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Project Profile On Fly Ash Bricks: Dharani Modular Constructions

Fly ash bricks are an eco-friendly alternative to traditional clay bricks that are made using fly ash, a byproduct of coal combustion in thermal power plants. The production process involves blending fly ash with lime and an accelerator, molding the mixture into bricks, and curing them at different temperatures and pressures to form a calcium silicate hydrate binder. Fly ash bricks require less energy and emissions during production compared to clay bricks. There is high demand for affordable housing in India, presenting an opportunity to increase production of fly ash bricks which could help meet needs while conserving natural resources and improving the environment compared to clay bricks. A proposed new fly ash brick production facility would cost approximately 44.2 lakh rupees to establish

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Mohan Kumar
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56 views

Project Profile On Fly Ash Bricks: Dharani Modular Constructions

Fly ash bricks are an eco-friendly alternative to traditional clay bricks that are made using fly ash, a byproduct of coal combustion in thermal power plants. The production process involves blending fly ash with lime and an accelerator, molding the mixture into bricks, and curing them at different temperatures and pressures to form a calcium silicate hydrate binder. Fly ash bricks require less energy and emissions during production compared to clay bricks. There is high demand for affordable housing in India, presenting an opportunity to increase production of fly ash bricks which could help meet needs while conserving natural resources and improving the environment compared to clay bricks. A proposed new fly ash brick production facility would cost approximately 44.2 lakh rupees to establish

Uploaded by

Mohan Kumar
Copyright
© © All Rights Reserved
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Download as PDF, TXT or read online on Scribd
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PROJECT PROFILE ON FLY ASH BRICKS

1. INTRODUCTION:
Pulverized fuel ash commonly known as fly ash is a useful by-product from thermal power stations using pulverized coal
as fuel and has considerable pozzolonic activity. This national resource has been gainfully utilized for manufacturing of
pulverized fuel ash-lime bricks as a supplement to common burnt clay building
bricks leading to conservation of natural resources and improvement in environment quality.
Pulverized fuel ash-lime bricks are obtained from materials consisting of pulverized fuel ash in major quantity, lime and an
accelerator acting as a catalyst. Pulverized fuel ash-lime bricks are generally manufactured by intergrading blending
various raw materials are then molded into bricks and subjected to curing cycles at different temperatures and pressures.
On occasion as and when required, crushed bottom fuel ash or sand is also used in the composition of the raw material.
Crushed bottom fuel ash or sand is also used in the composition as a coarser material to control water absorption in the
final product. Pulverized fuel ash reacts with lime in presence of moisture from a calcium hydrate which is a binder
material. Thus pulverized fuel ash lime, in presence of moisture form calcium-silicate hydrate which is a binder material
and hence this is a chemically ended bricks.
These bricks are suitable for use in masonry construction just like common burnt clay bricks. Production of pulverized fuel
ash-lime bricks has already started in the country and it is expected that this standard would encourage production and
use on mass scale. This stand lays down the essential requirements of pulverized fuel ash bricks so as to achieve
uniformity in the manufacture of such bricks.

2. MARKET DEMAND:
180 billion tons of common burnt clay bricks are consumed annually, approximately 340 billion tones of clay, about 5000
acres of top layer of soil dug out for bricks manufacture, soil erosion, emission from coal burning or fire woods, which
causes deforestation are the serious problems posed by brick industry. The above problems can be reduced some extent
by using fly ash bricks in dwelling units.
Demand for dwelling units likely to raise to 80 million units by year 2015 for lower middle and low income groups, involving
an estimated investment 0f $670 billion, according to the associated chamber of commerce and industry. Demand for
dwelling units will further grow to 90 million by 2020, which would require a minimum investment of $890 billion. The
Indian housing sector at present faces a shortage of 20 million dwelling units for its lower middle and low income groups
which will witness a spurt of about 22.5 million dwelling units by the end of Tenth plan period. There is ample scope for fly
ash brick and block units.
In Chennai alone, 10 million bricks are required for constructional activities every day. But good quality of bricks as well as
required quantity is not available moreover during the rainy seasons supply of clay bricks are very difficult. Therefore, in
order to fulfill the required demand there will be a great chance to start more units in the field of fly ash bricks.
At present 20 units are engaged and 40 lakh nos of bricks per month are manufactured in our state. And there will be
scope to start near about 100 units, which will be produced more than 2 crores no of bricks per month in future. Thus
marketing of these product are well shinning.

3. POLLUTION CONTROL
The technology adopted for making fly ash bricks is eco-friendly. It does not require steaming or auto-calving as the
bricks are cured by water only. Since firing process is avoided. There are no emissions and no effluent is discharged.
Facial masks and dust control equipment may be provided to the employees to avoid dust pollution more over all the raw
materials are kept under covered by polythene sheet to avoid air pollution.

DHARANI MODULAR CONSTRUCTIONS

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FINANCIAL ASPECTS
FIXED CAPITAL:
(a) Land & Building:
S.N

DESCRIPTION

AMOUNT

Land 45,000 Sq.ft

Lease hold or own

Production Building 1600 sq.ft

4,00,000

Storage building + Office 400 sq.ft

2,00,000

Curing Yard 5,000 sq.ft

2,00,000

Bore well & Overhead Water tank

1,00,000

Electric Power 35 HP

1,00,000

Other Misc.*

75,000

TOTAL

10,75,000

*Miscellaneous such as erection, electrification, office furniture, etc.


(b) Machinery & Equipment:
S.N

DESCRIPTION

QTY

RATE

AMOUNT

Fully Automatic machine


hydraulic operated with all
accessories and fitting

25,00,000

25,00,000

Pan Mixture 500 KG Capacity

2,00,000

4,00,000

Belt Conveyor with necessary


fittings

1,00,000

2,00,000

Wheel Barros

10

5000

50,000

Hydraulic pallet truck

25,000

75,000

Stacking Pallets 3X3

60

2000

1,20,000

TOTAL

33,45,000

Note: Above mentioned details (a & b) are based on fly ash consumption of 250 tons/month.
TOTAL PROJECT COST (Excluding Land)
a
b

Building
Machinery & Equipment
Total

DHARANI MODULAR CONSTRUCTIONS

10,75,000
33,40,000
44,20,000

Page 2

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