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ECOTECHPRESENTS
FLY SH BRICK N ENTREPRENEURSPPRO CH
FROM :
ECOTECH CONCRETE PRODUCTS PRIVATE LIMITED
PLOT NO. 810 (P), SATKENDURI BAKRESHWAR BYPASS ROAD
NUTANPALLY, DUBRAJPUR, DIST. BIRBHUM
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Material science is a complexcomposite, arising out of in-built
judgment in orienting the
characteristics and constituents ofvarious products to serve the human
race; and depending on the natures
gift, tapping the same for theapplication of human need.
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Bricks made out of clay is one such product
which proved its credence since the dawn ofcivilization. Brickwork is established as an
age-old construction media right from the
thatched house to multi-storeyed buildings.Natures kind-heartedness in gifting the
humankind with its bountiful resources, of
course, has a threshold limit and the
utilization of clay has reached such a point in
construction.
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This potential resource has been over
tapped, unmindful of the consequences,
as a result of which (except in limited
pockets of some river delta regions)
barren lagoons have replaced vaststretches of erstwhile fertile land. Added
to that, soil degradation and disturbances
in ecology are threatening the veryrudimentary pillars of welfare.
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In countries like India, where about 65%
of the population is still living ineconomically weaker and rural segments,
clay is unanimously the cost effective
building material to make the walls and
floors of their huts. But irreparable
exhaustion has taken place for such
versatile product, leaving no chances of
replenishment for millennia to come.
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In West Bengal, the industry estimate of registered clay brickmanufacturers stands at around 8,000 in numbers. There isalmost an equal number of unregistered brickfields taking the
State level aggregate to approx. 15,000 brickfields.Considering that the minimum annual production of abrickfield is around 30,00,000 pieces, the total clay brickproduction of the State works out to approx. 4,500 Crorepieces.
Taking into account that 10% of this production is carried outusing silt available along the river banks, approx. quantity ofclay bricks manufactured through excavation of top soil maybe assumed at approx. 4,000 Crore pieces, which destroys9.77 Crore cum top soil annually as under :-
4000 Crore pcs x 0.08632 cft/brick =345.28 Crore cft or
9.77 Crore cum of top soil weighing 12.80 Crore MT.
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For converting this estimated volume to flyash bricks, theminimum quantity of flyash required annually would work
out to :-
4000 Crore pcs x 0.0033 MT/brick x 50% (by weight) = 6.60Crore MT
Therefore, daily requirement of flyash is envisaged at =1,80,000 MT
So, even theoretically, most of the flyash can be recycled bybrick manufacturers, which in turn would save precious topsoil as well as abate carbon di-oxide emission, the processbeing devoid of sintering.
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DISTRICT WISE
ESTIMATED NO.
OF FLYASH
BRICK UNITS IN
WEST BENGAL
40 Units
12 Units
5 Units
2 Units
15 Units
7 Units
5 Units
8 Units
10 Units
15 Units
10 Units
5 Units
4 Units
2 Units
ESTIMATED TOTAL NO. OF UNITS = 140
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2 6
35
140
0
20
40
60
80
100
120
140
160
2000 2005 2010 2012
Estimated No. of Units in West Bengal
Estimated No. of
Units
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1% 3%
19%
77%
Estimated No. of Units in West Bengal
2000
2005
2010
2012
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Properties of Fly Ash brick / block
Compressive strength : 50 - 160 kg/sq.cm.
Water absorption : 1015 percentDensity : As pure mix : 1.4 gm/cc.
As mortar brick: 1.61.8 gm/cc.
Coefficient of softening (depending
on water consistency factor) : 2 -15 percent
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Durability
Once the hydrated compounds and related mineralogiesform out of flyash constituents upon activation with
cement or lime and gypsum, no further reactivity is
evident either internally or with extraneous media like
ground and air laden chemicals. This results in
dimensional stability and enhanced weather resistance ofpozzolanic products.
Pozzolanic applications have been well established as
durable materials of construction for the last 2 3millennium and Fly Ash Concrete is nothing but an
improved version of this established pozzolanic
chemistry.
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Environment Friendly
Notwithstanding the techno-economic virtues,Fly Ash bricks comply with the criteria for
environmentally friendly products and eligible
for Carbon Emission Reduction earnings in terms
of Kyoto Protocol on account of the main rawmaterial being an industrial by-product and the
manufacturing process being devoid of sintering
or auto-claving is totally energy conservative.
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What made Fly Ash brick/block attractive?
a) Fly Ash bricks do not lose strength unduly even on
soaking in water continuously. Hence plastering is optional
rather than necessary.
b) On account of size accuracy, plastering can be rationalized
adding additional savings on cement.
c) Well cured fly ash bricks absorb 4 12% of water only.
d) On account of less absorption, rationalization of plastering &
mortar, a finished fly ash brick wall is lighter and cheaper in
comparison to finished clay brick wall.
e) Fly ash bricks can be made to order with engineeringproperties comparable to cement concrete, befitting for
specialized applications such as canal lining, dam
construction, water tanks, etc.
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Why the Ministry of Environment & Forests,Government of India published the notification no :
S. O. 763 (E) dated : 14
th
. September, 1999 ?
Whereas it is necessary to protect the environment,conserve top soil and prevent the dumping and
disposal of flyash discharged from coal or lignitebased thermal power plants on land ;
And whereas, there is a need for restricting the
excavation of top soil for manufacture of bricks andpromoting the utilization of flyash in the manufactureof building materials and in construction activity.
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How flyash bricks and blocks are suitable alternativeto ordinary burnt clay bricks ?
The manufacture of flyash bricks and blocks does notrequire excavation of top soil and utilizes flyashgenerated by thermal power stations instead.
Flyash as all knows has its own problems of disposaland is otherwise a social menace with recycling
through production of building materials being thepreferred utilization.
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Flyash bricks and blocks being chemically
bonded does not require sintering anddispenses with the need for coal a non-
renewable fossil fuel. Further, as need for
burning the bricks and blocks is absent, the
manufacturing process is totally environment
friendly and contributes substantially to
reduction of carbon di-oxide emission - a
harmful greenhouse gas which is responsiblefor global warming.
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Flyash bricks and blocks have the followingadvantages over ordinary burnt clay bricks :-
Better finishHigh Strength
Less water absorption
No efflorescence
Lower unit weight and less load on foundation
Reduced energy consumption
No excavation of top soil which is otherwise suitable
for cultivationLower cost of bricks and blocks
Less mortar consumption
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Why is the flyash brick/block industry suffering in theState of West Bengal ?
The notifications published by the Ministry ofEnvironment & Forests, Government of India for 100%utilization of flyash bricks, blocks and tiles for allconstruction works within a radius of 100 kilometres
of a coal/lignite based thermal power plant is notbeing adhered to by both the Government andprivate construction agencies in the absence ofmonitoring by statutory authorities and/or impositionof penal provisions as provided by law. Even thermal
power plants generating the flyash do not use flyashbricks, blocks and tiles mandatorily in all itsconstruction works.
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The flyash bricks and blocks industry is
burdened with unfair tax regime vis--vis theclay brick manufacturers, who can get away
with evasion of VAT, Central Excise, ESI, PF
and other statutory duties or taxes inspite ofdoing enormous harm to the environment
through excavation of top soil, consumption
of non-renewable coal and emission of
carbon di-oxide.
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Some other bottlenecks that are acting as
hurdles to the development of this sun-riseindustry in West Bengal are as under :-
a) Entrepreneurs are entering the business on
a hype of making fast money devoid ofknowledge about the process technology and
marketing constraints.
b) There is less consciousness and focus on
product quality leading to a wide variation in
attributes amongst different manufacturers.
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c) Cannibalisation amongst manufacturers due
to inadequate demand for the product and
very slow evolution of market in absence of
use by Government departments and
agencies under their control.
d) Buyers need to be realistic while drawing up
specification and price so that manufacturers
are not compelled to compromise on the
binder, which constitutes 60 70 percent ofraw material cost of the product.
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Nature always summons for transformations in materialscience and that is how balance is atoned in resourceavailability to fulfill the varietal needs of human race.
Though talk of habits and attunements are populararguments, particularly in countries like India whileresponding to advent of innovative products, need forces tocompromise first and get appeased next.
The availability and use of clay is exactly at such crossroads.Lack of technological and material alternates held up clayusers all these years inspite of dire necessities andpressures. The profuse availability of fly ash on one handand FAL-G technology on the other have emerged to offer
respite on clay front. Hence it is time to say good-bye toclay bricks and welcome flyash brick manufacturing with abig hand for its techno-economic virtues.
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THANK YOU