In this article, you will learn all about Fly Ash Bricks such as How Flay Ash Brick made (Manufacturing Process), Fly ash Bricks vs red bricks (Difference Between Red Bricks and Fly ash Bricks) and the Advantage of fly ash bricks
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IS Code Specification for Bricks
IS code Specification of Fly Ash Bricks is IS 13757: 1993 – BURNT CLAY FLY ASH BUILDING BRICKS.
IS Code Specification of Clay Bricks is IS 1077: 1992 – COMMON BURNT CLAY BUILDING BRICKS
Fly Ash Bricks Manufacturing Process
let's talk about the manufacturing process of the fly ash bricks plant
Step 1: Fly Ash Bricks Raw Material Ratio
We have to take the Raw Material Ratio of brick 60:30:10 means if we are preparing 100 kg mix In which fly ASH 70% kg, OPC (20%), and anhydrite (10%) are to be taken. (This varies from vendor to vendor also from use. Here I provide a rough idea)
Step 2: Mixing of Materials
Mix all of these materials in a pan mixer or fly ash bricks machine Then add water as required. When raw material gets mix properly.
Step 3: Check Quality of Fly Ash Bricks
Make the mixture a ball shape in the palm and check that its finishing is good. Turn around and check that it is not breaking.
In order to make a ball shape, check that it is not sticking in your palm.
Step 4: Transportation of Mixture
After the mix is ready, it is moved manually or by conveyor belt to the machine hopper. If the pallets are applicable, then you put the pallet under the cavity, on which your bricks will come out.
Step 5: Use of Vibrator (If needed)
Now it is put into the mixing cavity through the feeder at the bottom of the hopper. If you have lumps in your mix, then it is necessary to have a vibrator in the working bed of your machine. So that air gaps are not made in the bricks so that the bricks are not broken during handling, curing and transportation. If there are no lumps, then there will be no vibrator required.
Step 6: Shape of Fly Ash Bricks
Now the final stage for making your fly ash bricks has arrived where you shape the bricks. Now the cavity is pressed with the punch tools fitted in the piston pluck of the hydraulic cylinder, whose pressing capacity is 10 ton per brick.
Now your cavity is lifted up without lifting the punch and the bricks on a pallet are taken out.
Step 7: Initial Setting and Curing
Now, these bricks will be taken to the stacking yard with the help of a trolley where they will be kept for initial setting for 24-48 hours.
When the initial setting of the bricks is done, then the bricks have to be cured for 14 to 28 days so that your bricks become stronger.
Now your fly ash bricks are ready for sale in the market.
In recent time fly ash bricks machine are used which increase the quality also
Difference Between Red Bricks And Fly Ash Bricks
Here we prepare fly ash bricks vs red bricks table to easily understand the difference between both bricks
Fly Ash Brick
Fly ash bricks are made from cement, slag and fly ash
Red bricks are manufactured from clay soil
The standard Fly ash bricks dimensions (fly ash bricks size) are 9” x 4” x 3”
The standard size of red brick is 9” x 4” x 3”
Fly ash brick has a more uniform shape as they are cast in machine mould
Red bricks do not have a uniform shape as they are hand mould made
Fly ash brick has a cement grey colour
Redbrick has colour red to light brown depending upon the type of clay used
Fly Ash Bricks has a compressive strength between 75 to 100 kg/cm2
Red Brick has a compressive strength between 30 to 35 kg/cm2
Fly Ash Bricks wastage on site is around 2 to 5%
Red Bricks wastage on site is around 10%
Fly Ash Bricks has water absorption of near around 6 to 12%
Red Bricks has water absorption of near around 20 to 25%
The average weight of fly ash brick is 2.6kg
The average weight of fly ash brick is 3.5kg
Cost/Price of fly ash brick is about Rs. 4 to 6
Cost/Price of red brick is about Rs. 5 to 8
Advantages of Fly Ash Bricks
Fly Ash bricks are lighter in weight hence they are highly suitable for high-rise building which is preferable to vertical construction.
Fly Ash bricks consume only 65kg cement for the construction of 1m3 of brickwork which is very less compare to red ordinary bricks
By using fly ash brick we can reduce cement consumption by up to 50% as these brick wall not required plastering on both sides
High compressive strength, fewer pours and light-weighted compared to clay bricks
In multi-story high rise building when structural load increase, this brisk has lightweight helps in reducing stress on building
Absorb less water compared to red bricks
It is cheaper than red bricks
Fly ash bricks are made of waste materials that come from the combustion of coal in thermal power plants. Clay bricks are made of clay that is collected from fertile land or the topsoil. This is the prime reason that makes fly ash bricks more preferable to clay bricks
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FAQ 1: What is the standard size of Fly Ash Bricks?
The standard size of fly ash brick is 9” x 4” x 3”
FAQ 2: What are the Main Advantages of Fly Ash Bricks?
Fly Ash bricks are lighter in weight hence they are highly suitable for high-rise building which is preferable to vertical construction, reduce cement consumption, It is cheaper than red bricks