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TECHNO-ECONOMICAL STUDY OF FAL -G BRICKS A CASE STUDY

Conference Paper · January 2010

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 National conference on Fly ash/Futuristic Materials in Civil Engineering Construction For
Sustainable Development. 2010

TECHNO-ECONOMICAL STUDY OF FAL -G BRICKS

A CASE STUDY

ABSTRACT:
Fly Ash-Lime-Gypsum bricks are well known as FAL-G Bricks. FAL-G bricks are slowly but
surely replacing conventional clay bricks for wall constructions. It is green and environment
friendly material. For achievement of real sustainable development, FAL-G bricks are the real
need. As per one statistics, 10% switchover to fly ash bricks will use 30 million tonnes of fly ash
every year, save environment and coal and yield a benefit of 300 crores by way of reduction in
brick cost production. In the present study, 19 different mixes of FAL-G bricks are tested for
parameters like: crushing strength, weight, density, water absorption and cost. The experimental
analysis suggests 3 different mixes of proportions of ingredients for FAL-G bricks to achieve
two ever conflicting targets: cost and quality.

Keywords: FAL-G Bricks, clay bricks, fly ash.

Introduction:
Looking to the environmental impact of clay bricks, it is high time that construction industry
shifts towards brick production which uses ingredients with no adverse effect on environment.
180 billion tones of clay brick production per year consumes 540 million tones of clay, makes
65000 acres of land barren, and consumes 30 million tones of coal equivalent, generates26
million tones of Carbon Dioxide. A 10% switchover to fly ash bricks will use 30 million tones of
fly ash every year, save environment and coal and yield a benefit of 300 crores by way of
reduction in brick cost production. Except for Fly ash-clay fired bricks, fly ash bricks do not
require clay and serve the dual purpose of conserving top soil and the constructive utilization of
fly ash. Technologies are also on verge of entering the markets for manufacture of cementing
material as well as fly ash bricks with fly ash content as high as 90%.Orissa Government in India
has banned the use of soil for the manufacture of bricks up to 20 km. of a thermal power station.

Rajiv Bhatt Dr. F S Umrigar Indrajit Patel Jayesh Pitroda

10/1 Civil Engg Dept Principal Applied Mechanics Dept Civil Engg Dept
A.D.I. T. B V M Engg. College B & B Institute of Technology B V M Engg. College
New V V Nagar V V Nagar V V Nagar V V Nagar
 National conference on Fly ash/Futuristic Materials in Civil Engineering Construction For
Sustainable Development. 2010

Fly ash made bricks uses all ingredients which are having minimum negative environmental
impact. Hence, Fly ash bricks are the materials for achievement of real sustainable development.
FAL-G bricks can be considered as bricks for the next generation. Indian construction industry is
growing at the rate of 9.2% against the world’s growth rate of 5.5%. Hence, India needs to shift
towards FAL-G bricks then using clay bricks for wall constructions.
FAL-G bricks are advantageous over conventional clay bricks as per following aspects: Less
water absorption, less weight, better finishing, high strength, less mortar consumption for joints
filling, less number of bricks requirement, reduced wastage. Looking to these advantages, more
and more stakeholders from construction industry are getting attracted towards using FAL-G
bricks instead of clay bricks. But, it requires proper use of mix of various available ingredients so
that quality is achieved along with minimum investment. Nataatmadja Andreas carried out
experimental investigations for FAL-G bricks in Australia and found that combination of 70/30
for fly ash/common sand with 15% liquid sodium silicate and 5% lime would produce best
performing brick in terms of strength, mould ability and water absorption.
In the present study, an attempt has been made to carry out techno-economical study of FAL-G
bricks. The study was carried out on the fly ash production plant of Charutar Vidya Mandal,
Vallabh-Vidyanagar. Charutar Vidya Mandal is biggest educational trust in Gujarat and uses
FAL-G bricks for all building constructions. The study has given findings in the form of different
mixes for FAL-G brick production for the central region of Gujarat.
Experimental work
To carry out techno-economical study of FAL-G bricks main ingredients are: Fly ash, Gypsum,
Lime, Stone dust and sand. In addition to these major materials, other less utilized ingredients
like: cement (from major plant and mini plant), blasting sand which is available from steel
industries as waste material. Table 1 gives information about source of various raw materials for
experimental work.

Rajiv Bhatt Dr. F S Umrigar Indrajit Patel Jayesh Pitroda

10/2 Civil Engg Dept Principal Applied Mechanics Dept Civil Engg Dept
A.D.I. T. B V M Engg. College B & B Institute of Technology B V M Engg. College
New V V Nagar V V Nagar V V Nagar V V Nagar
 National conference on Fly ash/Futuristic Materials in Civil Engineering Construction For
Sustainable Development. 2010

Table 1: Source of raw materials for FAL-G Bricks

Sr. No. Ingredients Source

1 Fly Ash NOVA, Ahmedabad

2 Sand Umeta (Near Vadodara)

3 Stone Dust Sevaliya (Near Dakor)

4 Sludge Lime Kosamba & Ankleshwar

5 Gypsum GIDC, Vadodara

6 Cement - Hathi OPC 53 Manufacturing Plant - Hathi

7 Cement - Vikrant OPC 53 Manufacturing Plant – Vikrant

8 Cement - Samrat OPC 53 Manufacturing Plant – Samrat

9 Blasting Sand Vitthal Udyognagar, Vallabh-

Vidyanagar

All above materials were prepared in different proportions to create different mixes. The detail of
above 19 different mixes is given below in Table 2.

Rajiv Bhatt Dr. F S Umrigar Indrajit Patel Jayesh Pitroda

10/3 Civil Engg Dept Principal Applied Mechanics Dept Civil Engg Dept
A.D.I. T. B V M Engg. College B & B Institute of Technology B V M Engg. College
New V V Nagar V V Nagar V V Nagar V V Nagar
 National conference on Fly ash/Futuristic Materials in Civil Engineering Construction For
Sustainable Development. 2010

Table 2: Proportions of Ingredients of Different Samples for FAL-G Bricks

No. of
Hopper Pond Stone Sludge Blasting Total
Sample Bricks Gypsum Cement
fly ash fly ash Sand dust lime Sand percentage
Tested
A 10 - 35.00% 10.00% 40.00% 12.00% 3.00% - - 100%
B 10 18.00% 18.00% 22.00% 26.00% 12.00% 4.00% - - 100%
C 10 24.00% 14.00% - 40.00% 20.00% 2.00% - - 100%
HATHI
D 10 40.00% - 28.00% 23.00% - - OPC-53 - 100%
9.0 %
HATHI
E 10 46.50% - 26.50% 22.50% - - OPC-53 - 100%
4.5 %
F 10 35.00% - - 50.00% 10.00% 5.00% - - 100%
G 10 50.00% - - 35.00% 10.00% 5.00% - - 100%
H 10 42.50% - - 42.50% 8.00% 7.00% - - 100%
SAMRAT
I 10 60.00% - 18.50% 18.50% - - OPC-53 - 100%
3.0%
SAMRAT
J 10 60.00% - 18.00% 18.00% - - OPC-53 - 100%
4.0%
SAMRAT
K 10 60.00% - 17.50% 17.50% - - OPC-53 - 100%
5.0%
VIKRANT
L 10 60.00% - 18.50% 18.50% - - OPC-53 - 100%
3.0%
VIKRNT
M 10 60.00% - 18.00% 18.00% - - OPC-53 - 100%
4.0%
VIKRNT
N 10 60.00% - 17.50% 17.50% - - OPC-53 - 100%
5.0%
O 10 60.00% - 15.00% 10.00% 10.00% 5.00% - - 100%
P 10 60.00% - 20.00% - 10.00% - - 10.00% 100%
Q 10 50.00% - 20.00% - 10.00% - - 20.00% 100%
R 10 40.00% - 20.00% - 10.00% - - 30.00% 100%
S 10 50.00% - - - 10.00% - - 40.00% 100%
Test results
Above 19 different brick samples were used to find the important properties like crushing
strength, water absorption, weight and density. To make the study from economy point of view
cost of each mix was also worked out from the present market rates and with the plant
manufacturing expenditure. The results for these properties are given in Table 3.

Rajiv Bhatt Dr. F S Umrigar Indrajit Patel Jayesh Pitroda

10/4 Civil Engg Dept Principal Applied Mechanics Dept Civil Engg Dept
A.D.I. T. B V M Engg. College B & B Institute of Technology B V M Engg. College
New V V Nagar V V Nagar V V Nagar V V Nagar
 National conference on Fly ash/Futuristic Materials in Civil Engineering Construction For
Sustainable Development. 2010

Table 3: Test results for different mixes of FAL-G Brick

AVERAGE
WT.BEFORE AVERAGE
% WATER CRUSHING COST/
SAMPLE ABSORPTION OF DENSITY
ABSORPTION STRENGTH KG / M3 NO
WATER IN KG.
N/MM2
A 2.911 9.061% 2.122 1723.03 1.74

B 2.959 10.654% 4.022 1753.48 1.76

C 2.888 6.823% 10.824 1711.40 1.93

D 3.240 5.589% 8.667 1788.81 2.64

E 3.298 5.871% 5.284 1820.84 2.12

F 2.868 8.980% 9.240 1699.55 1.70

G 2.967 9.268% 6.420 1758.22 1.77

H 3.116 9.003% 8.336 1846.51 1.76

I 2.907 10.667% 3.830 1604.96 1.79

J 3.003 9.461% 3.900 1820.00 1.91

K 2.914 9.133% 3.768 1608.83 1.97

L 2.859 10.136% 2.313 1578.46 1.67

M 2.967 9.188% 2.767 1563.63 1.90

N 3.089 8.241% 3.778 1705.45 2.04

O 2.797 12.920% 7.830 1695.15 1.74

P 2.872 10.280% 6.730 1740.60 2.83

Q 2.931 10.300% 7.770 1776.36 3.97

R 3.196 7.870% 7.390 1936.96 5.44

S 2.752 10.590% 6.590 1667.87 3.84

Discussion
From above study of 19 different mixes, following are some observations:
1. While using SAMRAT OPC – 53 grade as 3%, 4% & 5% and fly ash keeping constant as
60% water absorption decreases, compressive strength & cost of bricks increases along

Rajiv Bhatt Dr. F S Umrigar Indrajit Patel Jayesh Pitroda

10/5 Civil Engg Dept Principal Applied Mechanics Dept Civil Engg Dept
A.D.I. T. B V M Engg. College B & B Institute of Technology B V M Engg. College
New V V Nagar V V Nagar V V Nagar V V Nagar
 National conference on Fly ash/Futuristic Materials in Civil Engineering Construction For
Sustainable Development. 2010

with average density. A same phenomenon happens while using VIKRANT OPC- 53
grade as 3%, 4% & 5%. (Reference samples are I, J, K and L, M, N)
2. When pond fly ash decreases from 35% to 18% & 14% and lime is increased from 12% to
20%, then compressive strength increases as well as the cost. (Reference samples are A, B,
C)
3. When HATHI opc-53 grade cement is reduced from 9% to 4.5% and fly ash is increased
from 40 % to 46.5%, while sand and quarry dust is kept constant. Here water absorption
increases, average crushing strength decreases and the cost of bricks decreases. Density of
the bricks increases. (Reference samples are D & E)
4. When fly ash is reduced from 60% to 50% & 40% and blasting sand is increased
respectively from 10% to 20% and then 30%, other ingredients like sand and lime are kept
constant. In this case weight of the brick increases, % water absorption decreases, crushing
strength increases, along with cost and average density also increases. (Reference samples
are P, Q, R)
5. When fly ash is increased from 35% to 42.5% and then 50%, correspondingly quarry dust
is decreased from 50% to 42.5% & then to 35% with keeping other ingredient lime &
gypsum as constant. In this situation % water absorption increases, average crushing
strength decreases, cost of bricks increases. (Reference samples are F, H, G)
Following chart shows combined results
PERCENTAGE of all 24ABSORPTION
WATER samples for different properties.
Chart WT.
1: 19BEFORE
Mixes Of Fal-G Bricks: Properties
ABSORPTION OF WATER Comparisons
IN KG.
AVERAGE CRUSHING STRESS N/MM
COST PER NO.
PERCENTAGE WATER ABSORPTION
WT. BEFORE ABSORPTION OF WATER IN KG.
AVERAGE CRUSHING STRESS N/MM 2
COST PER NO.
14

12
14
10
12
8
10
6
8 Rajiv Bhatt Dr. F S Umrigar Indrajit Patel Jayesh Pitroda
10/6 Civil Engg Dept Principal Applied Mechanics Dept Civil Engg Dept
4 6 A.D.I. T. B V M Engg. College B & B Institute of Technology B V M Engg. College
New V V Nagar V V Nagar V V Nagar V V Nagar
2 4

0 2
A B C D E F G H I J K L M N O P Q R S
 National conference on Fly ash/Futuristic Materials in Civil Engineering Construction For
Sustainable Development. 2010

Conclusion and recommendations

The present study was done for finding most economical as well as technically feasible
mix for production of FAL-G Bricks in the central region of Gujarat. From the results and cost
analysis following mixes are suggested as the most feasible one:
Sample- 1 (F)
Fly Ash - 35%
Quarry Dust - 50%
Sludge Lime - 10%
Gypsum - 5%
Sample- 2 (O)
Fly Ash - 60%
Quarry Dust - 10%
Umeta Sand - 15%
Sludge Lime - 10%
Gypsum - 5%
Sample- 3 (G)
Fly Ash - 50%
Quarry Dust - 35%
Sludge Lime - 10%
Gypsum - 5%

Acknowledgment
Authors are highly grateful to the authorities of Charutar Vidya Mandal, Vallabh-
Vidyanagar for giving the permission for the necessary experimental work in their Fly Ash Brick
production plant.

References
1. Patel I N, Bhatt R B, (2008) “Experimental work of brick making from different industrial
wastes”, International Conference on Sustainable Concrete Construction, February 2008,
pp. 14-18.
2. Patel I N, Bhatt Rajiv and Bhatt Darshana,(2008) “Fly ash: A Green construction material
and use of FAL-G Bricks in institution structures – A Case Study”, Journal of Engineering
and Technology S P University, December 2008, Vol 19, pp. 23-34.

Rajiv Bhatt Dr. F S Umrigar Indrajit Patel Jayesh Pitroda

10/7 Civil Engg Dept Principal Applied Mechanics Dept Civil Engg Dept
A.D.I. T. B V M Engg. College B & B Institute of Technology B V M Engg. College
New V V Nagar V V Nagar V V Nagar V V Nagar
 National conference on Fly ash/Futuristic Materials in Civil Engineering Construction For
Sustainable Development. 2010

3. www.greenbusinesscentre.com
4. Tarsfun Cicek, Mehmet Tanriverdi (2007). “Lime based autoclaved Fly Ash Bricks”,
Construction & Building Material, 21, pp. 1295-1300.
5. Malaviya S K, Chatterjee B and Singh K K (1999), “Fly Ash- an emerging alternative
building material”, proceedings of National Seminar, February 26-27 1999, pp. 59.
6. www.tifac.org.in/do/fly/proj/brick.html
7. Rai M (1992), “Flyash sand lime bricks in India”, Technical Report, 4th CANMET / ACI
International Conference on pozolans, Central Building Research Institute , Roorkee,
India.
8. Nataatmadja Andreas (2010). “Development of low-cost fly ash bricks”,
http://www.docstoc.com/docs/23116529/Development-of-low-cost-fly-ash-bricks.
9. Http://www.wealthywaste.com/fly-ash-utilization-in-india

Rajiv Bhatt Dr. F S Umrigar Indrajit Patel Jayesh Pitroda

10/8 Civil Engg Dept Principal Applied Mechanics Dept Civil Engg Dept
A.D.I. T. B V M Engg. College B & B Institute of Technology B V M Engg. College
New V V Nagar V V Nagar V V Nagar V V Nagar

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