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Fly Ash Bricks
Fly Ash Bricks
1. Product
2. Quality Standards
IS : 12894 :2002
24 lakh bricks
Rs. 78 lakhs
March 2011
5. Prepared by
N.Sivalingam
Value
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
hydrate
women entrepreneur
and she have acquired EM Part I from the District Industries Centre,
Kanchipuram, 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.
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
i.
iii.
iv.
v.
vi.
vii.
4.RAW MATERIALS
Fly Ash s the inorganic mineral residue obtained after burning of
coal/lignite in the boilers. Fly Ash is that portion of ash which is
collected from the hoppers of ESPs and pond ash is collected from the
ash ponds. Bottom ash is that portion of ash which can be collected fro
the bottom portion of the boilers. The characteristics of fly ash depend
upon the quality of lignite/coal and the efficiency of boilers.
India depends upon primarily on coal for the requirement of power
and her power generation is likely to go up from 60,000MW in the year
2010.
increase. The generation of fly ash is also likely to increase. The fly ash
generation in India Thermal Stations is likely to shoot up to 170 million
tones in 2010 from the present level of 100 million tones. The disposal of
fly ash in the present method will be a big challenge to environment,
especially when the quantum increases from the present level.
The proposed unite will be using both type of fly ash depends upon the
availbality
4.a Characteristics of Fly ash
Silica
35-59 %
Alumina
23-33%
Calcium Oxide
10-16%
Loss on ignition
1-2%
Sulphur
0.5- 1.5%
Iron
0.5- 2.0 %
L.O.I
1.0 TO 2.0
3-15
Sio2
45.59
40-64
A12 o3
23-33
15-29
Fe2 o3
06-4.0
2-11
CaO
5.0-16.0
0.1-1.0
MgO
1.5-5.0
0.2-4.0
0-5. 0
0.1-1.7
So3
About 50 to 80% fly ash may be used for the production. Fly ash
conform to IS 3812/1981is one of the important aspects.
4.c. GUPSUM:
6
Fly Ash
Gypsum
Lime
Sand
--------------------------------------------------------------------------------Weighing
Pan Mixer
Conveyor
Kept as it is
for two days for setting
Water Curing
(7 to 10 days)
Drying
(one or two days)
Dispatch
Co-efficient of softening
bricks fly ash bricks have high affinity to cement mortar though it has
smooth surface, due to the crystal growth between brick and the cement
mortar the joint will become stronger and in due course of time it will
become monolithic and the strength will be consistent.
8. PRODUCTION CAPACITY PER ANNUM:
Quantity: 24 lakh bricks total value
Rs. 78,00,000/
by
providing
energy
meter.
This
products
followed by the
are
low
energy
No:
No
of H.P
m/s
Connected
12
15
Belt Conveyor
--
6
35
AMOUNT Rs
45,000 Sq.f
3,00,000
50,000
TOTAL
3,50,000
QTY
RATE
1
12,00,000
1
1
2,00,000
50,000
AMOUNT
12,00,000
2,50,000
50,000
15,00,000
60,000
15,60,000
22,000
20,000
16,02,000
Rs.
RATE AMOUNT
250
1,22,500
1,900
1,33,000
1,300
1,36,500
800
28,000
4,20,000
Rs.
DESIGNATION
NO
Production Manager
Un skilled workers
Office assistant
Watch man
1
22
1
1
25
Total
(c)Utilities Per Month :
S.N
1
2
SALARY
-3,750
4,000
3,500
DESCRIPTION
AMOUNT
2
3
4
5
6
7
Self
82,500
4,000
3,500
90,000
Rs.
TOTAL
S.N
Amount
19,583.
1,000
20,583
Rs.
DESCRIPTION
AMOUNT
11
1,000
3,000
2,000
5,000
1,000
3,000
15,000
DESCRIPTION
AMOUNT
Raw Material
1,17,600
Work in progress
1,09,583
Finished Good
1,05,917
2,06,900
TOTAL
12
5,40,000
Rs.
Lease hold
b. Building
3, 50,000
16, 02,000
d. Working capital
5, 40,000
Total
24,92,000
Rs.
4,92,000
Promoter contribution 5%
1,24,600
23,67,400
8,72,200/
Rs.
DESCRIPTION
AMOUNT
65,47,200
4,000
TOTAL
70,25,900
13
3,11,500
15,000
1,48,200
81,60,000
Cost of Production
70,25,900
= 11,34,100/-
b) Rate of Return
Profit/annum X 100
Turnover
11,34,100 X 100
81,60,000
11,34,10,000
81,60,000
13.90%
Profit/annum X 100
Total Capital investment
11,34,100 X 100
24,92,300
11,34,10,000
24,92,300
45.50%
14
Total Depreciation
Interest on investment
Insurance
40% of salary and wages
40% of other expenses &
Utilities excluding Insurance
=
=
=
=
1,67,200
3,11,500
4,800
4,32,000
1,92,398
========
11,07,898
====== ==
1107898 X 100
2241998
49%
15
Profit/annum
Suppliers Address:
A. Raw Materials Suppliers :
Fly ash -
16