A Green Eco friendly Project

Project Reports of Fly Ash Bricks

High Capacity Fly Ash Bricks & paverBlocks
Unit

Laxmi Engineering Works- Ahmedabad

Prepared by www.laxmiengineeringworks.co.in mpatel86lew@gmail.com

 A Green Eco friendly Project

PROJECT PROFILE ON FLY ASH BRICKS

1. Product : Fly Ash Bricks

2. Quality Standards : IS : 12894 :2002

3. Production Capacity quantity : 45 lakh bricks

4. Month & Year : July2017

5. Prepared by : MEHUL PATEL

Laxmi Engineering Works

Ahmedabad, Gujarat.

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 A Green Eco friendly Project
1. Projectat a Glance
1 Product Details : Bricks & Blocks
Type : Fly Ash-Lime-Gypsum (FAL-G) Based
NIC Product Code : 320901009
BIS Code : IS: 12894 : 2002

2. Assumptions

The following assumptions have been made while preparing this Project Report.

a. Land required mentioned is approximate. 75% of land required is for storage of

Finished Products.
b. The project can be started at a smaller land , if there is a good management
practice of marketing as per the prevailing orders. This helps holding a slim stock.

c. Fly to be provided free of cost by power plants. Only transportation to be

arraigned by Project. All raw material prices assumed is landing price at project
site.

d. The Unit aims for optimal fly ash utilization.

e. Production is estimated at moderate capacity, 1 shifts a day. for ratios analysis

f. 300 working days is considered in a year during the first year.

g. Boundary wall to be constructed from trail production bricks of Unit.

h. Sale price at site is estimated as per existing market Price.

i. Bricks of all sizes will be manufactured according to the market requirement,

though mainly 230mm x 110mm x 70mm are the major concentration area.

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 A Green Eco friendly Project

3. Introduction
FAL-G is not a brand name, but a product name like Ordinary Portland Cement
(OPC). This name is given for easy identification of its ingredients. FAL-G stands for Fly-
Ash-Lime-Gypsum. In recent days, Lime-Gypsum is being replaced by OPC cement as it is
cheap and also quick setting. The process itself is concept development based on a cement
theory called “Crystallo-Mineral Combination or setting behavior” in technical jargon. In a
recent development it was found that use of OPC in many places is not only economical but
also it provides quick setting, faster curing, improved strength, and overall better quality (
including strength)

Fly-Ash, an indispensable by-product of Thermal Power Plants, is an environmental

threat across the globe. Power plants are facing an ever increasing challenge disposal of this
polluting agent. This unit is proposed to manufacture FAL-G Bricks & Blocks by consuming
the Fly-Ash as one of the prime raw material. Secondly, it also helps environment by saving
the invaluable top soil by not using them in brick making like conventional brick making.
Thirdly, they need no burning, thus further enhancing their Eco-Friendly Brand. This is the
reason these bricks are also referred as Eco Bricks or popularly Green Bricks, (though the
color is gray).

Fly-Ash Bricks and Blocks are largely used in various constructions, such as load
bearing and pillar structure Buildings, Boundary walls, Roads, Culverts, Pavements, and
wherever conventional bricks can be used. The general Fly ash bricks fall in the strength zone
Of thus is much 2stronger then conventional Bricks. These bricks gain
strength over a period of time up to 2 years, where as the conventional bricks tend to lose
strength over a period of time. Because of this strength, the same mix can be also be used to
make the Paver Blocks in the same casting machine with interchanging the moulds.

These green bricks can attain very regular and uniform shapes. As no burning is
involved, so the shape also remains unchanged. As a result, the final Brick work with these
green bricks consumes less mortar to build, less mortar to plaster. Further, the FAL-G being
artificial cement itself, it forms a more uniform bond with cement, giving almost a
homogeneous structure. Not only this, even exposed brickwork (without plastering) is a good
durable structure. So people prefer to leave the Green Bricks Brickworks in garages,
boundary walls etc. un-plastered.

4. Advantages of using Fly- Ash Bricks.

Theadvantages areasfollows

1. Environmental friendly : Consumes Fly ash

2. Environmental friendly : Saves invaluable top soil

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3. Environmental friendly: needs no burning/backing.
 A Green Eco friendly Project

4. Strength: Higher Strength Bricks.

5. Uniform Shape: Easier and faster Brick working.

6. Uniform Shape: Less Mortar in Brick work.

7. Uniform Shape: Less Mortar in Plaster.

8. Artificial Cement: Gains strength over time.

9. Artificial Cement: Walls can be left exposed/un plastered.

10. Better heat & sound insulation compared to red Bricks

11. Far Lesser brakeage during handling & transportation.

12. Better Vibration resistance compared to red Bricks

5. Market

Shelter is third skin, according to a German Concept, which implies it’s importance
next to human Skin and Clothing. This also shows the attachment of human race to this
fundamental requirement.

Building Material accounts for major component of the construction cost. Depending
on the location they can contribute to 60 - 70 % of the cost of construction. With the ever
increasing population, the demand for housing increases. This directly creates demand for
this prime commodity of building.

Add to the above fact the area under discussion and its surrounding area is undergoing
a major infrastructure revolution. As Residential, Commercial, IT companies, and
Industrial establishments are coming in, we can conclude that the Bricks unit will prosper
and flourish in this environment.

There is a central government gadget notification mandating government departments

and CPWD to use 100% Fly Ash Bricks in their all constructions- directly of through
contractors. This factor will help the marketability of this product immensely.

Fly Ash policy of the Government also mandates that 20% of Fly ash Generated by a
power plant must be given free of cost to SME sector on a priority basis.

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 A Green Eco friendly Project

6. Carbon Credits Estimates

FAL-G Bricks have already qualified as a CDM projects in India for earning Carbon
Credits since January 2004. But as the conventional FAL-G Bricks Units are very small in
size, having a daily production of 3000 to 6000 Bricks per day, thus CDM Project for
this industry has been designed as a bundled approach. Already two bundles of FAL-G: CDM
projects have been registered and the third bundle is under process of registration. The first
bundles have already received their first trench of payment in August-2007.

This Unit, unlike the above said units is a high capacity Bricks Production Plant. Its
production capacity is around 20 times higher than conventional units discussed as above.
Thus this plant can be individually treated as a Single CDM project as well.

Generally, the existing FAL-G:CDM project estimates a saving of 350 Tons of

Carbon Credits for every Million of Bricks. Thus the Present Project of 24,000,000 will have
an annual Carbon Credits Generation of Approximately 8400 CERs. In present day market it
stands around EURO 17 per CER. ( data as on 2012-June )

POST SCRIPT ONCDMSTATUSASONDATE

The CDM projects which are aimed to get carbon credits or CERS have been on
hold post Dec-2012 scenario, as all the participating nations need to decide on a newer
framework. All the environmentalists are very much hopeful that the newer version of the
CDM framework will be more beneficial to the Green ventures like this project.

7. Raw Materials, Sources and Availability.

Fly-Ash:
A lot has been said about this raw material in this Project Profile itself. But
this Raw material is freely available in Thermal Power plants. There are no taxes on this item
whatsoever. Transportation charges are only to be attended by the entrepreneur.

However, the proposed Unit will get Fly Ash from locally available Thrmal
Powerplants, which is having best quality fly ash not only in the country, but also in the
whole world
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Lime/OPC:
 A Green Eco friendly Project

Lime used in this process is known as Hydrated Lime, which can be obtained
by Calcining Brunt Lime. One KG of Brunt Lime gives 2.2 Kgs of Hydrated Lime after
Calcining. Brunt Lime can be obtained from Kuddur, Andhra Predesh where Lime Kilns and
High Quality Brunt Lime are pettily available. Alternativily Hydrated lime is available as an
industrial by-product of Paper Mills

This Project however aims to utilize OPC cement as a substitute for Lime. It
will give faster strength to the bricks, besides giving improved consistent quality. It also
ensures a better cost effectiveness for the same. Using OPC will be a standardized practice
compared to Lime, as, unlike OPC, Lime quality changes widely across suppliers and across
seasons. The other prime advantages of using OPC (compared to Lime) is it’s easy
availability locally through nationwide Retail Network of Cement Companies.

Gypsm:

This too is an industrial waste. This is available at Fertilizer Plant as in

industrial wastes

Sand/Crusher Dust.

Sand is used as an economizer and to increase the strength of bricks to some

extant. Sand is procured locally. Crusher dust can also be successfully used in place of sand.

8. 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
preset 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 are a series of operations which is achived by

automatic PLC system. Pallet is pulled6into 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
 A Green Eco friendly Project
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.

A Compressive strength of 80 to 250 Kg/Cm2 is generally obtained from the mix
design, as suggested in the “Elaborated Details Page” of this Project Profile. The resulting
bricks will have around 5 %water absorption and around 1.5 to 1.7 Gms/CC Density.

Please refer the “ProcessFlowchartDrawing” given in following page

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 A Green Eco friendly Project

9. Process Flow Chart.

Crusher
Main
Fly Ash Dust/ OPC/lime Gypsm Raw Materials
Sand

From 20% 60 to 5 % OPC 6% Gypsum4%

to 70% 1% Or Quantity

Lime 10%

Twin Shaft Mixture Water

to mix ingredients

Bricks Casting on Machine

Stacking and drying Under Shade/ under plastic

Water Curing For 7 Days

Dryfor24Hoursand Eco-BricksReady forSale

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10. Quality Control:
1. Moisture Content in Fly Ash should not be more than 5%

2. The color of Fly Ash should be either Light Steel or Smoke Gray.

3. It should never contain un-burnt Carbon by not more than 5%

4. Phospho Gypsum should better be made acid free by washing, if it is acidic

5. Special emphasis should be given to curing.

6. Proper stacking and layering can greatly enhance the quality of Bricks & Blocks.

7. Fresh Laid bricks to be protected from rain showers by Polythene Sheets.

8. Fresh Laid bricks to be protected direct heavy sun drying by Polythene Sheets.

9. Controlled drying under PVC covers of Fresh Laid bricks is advisable.

10. Stacks should not be allowed to fully dry at any time (within first 6 days).

11. Pollution Control Needs

• There are no solid or liquid effluents out of this plant.
• The unit is a Green unit as it consumes Fly-ash, saves fertile top soil and earns CER
• Workman working in the Bricks production Unit to be provided with protective
equipments like dust masks, safety goggles, Gum Boots, Gloves etc.

12. Energy Conservation needs

The management has to be vigilant in ensuring higher productivity by the optimal
utilization of man and machine hours. Periodic checks on working stages, functioning of
machinery, their preventive.

Energy Conservtion:

Electrical Details in HP
S.No Name of Machine Power In HP
1 Automatic Flya Bricks Machine 12.5
2 Pan Mixer -2 15
Belt Conveyor 2
Vibro Motors -2 4
 Stracker 3
Other Electric Fittine 6
Total Power 42.5

A.
Land & Building
S NO Description Amts INR
1 Land Lease Hold 45,000 Sq.f
2 Building (60*40 =2400 feet) 3,00,000
3 Over Head 50,000
Total 3,50,000/-

B.
Machineries & Equipment Cost
S
No Description Amt INR
1 Automatic Flyash Bricks & Solid Blocks Making Machine with
High Pressure and Double Vibro .
Starcking system & 2 Mixer
Total 22,50,000/-
GST 18% 405000/-
Grand Total 26,55,000/-
Erection and Electrification Charges 20,000
Office Furniture 20,000
Total 26,95,000/-

Recuring Expenditure:
(a).Raw Material per Month
S No Description Quantity Rate Rs/ton Amts
1 Fly Ash 420 Mt 250 1,22,500
2 Sand 35 800 28000
3 Gypsum 70 1900 1,33,000
4 Lime 105 1300 136500
Total 420000

(b)Saleries & Wages per Month

S No Description NO Salry Amounts
1 Production Manager 1 Self
2 UN Skilled workers 14 6000 84000
3 Office Assistance 1 4000 4000
4 Watch Man 1 3500 3500
Total 91500
 (c)Utilities Per Months
S.N Power 40HP 4500Units(approx)@Rs %/Unit 22500
Water 1000
Total 23500

(d) Other Expanses

SN Description Amounts
1 Postage & Stationaries 1000
2 Repair and maintance 3000
3 Traveling and transportation 2000
4 POL 5000
5 Insurances 1000
6 Telephone 3000
Total 15000

RECURRING EXPENDITURE PER MONTH:

a + b + c + d = Rs.5, 50,000/-

Working Capital Assessments:

S No Description Amounts
1 Raw Metrial require for a week 1,17,600
2 Works In Progress ( for Month) 1,09,000
3 Finish Good ( for 5Days) 1,05,000
4 Bill recivable ( for 2 weeks) 2,06,000
Total 5,37,600

OTHER FINANCIAL ASSISTANCE Rs.

Total Project Cost
A. Land Lease hold b. Building 3, 50,000/-
B. Plant & Machinery 24,00,000/-
C. Working capital 25,00,000 /-
Total Capital Investments 52,50,000/-

Cost or Production per Annum

S No Description Amounts
Total Recuring Cost ( Recuring expenditure*12) 66,00,000/-
Intrest on total investments@12.5% 8,25,000/-
Total Depriciation on Machineries equipments@10% 2,40,000/-
Total Depriciation on Office funitures@10% 2,000/-
Total 76,67,000/-
Turnover Per Annum : Excepted sale 45 lakhs bricks(20working days) @ 3.5 per bricks
Rs.1,57,50,000/-

Profit Per Annum :

Turnover – Cost of Production
=1,57,50,000 – 76,67,000 =80,83,000/-
= Rs.80 lakhs (approx)

(a) % of profit on sales = Profit per annum X 100 / Turnover

= 28,00,000 X 100/ 1,57,50,000 = 50%

Cost of Bricks:
1) Using Cement :

Price Calculation method of Fly Ash Bricks ( 3kg- wieght)

S No Particulars Cost of Meterial INR Wieght ( KG/Bricks) Amt INR
1 Fly Ash (50%) 400/ton 1.5 0.60
2 Stone dust/Sand (40%) 300/ton 1.2 0.36
3 Cement (7%) 325/Bag 0.21 1.36
4 Water Uses 0.05
5 Labour Cost 0.40
6 Electricity 0.05
Total Cost INR 2.82
2) Using Lime & Gypsum:

Price Calculation method of Fly Ash Bricks ( 3kg- wieght)

S
No Particulars Cost of Meterial INR Wieght ( KG/Bricks) Amt INR
1 Fly Ash (50%) 400/ton 1.5 0.60
2 Stone dust/Sand (30%) 300/ton 0.9 0.27
3 Lime (5% dry)---(15% in wet) 5Rs / KG 0.15 0.075
4 Gypsum (5%) 5 Rs/Kg 0.15 0.75
5 Water Uses 0.05
6 Labour Cost 0.40
Electricity 0.05
Total Cost INR 2.20

Quality Specifications :

Bureau of Indian Standards formulated specifications for clay fly ash

bricks, lime fly ash bricks, common burnt clay bricks and calcium silicate bricks
which can be referred to as regards to the quality of Fal-G bricks.

IS:12894:1990 Specification for Fly Ash Lime

bricks. IS:13757:1976 Specification for Burnt clay fly ash

building
Bricks.

IS:4137:1989 Specification for calcium silicate

bricks. IS:3102:1976 Classification of burnt clay solid

bricks.
The other relevant BIS specifications are :

IS:3812:1981 Specification for Fly Ash for use as

Pozzolana and admixture.

IS:712:1984 Specification for Building limes.

IS:3495(Pt.I)1976 Methods of tests of burnt clay building

bricks.

For production of good quality fly ash bricks the quality of Fly Ash
should be as follows :

i) Moisture content of fly ash should not exceed 5% .

ii) Visual appearance of fly ash should be of light steel grey or
smok
y grey colour.
iii) Unburnt carbon content in the fly ash be around 5% .

The typical physical requirement of Fal-G bricks as per

customer’s specifications is as follows :

a) Compressive strength 60-250 kg/cm.2

b) Water absorption 5-12%

c) Density 1.5 gms./c.c.

 Supplier’s Address:

A. Raw Materials Supplier’s :

Fly ash -available from the local dealers.

Gyp sum -available from local dealers.

Lime stone, river sand and crusher dust are available from the

local dealers.

B. Machinery and Equipments:

LAXMI ENGINEERING WORKS,

86, SHUBH INDUSTRIAL ESTATE, NEAR ZAVERI ESTATE, B/H.
C.L.VIDYALAY, SINGARVA-KATHWADA, AHMEDABAD-382430,
GUJARAT, INDIA
Ph.: +91 9825045862, +91 9825045839
Web: www.laxmiengineeringworks.co

Proprietor, Marketing Head,

Mehul Patel PRAJESH PATEL

+91 9825045862 9825045839