Fly Ash Bricks PDF
Fly Ash Bricks PDF
Fly Ash Bricks PDF
Submitted by: -
BACHELOR OF ENGINEERING
In
Civil Engineering
CERTIFICATE
Date:
This is to certify that the dissertation entitled FLY ASH
BRICKS has been carried out by Pratik Solanki, Dipti Singh, Jigar
Sutariya, Kuldeep Thakur, Ravikumar Sukla
under my guidance in
Guide:
P. S. PAREKH
Applied Mechanics Department
SSEC, Bhavnagar
Head of Department
ACKNOWLEDGEMENT
We would like to express our deepest gratitude to our guide and motivator Prof.
P. S. PAREKH, Applied Mechanics Department, Shantilal Shah Engineering
College, Bhavnagar for her valuable guidance, sympathy and co-operation for
providing necessary facilities and sources during the entire period of this project.
We are very thankful to Mr. P. L. Jani and Mr. Bhaveshbhai Rathod for sparing
their precious time in sharing details about fly ash bricks and allowing fly ash
bricks plant visit which helped us a lot in completing our project.
SUBMITTERS
[1]
ABSTRACT
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 utilisation as main raw
material in the manufacture of bricks will not only create ample opportunities for
its proper and useful disposal but also help in environmental pollution control to a
greater extent in the surrounding areas of power plants.
Also 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.
The object of this project is to represent the information regarding Fly Ash bricks
and plant, properties and their uses in a most concise, compact and to the point
manner. And also in this project various laboratory experiments were carried out
on fly ash bricks samples. Some of them are Compressive strength study, water
absorption study etc.
[2]
TABLE OF CONTENTS
Acknowledgement
Abstract
Table of Contents
List of Tables
List of Figures
List of Abbreviations
1. Introduction
10
11
2.1. Introduction
12
13
14
15
17
18
19
21
24
25
25
[3]
25
25
25
3.1.5. Noise
26
26
26
27
27
30
34
35
37
38
40
[4]
LIST OF TABLES
Page No.
Table 1
Table 2
10
Table 3
16
Table 4
17
Table 5
27
Table 6
36
Table 7
38
Table 8
39
Table 9
41
[5]
LIST OF FIGURES
Fig. No.
Figure Description
Page No.
Fig. 1
Fig. 2
10
Fig. 3
12
Fig. 4
15
Fig. 5
19
Fig. 6
20
Fig. 7
31
Fig. 8
32
Fig. 9
35
[6]
CHAPTER 1
INTRODUCTION
Fly Ash: An Overview
Amount of Fly Ash Generated in India
Present Utilization of Fly Ash in India
[7]
1.1
Fly ash is the by-product of coal combustion collected by the mechanical or electrostatic
precipitator (ESP) before the flue gases reach the chimneys of thermal power stations in
very large volumes. All fly ash contain significant amounts of silicon dioxide (SiO2),
aluminium oxide (Al2O3), iron oxide (Fe2O3), calcium oxide (CaO), and magnesium
oxide (MgO) however, the actual composition varies from plant to plant depending on the
coal burned and the type of burner employed. Fly ash also contains trace elements such as
mercury, arsenic, antimony, chromium, selenium, lead, cadmium, nickel, and zinc.
These particles solidify as microscopic, glassy spheres (see fig.1) that are collected from
the power plants exhaust before they can fly away hence the products name: Fly
Ash. Chemically, fly ash is a pozzolan. When mixed with lime (calcium hydroxide),
pozzolans combine to form cementitious compounds.
The power requirement of the country is rapidly increasing with increase in growth of the
industrial sectors. India depends on Thermal power as its main source (around 65% of
power produced is thermal power), as a result the quantity of Ash produced shall also
increase. Indian coal on an average has 30% to 40% Ash and this is one of the prime
factors which shall lead to increased ash production and hence, Ash utilization problems
for the country.
Fly ash is one of the numerous substances that cause air, water and soil pollution, disrupt
ecological cycles and set off environmental hazards. Its also contains trace amounts of
toxic metals which may have negative effect on human health and on plants and the land
where the fly ash decomposed not gets reused.
[8]
The disposal of this waste material is a matter of great concern from the environmental
and ecological point of view. The safest and gainful utilisation of this material has been
one of the topics of research over the last few decades.
The advantages of fly ash utilisation are:
The options of ash utilization including the ash based products are at development stage
and need to be made more environments friendly by bringing ash revolution.
1.2
The principle source of energy in India is the coal and it will remain the major source of
thermal power for the next few decades. Nearly 65% power in India is generated through
thermal power plants (TPP). The high ash content of Indian coals (30% to 40%) is
contributing high volumes of fly ash. It is estimated at present nearly 160 million ton fly
ash is produced every year.
The fly ash generation is increasing in such a proportion that it will not be possible for the
cement industry alone to utilize the same. New avenues of gainful utilization of fly ash
have to be found and promoted. The generation of fly ash in different five year plans is
given in Table 1.
Coal
(million
Fly ash
(million
Plan
Period
Terminal
Year
Power
Generation,
MW
8th Plan
1996 - 97
50,000
210
80
9th Plan
2001 - 02
87, 000
285
110
10th Plan
2006 - 07
1, 16, 400
400
140
11th Plan
2011-12
1, 38, 3000
500
175
tons)
tons)
[9]
1.3
The present utilization of fly ash in various sectors is shown in table 2. Nearly 80
million tons of fly ash is reported being utilized out of 160 million tons generated during
2009 by Ministry of Science and Technology. Though percentage utilization has gone to
nearly 50% but in absolute terms, very large quantity of fly ash still remains unutilized.
Sector
In production of Portland Pozzolana
Cement
Cement Replacement at Concrete
batching Plants (RMC)
Filling in low lying areas
Roads and Embankments
Dyke Raising
Brick Manufacturing
Agriculture Sector
Other miscellaneous uses.
Total
MnT
% of utilization
32
40
08
10
14
12
4
3
3
4
80
18
17
5
2.5
2.5
5
100
Table 2 Present Utilization of Fly ash(source - Fly ash utilization Unit DST Govt. of India )
[10]
CHAPTER 2
FLY ASH BRICK
Introduction
Requirements Of Fly Ash Lime Bricks As Per IS 12894 : 2002
Clay Fly Ash Bricks
Fly Ash Lime Bricks
Fal-G Technology
Manufacturing Process
Advantages of Fly Ash Bricks
[11]
2.1
INTRODUCTION:
Production of burnt clay bricks requires consumption of coal leading to green house gas
emissions. The primary raw material used for bricks is the soil, which is often taken from
prime agricultural land, causing land degradation as well as economic loss due to
diversion of agricultural land. Use of traditional technologies in firing the bricks results in
significant local air pollution. The burnt clay brick industry in India produces over 180
billion clay bricks annually with a strong impact on soil erosion and unprocessed
emissions. At the same time, the thermal power plants in India continue to produce a huge
amount of fly ash, disposal of which poses significant challenges for the power plants.
Production of building materials, particularly bricks using fly ash is considered to be one
of the solutions to the ever-increasing fly ash disposal problem in the country. Although
there exist several technologies for producing fly ash bricks, the one that is gaining
popularity is the FaL-G technology.
The FaL-G technology works with the strength of fly ash, lime and gypsum chemistry.
The slow chemistry of fly ash and lime is manoeuvred by tapping ettringite phase to its
threshold limits through sufficient input of gypsum. Therefore, FaL-G does not require
heavy duty-press or autoclave, which is otherwise required in case of only fly ash and
lime. The FaL-G process completely eliminates the thermal treatment (except open air
drying) and does not require combustion of any fossil fuel.
[12]
The ingredients of the FaL-G bricks and blocks, fly ash, lime, and gypsum, are wellknown minerals that are widely used in industries. All these materials are available in
form of wastes and bi-products from industrial activities and are available in adequate
quantities in the areas, where the project activities are located. In certain cases, where byproduct lime is not available in adequate quantity, ordinary Portland cement (OPC) is
used as the source of lime, producing the same quality of bricks and blocks. The
technology is proved to be environmentally safe and sound.
Fly ash- lime-gypsum (FAL-G) is not a brand name but it is duct name, christened to the
mix for easy identification of its ingredients.
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 utilisation as main raw material in the manufacture of bricks will
not only create ample opportunities for its proper and useful disposal but also help in
environmental pollution control to a greater extent in the surrounding areas of power
plants. In view of superior quality and eco-friendly nature, and government support the
demand for Fly Ash Bricks has picked up.
Also 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.
Bricks made of fly ash can be broadly classified into following groups
Clay Fly ash bricks
Fly ash lime bricks
Mud Fly ash bricks
composition. Further more, the residual carbon content in fly ashes bring about an
economy in fuel consumption during firing of bricks.
In the process of bricks manufacturing from fly ash, about 25 to 80 % of clay can be
replaced by fly ash and the bricks are produced by conventional or mechanised processes.
The green bricks after drying in open air or drying shed are fired in conventional or high
draught kiln to obtain finished red clay fly ash bricks. The bricks thus produced are
lighter as the bulk density of fly ash is about one half of the clay.
Logistic problem of getting fly ash at the brick kiln or getting land near power stations to
make bricks there have prevented large scale commercialisation of technology.
[14]
2.2
[15]
Length (L)
mm
190
190
Width (W)
mm
90
90
Height (H)
mm
90
40
The following non-modular sizes of the bricks may also be used (see Fig.3A and Fig.
3B):
Length (L)
mm
230
Width (W)
mm
110
Height (H)
mm
70
230
110
30
For obtaining proper bond arrangement and modular dimensions for the brickwork, with
the non-modular sizes, the following sizes of the bricks may also be used:
Length (L)
mm
70
Width (W)
mm
110
Height (H)
mm
70 1/3 length brick
230
50
Tolerances
The dimensions of bricks when tested in accordance with 5.1.1 shall be within the
following limits per 20 bricks:
2.2.3 CLASSIFICATION:
The fly ash-lime bricks shall be classified on the basis of average wet compressive
strength as given in Table-3.
Average Wet Compressive Strength not less than
Class Designation
N/mm2
30
25
20
17.5
15
12.5
10
7.5
5
3.5
30
25
20
17.5
15
12.5
10
7.5
5
3.5
kg f/cm2
( Approx )
300
250
200
175
150
125
100
75
50
35
2.3
FaL-G TECHNOLOGY:
Fly ash- lime-gypsum (FaL-G) is not a brand name but it is duct name, christened to the
mix for easy identification of its ingredients.
[17]
FaL-G technology is based on the principles namely, that fly ash lime pozzolanic reaction
does not need external heat under tropical temperature condition, and strength of fly ashlime mixtures can be greatly augmented in the presence of gypsum.
FaL-G technology was developed by institute of solid waste research and ecological
balance, Vishakhapatnam. Fly ash lime mix in different proportions, is mixed in predetermined proportions with calcined gypsum which produces FaL-G having strong
binding properties and can be used as cement. It can be mixed with sand and/or aggregate
to produce building blocks of any desired strength.
2.4
RAW MATERIALS :
The raw material that is used for fly ash brick are:
FLY ASH :
Pulverized fuel ash commonly known as fly ash shall conform to Grade 1 or Grade 2
of IS 3812.
The proportion of the Fly ash is generally in the ratio 60-80%, depending upon the
quality of raw materials.
SAND/STONE DUST :
Deleterious materials, such as clay and silt in sand, shall preferably be less than 5
percent. About 10 to 20% may used.
Bottom ash used as replacement of sand shall not have more than 12 percent loss on
ignition when tested according to IS 1727.
LIME :
Quick Lime or hydrated lime or both can be mixed in the composition. Lime should
have minimum 40% CaO content.
GYPSUM :
Hydrated calcium sulphates are called gypsum. (CaSO42H2O). Gypsum should have
minimum 35% purity and 5 to 15% may be used.
[18]
2.5
MANUFACTURING PROCESS:
Fly ash, lime, sand and gypsum are manually fed into a pan mixer where water is added
in the required proportion for intimate mixing.
The proportion of the raw material is generally in the ratio 60-80% of fly ash 10-20%
lime, 10% Gypsum and 10% sand, depending upon the quality of raw materials.
The materials are mixed in pan mixture. After mixing, the mixture is conveyed through
belt conveyor to the hydraulic/mechanical presses. The homogenised mortar taken out of
roller mixer is put into the mould boxes. Depending on the type of machine, the product is
compacted under vibration / hydraulic compression etc.
The green bricks are dried up under sun from 24 to 48 hours, depending whether lime
route or cement route; the dried up bricks are stacked and subjected for water spray
curing once or twice a day, for 7-21 days, depending on ambience. The bricks are tested
and sorted before despatch.
[19]
[20]
2.6
[21]
these bricks are abundantly available closer to thermal power plants all over the
country for obvious reasons, finding dealers in all major cities and towns wouldnt be
a problem.
Applicability:
The blocks being available in several load bearing grades are suitable for use: Load bearing external walls, in low and medium size structures.
Non - load bearing internal walls in low and medium size structures.
Non - load bearing internal or external walls in high-rise buildings.
[23]
CHAPTER 3
FLY ASH BRICKS PLANT
(FaL-G UNIT)
Environmental Aspects and Potential Impacts
Comparison of FaL-G and Burnt Clay Brick Units
[24]
3.1
land or purchase the same through private negotiations. Therefore impact on local assets
is not considered to be a significant issue.
3.1.5 NOISE:
The noise level in units operated based on grid power is negligible. Both stationary and
mobile noise generating sources can adversely affect the ambient noise levels. Since the
noise from mobile sources shall be intermittent as well as transient, most of the potential
impacts shall be due to the continuous and stationary sources such as diesel generators &
engines, pumps, motors and other rotating equipment. As per the estimation, the resultant
noise level emitted from the operation of FaL-G unit is about 90-100 dB(A) which shall
be attenuated and mingled with ambient noise level within 200-300 m from the source.
[26]
Considerable numbers of presently operated units are taking adequate precaution during
transportation. However, some more precautions need to be taken during handling and
storage of raw materials in order to contain dispersion of fine dust in the atmosphere.
Though impacted area is very small as quantity involved is small and height of release is
almost ground level.
3.2
ISSUE
1. Air Emission
FAL-G UNIT
Source of Emission:
Source of Emission:
Transportation and
Handling of coal;
Combustion of coal;
Removal of bricks from
materials;
Operation of diesel engines
Transportation of bricks
kiln;
Removal and handling of
ash from kiln;
[27]
2. Loss of soil /
Transportation of bricks
Nil
Agriculture
land
3. Waste Water
Sources
Sources
Discharge
storm water
storm water
Management
Management
Septic tank
place
for
making
[28]
&
cost
effective
4. Heat Emission
Nil
5. Solid Waste
Negligible
Generation
[29]
CHAPTER 4
FLY ASH BRICKS PLANT VISIT
[30]
4.1
We have visited fly ash bricks plant which is located at Swaminarayan Temple (BAPS),
aksharvadi, Bhavnagar.
PLANT LOCATION:
Shri Swaminarayan Mandir, Aksharvadi is a good example of use of fly ash bricks in
Bhavnagar. We also visited the construction of hostel (Aksharpurshotam Chhatralay)
made for students beside the temple, where these bricks are being used.
On site, the engineer told the process of making the fly ash bricks. The material required
for making of fly ash bricks are used in this plant are fly ash taken from Nirma Chemical
Complex (Bhavnagar), Lime taken from Exel Crop. Ltd. (Bhavnagar), Gypsum purchased
from Baroda and Sand dust. The proportion of these raw materials is generally in the ratio
50-60% of fly ash 10-20% lime, 05-10% Gypsum and 15-20% sand, depending upon the
quality of raw materials are used in this plant.
In this plant, Fly ash bricks are made by mixing the ingredients (Fly ash + lime + gypsum
+ sand dust) in the appropriate proportion using mechanical mixer with the addition of
water. After mixing, the mixture is conveyed through belt conveyor to the mechanical
presses, in this paste has been moulded to shape of brick by applying 70-80 tons load over
the dye. The green bricks are dried up under sun from 24 hours and 7 days curing for
creating a good quality of fly ash bricks.
[31]
In this plant 8 to 10 workers work for one day produce around 6000 to 7000 bricks. The
bricks are environment friendly. And also it is cheaper than conventional clay bricks
comparatively.
PROPERTIES OF THIS BRICKS:
Size: 9 x 4 x 3 inch.
Colour: Reddish gray
Compressive strength of bricks is 55 to 100 kgf/cm2.
Water Absorption: 10 to 15 %
Light weight
This fly ash bricks are used in dome of Shri Swainarayan Temple, Aksharpurshotam
Hostel, Sabha Hall etc. Below pictures shows structure in which fly ash bricks are used.
[32]
Due to uniform size of bricks mortar required for joints & plaster reduces almost
by 50%.
Due to lower water penetration seepage of water through bricks is considerably
reduced.
The buildings using fly ash bricks are cool in summers and warm in winters. The
high insulating property, with low embodied energy, of our products reduces the
energy consumption of the buildings significantly by as much as 40-50%.
Fly ash bricks are sound absorbent and restrict sound transmission keeping the
interiors very pleasant and quiet.
Fly ash bricks resist salt and other sulphates attack, ensuring no efflorescence in
the structure.
We also have taken the bricks to conduct few experiments on it to justify the quality of
fly ash bricks. Experiments which we performed are visual analysis, measurement of
dimension, determination of water absorption and compressive strength of fly ash bricks.
In visual analysis and measurement of dimension we measured the length, depth and
height of given fly ash bricks as per clause 5.2.1, IS 12894:2002. Dimension of these FA
bricks are compared to normal bricks is more.
In water absorption test (as per IS 3495 (Part 2) : 1992) we compared the change in
weight of given FA bricks before and after soaking of brick in water for 24 hours.
In compressive strength test (as per IS 3495 (Part 1) : 1992) we determine compressive
strength of given FA bricks. Compressive strength of these bricks are around 55-60
kg/cm2 which is higher than normal clay bricks.
These experiment and result are described in chapter 5 - Testing of fly ash bricks.
[33]
CHAPTER 5
TESTING OF FLY ASH BRICKS
Measurement of Dimensions of Brick
Determination of Water Absorption
Determination of Compressive Strength
[34]
5.1
We have taken some bricks from fly ash bricks plant located at shri swaminarayan temple
to conduct few experiments on it to justify the quality of fly ash bricks. The experiments
and result are explained below:
Fig.9 Arrangement of bricks for measurement of (a) length, (b) width, and (c) height
[35]
The overall length of the assembled bricks shall be measured with a steel tape or other
suitable inextensible measure sufficiently long to measure the whole row at one stretch.
Measurement by repeated application of short rule or measure shall not be permitted.
If, for any reason it is found impracticable to measure bricks in one row, the sample may
be divided into rows of 10 bricks each which shall be measured separately to the nearest
millimetre. All these dimensions shall be added together.
Dimensions
Length, L
2370
237
Width, W
1150
115
Height, H
790
79
From the measurement done on 10 bricks, the total length, width and height obtained
were 2370 mm, 1150 mm and 790 mm.
By taking the mean for the dimensions of a single brick, a brick was 237 mm in length,
115 mm in width and 79 mm in height.
[36]
Sample
Weight
Weight
(dry) gm
gm
% of water
absorption
2679
3202
19.53
2666
3218
20.07
2675
3182
18.95
2683
3187
18.78
2672
3179
18.97
Average
19.26 %
i.
ii.
iii.
Prepare cement mortar (1:1) and fill the frog and all void in bed
faces with it.
iv.
Store the sample prepared in (iii) under damp jute bag for 3 days in
clean water.
v.
vi.
o Testing :i.
Place the specimen with flat faces horizontal and mortar filled
facing upwards between two plywood sheets and centre carefully
between plates of testing machine.
ii.
CALCULATION:
Compressive Strength ( N/mm2 ) =
[38]
OBSERVATION TABLE:
Sample
Width
(mm)
Height
(mm)
Avg.
Area of
bed
surface
(mm2)
Max
load at
failure
(KN)
Compressive
strength
(N/mm2)
230
100
78
23000
118
5.153
228
100
80
22800
104
4.582
228
100
76
22800
132
5.815
230
102
78
23000
127
5.546
230
100
80
23000
138
6.026
AVERAGE
5.425
( approx
54.25
kgf/cm2 )
From the result average compressive strength is 5.425 N/mm2 (approx 54.25 kg/cm2)
which is higher than normal clay bricks.
[39]
CHAPTER 6
CONCLUSION &
REFERENCES
[40]
6.1
CONCLUSION:
Fly ash utilization in the country has remained less than 30% during the past 5 years and
it might take several years to reach the final goal of cent percent utilization. It is estimated
at present nearly 160 million ton fly ash is produced every year, out of which hardly 4050 % is used in all possible applications.
To utilize such a huge quantity of ash, we have to take necessary actions from
government side and from nongovernment side for utilisation point of view.
Based on the results for the experiments done on Fly ash lime brick,
Compressive strength = 54.25 kg/cm2
% Water absorption = 19.26 %
The results shows the FaL-G bricks are more safe, economical and having higher strength
compare to conventional bricks. Comparison of Fly ash bricks and ordinary red clay
bricks are shown in below table.
Properties
Red Bricks
Remarks
Colour
Very
Uniform
Good Appearance
Density
Compressive
Strength
30 35 kg/cm2
55 100 kg/cm2
Higher Load
Bearing
Higher Load
Bearing
Water Absorption
15 25 %
10 14 %
High Tolerance
Up to 10 %
Less than 2 %
Thickness Vary on
the Both Sides of
Walls
Dimensional
Stability
Wastage During
Transit
Plastering
Less Dampness
Saving in Mortar
Up to 25 %
Saving in Cost Up
to 8 %
Saving in Plaster
Up to 15 %
Table 9. Comparison of Fly ash bricks and ordinary red clay bricks
[41]
Light weight
Economical
Environmental friendly
Thus, Fly ash brick is one of the best uses of fly ash. It may be concluded that the use of
fly ash in brick manufacturing industry is techno-economically viable, if utilized by
application of optimum technologies, which are available with commensurate levels of
automation and capacity generation. Fly ash brick manufacturing is a potential field of
application wherein large-scale utilisation of fly ash is possible.
From the previous chapters it can be understood that fly ash bricks are better alternative
to conventional burnt clay bricks in structural, functional and economic aspects. This
industry has the potential to consume at least 50% of the ash production in India. By use
of this aspect we can convert waste into wealth.
After looking into all the facets of fly ash brick industry and its different applications in
the previous chapters, in the end it is a request to all the government and nongovernment
organizations involved in generation, research and development and utilisation of fly ash,
to extend all possible help in terms of technology, resources or finance to the
entrepreneurs who are trying to come forward to set their plants in spite of tough
competition and numerous set back in marketing. If this much could be done, it will prove
to be a big stepping stone towards the present need of sustainable development.
[42]
6.2
1. IS 12894 : 2002
2. IS 3812
( Part 1) : 2003
( Part 2) : 2003
Concrete
3. IS 456 : 2000
4. IS 3495
(Part 1) : 1992
(Part 2) : 1992
(Part 3) : 1992
Determination of Effloration
[43]
6.3
REFERENCES:
WEB-SITES REFERENCE:
1. http://www.flyashbricksinfo.com
2. http://en.wikipedia.org/wiki/flyashbricks
3. http://www.flyash.info
4. http://www.fal-g.com/technology
[44]