Appearance

These bricks have a pleasing color like cement, are uniform in shape and smooth in finish, also, they
require no plastering for building work. The bricks are of dense composition, uniformly shaped
with/without a frog, free from visible cracks, warp-age, organic matter, pebbles and nodules of free lime.
They are lighter in weight than ordinary clay bricks and less porous too. The color of fly ash bricks can
be altered with the addition of admixtures during the process of brick making. They come in various
sizes, but generally are similar to the sizes of clay bricks.
Structural Capability
These bricks can provide advantages being available in several load-bearing grades, savings in mortar
plastering, and giving smart looking brickwork. High compressive strength eliminates
breakages/wastages during transport and handling, the cracking of plaster is reduced due to lower
thickness of joints and plaster and basic material of the bricks, which is more compatible with cement
mortar. Due to its comparable density the bricks do not cause any extra load for design of structures and
provides better resistance for earthquake loads due to panel action with high strength bricks.
Compressive strength of fly ash sand lime bricks is av. 9.00 N/mm2 (as against 3.50 N/mm2 for
handmade clay bricks).
Thermal properties
Thermal conductivity is 0.90-1.05 W/m2 C (20-30% less than those of concrete blocks). These bricks
do not absorb heat; they reflect heat and gives maximum light reflection without glare.
Sound insulation
It provides an acceptable degree of sound insulation.
Fire and vermin resistance
Fly ash bricks have a good fire rating. It has no problems of vermin attacks or infestation.
Durability and moisture resistance
These blocks are highly durable, after proper pointing of joints, the bricks can be directly painted in dry
distemper and cement paints, without the backing coating of plaster. Rectangular faced with sharp
corners, solid, compact and uniformly Water absorption is 6-12% as against 20-25% for handmade clay
bricks, reducing dampness of the walls.
Toxicity and Breath-ability
There are no definite studies on the toxic fume emissions or the indoor air quality of structures built with
flyash bricks, though claims of radio active emissions by these blocs have been made at some scientific
forums.
Flyash as a raw material is very fine and care has to be taken to prevent from being air-borne and
causing serious air pollution as it can remain airborne for long periods of time, causing serious health
problems relating to the respiratory system. Though block manufactured from flyash has no such
problems.
Sustainability
(environmental impacts)
Fly ash is a cocktail of unhealthy elements silica, aluminum, iron oxides, calcium, magnesium,
arsenic, mercury, and cadmium, and poses serious environment and health hazards for a large
population. But the brick is better off, for flyash changes into a non-toxic product when mixed with lime
at ordinary temperature as the calcium silicate hydrates and forms a dense composite inert block. Thus
having the potential as a good building material, while offsetting about 100million tonnes of flyash
annually produced in India by the numerous thermal power plants, which could cause serious
contamination of land, groundwater and air.
Buildability, availability and cost
The blocks have an easy workability and high compressive strength eliminates breakages/wastage
during handling giving a neat finish, with lower thickness of joints and plaster. The construction
technique remains the same as regular bricks ensuring easy change of material, without requiring
additional training for the masons. Though these bricks are abundantly available closer to thermal power
plants all over the country for obvious reasons, finding dealers in all major cities and towns wouldnt be
a problem.
Applicability
The blocks being available in several load bearing grades are suitable for use:
Load bearing external walls, in low and medium size structures.

 Non-load bearing internal walls in low and medium size structures.

Non-load bearing internal or external walls in high-rise buildings.
FLY ASH BRICKS
With changing time and modes of construction and the type of form work which are taking place today
has led to development of many new type of construction material which are now a days are widely used
and also widely demanded. In this era the most important construction material which has change from
time to time is the bricks. It is the foremost material for all type of construction without it the
construction on any structure remains incomplete.
According to the construction work requirement of bricks also used to vary depending upon what type of
construction work is to be done for example mud bricks were used to provide thermal comfort etc.. In
the same era not new nor we can say that it is old also a new type of brick is emerging at a fast rate for
the construction work and its name is FLY ASH BRICKS though it is not widely demanded but it has
been introduce to some of the major projects. In this report it will show the process of manufacturing of
fly ash bricks , its uses , and it is economical compared to the other bricks. All the detailing about FLY
ASH BRICKS will be done in this report..
SCOPE
Since this bricks have not been used on large scale for the construction work. But it has good scope in
future, because this brick is being manufactured from the waste material known as fly ash which
generally comes from the industrials waste in mass, manufacturing of this bricks avoid the difficulty of
dumping fly ash too.since the natural resources are becoming limit so what makes it availability and
easy way to manufacture will increase its scope for the construction work.
Fly ash bricks also reduce the chances of pollution during its construction work which is not same in all
the bricks manufacturing process. High compressive strength, better workability, fire
resistance..and all these quality of the bricks will increase its future scope of construction work.
Soon we will find that in lots of construction work fly ash bricks are being widely used.
TYPES OF BRICKS
THERE ARE DIFFERENT TYPES OF BRICKS AVAILABLE SOME OF THEM ARE AS
FOLLOW :
MUD BRICKS
RAIL KLINS
BULL TRENCH KLINS
DRY PRESSED BRICKS
EXTRUDED BRICKS
CALCIUM SILICATE BRICKS
FLY ASH BRICKS
CEMENT CONCRETE BRICKS
BURNT CLAY HOLLOW BRICKS
STABILISED SOIL BRICKS
SAND LIME BRICKS
BURNT CLAY JALLIES BRICKS
DETAILS OF FLY ASH BRICK
Description:
Not too old but not too new also it is that type of brick which is composed of fly ash and water
compressed 4,000 psi (27,939 kPa) for two weeks. Owing to the high concentration of calcium oxide in
fly ash, the brick is considered "self-cementing". The brick is toughened using an air entrainment agent,
which traps microscopic bubbles inside the brick so that it resists penetration by water, allowing it to
withstand up to 100 freeze-thaw cycles. Since the manufacturing method uses a waste by-product rather
than clay, and solidification takes place under pressure rather than heat, it has several important
environmental benefits. It saves energy, reduces mercury pollution, alleviates the need for landfill
disposal of fly ash, and costs 20% less than traditional clay brick manufacture.

MANUFACTURING PROCESS
Materials required:
Fly ash
Lime gypsum
Sand
Process involved:
Mixing the ingredients
Pressing the mix in machine
Curing the brick for stipulated period
Detail description of manufacturing process:
The process of manufacturing of fly ash bricks is based on the reaction of lime with silica of fly ash to
form calcium silicate hydrate ( c-s-h ) which binds the ingredients to form brick. The quality of bricks
obtained are highly dependant on the quality of fly ash. The manufacturing of LIME-FLY ASH bricks
are generally designed such that they stand at par with burnt clay bricks used conventionally.
FLYASH: (usage 60-70 %) Apart from conforming to IS requirement the minimum requirement for
manufacturing of fly ash bricks are as follow :
Loss of ignition --- should not be more than 12 %
Availability of Mgo ---should not be more than 5%
Availability of siO2 --- should not be more than 35 %
Availability of Al2O3 --- should not be more than 15 %
LIME: (usage 8-15%) Lime is very important ingredients used for manufacturing of bricks , hence it
should satisfy following minimum requirement : Lime , while slaking process should not attain less than
60 degree Celsius temperature and slaking time should not be more than 15 minutes .
Availability of Cao should be minimum 60% .Mgo content should be maximum of 5% .
GYPSUM: (usage 2- 5%) It is added to mix in order to accelerate hardening process and acquiring the
early strength . It should have minimum 35% of purity .
SAND: (usage 0- 8%) Additional of sand is optional , but to enhance the gradation , of the mix , addition
of coarse sand is quite preferable . Addition of sand also enchance the resitivity of mix to formation of
laminar cracks caused due to entrapped air .
MIXING PROCESS
After all the materials are taken in the required proportion as mention above the first step involved is the
mixing of the ingredients a fig below is shown how the mixing of these materials is done
PRESSING THE MIX IN THE MACHINE
After the mixing process is over than the foremost steps comes in that is the pressing of the mix in the
machine for getting the good shape of the bricks and good strength also. Fig below show the machine
which is used for the pressing purpose.
CURING OF THE BRICKS
After the mixing and pressing process is over curing is very important if it is not cured properly than the
proper strength is not gained and as a result final bricks form cannot be used for the any type of the form
work. Proper curing of bricks is very important for the bricks to regain its strength. It should be cured
for a period of two weeks. Since it is prepared from the waste material so it regains a cementations
property after proper curing is done.
After the curing process is over the brick is now ready for the use. Next we will see some advantages
and disadvantages of fly ash bricks...
ADVANTAGES:
It is Durable.
It has low water absorption tendency.
It also consumes low mortar.
It economical and ecofriendly.
Low energy consumption.
No emission of green house gases.
DISADVANTAGES:
Needs skill labors.
Needs lot of care while manufacturing.
Initial cost is more.

APPLICATION: Since this type of bricks has not been used widely and on large scale but
recommendation and projects are being passed to use this brick for the construction work. Till now this
bricks has been used for the building construction purpose..below we have a fig which the
construction work being carried out using fly ash bricks.
CONCLUSION: After doing the through study and knowing the way how the fly ash bricks are
manufactured and its importance in the construction field we can say that in near future this brick is soon
going to replace all the bricks and blocks which are now a days used for the construction purpose. With
decreasing natural resources and boom in construction field will definitely increase the demand for fly
ash brick as it has lots of quality and advantages than other bricks some quality are like high
compressive strength, low resistance, low mortar consumption etc. Since it also accounts 20% less cost
for its construction than the clay burnt bricks..so all these and the present situation will make this
brick as the most important material for the construction work.