What Is Fly Ash Bricks?
Fly ash bricks are a building component in civil engineering; mostly, they are masonry material. Generally, class C and class F-fly ash, sand/stone dust and water is the ingredient of fly ash bricks.
Fly ash bricks are also termed as ‘self-cementing’ bricks. Fly ash bricks are made of the recycled product, so it’s also an eco-friendly product.
Sometimes cement is also added to it as a cementing material. Due to the uniform structure, it.
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Advantages & Disadvantages of Fly Ash Bricks
The advantages and disadvantages of fly ash brick are as follows.
Advantages of Fly Ash Bricks
#1. Strength of Fly Ash Bricks
- As compare to regular fire clay bricks, fly ash bricks have greater compressive strength.
- The compressive strength of fly ash brick is near about 9-10N/mm2.
- The thickness of those bricks are low, so it reduces cracks in plaster.
- It has a good earthquake resisting property.
- It increases the strength of the structure.
#2. Durability of Fly Ash Bricks
- These fly ash bricks are highly durable but less permeable.
- Due to lower permeability, it reduces the efflorescence effect on brick.
- These bricks prevent dampness on the wall because it is less porous, and that’s why it does not absorb more water.
- It’s highly resistive against acid, water, and sulfate.
#3. Appearance of Fly Ash Bricks
- The key thing about these fly ash bricks is its appearance.
- Fly ash bricks are cement-like colour, smooth, even surface, and uniform finish.
- Due to the smooth surface, the amount of plaster is reduced to 40% than common plastering.
- Plaster of Paris or putty can be applied directly on this.
- Those bricks are free from organic matter, pebbles, etc.
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#4. Thermal Property of Fly Ash Bricks
- Fly ash bricks have an excellent thermal property because of the thermal conductivity of fly ash brick is 0.9-1.05 W/mm2, so it absorbs minor heat. For this reason, the building is cool in the summer.
#5. Sound Insulation of Fly Ash Bricks
- Fly ash bricks have decent sound insulation property than ordinary bricks.
#6. Fire Resistance of Fly Ash Bricks
- Fly ash bricks are good in fire-resisting than regular fire clay bricks.
#7. Sustainability of Fly Ash Bricks
- The main ingredient of fly ash bricks is fly ash, and it comes from the thermal power plant. So, it doesn’t damage the environment again; that’s why it’s an environmentally friendly product.
#8. Availability of Fly Ash Bricks
- Those bricks are generally available near the thermal power station areas, but now days, it’s nearly available in all the places.
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Disadvantages of Fly Ash Bricks
There are not so many disadvantages of fly ash bricks, but some are also there. Those are the following-
- All fly ash bricks are not suitable for construction. It’s necessary to use high-quality fly ash bricks to resist harmful effects.
- If the fly ash bricks are not appropriately prepared, then it has no strength and not suitable for construction.
- These bricks are only available in modular size. Larger size bricks are not produced due to cracks.
- Bonding is less due to a smooth finish; that’s why we need to care about when masonry work is running.
- In plastering work, plaster doesn’t make a suitable bond with those bricks due to the smooth surface.
- Fly ash bricks are not suitable in the winter area region.
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Fly Ash Bricks Cost
Fly ash brick cost is not higher than ordinary fire clay bricks. The price cost of fly ash bricks are depended upon the following materials-
- Cost of raw material
- The proportion of raw material
- Level of automation
- Technology adopted
- Cost of finance
- Economic of scale
So, above those following points, the cost of fly ash bricks are varying from 8-10 rupees per piece where regular fire clay bricks price is near about 11-12 rupees per piece.
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How to Make Fly Ash Bricks
The process of manufacturing fly ash bricks is mainly done by machine. The steps are following-
- At first, add fly ash at an amount of 57-65%. Fly ash is the fundamental material of this type of bricks.
- Then river sand or stone dust 18-27%. It acts as a filler material for fly ash bricks.
- Hydrated lime 9-12%. This is the binding material of fly ash bricks.
- Gypsum 5%, sometimes cement is also added with this mixture.
- Then those above products are adequately mixed.
- After that process, those bricks need compression. So, they are compressed at 28 MPa.
- Next, it needs a curing process. It cured for 24 hours in a 66°C steam bath.
- Then, the bricks are toughened with an air entrainment agent and last 100 freeze-thaw cycles.
So, this is the whole process of manufacturing fly ash bricks. It does not require great manpower; that’s why the cost of this product is low. The proportion of those materials are also correctly maintained because of the whole process is done by machine.
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Compressive Strength of Fly Ash Bricks
- As compared with normal fire clay bricks, fly ash bricks have more compressive strength.
- When the fly ash bricks are constructed, then it got extreme pressure (near about 28 MPa).
- Where the ordinary fire clay bricks have a compressive strength of 3.5 N/mm2, the compressive strength of fly ash bricks is 10-12 N/mm2.
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Fly Ash Brick Size
- Fly ash bricks are produced in various sizes, but usually, the available size in the marketplace is 230mm x 110mm x 70mm.
- The weight of that particular size of brick is 6 kg. So, it reduces the dead load of the structure due to its lightweight.
- Due to this type of compact uniform size and high compressive strength, there is no breakage in the transportation system.
Fly Ash Block Size
- Fly ash block is the bigger version of fly ash brick. The same material produces it, and the same process is applied for preparing it.
- The size of fly ash brick is 24in x 8in x 4in
- These blocks are mainly used in the partition wall and the sidewall.
- The cost of fly ash block is approximately 50 rupees per piece in India (but it varies in a different place)
So, we see that the fly ash brick is economical, and it’s decent to use for residential purposes as well as commercial purposes.
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Fly Ash Bricks Advantages
- They are light in weight and hence are very suitable for multi-floored buildings.
- Fly ash bricks absorb less heat and considering the Indian climate, it makes it better when compared to clay bricks.
- From the cost front, it requires less mortar during construction.
Fly Ash Bricks Disadvantages
- Depending on the mixture mechanical strength can be low. This can be partially rectified by adding marble waste or mortar between blocks.
- Large size can have more breakages depending on the mix of materials.
- It has high thermal conductivity. Extra insulation is required in colder regions.
Fly Ash Bricks Rate
|1||12 Inch X 4 Inch X 2 Inch||4 to 8 Rupees Per Pics|
|2||9Inch X 4 Inch X 3 Inch||3 to 7 Rupees Per Pics|
|3||9 inch X 3 inch X 2 inch||3 to 7 Rupees Per Pics|
|4||300 mm X 100 mm X 50 mm||4 to 8 Rupees Per Pics|
|5||230 mm X 100 mm X 75 mm||3 to 7 Rupees Per Pics|
|6||230 mm X 75 mm X 50 mm||3 to 7 Rupees Per Pics|
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Fly Ash Bricks Manufacturing Process
- The mixing proportion is generally 40-50% Fly Ash, 50-40% Sand 10% lime and 4% water.
- Fly ash reacts with lime in the presence of moisture to form calcium silicate hydrate which is the binder material.
- The raw mix is moulded in the moulding press/machine, pressed under a pressure into bricks.
Fly Ash Brick Size
- It reduces the dead load on structures due to light weight (2.6 kg, dimension: 230 mm X 110 mm X 70 mm).
- Due to high strength, practically no breakage during transport and use.
- Due to the uniform size of bricks mortar required for joints and plaster reduces almost by 50%.
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