Project Report Of

Fly-Ash Bricks Plant

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INDEX

PARTICULERS PAGE NO.

1. Introduction of Company 3

2. Fly Ash Bricks 4

3. Raw Material & Availability 4

4. Fly Ash Lime & Gypsum (FAL) 4

5. Advantages of Fly Ash Bricks 5

6. Basis & Presumption 5

7. Eco Friendliness 5

8. Technical Features of Flyash Bricks Making Plant 6

9. Market & Development 7

10. Comparison Table between Clay Bricks and Fly Ash Bricks 7

11. Cost of Product 8

12. Important Note 8

13. Test Certificate For Strength of Bricks 9

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I NTRODUCTION O F C OMPANY

"KARMYOG INDUSTRIES" is based in Gujarat, INDIA. We have been committed to achieve the highest standards of quality through out since 1980 under name of Kishan Engineer Works. Having Years of Experience in the field of Hydraulic Machinery making, KARMYOG INDUSTRIES - a partnership firm, decided to venture into the hydraulics and earth moving machinery business in the year 1996, to satisfactorily meet with the growing market demands of various industries. Currently, our cost effective product range, technological expertise, cost down production process and prompt delivery have efficiently provided us a base of a leadership status in the market. We are an acknowledged manufacturer and exporter of, Tractor Mounted Loader, Grabs for Hydra Crane, Mini Dumper, Dozer, Furnace Charger, Bricks Making Machine, Concrete Block Making Machine, Fly Ash Bricks and Fully Automatic Machine. Our products are manufactured, while keeping in mind, the whole field of modern challenges and customer requirements. Furthermore, they are applauded for their strength and efficiency.

OUR QUALITY:

Quality has always been the guiding force for us. Our uncompromising endeavor towards an impeccable quality and perfection has established us as the company to reckon with. Our team of quality control inspectors maintains a strict vigilance at all levels of the production stage to assure customers of only world-class products. We take special care regarding the procurement of raw material, which are sourced from the reputed and well-established distributors and suppliers, having several years of industrial expertise.

OUR PRODUCT:

We are the leading manufacturer and exporter of the following range of products, which includes:

Front End Loader Fly Ash Bricks Machine Concrete Block Making Machine Paver making Automatic Machine Mini Dumper Dozer Batching Plant

OUR STRENGTH: High Level of Expertise. Continual research and development to incorporate new technologies. State of the art infrastructure empowered with a cutting edge technology, in

house manufacturing unit and ultra modern machineries. Continual improvement in the products and services. Highly skilled and dedicated workforce. Least maintenance required for our products. Prompt after sales support. Delivery of machinery in the shortest possible lead-time. Capacious warehouse having capability to store bulk amount of products as

per the specific requirements of the customers.

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F ly Ash Bricks

Fly Ash bricks are made of Fly Ash, Lime, Gypsum and Sand. These can be extensively used in all building constructional activities similar to that of common burnt clay bricks. Since fly ash is being accumulated as waste material in large quantity near thermal power plants and creating serious environmental pollution problems, its utilization as main raw material in the manufacture of bricks will not only create ample opportunities for its proper and useful disposal but also help in environmental pollution control to a greater extent in the surrounding areas of power plants.

R AW M ATERIALS AND A VAILABILITY

(A) FLYASH: The left out after burning of coal is generally available in Thermal power stations. Paper mills or where steam boilers burning coal are used. The fly ash available in these industries is good quality and normally free of cost. The FAL-G brick making units can be put up in a radius of 150-250Kms. from the fly ash source.

(B) LIME: The lime used in this process is hydrated lime powder, which will be available locally. Low cost and high quality lime will be available in Oxygen, Acetylene, and paper manufacturing Plants. The lime is a waste in these industries and can be very well used in making Fal-G-bricks.

(C) GYPSUM: The calcined gypsum is available at the rate of 300-400 Rs. / Ton. (Freight extra). The locally available gypsum can be fired in a kiln to get calcined gypsum

(D) SAND: Sand is used as an economizer and to increase the strength of brick to some extent. Any locally available cheap sand can be used in making the bricks. Any coloring material can be added to give desired color but the cost will be high and it can be stored as a premium brick.

F LY A SH L IME AND G YPSUM (FAL) M IX

The FAL-G mix is nothing but a slow setting pozzalona cement mix. The process is same as mixing cement in cement factories where as the clay and limestones are burnt with coal gypsum is mixed and ground to make cement.

In FAL-G mix also the fly ash which is a burnt clay particles (Oxidizes of clay) obtained from burning of coal which contains clay from the mines when hydrated lime powder, gypsum are mixed and ground in a pan mixture gives the slow setting pozzalona cement. And it is also added to bring down the cost of mix of brick in our process.

While the mix is pressed at low moisture content in the Brick Machine which is specially and indigenously designed to give high pressure load, at slow rate, in the order of 250 kg/ Square inch.

At this rate of pressure and with holding the pressure for a desired time gives ultimate strength to the FAL-G bricks.

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A DVANTAGES OF F LY A SH B RICKS Compressive strength is more than conventional fire clay bricks. More resistant to salinity and water seepage problem than conventional

bricks. More lighter than conventional bricks. Uniform in shape & size. More durable as strength increases with passage of time. Less mortar consumption in masonry & saving in plastering cost because of

its uniform shape and size.

Technical particulars of Fly ash bricksCompression strength:  155 kg/Cm Sq (approx) Water absorption : 5 to 12 %Density                       : 1.5 gms/ccCo efficient of softening (depending upon water consistency factor)Unlike the conventional clay bricks, Fal-G bricks have high affinity to cement mortar though it has smooth surface, due to the crystal growth between brick and the cement mortar the joints will become stronger and in due course of time it will become monolithic.

The strength of the brick will be consistent(Depends on raw material used)

B ASIS AND P RESUMPTIONS

I. It is assumed that the unit will operate on single shift basis (8 hours) for 300 working days in a year.

ii. The salary and wages for staff and labor has been taken into consideration on the basis of prevailing market rates.

iii. To reach the full plant capacity, it requires 1 year after trial production.

iv. Interest rate at 14% is considered in the project profile for both recurring and nonrecurring investment.

vi. Operative period of project is around 10 years considering technology obsolescence rate and period of repayment of loan.

ECO FRIENDLINESS:

Fly ash bricks are the best method for disposal of the fly ash, the by – product in the thermal power station and since the usage of fly ash in bricks is protecting the valuable fertile top soil so it is Double Eco Friendly. The manufacturing process of

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Fly Ash Bricks does not involve any emission of green house gas because unlike the normal Fire Clay Bricks, Fly ash bricks do not use any fire knell.

T ECHINICAL F EATURE O F F LYASH B RICKS M AKING P LANT

OUR Fly ash brick making plant has been designed to manufacture fly ash bricks with Eco-friendly technology. It is a simple & cost effective technology available in the country. The heart of the plant is an indigenously designed, a relatively low cost & high productivity machine. Other component machines of the plant Pan Mixture, Conveyor, Pallet trucks, Wheel Borrows & wooden Pallets are economically & efficiently designed to give a maximum output.

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 the firing process is avoided, there are no emissions and no effluent is discharged. On the other hand, it solves the problem of fly ash disposal.

BRICKS MACHINE:1. Brick Machine is hydraulically operated, automatic, controlled by electronic

circuits. This can be mastered with little basic electrical knowledge.2. Brick making machine develops 50 To 100 tons of compressive force over the

bricks uniformly and hold the pressure for required time allowing the materials to flow and form.

3. The machine structure is carefully designed to take up the heavy cyclic loads.4. Monogram on the brick can be embossed.5. Very high production at relatively low cost.

PAN MIXTURE:1. A sturdily constructed machine with heavy rollers to grind and mix the material

thoroughly.2. Drive through trouble less, quality worm reduction gearbox.3. Easy bottom unloading mechanism with door arrangement.4. Capacity: 300kg to 800kg/batch.5. Power (Motor): 10hp to25hp.6. Manufacturing: Mixing of raw materials of Fly- Ash.7. Bricks and Concrete.8. Discharge: Bottom Door Opening Manual.9. Mixing: By Heavy Rollers and Hand faced Scrapers.

CONVEYOR:1. Frames and intermittent bins fabricated sturdily2. The fly ash mix can be regulated according to the speed of the brick-

making machine.

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3. Nylon with rubber top conveyor belts.4. Friction less idlers.

HOPPER:

A collecting Hopper is provided on the upper side of the main body.It collects mixed material from conveyor belt & stores it. The required quantity of the mixed material is then dispatched automatically from hopper & bricks are manufactured.

PALLET TRUCKS:

Novel and ergo metric design to handle the bricks with pallets for effortless and easy transportation of fly ash bricks with reduced labor

CONTROL PANEL:

A fully automatic FA Bricks machine includes control panel with PLC system to help automation of raw material feeding, mixing, conveyor belt operating to bricks formation & bricks output. One skilled worker can handle the system & it helps in reducing of dependency on labors as well as getting work done faster.

MARKET AND DEVELOPMENT SCOPE OF THE UNIT:

The scope of this kind of unit is very bright in the coming days. Government of India is more insisting all the existing Bricks kilns to use Fly ash for the Bricks where those kilns are not in use of Fly Ash and Cement. So in the coming days Govt. is going to make it mandatory to all the govt. construction works to use only Fly Ash Bricks. So the demand for this product is set for a tremendous growth in future. Also Fly Ash Bricks in quality is much better than ordinary fire clay bricks. The Fly Ash Brick is stronger and has longer life clay bricks. So use of these Bricks is increasing day by day. So the future scope of this unit is very bright and colorful. Central Public Works Department (CPWD) has been already incorporated these bricks in their specifications for use in all types of their constructions. Bureau of Indian Standards has formulated code viz IS 12894 especially for Fly ash Bricks.

MAN POWER & TRANSPORT REQUIREMENT:

In order to run the unit efficiently the concern proposed to employ the request staff as per annexure attached. The location of the unit is also well connected by transport facilities.

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COMPARISON TABLE:

CHARACTERISTICS ORDINARY FIRE

CLAY BRICK

FLY ASH BRICKS

Strength Strong StrongerLife Long Very LongerCost Costlier CheaperWeight Heavier LighterEco-Friendliness The Process Emits

Green House Gases(Enemy of ecology)

Very Eco Friendly (actually helps in disposal of Fly Ash wastes from Thermal Power stations)

C OST O F P RODUCT

The Production per shift (8hrs) 11520 bricks (per day) requires material 31.67 Ton.Net Weight 3.000 Kg/Bricks- (Standard Size 230x110x75mm) (6 bricks/per stroke)Per month Production approx. 2,90,000 bricks

(a) Production of Bricks using Cement (cost per bricks):

Raw Material

Proportionate/Brick

Kg. Material Cost

Material Cost/Kg.

Cost Per Brick

1 Fly ash 52% 1.56 350/Ton

0.35 0.546

2 Stone Dust 41% 1.23 500/Ton

0.5 0.615

3 Cement 7% 0.21 300/Bag

6 1.26

4 Electricity 110 UNIT 5/UNIT 0.035 Water Expense Approx. Appro

x.0.04

6 Labor 0.086

7 Interest 0.068 Depreciati

on0.05

6Total 2.69

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** There could be little variation in composition depending on Raw Material availability.

(b) Production of Bricks using Lime (cost per bricks): Raw Material

Proportionate/Brick

KG. Material Cost

Cost Per Brick

1 Fly ash 55% 1.65 350/Ton 0.35 0.57752 Stone

Dust25% 0.75 500/Ton 0.5 0.375

3 Lime 15% 0.45 3000/Ton 3 1.354 Gypsum 5% 0.15 1000/Ton 1 0.155 Electricity 110 UNIT Per Shift Rs. 5/UNIT 0.036 Water Approx. 0.047 Labour 0.0868 Interest 0.079 Depriciati

on0.06

Total 2.7385

** There could be little variation in composition depending on Raw Material availability.

(c) Staff & Labour: Description Nos. Salary/Month Total SalaryOperator 1 6,500 6,500Unskilled Labour

10 4,500 45,000

TOTAL 51,500

Land & Building 2 acre of land on Lease

50000/acre/anum

100000

Office Building(200 Sqft)

Rs. 500/sqft 100000

Furniture 15000Computer, Printer

25000

Electricty Connection

150000

Total 390000

Total Costing of ProjectPlant & Machinery 300000

0Material 150000

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Electricity 200000Labour for one Year 618,000Other 390000

Total 4358000

Approx. Profit Ist Year

Approx. Profit IInd Year

Rate/ Brick 3.5 Rate/ Brick 3.5Production @70% Ist Year

3456000

Production @85% IInd Year

2937600

Sale 12096000

Sale 10281600

Gross Profit Approx 2592000

Gross Profit Approx 2203200

(d) Electricity Require:

Electricity 30 HP for Machine 2HP for Submersible Water Pump 5 HP for Lighting & Misc. Usage

Important Note:

Product Code: IS 12894-2000 Product Costing: Depends upon the area cost of raw material. Unit (Machine includes): Bricks making machine, Conveyor belt,

Hooper, Pan Mixture & Green Bricks Railing, Bricks Shifting Trolley.

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