A

PROJECT PRESENTATION ON

COST EFFECTIVE 100% FLY ASH BURNT BRICKS

Presented
By

SAMEER S. SHAIKH
VISHALKUMAR R. GUPTA
ANURAG R. BHARMAL
GANESH B. ATAKE
NIKHIL SHINDE

Under the guidance of

Prof. S.S . CHAVAN

 Description: Fly ash

What is fly ash?

• 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 aluminum silicate
composition.

Photomicrograph made with a Scanning Electron

Microscope (SEM): Fly ash particles at 2,000 x magnification
 Properties of fly ash
The physical and chemical properties of Fly Ash are tabulated below
i. Physical Properties
Specific Gravity 2.54 to 2.65 gm/cc
Bulk Density 1.12 gm/cc
Fineness 350 to 450 M2/Kg

ii. Chemical Properties

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 %
• Presence of silica in fine form makes it excellent pozzolanic material. Its abundant
availability at practically nil cost gives a very good opportunity for the construction agencies.
 SODIUM SILICATE
• Sodium Silicate is a colourless compound of
oxides of sodium and silica.
• It has a range of chemical formula varying in
sodium oxide (Na2O) and silicon dioxide or
silica (SiO2) contents or ratios.
• It is soluble in water and it is prepared by
reacting silica sand and sodium carbonate at a
high temperature ranging from 1200 to
1400OC.
• According to IS 381, both the solid and liquid form of sodium
silicate are of two grades: neutral and alkaline.
• The quality requirements according to the IS 381 are as
follows:
• Neutral sodium silicate shall be clear, free from dirt and other
visible impurities.
• Liquid sodium silicate shall be thick, viscous, translucent
mass of water white or slightly grey colour.
• Solid sodium silicate shall be in the form of glassy lumps of
pale grey or green colour.
• The particle size shall be as mutually agreed to between the
purchaser and the supplier to meet the special requirements.
 SCOPE AND OBJECTIVE OF STUDY
• 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.
• 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.
• In spite of the recognition of the size of fly ash utilization disposal
problem and availability of technologies appropriate for Indian fly
ashes and applications, India utilizes hardly about 3% of the total
fly ash generated.
• In Chennai alone 1 crore bricks are required for
constructional activities in every day.
• But good quality of bricks as well as required
quantity are not available moreover during the
rainny seasons supply of clay bricks are very
difficult.
• Therefore, in order to fulfill the required demand
there will be a great chance to start more units in
the field of fly ash bricks.
• 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.
 TEST TO BE CARRIED OUT
• Compressive strength
• Modulus of rupture
• Initial rate of absorption
• Absorption capacity
• Average density
 LITERATURE REVIEW

• It was found that fly ash-addition into clay bricks does

not improve brick properties. Fly ash bricks was
studied by R.L.DAY.
• They used fly ash from western Canada as a main
composition up to 70-100% mixed with bottom ash
and NaOH, Na2CO3 or Na2SiO3 were added for better
solidity of brick samples.
• After firing at 900 and 1000 oC in 3 h, compressive
strength of specimens containing pure fly ash and 10%
Na2SiO3 additive was almost 9 MPa.
• . A.H.J. Wagener used pure fly ash for fired
brick production In process, 1% dextrin was
added as a binder. It was noted that the
products can reach acceptable appearances.
• Bricks was manufactured by C.F. Cockrell and
H.E. Shafer via fly ash, coarse aggregate, HCl
and Na2SiO3 solution as body compositions.
The samples carried very good properties of
compressive strength with 1.9-6.1 MPa .After
drying and 39.0-53.6 MPa after firing.
• N.V. Pak and L.M. Artemova studied fly ash
hollow bricks used as wall bricks.
• Their body-compositions consisted of 85% fly
ash, 15% ferroalloy waste (binders) and 14-
16% water, consequently pressed at 30 MPa
and fired at 1000 0C for 16 h.
• Their brick properties were 16.4 MPa for
compressive strength, 1.4 g/cm3 for bulk
density, 20.2% water absorption and 25 cycles
for freeze resistance.
• This present work focused on the possibility
of brick-production made of Thailand-fly ash,
in point of firing 100% fly-ash samples
prepared by compaction.
• The aim of this study is to investigate the
potential use of 100% as-received fly ash for
brick-making in order to keep cost at
acceptable levels.
 METHODOLOGY

• Manufacturing of 100 % fly ash brunt bricks as per

previous project with modifications.

• Applying various pressures as a comparative

measure.

• Burning the bricks in traditional clinker for cost and

strength comparison.
• Specimen of different proportion , binders and fly ash will be prepared
and their strength, absorption capacity, etc will be tested at different
curing period and same is compared with Standard red bricks available
in market.

•Making moist granulates of fly ash provided easy forming, packing and
easy handling. Such a fly ash carried plasticity and therefore can be
extruded.
Experimental procedure, therefore, was the main point to form such a
pure fly ash into pressed pieces.

•Making moist granulates of fly ash, the key point, provided easy
forming, good packing and easy handling.
• Fly ash-granulates can be produced since fly ash, when adding a
definite amount of water, behaves as clay-like material.

•Such a fly ash carried some plasticity and therefore can be

extruded through sieve into moist granulates.

• It was found that the more water-content was used, the longer the
granulates was gained providing the higher green density of brick
samples.

•Photos of granulates were not given in the previous work through

sieve into granulates. It was found that more the water content was
used the longer the granulates was obtained gaining the green
density of brick samples.
•Fine particles needed more water to generate the certain
plasticity due to high specific surface area. Finer particles
can compact more easily with each other.
•The results of bending strength and compressive strength
as function of firing temperature will be plotted to graph.
As a matter of fact the fly ash contains many glassy
compounds and fluxing agents such as hematite.
•These every low softening point can generate bonded
products which are strong in compression.
RATE ANALYSIS
THANK YOU