FLYASH BRICK MAKING TECHNOLOGYA TECHNICAL DISCUSSION

TECHNOLOGY OVERVIEW
The FaL-G technology works with the strength of fly ash, lime and gypsum chemistry. The slow chemistry
of fly ash and lime is maneuvered by tapping ettringite phase to its threshold limits through sufficient
input of gypsum.

Therefore, FaL-G does not require heavy duty-press or even autoclave (high pressure or normal pressure
steam curing), which are 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.

The ingredients of the FaL-G bricks and blocks, fly ash, lime, and gypsum, are well-known 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 by-product 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.

PROCESS & TECHNOLOGY SELECTION

This choice is mostly with the entrepreneur. But now a day, we feel that mostly 2 factors decide the
selection choice.
1. PROCESS SELECTION --- LIME ROUTE OR OPC (CEMENT) ROUTE
2. TECHNOLOGY SELECTION PRESSURE METHODE OR VIBRATION METHODE

1. PROCESS SELECTION- THE MAJOR PART HERE IS THE SELECTION OF

BINDING MATERIAL- LIME OR CEMENT ROUTE?
Many people think that FAL-G bricks means FlyAsh+Lime+Gypsum. Actually OPC cement consists of
Lime+Gypsum and lime is activated. So OPC cement can give a very good strength, and can replace lime
and gypsum completely. Many a people are not aware of this fact.
Economics
Many people think that lime is cheaper. So the lime formula may give the lower cost of production.
The fact is that; Hydrated lime may be cheaper than OPC cement by about 25%. But the hard fact is that
the quantity requirement of hydrated lime is 100% more than that of OPC cement. As OPC and Lime are
Article written by Project consultant N.Gangadhar Reddy.
He is available at info@indiablockmachine.com , Mobile/whatsapp - +91-8763966666

FLYASH BRICK MAKING TECHNOLOGYA TECHNICAL DISCUSSION

replacement of each other (as a binding material), Lime route binding material price might be around.
50% higher than OPC route binding material Price
The following table also explains the advantages of OPC cement route vs Lime route
Sl no
1
2

PARAMETERS
Cost of binding
material
Ease of purchase
of binding
material
Quality aspects
which affects
consistency of
blocks strength

Lime as binding material

Cement as binding material

Likely to be costlier

Likely to be cheaper

Lime needs to be ordered in bulk

(25 tons at least), as retail market
do not exist

Cement can be purchased as and

when we need. There is a wide
retail network
Cement comes under mandatory
category of ISI certification. Means,
all the cement which comes to
market must be batch tested and
approved. So this ensures a steady
quality

Lime from different supplier vary

widely in quality.
Even Lime from same supplier vary
widely from time to time

Lime uses used cement bags to

pack. Sometimes very high quality
lime uses jumbo bags to pack
4

Packing of
material

generally, lime ages fast. Used bags

force it to age faster.
Thus lime loses quality at a faster
rate than cement
Lime swells as it comes in contact
with moisture. It also swells as it
ages. In lime there is a tendency
tear opening the bags in which
they are kept.

Storage easiness

Usage easiness

Lime also is difficult store in rooms.

The lime bags stacked near to walls
push to walls of the store and crack
them. The cracks then allow more
air and it leads to faster cracks
generation
Lime needs to be hydrated before
using. The process involves putting
lime in water tanks from 8 to 36
hours (depending on activeness of
lime ) . it needs additional
manpower and also big storage
tanks.

Cement uses standardized and

approved packing as per BIS
standards. So the moisture
contamination is relatively less.
Cement can offer better self-life
than lime

Cement can be conveniently stored

in any room. Cement do not swell.
Thus it does not harm the storage
room or its walls

Cement is very convenient to use.

It can be obtained in bag form and
used.
Or else it can be obtained in bulk
form by bulker and kept in storage

Article written by Project consultant N.Gangadhar Reddy.

He is available at info@indiablockmachine.com , Mobile/whatsapp - +91-8763966666

FLYASH BRICK MAKING TECHNOLOGYA TECHNICAL DISCUSSION

Lime sludge can be directly used,
but lime sludge is difficult to
transport and needs big storage
tanks

silos and be used vide screw

conveyers.

Cement is easy to batch process.

Hydrated lime or lime sludge
cannot be used in an automated
batching plant.

Feeding option

So, it is difficult to know the exact

water lime ratio in the mix which
confuses how much weight or how
much volume to be added.
For both the above cases, manual
labor is a must to fetch lime from
the tanks and load it on to mixtures

Generally, lime mix needs to be

dough like. Also lime lumps need to
be crushed. Thus a Roller pan
mixture is very essential.

Mixture types

Roller pan mixture is heavier, uses

more power, takes more time to
mix, and have a higher wear and
tear rate.
Generally, no hardened liner plates
are provided. So the total mixture
shell needs quick replacement

Initial Setting
time

Lime takes higher initial setting

time. So it may sometimes require
48 hours for initial setting

In case of bag cement, we know

that it is 50 kgs. So batching can
beset accordingly and fine-tuned
quality can be achieved.
Bag to hopper-screw system can
also be used for precise weighing in
batching plants
In case of bulk cement, we can
precisely weight the cement in a
batching plant
Pedal pan mixture or twin shaft
mixtures can be used.
Both the above mixtures use very
less power.
Both these is easier to maintain
and have a very low wear and tear.
When the big quantity mix is
required, twin shaft mixture can be
used.
Liner hardened plates are generally
provided to extend the life of
mixture machine
Cement, because of its active
ingredients, uses less initial setting
time. Typically, initial setting time
of cement is around 6 to 12 hours

The curing period for lime to

achieve 95% of its desired strength
is 28 days. This is too long a time.

10

Final setting time

(curing period)

Uses 4 times more water to cure

the bricks than cement route
This really affects the working
capital, as stock in progress is
28days.

Ideally the curing period of cement

is 7 days.
Uses 25% of water for curing in
comparison with lime route mix

Article written by Project consultant N.Gangadhar Reddy.

He is available at info@indiablockmachine.com , Mobile/whatsapp - +91-8763966666

FLYASH BRICK MAKING TECHNOLOGYA TECHNICAL DISCUSSION

11

Steam curing
requirement

12

Pressure &
vibration
technology

This is the reason many

entrepreneurs may need steam
curing system for Lime based bricks
Pressure technology can be used.
Vibration technology cannot be
used

Usage of 6 mm
and bellow stone
chips for corner
strength

Generally, in line route, as the mix

is sticky like a dough, so it is not
possible to use small stone chips,
as it will need vibration technology
to stabilize

14

Green Block
handling by hand

Possible- as the lime has higher

water content and forms a dough
like mix, bricks can be handled as
soon as they are formed

15

Scale of
production

13

16

Verdict

So generally, lime is used in a small

scale bricks plants having low brick
production ideally 2000 to 10000
bricks per day
Generally, you have to use lime if
1. You have the pressure only
technology
2. You have to use roller
mixture if you have lime
mix
3. You have manual handling
of green bricks
4. You have low initial
investment, then you can
go in for a small production
capacity
5. No availability of 2 mm to 6
mm stone chips, and you
have only finer materials
like fly ash and sand

Steam curing is not needed, though

some over enthusiast
entrepreneurs keep steam curing
or humanizers.
Both pressure and vibration
technology can be used
6mm stone chips can be used in
any percentage as there is no
stickiness in the blocks. So
vibration can move around the
micro particle to cover the void
spaces
Difficult- the cement uses less
water and also there is no dough
like mix. So handling raw formed
bricks by hand may be riskier. So
generally cement based bricks
need automatic stackers to handle
the bricks
Generally, Cement route is
preferred where the brick
production is very high from 10000
to 100000 bricks per day
Generally, you have to use Cement
if
1. You have a high scale of
production
2. You have automated
batching plant
3. You have to use 6 mm
aggregates for perfect
edges and good strength
4. If you need to reduce the
curing time and stock
under progress
5. You have to use less water
in manufacturing and
curing

Article written by Project consultant N.Gangadhar Reddy.

He is available at info@indiablockmachine.com , Mobile/whatsapp - +91-8763966666

FLYASH BRICK MAKING TECHNOLOGYA TECHNICAL DISCUSSION

2. TECHNOLOGY SELECTION PRESSURE METHODE OR VIBRATION METHODE
Sl no

PARAMETERS
Materials used

Mix requirement

PRESSURE TECHNOLOGY
Pressure technology cannot use
bigger raw materials used. It can
only use, fly ash, lime, gypsum and
sand
Mix needs to be like Dough, sticky
and mix must have more water
content

Mixture
requirement

Roller pan mixture is the best

Power
requirement

Initial power and the unit

consumption is higher because it
uses a heavy hydraulic press

Time of stroke

For the same number of bricks per

stroke, the time requirement is
higher as big piston takes time to
move

Type of blocks

Generally, only Fly ash based bricks

and sand-lime bricks can be
produced

Strength of blocks

Strength of blocks is limited to M12 grade, which is good for bricks

Technology levels

Generally easy to manufacture.

Simple technology. Technology is
old and simple.
Automation levels are simple

capacity

Generally, this is used for low

production. Less than 12 bricks per
stroke

Brick removal

Generally, cast bricks can be

handled and removed by hand

Labor
requirement

Average labor requirement is 2 to 3

labors per 1000 bricks

VIBRATION TECHNOLOGY
Vibration technology will need at
least 5 percent of stone chips, as
vibration rearranges particles
inside micro gaps
Mix need not be like dough, is
generally a dry mix.
Paddle pan mixture or twin shaft
mixtures can be used
For the same number of bricks
production per stroke, power
requirement is reduced by more
than 65% in this technology
For the same number of bricks per
stroke, the time requirement is
lesser as vibration time is same.
Generally flash bricks, concrete
solid blocks, concrete hollow
blocks, paver blocks and kerb
stones can be produced
Strength can go up to m-45 for
special class paver blocks with
micro fiber reinforcement
High end technology has come.
Vibrators have moved from fixed
frequency vibrators to variable
frequency (VFD) vibrators to
energy saving hydraulic vibrators. A
lot of automation have come in
This is generally used in high
production like more than from 2
to 50 blocks per stroke
Bricks cannot be removed by hand.
As the mix is dry mix and number
bricks is high, so a stacker is
recommended
Average labor requirement is 0.5 to
0.7 labors per 1000 bricks

Article written by Project consultant N.Gangadhar Reddy.

He is available at info@indiablockmachine.com , Mobile/whatsapp - +91-8763966666

FLYASH BRICK MAKING TECHNOLOGYA TECHNICAL DISCUSSION

Note on DONGYUE brick and block machines
1. Adopting GERMAN technology to use both PRESSURE AND VIBRATION so that machine flexibility
is enhanced.
2. Along with vibration and pressure, micro hammering effect can be utilized to further reduce time
and electricity.
3. Used PLC computer programmer to use pressure, vibration and micro hammering to get best
output qualitatively and quantitatively.
4. Because, both the pressure and vibrations is used, the machines can use both lime route and
cement route products, by controlling the pressure and vibration settings in the PLC screen
5. Also, this machines can take a mix of lime and cement, if so desired.
6. All types of bricks and blocks can be produced. Fly ash bricks, concrete bricks, concrete solid blocks
concrete hollow blocks, concrete cavity blocks, concrete paver blocks, kerb stones, plain faced
paver blocks.
7. If we take color mixture add on, an automated production of color paver blocks and color parking
blocks can be made.
8. Batching plant and loader combination is best in reducing manpower from an average 6 to 1.
9. Similarly, stacker and forklift combination replaces 6 labors with one forklift operator. Automated
PLC also saves a lot of manual procedures.

Article written by Project consultant N.Gangadhar Reddy.

He is available at info@indiablockmachine.com , Mobile/whatsapp - +91-8763966666