fky ash properties

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Fly-Ash brick

Submitted by:Savita Malik7th semester

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What is Flyas brick?

Fly ash brick (FAB) is a building material, specifically masonry units,


Raw material for Fly ash brick

The raw materials for fly ash brick are: fly ash, sand/stone dust, lime, gypsum and cement. Fly ash bricks are lighter than clay bricks.

Assorted fly ash bricks of different colors made at ET. (Thebricks have natural color of low-carbon fly ash; the darkones have natural color of high-carbon fly ash; the red ones are made with 1 to 2% of commercially available red colored pigments.


Raw material for Fly ash brick

COMPOSITION:The important compositions of fly ash bricks are as follows;FLY ASHCEMENTSANDWATER


SOURCES OF FLY ASH:72% of India’s power plants are coal based. These power stations generate nearly 40 million tones of fly ash annually. Fly ash contains Co2 emitted from Thermal power plants, industries using coal as a fuel emits unwanted ash and smoke from which fly ash is produced. In all the power plants and industries, they separate the fly ash by using the cyclone converter. This fly ash is then used as a raw material for manufacture of bricks.

NATURE OF POLLUTION CAUSED BY FLY ASH:Fly ash causes severe pollution of air and water, and its disposal gobbles up large tracts of land. Well-planned programs for proper management of fly ash are therefore being undertaken to enhance the use of fly ash in various applications, so that our already perilously imbalanced environment can be protected


Manufacturing:

• It contains Class C fly ash and water.• Compressed at 4,000 psi.• Cured for 24 hours in a 150 °F (66 °C) steam bath,• Then toughened with an air entrainment agent, the bricks last for more than 100 freeze-thaw

cycles.•Owing to the high concentration of calcium oxide in class C fly ash, the brick is described as "self-cementing". •The manufacturing method saves energy, reduces mercury pollution, and costs 20% less than traditional clay brick manufacturing.


Manufacturing:

The fly ash brick is nothing but a slow setting pozzalona cement mix. The process is same as making cement in cement factories whereas the clay and limestone are burnt with coal and gypsum. And it is mixed and ground to cement.In fly ash mix also the fly ash, which is burnt clay particles (oxides of clay) obtained from burning coal, which contains clay from the mines. When hydrated lime powder, gypsum are mixed and ground in a pan, the mixture gives a slow setting pozzalona cement.While the mix is pressed at low pressure at low moisture content in hydraulic machine, which is specially designed to give high pressure load at a slow rate, in the order of 350kg/square inch.At this of rate of pressure and with holding the pressure for a desired time gives ultimate strength to fly ash bricks.


Manufacturing Plant of Fly ash brick


Fly Ash Bricks - Technical Specifications

(1) Fly Ash Brick Size Details :

Size [4 Inches ] :- 230 x 100 x 75 mm

230 x 100 x 100 mm

Size [6 Inches ] :- 230 x 150 x 80 mm

230 x 150 x 100 mm Can be available in other suitable sizes depending on the quantity.

(2) Compressive Strength :

Avg. 7.5 N / Sq.mm.( As against 3.5 N/Sq. mm for handmade clay bricks )

(3) Water Absorption :

8-12 % ( As against 20 to 25% for clay bricks )

(4) Efflorescence :

Nil


(5) Density : 1700 Kg/m3

(6) Weight:

230x100x75 mm ( Weight about 4.75 to 5.00 kgs.approx )

230x150x75 mm ( Weight about 2.75 to 3.00 kgs.approx )

(7) Composition : (i) Cement : Best Quality OPC 53 Grade Cement /

Gypsum Powder,Lime Powder (ii) Thermal Station Fly Ash(iii) Crushed Sand / Stone Dust(iv) Chemicals

(8) Thermal Conductivity : 0.90 – 1.05 W/m2 0 C

( 0.75 – 0.90 K cal/m2 hr 0C )

(9) Drying Shrinkage : Maximum Average drying test shrinkage 0.035-0.04 %

(10) Brick Colour :- Gray / Dark Gray


PROCESSED FLY ASH PLASTER – INSTENT SUNLA.:

•Coverage – 300 sqft. Area covered in 40 Kg. bag. • Coating – Super smooth bright coating. • Life –Long lasting self life due to Pozzolonic properties.• Thermal Insulation – good thermal insulating properties.• Sound absorption – very good sound absorption properties.• Packing –Available in temper proof 40 Kg & 17 Kg. packs only.• Eco-Friendly – Totally envoirmental eco friendly product.• Utilization – use 1.5 Thapi cement in one patty of sunala.• Perfectly blended mixture to obtain uni-grade surface.• Economically improved & tested


•Monitoring and improvement of achieve continual improvement of the quality management system & they are dried and water cured for 14 days.•The bricks are tested and sorted before dispatch. Inspection and quality control: the bureau of Indian standards has formulated and published the specification for maintaining quality of product and testingpurpose. IS: . Compressive strength achievable:Avg. 7.5 N / Sq.mm ( As against 3.5 N/Sq. mm for handmade clay bricks )Water absorption: 8-12%; density- 1700 Kg/m3. co-efficient of softening (depending upon water consistency factor) unlike conventional clay bricks fly ash bricks have high affinity to cement mortar the joint will become stronger and in due course of time it willbecome monolithic and strength will be consistent.

Quality Checking Process :


ADVANTAGES:1.compressive strength is more than conventional clay bricks2.More resistant to salinity and water than conventional bricks3.More lighten than conventional bricks4.Uniform in shape & size and more durable as strength increases with passage of time5.Less mortar consumption in masonry & saving in plastering cost.

DISADVANTAGES:1.Mechanical bonding strength is weak. But this can be rectified by adding marble waste.2.Limitation of size. Only modular size can be produced. Large size will have more breakages.


The prices of fly ash bricks are likely to increase by 20-25 paise per brick because of the hike in cement prices. “Each fly ash brick used to cost Rs 1.50-Rs 2.00 a year ago. But the manufacturers were forced to raise its price to Rs 2-Rs 3 each recently. In view of rising cement prices.

Price of fly ash brick :

fky ash properties

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