Feasibility Report for Production & Supply/Sale of

Fly Ash Bricks In Pakistan

Executive Summary:
Fly Ash is basically the by-product from coal power plants. Currently this Fly Ash is being used
for the following purposes:
1 - Concrete production, as a substitute material for Portland cement and sand
2 - Embankments and other structural fills (usually for road construction)
3 - Grout and Flowable fill production
4 - Waste stabilization and solidification
5 - Cement clinkers production - (as a substitute material for clay)
6 - Mine reclamation
7 - Stabilization of soft soils
8 - Road sub base construction
9 - As Aggregate substitute material (e.g. for brick production)
10 - Mineral filler in asphaltic concrete
11 - Agricultural uses: soil amendment, fertilizer, cattle feeders, soil stabilization in stock feed
yards, and agricultural stakes
12 - Loose application on rivers to melt ice.
13 - Ash brick manufacturing at location of Thermal Power Plant itself. Usually, top soil is used
for brick manufacture. Top soil is suitable for Irrigation. Use of Fly ash brick stops the depletion
of top soil.
14 - Other applications include cosmetics, toothpaste, kitchen counter tops, floor and ceiling
tiles, bowling balls, flotation devices, stucco, utensils, tool handles, picture frames, auto bodies
and boat hulls, cellular concrete, geo polymers, roofing tiles, roofing granules, decking, fireplace
mantles, cinder block, PVC pipe, Structural Insulated Panels, house siding and trim, running
tracks, blasting grit, recycled plastic lumber, utility poles and cross arms, railway sleepers,
highway sound barriers, marine pilings, doors, window frames, scaffolding, sign posts, crypts,
columns, railroad ties, vinyl flooring, paving stones, shower stalls, garage doors, park benches,
landscape timbers, planters, pallet blocks, moulding, mail boxes, artificial reef, etc.
(Reference Document is attached as “ANNEXURE – I)

Here only the Fly Ash Bricks will be discussed in detail. Brief summary is presented below:
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. 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.

Market Survey Report

In Pakistan currently very low percentage of people are known to this method. However our
neighboring country “India” has done a lot of work on it. Thus it is high potential project in
Pakistan for beginners. But before we proceed with it further we must know the following facts
of market:

1 – How many plants are currently operating in Pakistan producing “Normal Clay Bricks”?
Answer: There are 22,000 plants are installed and 15,000 are operationl on average. Each plant
produces 30,000 normal clay bricks ech day. Thus there are 450 Million normal clay bricks
manufactured each day in Pakistan. If we are able to capture 1% market then we have to
produce 4.5 Milion Fly Ash Bricks each day.

2 – How much is the cumulative production of “Normal Clay Bricks” in Pakistan?

Answer: 450 Million

3 – What are the raw materials for making “Fly Ash Bricks”?
Answer: Fly Ash (major Part), Lime, Gypsum & River Sand / Stone Dust.

4 – What are the composition ratios for making Fly Ash Bricks?
Answer: Its all depends on the quality want to produce.
For a good standard quality below combination of ratios can be used:
A) Mix Proportion For Fly Ash Bricks manufacturing – (Here Hydrated Lime is used instead
of Sludge Lime)
 Fly ash – 57 to 65%
River Sand or Stone dust – 18 to 27%
Hydrated Lime – 9 to 12 %
Gypsum – 5%

This is the widely practiced mix proportion to make quality fly ash bricks. Hydrated lime is easily
available and this is the most common method followed by many successful brick makers.

B) Mix Proportion For Bricks manufacturing using

Fly Ash (major part) – 55 to 60%

River Sand or Stone dust – 20 to 25%
Sludge Lime –15 to 22%
Gypsum – 5%

Sludge Lime is less expensive than Hydrated Lime, this mix ratio is more profitable than other
two proportions listed below. Sludge lime is a waste material and hence it costs less than
hydrated lime. Sludge lime is normally wet and has lumps, However it can be used to make
quality fly ash bricks.

C) Mix Proportion for Fly Ash Bricks Manufacturing using cement instead of gypsum and
Lime

Fly Ash – 50 to 60%

River Sand or Stone Dust – 30 to 40%
Cement – 8 to 12%
In this Mix design, gypsum and lime are replaced with cement. This mix ratio is not so popular
and not a profitable design for entrepreneurs. Cement is more expensive than Gypsum and
Lime, hence this formula is useful only during non-availability of gypsum and lime.

For profitable business.

Fly Ash (major part) – 55 to 60%

River Sand or Stone dust – 20 to 25%
Sludge Lime –15 to 22%
Gypsum – 5%

5 – Availability of all raw materials & prices required to make Fly Ash Bricks?
Answer: This chapter has to be covered based on local market availability. However here below
is the data for Fly Ash Availability:
Pakistant is generating 6,898 MW electricity from Coal Power Plants and cumulative Fly Ash
generating capacity is calculated @ 750 Metric ton / MW. Thus there is appr. 5.2 Million tonnes
of Fly Ash is available in Pakistan. (Reference Document is attached as ANNEXURE – II)
Useful links for purchasing are mentioned below:

A - http://flyash.com.pk/dt_portfolios/donec-in-maximus-augue-2/
+92 301 233 8 777
 info@flyash.com.pk
B - https://www.pcq.com.pk/construction-industries-should-use-fly-ash-as-construction-
material/
Mobile: +92 334 5644485
Email: marketing@pcq.com.pk

C - https://www.flyash.pk/2018/12/15/supply-and-production-of-fly-ash-in-pakistan/
Emailinfo@flyash.pk
Office021 34376639

D - https://sterlingash.com.pk/
Phone : Tel: +92 21 35295552-4
E-mail: purchase@elsons.com.pk

E - https://twil.pk/fly-ash-sales/
E-mail: info@twil.pk
Mobile: +923099968888

F – For further suppliers list go to https://www.go4worldbusiness.com/suppliers/pakistan/karachi/fly-

ash.html

6 – Price of “Normal Clay Brick” & “Fly Ash Brick”?

Answer: Price of Normal Clay Brick is appr. 10.5 to 12 / piece Ex-works.
Price of Fly Ash Brick is appr. 10 to 12 / piece Ex-works.

Conclusion:
Based on above data and market survey the following are the conclusive remarks:
1 – If 1% of Pakistani market is replaced with “Fly Ash Bricks” then production capacity should
be 45 Million / Day.
2 – Ex-works cost of brick seems low. However further working on raw materials availability,
location of plant, capacity of plant, market demand is to be evaluated.
3 – Currently Government is discouraging the “Normal Clay Bricks” manufacturing plants as it is
polluting the environment. Thus we can also influence Government & can give them proposal in
the following shapes:
A – Encourage the industry to produce Fly Ash Bricks and our scope is to provide the plant
machinery / complete set up.
B – Supply the bricks on Government projects by making then understand the difference
between normal clay & fly ash bricks.
4 – We must have Digital marketing Application / Website / Other Social Media Sources like
facebook, linkedin, pinterest, Instagram, twitter etc as “Future Of Marketing Business Is Online”
5 – In every aspect like accuracy, shape, color, heat coefficient, hardness, alkaline / acid attack
resistivity, compressive strength & above all no heat requirement “Fly Ash Brick” is having
capability of replacement for “Normal Clay Brick”.

Project Costing
Reference Documents Are Attached As
1 – ANNEXURE –III
2 – ANNEXURE – IV
3 – ANNEXURE – V

Other Reference Documents

1 - ASTM C-618 Fly Ash Code
2 - Ash Testing By SGS
3 - Fly Ash Product Data Sheet
4 - Fly Ash Safety Data Sheet
5 - Comparison-between-Pakistan-Fly-Ash-and-ASTM-limits-for-Fly-Ash