Perspective Study on Fly Ash -

Lime-Gypsum (FaL-G) Brick And Its

Optimum Ingredients Percentage

A New Trend in Brick

Manufacturing
 What is FaL-G Bricks ?
Fa for fly ash
L for lime
G for gypsum
FaL-G is a brick which is manufactured by
fly ash, lime, gypsum through hydration
reaction with water.
 Advantage
Utilization of industrial wastes (fly ash,
gypsum)
Environmental pollution reduction and
agricultural aspect
Replacing burnt clay bricks and thus fuel
saving and flue gas emission reduction
Cheap housing
 Fly Ash From Power Plant
52000 MT annually from Baropukuria
power plant
325000 MT annually from Rampal power
plant by 2018
Total 377000 MT annually fly ash
production by 2018
What use are they of?
 Gypsum
Gypsum is obtained in the de-sulfarization
unit from power plant.
Industrial By Product of Phosphoric acid
Plant
 Preparation of Fal-G Brick &
Experimental Procedure
Soaking of lime for 6 to 8 hours
Mixing of weighed fly ash soaked lime ,
gypsum and water in mixing machine
Compression of the semi solid mixture in the
mould by mechanical hand press
After two days the solid binder is separated
from mould
Dry curing for two days
Normal water curing and drying
Capping and compressibility test
 Table of Data
Sample No: Lime(%) Gypsum(%) Fly Ash(%)

M-1 10 5 85 4.446
M-2 10 10 80 5.351
M-3 10 15 75 6.255
M-4 10 20 70 6.798
M-5 10 23 67 6.978
M-6 10 25 65 6.617
M-7 10 30 60 6.788
M-8 10 35 55 6.436
M-9 10 40 50 6.074
M-10 10 45 45 5.573
M-11 4 20 76 3.904
M-12 6 20 74 4.573
M-13 8 20 72 6.275
M-14 10 20 70 6.798
M-15 12 20 68 6.800
M-16 14 20 66 6.381
M-17 16 20 64 6.106
Chemical Composition of Fly
Fly ash Ash
The main ingredient of FAL- G collected from Boropukuria Power Plant, fly ash
has the following composition : X-RF analysis
Constituents Percentage

SiO2 50.20

Al2O3 40.10

Fe2O3 3.32

CaO 1.29

MgO 0.20

SO3 0.45

P2O5 0.66

TiO2 2.38

Na2O 0.06

K2O 0.93

Loss on Ignition 2.3

Gypsum (Chemical composition) By X-RF
Constituents Percentage

SiO2 0.63

Al2O3 0.14

Fe2O3 0.38

CaO 32,80

MgO 2.18

SO3 45.72

P2O5 -

TiO2 -

Na2O -

K2O -

Loss on Ignition 1.16

 Lime (Chemical Composition) by X-RF
Constituents Percentage

SiO2 0.97

Al2O3 0.44

Fe2O3 0.29

CaO 95.23

MgO 1.07

SO3 0.63

P2O5 -

TiO2 -

Na2O -

K2O -

Loss on Ignition 1.87

Crystal water -
Lime Percentage Calculation
Dimension of a typical half size FaL-G
brick =5”×5”×3”
Total average weight of a typical half size
brick is =3 Kg
Fly Ash weight=0.7×3 Kg=2.1 Kg
(assuming Fly ash is 70% of total weight)
Let weight of lime = m Kg
Gypsum weight=3-2.1-m=0.9-m
Lime Percentage Calculation
(Continued)
Lime Percentage Calculation
(Continued)
Lime Percentage Calculation
(Continued)
Optimum Gypsum Percentage
Lime=10%,curing period =30 days
Optimum Gypsum Percentage 20-23%
 Optimum Lime Content
Gypsum=20,curing period=30 days
Optimum Lime Percentage=9-13%
Maximum Fly Ash Percentage
Lime: gypsum= 1:1
Maximum Fly Ash Percentage= not more
than70%
Impact of Curing Period on
Strength(Optimum %)
Thank You