A

PROJECT REPORT
ON
“FLY ASH BRICKS”

SUBMITTED FOR THE REQUIREMENTS OF THE AWARD OF DIPLOMA IN CIVIL

ENGINEERING UNDER THE STATE COUNCIL FOR TECHNICAL
EDUCATION, ASSAM

DEPARTMENT OF CIVIL ENGINEERING

KARIMGANJ POLYTECHNIC, MAIZGRAM
ASSAM – 788712

SESSION: 2024

UNDER THE GUIDENCE OF:-

MR. ANSAR MAZUMDER

DEPARTMENT OF CIVIL ENGINEERING
AS SENIOR INSTRUCTOR
KARIMGANJ POLYTECHNIC, MAIZGRAM
 A
PROJECT REPORT
ON
“FLY ASH BRICKS”

SUBMITTED FOR THE REQUIREMENTS OF THE AWARD OF DIPLOMA IN CIVIL

ENGINEERING UNDER THE STATE COUNCIL FOR TECHNICAL
EDUCATION, ASSAM

DEPARTMENT OF CIVIL ENGINEERING

KARIMGANJ POLYTECHNIC, MAIZGRAM
ASSAM – 788712

SESSION: 2024

UNDER THE GUIDENCE OF :- SUBMITTED BY :-

MR ANSAR MAZUMDER SULAIMAN RAHMAN LASKAR KAR/21/CV/007

DIPLOMA
SENIOR INSTRUCTOR IN THE
DEPARTMENT OF CIVIL ENGINEERING
KARIMGANJ POLYTECHNIC, MAIZGRAM
SANDIP NATH KAR/21/CV/001
MAFUJ BARBHUIYA KAR/21/CV/012
JOYDEEP PAUL KAR/21/CV/011
ROHIT CHOUDHURY KAR/21/CV/004
ROHIT CHETRI KAR/21/CV/054
 TABLE OF CONTENT
1.INTRODUCTION
2.BACKGROUND AND SIGNIFICANCE
3.RAW MATERIALS
4.MANUFACTURING PROCESS
5.MACHINERY AND EQUIPMENT
6.QUALITY CONTROL
7.ENVIROMENTAL IMPACT
8.CONCLUSION
9.REFERENCES
 INTRODUCTION

 BRIEF INTRODUCTION FLY ASH BRICKS

Fly ash is a fine, glass-like powder recovered from gases
created by coal-fired electric power generation. Fly ash
materials is solidified while suspended in the exhaust gases
and is collected by electrostatic precipitators or filter bags.
Since the particles solidify while suspended in the exhaust
gases, fly ash particles are generally spherical in shape and
range in size from 0.5 µm to 100 µm. They consist mostly of
silicon dioxide (SiO2), aluminium oxide (Al2O3) and iron
dioxide (Fe203)

 IMPORTANCE IN THE CONSTRUCTION INDUSTRY

Fly ash bricks have gained significant importance in the
construction industry due to their numerous benefits over
traditional clay bricks. Here are several key reasons why fly
ash bricks are important in construction:
1. Environmental Benefits
 Utilization of Industrial Waste: Fly ash, a by-product of coal
combustion in thermal power plants, is utilized in the
production of fly ash bricks. This helps in reducing the
disposal problem of fly ash, which is a major environmental
concern.
 Reduction in Carbon Footprint: The production of fly ash
bricks requires less energy compared to traditional clay
bricks, thereby reducing carbon emissions. Additionally, it
 eliminates the need for soil excavation, preserving topsoil
and preventing land degradation.
Sustainable Building Material: Using fly ash bricks
contributes to sustainable construction practices by
promoting the recycling and reuse of industrial waste.
2. Economic Benefits
 Cost-Effective: Fly ash bricks are generally cheaper to
produce than traditional clay bricks. The use of industrial by
products reduces raw material costs, and the manufacturing
process is less energy-intensive.
 Government Incentives: Many governments offer incentives
and subsidies for the use of eco-friendly construction
materials, including fly ash bricks. This can further reduce
the overall cost of construction projects.
3. Superior Quality and Durability
 High Strength and Uniformity: Fly ash bricks have a high
compressive strength and uniform size and shape, which
ensures better quality control during construction and
results in stronger, more stable structures.
 Low Water Absorption: These bricks absorb less water
compared to clay bricks, which reduces the risk of
efflorescence and increases the longevity of the building.
 Thermal Insulation: Fly ash bricks provide good thermal
insulation, helping to maintain comfortable indoor
temperatures and reducing the need for heating and cooling,
thereby saving energy.
 4. Construction Efficiency
 Ease of Use: The uniform size and shape of fly ash bricks
make them easier to handle and lay, resulting in faster
construction times and reduced labour costs.
 Reduced Plastering Costs: The smooth surface of fly ash
bricks requires less plastering and finishing, which can
further reduce construction costs and time.
 Less Breakage: Due to their higher strength and durability,
fly ash bricks experience less breakage during transportation
and handling, leading to lower wastage and cost savings.
5. Compliance with Standards
 Adherence to Building Codes: Fly ash bricks meet various
building standards and codes, ensuring that constructions
using these bricks are compliant with regulatory
requirements.
 Quality Certification: Many fly ash brick manufacturers
obtain quality certifications, which can assure builders and
developers of the reliability and performance of the
material.
6. Environmental Regulations
 Compliance with Environmental Laws: The use of fly ash
bricks helps builders comply with environmental regulations
that restrict the use of traditional clay bricks due to their
impact on top-soil depletion and air pollution.
 BACKGROUND AND SIGNIFICANCE
 History Of Fly Ash Bricks
concerns and advancements in building technology. Here
is a detailed look at the history of fly ash bricks:

1. Early Developments
 Origins of Fly Ash Utilization:
Fly ash is a by-product of coal combustion in thermal power
plants. For many years, fly ash was considered waste and
posed significant disposal problems. Early attempts to utilize
fly ash date back to the mid-20th century, primarily focusing
on its use in concrete as a partial replacement for cement.

2. Emergence of Fly Ash Bricks

 Initial Research and Development:
In the 1950s and 1960s, researchers began exploring the use
of fly ash in the production of bricks. These early experiments
aimed to find a productive use for the growing amounts of fly
ash being generated.
 Initial methods involved mixing fly ash with clay to produce
bricks, but these early products were not widely adopted
due to technical challenges and lack of awareness.
 Technological Advances
The 1980s and 1990s saw significant advancements in the
technology and methods used to manufacture fly ash
bricks. Improved mixing and curing processes led to higher
quality and more durable bricks.
The introduction of hydraulic and mechanical presses
allowed for better compaction of the fly ash mixture,
resulting in stronger bricks.
3.Environmental and Economic Drivers
 Environmental Legislation:
Increased environmental awareness and regulations in the
late 20th century pushed industries to find sustainable
ways to manage industrial waste.
Governments in many countries began encouraging the
use of fly ash in construction to reduce the environmental
impact of clay brick manufacturing and to manage fly ash
waste effectively.
 Economic Considerations:
Rising costs of traditional building materials and the
economic benefits of using industrial waste as raw material
made fly ash bricks an attractive alternative.
Fly ash bricks were promoted for their cost-effectiveness,
reduced construction costs, and lower energy consumption
in production.
4. Adoption and Standardization
 Widespread Adoption:
By the early 2000s, fly ash bricks had gained significant
acceptance in the construction industry, particularly in
countries with large coal-fired power plants, such as India,
China, and the United States.
Builders and developers began to recognize the benefits of
fly ash bricks, including their strength, durability, and
environmental advantages.
 Standardization and Certification:
The adoption of fly ash bricks was supported by the
development of standards and certifications to ensure
quality and performance. Organizations like the Bureau of
Indian Standards (BIS) and the American Society for
Testing and Materials (ASTM) established guidelines for
the production and use of fly ash bricks.
5. Modern Developments
 Technological Innovations:
Recent years have seen further innovations in the
manufacturing process, including the use of automated
plants and improved curing techniques.
Research continues to enhance the properties of fly ash
bricks, making them more versatile and reliable for various
construction applications.
 Government Policies and Incentives:
Governments around the world have introduced policies
and incentives to promote the use of fly ash bricks. These
include tax benefits, subsidies, and mandatory usage in
certain types of construction projects.
In India, for example, the government mandates the use of
fly ash bricks within a certain radius of coal-fired power
plants to encourage their adoption.
6. Future Prospects
 Sustainable Construction:
As the construction industry moves towards more
sustainable practices, the use of fly ash bricks is expected to
grow. Their role in reducing carbon emissions and promoting
the recycling of industrial waste aligns with global
sustainability goals. Continued research and innovation are
likely to enhance the performance and applicability of fly ash
bricks, making them a staple in eco-friendly building
practices.
 RAW MATERIALS

 Fly Ash Bricks Composition

Here we provide information about fly ash bricks
composition. We describe a process with which material you
can manufacture fly ash bricks in less price. The fly ash bricks
are made with mainly three different mixing ratios. The price
of brick is mainly depending on which fly ash bricks mixing
ratio is used. The cost of fly ash bricks is depending on which
composition is used. But whatever fly ash bricks mixing ratio
is used and along with that, you have to maintain the quality
too. You can make quality bricks with using best mixing ratio
and raw materials as per market requirements. Business is
about how to increase profit by using the proper mixing ratio
to manufacture fly ash brick at a low cost. Here we explain
the 3 very trusted and proven mixing ratios to manufacture
fly ash bricks.
 Mix Proportion for Fly Ash Brick Manufacturing
 Fly Ash – 55 to 60%
 Sand or Stone dust – 20 to 25%
 Sludge Lime – 15 to 22%
 Gypsum – 5%
The material is used to manufacture a fly ash brick is depend
on raw material availability and requirement of bricks. It is
suggested to use Sludge Lime as it is less expensive than
Hydrated Lime. The above mixing ratio is more profitable
mixing ratio than below two. The Sludge lime is waste
material and costs less than hydrated lime. Sludge lime is
usually wet and has lumps and it is used to make quality fly
ash bricks.
 Mix Proportion for Fly Ash Brick Manufacturing
Here Hydrated lime is used instead of Sludge lime.
 Fly Ash – 57 to 65%
 River Sand or Stone dust – 18 to 27%
 Hydrated Lime – 9 to 12%
 Gypsum – 5%
This mixing ratio is widely used to make quality fly ash bricks.
As hydrated lime is easily available this fly ash brick
compositions are used by many fly ash brick manufacturers.
 Mix Proportion for Fly Ash Bricks Manufacturing With
Cement Instead Of Gypsum And Lime
 Fly Ash 50 – 60%
 River Sand or Stone Dust – 30 to 40%
 Cement – 8 to 12%
In this mixing ratio, the cement is used instead of gypsum
and lime. This ratio is not so used because it is costly and not
preferred by entrepreneurs. The price of cement is more
than gypsum and lime; thus, this mixing is used only when
gypsum and lime are not available.
 MANUFACTURING PROCESS
The Process of manufacture is simple and suitable to start. A
mix of Fly Ash, Cement, Gypsum and Sand/Crusher Dust are
automatically weigh batched in a batching plant.
1. Loading of Raw materials‐ Mini Loader Loads materials into
Batching plant
2. Automatic Batching – The Raw materials are automatically
weighed as per the present weights by means of Load cells
and its control circuit. Cement, if it is available in Bulk, then
silo and screw controller is used to auto weight. Otherwise,
the batching is programmed as per 1 bag of cement.
3. Mixing ‐ From the batching plant the mixture hopper pulls
the materials and then the mix is blended homogenously and
intimately in a semi wet form in a Twin shaft mixture. The
Water is automatically added as per time set. The TWIN
SHAFT mixture ensures that a perfect mix is done in shortest
possible time.
4. Carrying to Brick machine ‐ The mix is carried to the casting
machine by means of conveyer belt.
5. Automatic Brick Making‐ there is a series of operations
which is achieved by automatic PLC system. Pallet is pulled
into the Machine. The mix is then collected fed into the
machine moulds. There is a T boggy which uniformly spreads
the materials in the moulds. Automatic PLC controlled
Vibration and hydraulic pressure is given for a while and
bricks are cast on the pallets. The dual application of Pressure
and vibration (in a patent pending micro‐ sequence
application) ensures perfect compaction with best quality of
bricks
6. Automatic Stacking ‐ The pallets along with the freshly cast
bricks are rolled on a roller platform to the pallet stacker. The
Pallet stacker stacks the pallets along with the bricks
automatically and the
7. Fork lift shifting– The Final stack of 5 to 10 pallets and
bricks are lifted with a Fork Lifter and carried to the drying
bay/room for 24 Hours for initial setting.
8. Curing ‐ Soon after the initial setting, the Blocks/ Bricks are
stacked for curing in layers. The layers are stacked in a way to
enable water and air to go all around, to ensure proper
curing and drying. The curing process is continued for 7 days.
The blocks are allowed to normally dry for a day. Now they
are ready for dispatch. Alternatively, the blocks/bricks can be
steam cured for 8 hours or mist cured for 24 hours
immediately after production, and made ready for dispatch
immediately.
9. Dispatch ‐ the cured bricks can be dispatched to market.
FLY ASH BRICKS PROCESSING PLANT CEMENT EQUIPMENT

MANUFACTURING IN PROCESS
 MACHINERY AND EQUIPMENT
1. Fly Ash Brick Making Machine
 Types:
automatic fly ash brick making machine: fully automated
systems that handle raw material mixing, moulding, and
curing processes. Semi-automatic fly ash brick making
machine: partially automated systems that require manual
intervention at various stages of production.
manual fly ash brick making machine: machines that require
significant manual labour for operation, suitable for small-
scale production.
components:
Hopper: Holds and feeds the raw materials into the machine.
Conveyor Belt: Transports raw materials from the hopper to
the mixer.
Mixing Unit: Mixes fly ash, cement, lime, gypsum, and water
uniformly.
Moulding Unit: Shapes the mixture into bricks using hydraulic
or mechanical pressing.
Control Panel: Manages the machine operations and settings.
2. Pan Mixer
Purpose: Ensures uniform mixing of raw materials, which is
crucial for the quality and strength of the bricks.
Features: - High-speed mixing blades for thorough mixing.
Durable construction to handle abrasive materials.
Various capacities to suit different production scales.
3. Belt Conveyor
Purpose: Transports raw materials between different stages
of the manufacturing process.
Features: -
 Adjustable speed to control material flow.
 Sturdy design to handle heavy loads and continuous

operation.
 Low maintenance requirements.
4. Hydraulic Press Machine
Purpose: Applies high pressure to the mixed material to form
bricks.
Features:
 Hydraulic system for consistent pressure application.
 Adjustable moulds for producing bricks of different sizes
and shapes.
 High production capacity with minimal labour input.
5. Curing System
Purpose: Ensures proper curing of bricks to achieve desired
strength and durability.
Types:
 Steam Curing Chamber: Uses steam to accelerate the
curing process.
 Water Curing System: Involves immersing bricks in
water tanks for curing.
Features:
 Controlled temperature and humidity for optimal curing
conditions.
 Efficient design to minimize energy consumption and
maximize output.
6. Batching Machine
Purpose: Measures and batches raw materials in precise
proportions.
Features:
 Automated weighing system for accurate
measurements.
 Programmable controls for different batching
requirements.
 High efficiency to match production demands.
7. Pallet Trucks
Purpose: Used for handling and transporting cured bricks.
Features:
 Easy manoeuvrability for transporting bricks within the
plant.
 Durable design to handle the weight of bricks.
 Available in manual and electric models.
8. Vibrating Table
Purpose: Removes air pockets from the brick mixture before
moulding to ensure uniform density.
Features:
 Adjustable vibration intensity.
 Robust construction for continuous use.
 Simple operation and maintenance.
9. Storage Silos
Purpose: Stores raw materials like fly ash, cement, and lime
in bulk.
 Features:
 Large capacity for continuous production.
 Efficient material discharge system.
Protection against moisture and contamination.
10. Quality Control Equipment
Purpose: Ensures that bricks meet specified quality
standards.
Tools:
 Compressive Strength Tester: Measures the strength of
bricks.
 Moisture Content Analyzer: Checks the moisture content
in the raw materials and finished bricks.
 Dimension Measurement Tools: Ensures uniformity in the
size of bricks.
 QUALITY CONTROL
1. Raw Material Testing
 Fly Ash:
 Chemical Composition: Ensure that the fly ash complies
with the standards specified by regulatory bodies such
as ASTM or IS codes.
 Fineness: Measure the fineness of fly ash to ensure it is
within acceptable limits, as finer particles contribute to
better bonding.
 Loss on Ignition (LOI): Test for the amount of unburnt
carbon in fly ash, which should be minimal.
 Lime:
 Purity: Test for the percentage of calcium oxide to
ensure it meets the required purity levels.
 Fineness: Ensure lime is finely ground for better reaction
with fly ash.
 Cement:
 Consistency: Perform tests to ensure cement quality,
such as setting time, fineness, and compressive strength.
 Gypsum:
 Purity: Check for the purity and fineness of gypsum used
in the mixture.
 Water:
 Quality: Ensure water is free from impurities and meets
the standards for construction use.
2. Mix Proportioning
  Consistency: Maintain consistent proportions of fly ash,
lime, gypsum, and water in the mix.
 Trial Mixes: Conduct trial mixes to determine the
optimal mix ratio that provides the desired properties in
the bricks.
3. Mixing Process
 Uniformity: Ensure thorough and uniform mixing of raw
materials to achieve homogeneity.
 Mixing Time: Follow the recommended mixing time to
allow proper blending of materials.
4. Moulding
 Machine Settings: Calibrate moulding machines to apply
the correct pressure and achieve uniform compaction.
 Brick Dimensions: Regularly check the dimensions of
bricks to ensure they meet the specified size and shape
requirements.
5. Curing
 Curing Method: Adopt appropriate curing methods such
as water curing or steam curing to achieve the required
strength and durability.
 Curing Period: Ensure the bricks are cured for the
recommended duration, typically 14 to 21 days for
water curing.
 Moisture Control: Maintain optimal moisture levels
during curing to prevent cracking and ensure proper
hydration of cementitious materials.
6. Quality Tests on Finished Bricks
 Compressive Strength:
 Perform compressive strength tests to ensure bricks
meet the required strength specifications (e.g.,
minimum 7.5 MPa or as per standards).
 Water Absorption:
 Test for water absorption to ensure it is within the
acceptable range (e.g., less than 20% by weight).
 Efflorescence:
 Inspect bricks for efflorescence (white salt deposits)
which should be minimal or absent.
 Dimensional Tolerance:
 Measure the dimensions of bricks to ensure they are
within the specified tolerances.
 Density:
 Check the density of bricks to ensure consistency and
quality.
7. Documentation and Record Keeping
 Maintain detailed records of raw material test results,
mix proportions, production parameters, and quality
test results.
 Implement a traceability system to track batches and
identify any issues that may arise.
8. Regular Inspections and Audits
 Conduct regular inspections of the manufacturing
process, machinery, and final products.
  Perform periodic audits to ensure compliance with
quality standards and identify areas for improvement.
9. Training and Development
 Provide training to staff on quality control procedures,
equipment operation, and safety practices.
 Keep the team updated with the latest standards and
technological advancements in fly ash brick
manufacturing.
 ENVIROMENTAL IMPACT
1. Utilization of Industrial Waste
 Fly Ash Recycling: Fly ash bricks are made from fly ash, a
by product of coal combustion in thermal power plants.
By utilizing this waste product, fly ash bricks help reduce
the amount of fly ash that would otherwise be disposed
of in landfills or ash ponds, mitigating associated
environmental problems.
2. Reduction of Air Pollution
 No Firing Required: Unlike traditional clay bricks, fly ash
bricks do not require firing in kilns, which significantly
reduces air pollution. The brick production process for
fly ash bricks is energy-efficient and does not release
harmful gases like sulphur dioxide (SO2), nitrogen oxides
(NOx), and carbon dioxide (CO2).
3. Conservation of Topsoil
 No Clay Extraction: Traditional clay brick manufacturing
involves the extraction of topsoil, leading to land
degradation and loss of fertile soil. Fly ash bricks, on the
other hand, do not require clay, thereby preserving
topsoil and contributing to sustainable land use.
4. Energy Efficiency
 Lower Energy Consumption: The production of fly ash
bricks consumes less energy compared to traditional
 clay bricks. The process involves mixing fly ash with
other ingredients like lime, gypsum, and sand, followed
by pressing and curing, which is less energy-intensive
than firing bricks in kilns.
5. Reduction of Carbon Footprint
 Lower CO2 Emissions: The manufacturing of fly ash
bricks emits significantly less CO2 compared to clay brick
production. This reduction in greenhouse gas emissions
contributes to mitigating climate change.
6. Enhanced Durability and Insulation
 Thermal Insulation: Fly ash bricks provide better thermal
insulation, leading to energy savings in buildings.
Improved insulation reduces the need for artificial
heating and cooling, thereby conserving energy.
 Durability: Fly ash bricks are known for their high
strength and durability, which means buildings
constructed with these bricks have a longer lifespan and
require less maintenance, further reducing
environmental impact over time.
7. Reduced Water Usage
 Efficient Water Use: The production process of fly ash
bricks uses less water compared to clay bricks. This is
particularly beneficial in regions where water scarcity is
an issue.
8. Minimized Waste Production
  Less Waste: The manufacturing process of fly ash bricks
produces minimal waste, as the raw materials can be
accurately measured and used efficiently, and any
defective bricks can often be recycled back into the
production process.
9. Promotion of Sustainable Building Practices

 Eco-Friendly Construction: Using fly ash bricks supports

green building practices and contributes to achieving
sustainability certifications like LEED (Leadership in
Energy and Environmental Design). These certifications
promote environmentally responsible construction and
building operations.
 CONCLUSION
In conclusion, the project on fly ash bricks underscores their
significant role in promoting sustainable construction
practices. Fly ash bricks, made from the by-product of coal
combustion, present a viable solution to several
environmental challenges associated with traditional clay
brick manufacturing. By utilizing industrial waste, fly ash
bricks help in reducing landfill disposal issues and minimizing
the exploitation of natural resources such as topsoil.
The environmental benefits of fly ash bricks are numerous.
They contribute to improved air quality by eliminating the
need for firing in kilns, which in turn reduces the emission of
harmful gases and particulates. Additionally, the
conservation of topsoil and reduction in carbon footprint are
substantial environmental advantages that align with global
sustainability goals.
Economically, fly ash bricks offer cost-effective solutions for
construction projects due to their lower production costs and
the availability of raw materials. Their superior strength,
durability, and thermal insulation properties make them an
excellent choice for a wide range of building applications.
These bricks not only ensure the structural integrity of
buildings but also contribute to energy efficiency by
improving thermal insulation.
The project highlights the importance of quality control
measures in the production process to ensure the consistent
performance of fly ash bricks. Regular testing of raw
materials and finished products, along with adherence to
established standards, is crucial for maintaining the high
quality of these bricks.
Furthermore, the project illustrates the potential for
widespread adoption of fly ash bricks in the construction
industry. The scalability and replicability of their
manufacturing process make it feasible to implement in
various regions, particularly those with access to fly ash from
thermal power plants.
In summary, fly ash bricks represent a significant
advancement in sustainable construction, combining
environmental, economic, and performance benefits. Their
adoption contributes to a more sustainable future by
addressing critical environmental issues, reducing
construction costs, and enhancing building performance. The
positive impact of fly ash bricks on both the environment and
the construction industry makes them an essential
component of modern, eco-friendly building practices.
 REFERENCES
 BIS Standards:
Bureau of Indian Standards (BIS). (2003). IS 3812-1:2003,
Pulverized Fuel Ash-Specification, Part 1: For Use as Pozzolana in
Cement, Cement Mortar and Concrete. New Delhi: BIS.
Bureau of Indian Standards (BIS). (1992). IS 12894:1992,
Specification for Fly Ash Lime Bricks. New Delhi: BIS.
 Research Papers and Articles:
Joshi, R. C., & Lohita, R. P. (1997). Fly Ash in Concrete: Production,
Properties and Uses. CRC Press.
Malhotra, V. M., & Ramezanianpour, A. A. (1994). Fly Ash in
Concrete. CANMET, Canada Centre for Mineral and Energy
Technology.
 Books:
Mehta, P. K., & Monteiro, P. J. M. (2006). Concrete:
Microstructure, Properties, and Materials. McGraw-Hill Education.
 Government and Industry Reports:
Central Pollution Control Board (CPCB). (2007). Fly Ash Utilization
Notification, 1999 and Amendments. Ministry of Environment,
Forest and Climate Change, Government of India.
National Thermal Power Corporation (NTPC). (2016). Fly Ash
Utilization Report. NTPC Limited.
 Web Resources:
Fly Ash Brick Technology. (n.d.). Retrieved from
flyashbrickinfo.com
The International Ash Utilization Centre (IAUC). (n.d.). Fly Ash
Utilization in India. Retrieved from ashutilization.org