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Fly ash brick manufacturing is a process that involves using fly ash, a byproduct of coal combustion in power plants, as a primary ingredient to produce bricks. These bricks are known for their strength, durability, and eco-friendliness. Here’s a general overview of the manufacturing process:
- Fly Ash: The primary material, collected from coal-fired power plant emissions.
- Binding Agents: Lime (quicklime or hydrated lime) and cement are often used as binding agents.
- Aggregates: Fine aggregates like sand added to improve the texture and strength of the bricks.
- Water: To achieve the right consistency and hydration for the mixture.
- Fly Ash Processing: Fly ash is collected and sieved to remove large particles and impurities.
- Fly Ash Processing: Fly ash is collected and sieved to remove large particles and impurities.
- Mixing: Fly ash, cement, and aggregates are thoroughly mixed in a specific proportion, usually in a mechanical mixer.
- Proportioning: The materials are mixed in precise proportions. A typical mix might be around 60-70% fly ash, 15-20% aggregates, 10-15% cement, and water.
- Water Addition: Water is added to the mixture to achieve the desired consistency. The amount of water is carefully controlled to ensure proper hydration.
- Preparation of Molds: Molds are prepared according to the size and shape of the bricks required which are automated.
- Filling Molds: The mixed material is poured into the molds. The mixture is compacted to ensure uniform density and reduce air voids.
- Hydration Curing: The bricks are then removed from the molds and placed in a curing area where they are kept moist for several days. This process helps in the chemical reactions between fly ash, and cement, leading to the formation of a strong and durable material.
- Air Drying: The bricks are air-dried to remove excess moisture. This can take 2-3 days, depending on the environmental conditions.
- Strength Tests: The bricks are tested for compressive strength, durability, and other quality parameters.
- Dimensional Checks: Ensuring the bricks meet the required dimensions and tolerances.
- Stacking: Once cured and dried, the bricks are stacked for storage or transportation.
- Packaging: Depending on the requirements, the bricks would be loaded in vehicle for delivery.
Fly ash brick manufacturing involves mixing fly ash with binding agents and aggregates, molding the mixture into bricks, curing and drying them, and finally testing and packaging them for use. The process emphasizes efficiency and sustainability, leveraging a byproduct of coal combustion to create a valuable construction material.
Our product
FLY ASH BRICK
190 × 90 × 90 MM 7.48× 3.54 × 3.54 INCH
Physical Test Results of Bricks (As Per IS: 3495, Part - 1, & 2, RA-2019)
| Brick ID | Weight of Bricks (gm) | Load (KN) | Area (mm²) | Compressive Strength (N/mm²) | Brick Id | Water Absorption (%) |
|---|---|---|---|---|---|---|
|
1 |
2490 |
112 |
17100 |
6.55 |
A-1 |
20.08 |
|
2 |
2825 |
187 |
17100 |
10.94 |
B-1 |
12.03 |
|
3 |
2865 |
113 |
17100 |
6.61 |
C-1 |
16.23 |
|
4 |
2900 |
207 |
17100 |
12.11 |
D-1 |
14.83 |
|
5 |
2815 |
76 |
17100 |
4.44 |
E-1 |
11.90 |
|
– |
Average |
139 |
17100.00 |
8.13 |
– |
15.01 |
DETERMINATION OF EFFLORESCENCE OF BRICKS ACCORDING TO IS 3495 Part-3: 2019
| S.No. | Requirement's | Test Result | |
|---|---|---|---|
|
1 |
Nil |
When there is no Perceptible deposit of Efflorescence. |
20.08 |
|
2 |
Slight |
When Not More Than 10% of the exposed area of the Brick is covered with a thin deposit of salts. |
20.08 |
|
3 |
Moderate |
When there is a Heavier Deposit than under “Slight” & Covering up to 50% of the Exposed area of the Brick Surface But Unaccompanied by Powdering or Flaking of the Surface. |
20.08 |
|
4 |
Heavy |
When there is a Heavier Deposit Of Salts Covering 50% or More of the Exposed area of the brick surface but Unaccompanied by powdering of Flaking of the Surface. |
20.08 |
|
5 |
Serious |
When there is a heavy Deposit of Salts Accompained by Powdering & / or Flaking of the Exposed Surfaces. |
20.08 |
Dimension of Bricks according to IS 13757: 1993, RA-2021
| S.No. | Name of Test Conducted | Test Result's | Unit | Requirment for Modular Size Brick's | Requirment for Non - Modular Size Brick's |
|---|---|---|---|---|---|
|
1 |
Length |
3850 |
(mm) |
3720-3880 mm (3800±80mm) |
4520-4680 mm (4600±80mm) |
|
2 |
width |
1820 |
(mm) |
1760-1840 mm (1800±40mm) |
2240-2160 mm (2200±40mm) |
|
3 |
Height |
1830 |
(mm) |
For 90mm high 1760-1840 mm (1800±40mm) |
For 70mm high 1440- 1360 mm (1400±40mm) |
|
– |
(mm) |
For 40mm high 760-840 mm (800±40mm) |
For 30mm high 640-560 mm (600±40mm) |
