Fly

Ash Bricks

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 control environmental
pollution to a greater extent in the surrounding areas of power plants. There is a central
government gadget notification mandating government departments and CPWD to use 100%
Fly Ash Bricks in their all constructions- directly or through contractors.

Raw materials for Fly Ask Bricks

Fly Ash: The government has ordered the power plants to supply Fly ash, which is an
industry waste material free of cost to the manufacturing industries. The nearest power plan
to Anandapuram junction where we are setting up the bricks factory is NTPC so the only cost
incurred is the transportation of the raw material.

Sand/Crusher dust: Sand is used as an economizer and to increase the strength of bricks to
some extent. Sand is procured locally. Crusher dust can also be successfully used in place of
sand in case of sand’s unavailability. The costing is Rs. 6,500 for 9 tones

OPC: This Project aims to utilize OPC cement as a substitute for Lime. It will give faster
strength to the bricks, besides giving improved consistent quality. It also ensures a better cost
effectiveness for the same. Using OPC will be a standardized practice compared to Lime, as,
unlike OPC, Lime quality changes widely across suppliers and across seasons. The other
prime advantages of using OPC (compared to Lime) are it is easy availability locally through
nationwide Retail Network of Cement Companies. The approximate costing for a 25 KG of a
53 grade cement bag is around Rs.280

Stone Chips: This is the waste that is produced while cuttingthe huge rocks small. This is
easily available in the market and costs approximately around Rs. 700 per ton
Gypsum: This too is an industrial waste. This is available at Fertilizer Plant as in industrial
wastes. This costs around Rs. 6000 per 18 tonnes

Process of Making Bricks

The Process of manufacture is simple and suitable to start. A mix of Fly Ash, Cement,
Gypsum and Sand/Crusher Dust are automatically weigh batched in a batching plant.

1. Loading of Raw materials- There is a Low height Batching plant. It can be loaded either
manually or by Mini Loader.

2. Automatic Batching – The Raw materials are automatically weighed as per the preset
weights by means of Load cells and its control circuit. Cement, if it is available in Bulk, then
silo and screw controller is used to auto weight. Otherwise, the batching is programmed as
per 1 bag of cement.

3. Mixing - From the batching plant the mixture hopper pulls the materials and then the mix
is blended homogenously and intimately in a semi wet form in a PAN mixture. The Water is
automatically added as per time set. The TWIN SHAFT mixture ensures that a perfect mix is
done in shortest possible time.

4. Carrying to Brick machine - The mix is carried to the casting machine by means of
conveyer belt.

5. Automatic Brick Making- there are a series of operations which is achieved by automatic
PLC system. Pallet is pulled into the Machine. The mix is then collected fed into the machine
moulds. There is a T boggy which uniformly spreads the materials in the moulds. Automatic
PLC controlled Vibration and hydraulic pressure is given for a while and bricks are cast on
the pallets. The dual application of Pressure and vibration (in a patent pending micro-
sequence application) ensures perfect compaction with best quality of bricks

6. Automatic Stacking - The pallets along with the freshly cast bricks are rolled on a roller
platform to the pallet stacker. The Pallet stacker stacks the pallets along with the bricks
automatically and the

7. Brick Shifting– The Final stack of 4 to 6 pallets and bricks are lifted with either a Manual
pallet lift or a Fork Lifter and carried to the drying bay/room for 24 Hours for initial setting.
8. Curing - Soon after the initial setting of 1 day, the Blocks/ Bricks is stacked for curing in
layers. The layers are stacked in a way to enable water and air to go all around, to ensure
proper curing and drying. The curing process is continued for 7 days. The blocks are allowed
to normally dry for a day. Now they are ready for dispatch. Alternatively, the blocks/bricks
can be steam cured for 8 hours or mist cured for 24 hours immediately after production, and
made ready for dispatch immediately.

9. Dispatch - the cured bricks can be dispatched to market. The final strength of bricks will
be around 80 to 120 Kg/Cm2 , water absorption of 6 to 10% and around 1.5 to 1.7 Gms/CC
Density

Personal Profile
I am PK Kiran Kumar an MBA graduate from the prestigious University of Hertfordshire
(Member of Association of MBA’s), London. I always had fascination towards being a part
of creating something which can be used for years. When I heard about Fly ash bricks which
are an alternative to the traditional red bricks, I started researching about the technicalities of
the product and the ways in which this can be used. This great alternative can help control the
environmental pollution that comes from burning the red bricks and since fly ask is an
indispensable by-product of Thermal Power Plants, is an environmental threat across the
globe, recycling it is a great idea. I have joined companies like Magnum and Biswakarma to
get first-hand experience of both operations and on ground manufacturing. After gaining
complete confidence I have now determined to start this on my own here in Anandapuram.

Industry

Shelter is third skin, according to a German Concept, which implies it’s importance next to
human Skin and Clothing. This also shows the attachment of human race to this fundamental
requirement. Building Material accounts for major component of the construction cost.
Depending on the location they can contribute to 60 - 70 % of the cost of construction. With
the ever increasing population, the demand for housing increases. This directly creates
demand for this prime commodity of building. Add to the above fact the area under
discussion and its surrounding area is undergoing a major infrastructure revolution. As
Residential, Commercial, IT companies, and Industrial establishments are coming in, we can
conclude that the Bricks unit will prosper and flourish in this environment. There is a central
government gadget notification mandating government departments and CPWD to use 100%
Fly Ash Bricks in their all constructions- directly or through contractors. This factor will help
the marketability of this product immensely.

Location
The reason why I have chosen Anandapuram is because it is currently located in the most
happening and developing areas. Anandapuram has the maximum number of redbrick
manufacturers in the city and is considered as the brick hut in the vicinity so obviously people
come around the place for bricks and since government is advocating the alternative methods
of achieving better strength bricks through Fly Ash, the sale volume can be higher. The
location also has access to Madhurawada, Bheemili, Tagarapuvalasa and Pendurthi which
makes it easier to market and sell the bricks.

Quality
When was the last time you heard you can test the quality of bricks?

We are Shubham Eco Products have determined to ensure the quality of manufactured bricks
and to create a brand for ourselves. We will deploy a brick testing machine in the factory unit
where consumers can test the quality of our bricks against other bricks. This will create a
trust factor among public. This service is provided at free of cost.

Marketing & Promotions

No matter how good the product is, it has to sell. Branding a product and marketing
efficiently will be the key to success. We will use Digital Platforms like website
(www.shubhambricks.com) and social platforms like Facebook and Instagram to extensively
promote our products in the neighbourhood. We will also do talks about usage of the raw
materials and also the importance of maintaining quality in our products. If budget permits
we would want to do Auto ads and bus ads(may be after 3 month of production). We have a
good network of builder community where we can do a one on one in explaining the benefits
of the product. We also plan to give a brick free of cost to each builder to keep it and test it
and call us to order if they are satisfied with the product.