m and is found 2.972. The fineness modulus gives the idea about
average size of

~ 29 ~
particles in the fine aggregates. The value 2.972 indicates medium size sand.
The
details of sieve analysis are presented in Table 3.1, and the grading curve is
shown in
With sieve analysis data and fineness modulus value, sand is considered
as zone II grading sand of IS: 383 1970, which is considered as good fine
aggregate
for concrete production. The grading limits of zone II sand for fine aggregates
as per
IS: 383-1970.

Table 3.2.1: Grading limits of Fine Aggregates IS: 383-1970

IS SIEVE

Percentage passing by weight for

DESIGNATI
ON

Grading - I

Grading - II Grading - III

Grading IV

10 mm

100

100

100

100

4.75 mm

90-100

90-100

90-100

95-100

2.36 mm

60-95

75-100

85-100

95-100

1.18 mm

30-70

55-90

75-100

90-100

600 micron 15-34

35-59

60-79

80-100

300 micron 5-20

8-30

12-40

15-50

150 micron 0-10

0-10

0-10

0-15

Sand is an extremely needful material for the construction but this

important material
must be purchased with all care and vigilance. Sand which is used in
the construction
purpose must be clean, free from waste stones and impurities.

SAND:

3.2.5 Water
Ordinary tap water was used in the production of bricks.
water is one of the most important elements in construction but people still
ignore
quality aspect of this element. The water is required for preparation of
mortar, mixing
of cement concrete and for curing work etc during construction work. The
quality and
quantity of water has much effect on the strength of mortar and cement in
construction work.
Quality of Water
The water used for mixing and curing should be clean and free from injurious
quantities of alkalis, acid, oils, salt, sugar, organic materials, vegetable
growth and
other substances that may be deleterious to bricks, stone, concrete or steel.
Potable
water is generally considered satisfactory for mixing. The pH value of water
should
be not less than 6.

Water Reducing Admixtures

The water reducer admixture improves workability of concrete/mortar for the
same
water cement ratio. The determination of workability is an important factor in
testing
concrete admixture. Rapid loss of workability occurs during first few minutes
after
mixing concrete and gradual loss of workability takes place over a period
from 15 to
60 minutes after mixing.

3.4 Types of Flyash Bricks

Fly ash bricks can be divided into the following types :
i) FAL-G (fly ash-lime-gypsum) Bricks:
Fly ash-lime-gypsum bricks/blocks technology has been developed
successfully by
National Thermal PowerCorporation ( NTPC ), Bhanu International and
Ahmadabad Electricity Company ( AEC ) for manufacturing bricks/blocks
which can
replace burnt clay bricks as walling material. It is also known as Fly AshLimeGypsum (FaL-G)bricks. It is not a brand name but it is duct name,christened
to the
mix for easy identification of its ingredients.
Fal-G bricks and blocks are manufactured without using thermal energy, in
contrast to
the sintering involved in the production of clay bricks.

ii) Clay- Flyash Bricks :

Manufacturing process of clay flyash bricks by manual or extrusion process
involves
mixing of flyash (60 %) with clay of moderate plasticity. The green bricks are
dried

under ambient atmospheric conditions or in shed to equilibrium moisture

level of
below 3 percent. Dried bricks are fired in traditional brick kilns at 1000
30 C with
a soaking period of 5 7 hoursat maturing temperature.
iii) Flyash Sand Lime Bricks :
In presence of moisture, fly ash reacts with lime at ordinary temperature and
forms a
compound possessing cementitious properties. After reactions between lime
and
flyash,calcium silicate hydrates are produced which are responsible for the
high
strength of thecompound.
This processes involves homogeneous mixing of raw materials (generally fly
ash,sand
andlime), moulding of bricks and then curing of the green bricks. Some
technologies
call forusage of chemical accelerator like gypsum.
iv) Cold Bonded Lightweight Flyash Bricks, Blocks and Tiles:
The material can be produced in a variety of building blocks, bricks and tiles,
depending onlocal markets and regulations. Keraton consists of cheap and
ubiquitous
raw materials such asfly ash and / or other waste materials. These materials
are mixed
and a cold bonding agent isadded. The mixed raw material is cast in moulds,
after
which the moulds are processed in amicrowave oven for transportation to
the building
site.

The products can be applied as a lightweight material in the house building

industry

and utility building, such as stables, barns, garages, etc. A surface treatment
or coating
for coloring is possible. Strong points are theability to use fly ash, the
insulation
properties and the production flexibility.

v) Flux Bonded Flyash Bricks Blocks and Tiles:

The process is similar to the one in the conventional tile industry: fly ash is
mixed
with lessthan 10 % plastic clay and a few additives and tiles, bricks or blocks
are
pressed. Theseshapes are fired in the range of 900C to 1000C to make the
final
product. More than 85% of flyash is used in the process.

3.5 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.
Demand for dwelling units likely to raise to 80 million units by year 2015 for
lower
middle and low income groups, involving an estimated investment 0f $670
billion,
according to the Associated chamber of commerce and industry. Demand for
dwelling
units will further grow to 90 million by 2020,which would requires a minimum
investment of $890billion. The Indian housing sector at present faces a
shortage of
20million dwelling units for its lower middle and low income groups which
will
witness a spurt of about 22.5million dwelling units by the end of Tenth plan
period.

There is ample scope for fly ash brick and block units.
1. India ranks as one of the largest generators of fly ash in the world, mainly
from its
80 plus thermal power stations (TPS) widely distributed within the country.
The low
utilisation levels of fly ash in civil engineering purposes & building
components,
currently is at 15% (2002-03) of the total fly ash generated annually in India.
2. Research both in India and abroad has amply proved that the building
components
produced using fly ash are competitive, both in quality and cost, as
compared to
traditional building materials. A techno-feasible study on utilisation of fly ash
as
building material in major cities of India, beginning with Hyderabad, initiative
taken

by BMTPC is laudable.

4. METHODOLOGY
Fly ash bricks are nowadays mostly used for construction and gaining its
popularity over builders and engineers because of its high strength,
uniformity and
less consumption of mortar plastering. Above to this it is eco friendly bricks
which
saves environmental damage caused by burnt clay bricks and saves top
agricultural
soil which was the main raw material in the burnt clay bricks.
73% power generated in INDIA is from Thermal Power and 90% of it is coal
based.
Ash content is 27% to 42% of the coal used.Increase in FLYASH generation
has risen
from 4 crore to 11crore ton in the last decade and will rise to 1100 crore ton
in coming
decade. Approximately 10,000 hectares of top soil is being lost every year
for brick
manufacturing and road construction.
If we continue in this format, very soon, we will not have sufficient soil to
produce
our minimum required food.

4.2 Manufacturing of Fly ash Bricks

For manufacturing Flyash bricks , most of the machine manufacturers
suggest the
following two mixing ratio, you can choose profitable mixing ratio to survive
in the market
if you are facing low availability of Flyash .At the same time you should
maintain the
quality too.
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.

There are several techniques for manufacturing construction bricks from fly
ash, producing
a wide variety of products.
One type of fly ash brick is manufactured by mixing fly ash with an equal
amount
of clay, then firing in a kiln at about 1000 degrees C. This approach has the
principal benefit of reducing the amount of clay required.
Another type of fly ash brick is made by mixing soil, plaster of paris, fly ash
and
water, and allowing the mixture to dry. Because no heat is required, this
technique
reduces air pollution. More modern manufacturing processes use a greater
proportion of fly ash, and a high pressure manufacturing technique, which
produces
high strength bricks with environmental benefits.

4.3 Characteristics of FlyAsh Bricks

The standard size of the brick is 230x110x70.
The bricks are manufactured and tested as per IS 12894-2002.
Fly ash bricks are sound, compact and uniform in shape, size and colour.
Smooth
rectangular faces of the bricks are accompanied with sharp and square
corners.
Fly ash Bricks are available in various colours and shapes. The above
picture shows the
bricks in dark peach colour with three holes on it. These holes are used for
grouting. The
mortar is poured into these holes for proper bonding in between the bricks .
They are free from visible cracks, warpage, flaws and organic matter.
Economical & environment friendly.
28% lighter than ordinary clay bricks.
Compressive strength: 7.5N/mm2 on an average.
Water absorption: <8%.

4.4 Technical Specifications

(1) Fly Ash Brick Size Details :
Size :
[4 Inches ] :- 230 x 100 x 75 mm
:- 230 x 100 x 100 mm
Size :

[6 Inches ] :- 230 x 150 x 80 mm

:- 230 x 150 x 100 mm

(2) Density :

1700 Kg/m3
(3) Weight:

230x100x75 mm ( Weight about 4.75 to 5.00 kgs.approx )

230x150x75 mm ( Weight about 2.75 to 3.00 kgs.approx )

(4) Load Bearing Capacity:

More than 25% as compare to clay bricks

(5) Composition :

(i) Cement : Best Quality OPC 53 Grade Cement / Gypsum Powder,Lime

Powder
(ii) Thermal Station Fly Ash
(iii) Crushed Sand / Stone Dust
(iv) Chemicals

(6) Thermal Conductivity :

0.90 1.05 W/m2 0 C

( 0.75 0.90 K cal/m2 hr 0C )

(7) Drying Shrinkage :

Maximum Average drying test shrinkage 0.035-0.04 %

(8) Brick Colour :Gray / Dark Gray

4.4 Comparison of normal clay bricks and Fly ash bricks

NORMAL CLAY

FLY ASH BRICKS

BRICK
Varying colour as Uniform pleasing
per soil
like cement
Uneven
shape
hand made
Lightly bonded
Plastering required
Heavier in weight
Compressive
strength is
35 Kg/cm2
More porous

colour

as Uniform in shape
smooth in finish

and

Dense composition
No plastering required
Lighter in weight

Compressive strength
around around 100 Kg/cm2

is

Less porous

Thermal conductivity
Thermal conductivity
1.25 1.35 0.90-1.05 W/m2 C
W/m2 C
Water absorption 20- Water absorption 20-25%
25%

4
.6 Fly ash bricks plant visit

We have visited fly ash bricks plant which is located at near poornima university,
ramchandpura, jaipur

PLANT LOCATION:

Near Poornima University

map here of plant

Goner Road,
Ramchandpura,

Fig. 7 Fly ash bricks plant location

Jaipur -000000

Amit company is a good example of use of fly ash bricks in Jaipur. We also visited the
construction of hostel (Name of place which use these bricks) made for students beside the ,
where these bricks are being used.
On site, the engineer told the process of making the fly ash bricks. The material required for
making of fly ash bricks are used in this plant are fly ash taken from Power Plant (Kota), Lime
taken from Exel Crop. Ltd. (Jaipur), Gypsum purchased from Jaipur and Sand dust. The
proportion of these raw materials is generally in the ratio 50-60% of fly ash 10-20% lime, 0510% Gypsum and 15-20% sand, depending upon the quality of raw materials are used in this
plant.
In this plant, Fly ash bricks are made by mixing the ingredients (Fly ash + lime + gypsum + sand
dust) in the appropriate proportion using mechanical mixer with the addition of water. After
mixing, the mixture is conveyed through belt conveyor to the mechanical presses, in this paste
has been moulded to shape of brick by applying 70-80 tons load over the dye. The green bricks
are dried up under sun from 24 hours and 7 days curing for creating a good quality of fly ash
bricks.

4.7 BRICK MAKING MACHINE

The technology consist of regular mechanical type and hydraulic version.

The hydraulic version is latest and gives higher production output with
minimal inputs like
in labour and power. The strength of bricks in hydraulic version is better than
the others. It
gives the pressure of 25 to 50 Ton in lieu of 15 ton in mechanical versions.
Embossing the
monogram of company on the bricks is easy. Production is high. Continuous
operation is
possible.

1.Fly ash Brick making machine, vibrator, hydraulic power pack

motor and Control
panel
It is hydraulically operated automatic machine. The structure is capable of
handling load up
to 100 bar. Different size of mould can be fitted with machine. Embossing on
brick is easy.
It give high production at minimal power loads. Circulated water cooling
ensure longer
operation.
2.Pan mixing machine with gear box and motor:
A mechanical sturdy constructed with heavy rollers to grind the raw
materials efficiently.
Drive by worm reduction gear box. Easy unloading mechanism with proper
door
arrangements.
3.Belt conveyer system
A fabricated belt conveyer to take the raw materials of 1.5 tiem more than
the capacity of
machines. The raw materials can regulated according to the requirements.
Rubber with
nylon coated belts.
4.Hydraulic pallot trolley
The trolley capable of transporting maximum bricks to stocking area
operated
hydraulically, which reduce the manpower and cracks of bricks.
We in Agni Engg. & Industreis manufacturing the following capacity machines

4.8 ADVANTAGES & DISADVANTAGES

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
inmortar 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 withcement mortar.

iii. Thermal properties
Thermal conductivity is 0.90-1.05 W/m2 C (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. Fire and vermin resistance
Flyash bricks have a good fire rating. It has no problems of vermin attacks or
infestation.

Disadvantages :
Actually, the disadvantages listed by some people about fly ash bricks are
imaginary. But
the flyash bricks manufacturing process involves strong health hazard for the
labors. The
fly ash is a very tiny particle and it penetrates in to lungs and cause serious
health trouble to
the labors engaged in flyash bricks manufacturing process.
So many reports have proved this dangerous nature of fly ash, and still no
awareness is
created among the labours in the thermal power plants, cement factories,
Brick
manufacturing units etc..

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 is one of the numerous substances that cause air, water and soil
pollution,
disrupt ecological cycles and set off environmental hazards.
The combustion of powdered coal in thermal power plants produces fly
ash.
The high temperature of burning coal turns the clay minerals present in the
coal
powder into fused fine particles mainly comprising aluminium silicate. Fly ash
produced thus possesses both ceramic and pozzolanic properties.
When pulverised coal is burnt to generate heat, the residue contains 80 per
cent fly
ash and 20 per cent bottom ash. The ash is carried away by flue gas
collected at
economiser, air pre-heater and ESP hoppers. Clinker type ash collected in the
waterimpounded hopper below the boilers is called bottom ash.

4.9 USES:
Several factors have impeded fly ash utilization in India, while it is being
extensively used

globally. Coal-based thermal power stations have been operational for more
than 50 years
but the concept of developing environment-friendly solutions for fly ash
utilization is only
about 15 years old. Overall fly ash utilization in India stands at a fairly low
level of about
15 per cent of the quantity generated. Various possibilities for its use are
under research.

Among numerous factors that account for the low level of utilization, the
chief
factors are:

Poor understanding of the chemistry of fly ash and its derivatives for
proper end
applications
Absence of standards and specifications for fly ash products
Lack of reliable quality assurance for fly ash products Poor public
awareness
about the products and their performance
Non-availability of dry fly ash collection facilities Easy availability of land
with
top soil at cheap rates for manufacturing conventional bricks
Lack of proper coordination between thermal plants and ash users.
Fly ash utilization in the country is gaining momentum owing to the
stringent
regulations that the MoEF has stipulated, as also to increased awareness
about
the benefits of using fly ash for various products.
Fly ash from coal-fired thermal power stations is an excellent potential raw
material for the manufacture ofconstruction material like blended cement, fly
ash bricks, mosaic tiles and hollow blocks. It also has other, high volume

applications and can be used for paving roads, building embankments, and
mine
fills.

5. TEST RESULTS AND DISCUSSION:

5.1 General
The results of all the tests carried out on Fly ash bricks and also the technical
aspects are presented and discussed in this chapter.

5.2 TEST RESULTS :

5.2.1 WATER ABSORBTION TEST:
(24-hour Immersion Cold Water Test)
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 * 100
M1
Weight
Sample
(dry) gm

Weight
(wet, after
24 hr)
gm

% of
water
Absorpt
ion

3550

3825

7.746

3722

3942

5.910

3740

3953

5.695

AVERAGE

6.450

5.2.2 COMPRESSIVE STRENGTH TEST :

APPARATUS:
Compression testing machine, measuring tape or scale, surface grinder, plywood sheets.
PROCEDURE:
Preparation of Sample :-

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.
2

ii. Load is applied axially at a uniform rate 14 N/mm per minute till failure
occurs; Note the maximum load at failure.
CALCULATIONS:
2

Compressive Strength (N/mm ) =

OBSERVATION TABLE:

Sample

Dimension of Fly ash Bricks

Length
(mm)

Width
(mm)

Height
(mm)

Avg.
Area of
bed
surface
2
(mm )

Max
load at
failure
(KN)

Compressive
strength
(N/mm2)

225

110

75

23000

118

5.153

225

110

75

22800

104

4.582

225

110

75

22800

132

5.815

AVERAGE

5.425
( approx
54.25
2
kgf/cm )

6. CONCLUSIONS:
In this chapter conclusions of the so far done-study/Experimental work of this
project
are given . Following conclusions are given from the present study:
There is an imperative need to produce more building materials for various
elements
of construction and the role of alternative and innovative options would
come into
sharp focus, considering the short supply, increasing cost and energy and
environment
considerations for traditional and conventional materials. The possibility of
using
innovative building materials and technologies, more so covering waste
material like
Ifyash have been considered as a felt need.
Series of institutional support for land, for land, finance, regulatory, media,
marketing
support, testing support and awareness creation would be needed and some
of the
existing initiatives would have to be substantially strengthened, more
importantly,
entrepreneurship for the production of appropriate flyash based walling,
roofing and
flooring materials including Portland Pozzolana Cement and other cements to
ad1ieve
better strength, energy saving, conservation of natural resources besides
cost
efficiency, would have to be increasingly supported and developed.

Fly ash utilization in the country has remained less than10% during the past
5 years
and it might take several years to reach the final goal of cent percent
utilization.
Every year nearly 70 million tonnes of ash is producedin India, of which NTPC
stations alone contribute to theextent of about 22 million tonnes.

The results shows the FaL-G bricks are more safe,economical and having
higher
strength compare toconventional bricks.According to case study the fly ash
bricks
withConventional masonry work have 28% saving in costwith common red
brick and
conventional masonrywork. The masonry work with new technology Rat-Trap
bond
in fly ash bricks have 33% saving in cost ascompared to common bricks.
Further 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. and also
The compressive strength of bricks increases with lime proportion.
The bricks made under pressure has increased compressive strength
according
as the pressure was applied
As long as the percentage between lime and fly ash is unchanged, the
change
in soil percentages does not affect compressive strength significantly.