Thursday, May 7, 2020

Fly Ash Brick | Raw Materials | Manufacturing Process

Fly Ash Brick

 Fly ash brick  is a building material, explicitly masonry units, containing class C or class F fly ash and water. 

 Compacted at 28 MPa and restored for 24 hours in a 66 °C steam shower, at that point toughened with an air entrainment specialist, the bricks keep going for Inferable from the high centralization of calcium oxide in class C fly ash, the brick is portrayed as "self-establishing".

 The assembling strategy spares vitality, diminishes mercury contamination, and costs 20% not exactly customary mud brick fabricating.


Manufacturing process of fly ash bricks
Fly ash brick


    Raw Materials requirements of Fly Ash Brick

     Fly ash frames the significant segment of the raw materials for Fly ash bricks. In this manner it controls to a large extent the properties of the completed item. As the ash is non- plastic, a binder must be included either plastic clay or Portland concrete.
     Fly ash content ranges from 60 to 80%. Lime is another raw material required for the creation of fly ash bricks.
     It is by and large attractive to utilize a high calcium lime of sensible virtue as it is the most significant constituent which responds with silica and alumina and so on present in the fly ash to frame the binder under hydrothermal conditions.Lime content range from 20 to 30%.

    Fly Ash Brick Manufacturing Process

     It is proposed to have plant capacity of 30,000 fly ash bricks for each day. Thinking about 300 working days, absolute creation of bricks per annum would be 90, 00,000.
     Lime is finely ground in a ball mill. Fly ash, finely ground speedy line and sand in imperative extents are taken care of in twofold move paddle mixer or U-shaft mixer (Twofold shaft mixer) by methods for a feeder.
     At that point 4% water is included and cozy blending is finished. The blending extent is commonly 40-half Fly Ash, 50-40% Sand 10% lime and 4% water.
     Fly ash responds with lime within the sight of dampness to frame calcium silicate hydrate which is the folio material. The crude blend is molded in the embellishment press/machine, squeezed under a pressure into bricks.
     The bricks are then with drawn from the trim machine and they are air dried under the sun and saved for 1 day. The bricks are autoclaved in which relieving is finished by steam at typical weight and relieved for 6 - 8 hours.
    The last items are sifted through and examined for quality and stacked in the go-down.

    What is a costs of fly ash bricks ?
    Following 15 – 20 days of creation, the fly ash bricks are sold in the market at a cost of Rs. 2.50 rupees per brick. Generally the bricks are utilized for development of building. This unit produces 4000 bricks for each day.


    Advantages of fly ash brick


    It lessens dead load on structures because of light weight :2.6 kg, dimension: 230 mm X 110 mm X 70 mm.

    Same number of bricks will cover more area than mud bricks

    High fire Protection

    Because of high quality, essentially no breakage during transport and use.

    Because of uniform size of bricks mortar required for joints and mortar lessens nearly by half.

    Because of lower water entrance leakage of water through bricks is impressively diminished.

    Gypsum mortar can be legitimately applied on these bricks without a sponsorship layer of lime mortar.

    These bricks don't require absorbing water for 24 hours. Sprinkling of water before use is sufficient.

    Disadvantages of fly ash brick


    Mechanical strength is low, yet this can be amended by including marble waste or mortar between block.

    Confinement of size. Just secluded size can be delivered. The enormous size will have more breakages.

    It is just useful for the spots like subtropical area or area where atmosphere is warm in light of the fact that it doesn't ingest heat. Be that as it may, during cold it isn't useful.

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