THERMAL INDUSTRY WASTE: OPPORTUNITIES

FOR DEVELOPMENT OF LOW COST FLY ASH

BRICKS

Abstract: Fly ash is generated in large quantities especially by thermal power plants. A lot
of research has been carried out for effective utilization of fly ash in building industry. Use
of fly ash in manufacturing brick is one such subject which is being studied by researchers.
Fly ash brick (FAB) is a building material, specifically masonry units, containing class C fly
ash or Class F Fly ash and water. Fly ash is finely divided residue resulting from the
combustion of powdered coal, transported by the flue gases and collected by electrostatic
precipitators. Its proper disposal has been a cause of concern since long, which otherwise
leads to pollution of air, soil and water. The disposal and utilization of this fly ash is a matter
to ponder. The World Bank has cautioned India that by 2015, land disposal of coal ash
would require about 1000 Km2 of land. To overcome this problem and to encourage the
utilization of fly ash, Government of India in 2003 made it mandatory to use at least 25% fly
ash with soils on weight to weight basis for manufacture of bricks within a radius of 100 Km
from coal or lignite based thermal power plants. Several researchers and organizations have
put forward the methods for use of fly ash in brick making. For last several decades attempts
are being made to find a suitable method for the disposal and proper utilization of fly ash.

Keywords: Lime, gypsum, Quarry dust, Sand, Fly ash, Compressive Strength, Water
absorption, Durability

INTRODUCTION

Pulverized fuel ash commonly known as Fly ash is a useful by product from thermal power
stations using pulverized coal as fuel and considerable pozzolonic activity. This national
resource has been gainfully utilized for manufacture of pulverized fuel ash- lime bricks as a
supplement to common burnt clay buildings bricks leading to conservation of natural resources
and improvement in environment quality. Fly ash is the inorganic mineral residue obtained
after burning of Coal/Lignite in the boilers. The characteristics of Fly ash depend upon the
quality of lignite/coal and the efficiency of boilers.

TABLE 1
FLY ASH GENERATION V/S UTILIZATION: SCENARIO OF WORLD
Sr. No. Country Annual Ash Production Ash Utilization % Of
(Million Tones) Ash Produced
1 USA 75 65%
2 CHINA 100 45%
3 INDIA 112 38%
4 GERMANY 40 85%
5 UK 15 50%
Source: Journal of engineering and technology, S.P U., Vol-19, Dec.2006
 TABLE 2
CLASSIFICATION OF FLY ASH
Class F Fly Ash Class C Fly Ash
It is achieved by burning anthracite and It is achieved by burning of younger lignite
Bituminous coal. and sub bituminous coal.

Fly ash contains less than 20% lime. Fly ash contains More than 20% lime.
It requires an activator for making It does not require an activatorfor making
cementatious products. cementatious products.

Source:http://www.caer.uky.edu/kyashe Source:http://www.caer.uky.edu/kyasheducatio
ducation/flyash.shtml n/flyash.shtml

PHYSICAL PROPERTIES OF FLY ASH

Fly ash consists of fine, powdery particles that are predominantly spherical in shape,
either solid or hollow, and mostly glassy (amorphous) in nature. The carbonaceous material
in fly ash is composed of angular particles. The particle size distribution of most bituminous
coal fly ashes is generally similar to that of silt (less than a 0.075 mm or No. 200 sieve).
Although sub bituminous coal fly ashes are also silt-sized, they are generally slightly coarser
than bituminous coal fly ashes.
The specific gravity of fly ash usually ranges from 2.1 to 3.0, while its specific
surface area (measured by the Blaine air permeability method) may range from 170 to 1000
m2/kg.
The color of fly ash can vary from tan to gray to black, depending on the amount of
unburned carbon in the ash. The lighter the color, the lower then carbon content. Lignite or
sub bituminous fly ashes are usually light tan to buff in color, indicating relatively low
amounts of carbon as well as the presence of some lime or calcium. Bituminous fly ashes are
usually some shade of gray, with the lighter shades of gray generally indicating a higher
quality of ash.
 TABLE 3
CHEMICAL COMPOSITION OF FLY ASH {ACCORDING TO IS: 3812 (PART 1)-
1966 CLAUSE: 5.1}
Sr. Characteristic Requirement
No.
1. Silicon dioxide (SiO2), plus aluminum oxide (Al2O3), 70.0
percent by weight, min.
2. Silicon dioxide (SiO2), percent by weight min. 35.0
3. Magnesium oxide (MgO), percent by weight, by weight 5.0
Max.
4. Total sulphur trioxide (SO3), percent by weight, Max. 3.0

5. Available alkalies as sodium oxide (Na2O), percent by wt. 1.5

max.

6. Loss on ignition, percent by wt. Max. 12.0

Source: Prof. Jayesh R Pitroda, Thesis, “Techno-Economical Study Of Fal-G Bricks In

Central Gujarat Region Of India”, S.P. University Vidyanagar, Gujarat, June 2009

ADVANTAGES OF FLY ASH

Low water/cement ratio.
Low permeability.
Resistance to sulfate.
Minimization of alkali-silica reaction.
Minimum segregation.
Decreasing in heat of hydration.
Increasing the strength.
Smooth concrete surface.
Environment-friendly.

DIS ADVANTAGES OF FLY ASH

Slower strength gain.
Seasonal limitation.
Increase in air entraining admixture.
AREAS OF FLY ASH UTILIZATION:
Concrete production.
Stabilization of soft soils.
Mineral filler in asphaltic concrete.
Agricultural uses, soil amendment, fertilizer.
Fly ash bricks.
Fly ash is used in roller compacted concrete dams.
Fly ash has been used as a component in geopolymers.
Embankment and fills.
Road pavement.
Portland pozzolana cement.
Cement concrete and mortar.
Light weight aggregates.
Waste treatment and stabilization.
Fly ash use as an admixture to stabilize sewage sludge and other toxic sludge.
Back filling of open cast mine.

TEST OF BRICK

A. COMPRESSIVE TEST (IS: 3495(P-1)1992)

The brick specimens are immersed in water for 24 hours. The frog of the brick is filled flush
with 1:3 cement mortars and the specimen is stored in damp jute bag for 24 hours and then
immersed in clean water for 24 hours. The specimen is placed in compression testing
machine with 6 mm plywood on top and bottom of it to get uniform load on the specimen.
Then load is applied axially at a uniform rate of 14 N/mm2. The crushing load is noted. Then
the crushing strength is the ratio of crushing load to the area of brick loaded. Average of five
specimens is taken as the crushing strength.

Figure: 1 Setup of Compressive Testing Machine

 B. WATER ABSORPTION TEST (IS: 3495(P-2)1992)

Brick specimen is weighed dry. Then they are immersed in water for a period of 24 hours.
The specimen are taken out and wiped with cloth. The weight of each specimen in wet
condition is determined. The difference in weight indicates the water absorbed. Then the
percentage absorption is the ratio of water absorbed to dry weight multiplied by 100. The
average of five specimens is taken. This value should not exceed 20 per cent. Sharp edges. To
check it, 20 bricks are selected at random and they are stacked along the length, along the
width and then along the height.

C. DURABILITY TEST (IS: 4860)

Each of the various brick types was built into a panel of ten courses of three bricks in half
bond, with weather pointed joints. The mortar used was the 1:3 mortar. All panels were air
cured within the laboratory for at least twenty one days. Panels were then fully immersed in
water for seven days before being installed in the test cabinet. The test cabinet subjects one
face of the panel to repeated cycles of freezing and thawing; the remaining face and sides of
the panel being insulated with 25mm thick, extruded polystyrene. The test was run for 100
cycles. Damage was assessed visually and by checking for any incipient separation of the
surface layer of the brick by tapping the surface with a small mild steel rod.

D. FREEZE/THAW CYCLE

Figure: 2 Freeze / Thaw Cycle

E. FLEXURE TEST (IS: 9399-1987)

It is a way of determining the flexural strength of how something will react when it is being
bent, and we do this by supporting the specimen by two bearing surfaces and applying an
axial compressive load at its center by either a third bearing load, or a further two bearing
load points. In this method, take 5 bricks for each sample. Apply mortar 1:3 (cement: sand)
on each samples. Keep bricks dry for 24 hours. Put these bricks in curing for one day. Take
out bricks and keep them until they become dry. The bricks having size of
(230mmx115mmx75mm) put in to machine along 115mm side and apply a compressive load
until they break. Note down the readings. Now put bricks along 75mm side and apply a
compressive load until they break. Note down the readings.

Figure: 3 Setup of Flexure Testing Machine

Source: www.ptli.com

MATERIALS USED FOR FLY ASH BRICKS:

Following is the actual brick manufacturing process followed on case study plant:-

1. Various raw materials of brick mix in desired proportion are blended intimately in dry or
wet form. Water/brick-mix ratio is maintained as explained above.
2. The wet brick-mix is fed into the machine mould. The vibration is given for a while and
the mould is again fed. The striper head is pressed and vibration is given simultaneously
for about 8 seconds. The mould is lifted and bricks produced pallet is removed and kept on
the platform for air drying.
3. Next day the bricks produced on the previous day are put in the stack. The stack is formed
with care to see that curing water and air for drying reach to every brick.
4. The bricks are ready for dispatch after 22 days from the date of manufacture.
5. The comprehensive strength of the bricks produced from the brick-mix and the
manufacturing process suggested here in will be 80 kg/cm² to100 kg/cm².
It is observed that the bricks produced are found to be superior then that of conventional Red
burnt clay bricks.
MIX PROPORTIONS

 Fly Ash = 120 kg 60%

 Sand = 40 kg 20%
 Quarry Dust = 20 kg 10%
 Lime = 20 kg 10%

Total = 200 kg

BRICK TESTING RESULTS:

A. ABSORPTION TEST
TABLE 4
ABSORPTION TEST RESULTS
Sr. Wt. before absorption Wt. after absorption of % Av. % absorption
No. of water in kg water in kg absorption
A1 2.64 2.79 5.37
A2 2.69 2.86 5.94
A3 2.65 2.72 2.57 5.08
A4 2.59 2.76 6.16
A5 2.63 2.78 5.37
Remarks: Maximum % absorption is permitted to 20% , 5.08 % ≤ 20 % so O.K.

B. CRUSHING STRENGTH TEST (21 DAYS TESTING)

Tested on: Compressive Test m/c set for 50 tonnes
TABLE 5
CRUSHING STRENGTH TEST RESULTS

Cross Stress for

Tested Load for Average
Sectional Complete
Sr. No. After Complete Crushing of
Area in sq. Crushing
(days) Crushing Tonnes Stress N/mm2
cm. N/mm2
A1 21 264 19.0 7.19
A2 21 264 24.6 9.31
A3 21 264 23.6 8.93 8.63
A4 21 264 25.2 9.54
A5 21 264 21.6 8.18
Remarks:
Normal Clay Bricks: - Minimum Crushing Stress required = 3.5 N/mm2, 8.63N/mm2 ≥ 3.5
N/mm2 so O.K.
Fly Ash Bricks: - Minimum Crushing Stress required = 7.5 N/mm2, 8.63N/mm2 ≥ 7.5 N/mm2
so O.K.
ADVANTAGES OF FLY ASH BRICK
Due to high strength, practically no breakage during transport and use.
Due to uniform size of bricks mortar required for joints and plaster reduces almost by
50%.
Due to lower water penetration seepage of water through bricks is considerably reduced.
Gypsum plaster (plaster of Paris) can be directly applied on these bricks without a
backing coat of lime plaster.
These bricks do not require soaking in water for 24 hours. Sprinkling of water before use
is enough.

DIS ADVANTAGES OF FLY ASH BRICK

Mechanical bonding strength is weak. But this can be rectified by adding marble waste.
Limitation of size. Only modular size can be produced. Large size will have more
breakages.

COMPARISON - BURNT CLAY BRICKS AND FLY ASH BRICKS

TABLE 3
COMPARISON - BURNT CLAY BRICKS AND FLY ASH BRICKS
Sr. No Particulars Burnt Clay Bricks Fly-Ash Bricks
1 Manufacturing Hand Molding, Air Drying M/C & Hand
And Burning Molding , Air Dried
And Water Used At
Ordinary Temperature.
2 Color Red Gray
3 Size & Shape Un- Uniform Size & Shape Uniform Size &
Shape(230*115*
75mm³)
4 Finish Rough Finish Smooth Finish
5 Water Absorption Above 20% Below 20%
6 Efflorescence Moderate Slight
7 Breakage 15% 2%
8 Water Seepage Moderate Almost Nil
9 Erosion Property Often Seen Nil
10 Durability Good Good Better Than Clay
Bricks
 11 Compressive 35 Kg/Cm² 90-140 Kg/Cm²
Strength
12 No. Of Bricks For 550-600 Nos 450-500 Nos
1 M³ Of Brick
Masonry
13 Wastages In 5% 2%
Transport &
Molding
14 Environmental Lot Of Fertile Top Soil Is Waste Material Fly
Effects Used And The Land Is Ash Is Used And
Unsuitable For Cultivation Problem Of Its
Disposal Is Solved
15 Economics All Economical Properties 1.Lesser Handling
Contrary To Fly Ash Bricks Breakage.
2.Less No.
3.Plaster Can Be
Avoided.
4.Resistance Salinity.

ACKNOWLEDGEMENT

The Authors thankfully acknowledge to Dr.C.L.Patel, Chairman, Charutar Vidya Mandal,

Er.V.M.Patel, Hon.Jt. Secretary, Charutar Vidya Mandal, Mr.Yatinbhai Desai, Jay Maharaj
construction, Dr.B.K.Shah, Associate Professor, Structural Engineering Department, B.V.M.
Engineering College, Vallabh Vidyanagar, Gujarat, India for their motivational and
infrastructural support to carry out this research.

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