ECOTECH

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• ECOTECH
• PRESENTS
• FLYASH BRICK AN ENTREPRENEURS APPROACH

FROM ECOTECH CONCRETE PRODUCTS PRIVATE
LIMITED PLOT NO. 810 (P), SATKENDURI BAKRESHWAR
BYPASS ROAD NUTANPALLY, DUBRAJPUR, DIST. BIRBHUM
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Material science is a complex composite, arising
out of in-built judgment in orienting the
characteristics and constituents of various
products to serve the human race and depending
on the natures gift, tapping the same for the
application of human need.
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Bricks made out of clay is one such product which
proved its credence since the dawn of
civilization. Brickwork is established as an
age-old construction media right from the
thatched house to multi-storeyed buildings.
Natures kind-heartedness in gifting the
humankind with its bountiful resources, of
course, has a threshold limit and the utilization
of clay has reached such a point in construction.
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This potential resource has been over tapped,
unmindful of the consequences, as a result of
which (except in limited pockets of some river
delta regions) barren lagoons have replaced vast
stretches of erstwhile fertile land. Added to
that, soil degradation and disturbances in
ecology are threatening the very rudimentary
pillars of welfare.
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In countries like India, where about 65 of the
population is still living in economically weaker
and rural segments, clay is unanimously the cost
effective building material to make the walls and
floors of their huts. But irreparable exhaustion
has taken place for such versatile product,
leaving no chances of replenishment for millennia
to come.
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• In West Bengal, the industry estimate of
  registered clay brick manufacturers stands at
  around 8,000 in numbers. There is almost an equal
  number of unregistered brickfields taking the
  State level aggregate to approx. 15,000
  brickfields. Considering that the minimum annual
  production of a brickfield is around 30,00,000
  pieces, the total clay brick production of the
  State works out to approx. 4,500 Crore pieces.
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• Taking into account that 10 of this production
  is carried out using silt available along the
  river banks, approx. quantity of clay bricks
  manufactured through excavation of top soil may
  be assumed at approx. 4,000 Crore pieces, which
  destroys 9.77 Crore cum top soil annually as
  under -
• 4000 Crore pcs x 0.08632 cft/brick 345.28 Crore
  cft or
• 9.77 Crore cum of top soil weighing 12.80 Crore
  MT.

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• For converting this estimated volume to flyash
  bricks, the minimum quantity of flyash required
  annually would work out to -
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• 4000 Crore pcs x 0.0033 MT/brick x 50 (by
  weight) 6.60 Crore MT
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• Therefore, daily requirement of flyash is
  envisaged at 1,80,000 MT
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• So, even theoretically, most of the flyash can be
  recycled by brick manufacturers, which in turn
  would save precious top soil as well as abate
  carbon di-oxide emission, the process being
  devoid of sintering.

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DISTRICT WISE ESTIMATED NO. OF FLYASH BRICK
UNITS IN WEST BENGAL
2 Units
12 Units
8 Units
5 Units
10 Units
40 Units
15 Units
2 Units
15 Units
10 Units
7 Units
5 Units
5 Units
4 Units
ESTIMATED TOTAL NO. OF UNITS 140
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• Properties of Fly Ash brick / block
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• Compressive strength 50 - 160 kg/sq.cm.
• Water absorption 10 15 percent
• Density As pure mix 1.4 gm/cc.
• As mortar brick 1.6 1.8 gm/cc.
• Coefficient of softening (depending
• on water consistency factor) 2 -15 percent

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• Durability
• Once the hydrated compounds and related
  mineralogies form out of flyash constituents
  upon activation with cement or lime and gypsum,
  no further reactivity is evident either
  internally or with extraneous media like ground
  and air laden chemicals. This results in
  dimensional stability and enhanced weather
  resistance of pozzolanic products.
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• Pozzolanic applications have been well
  established as durable materials of construction
  for the last 2 3 millennium and Fly Ash
  Concrete is nothing but an improved version of
  this established pozzolanic chemistry.

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• Environment Friendly
• Notwithstanding the techno-economic virtues,
  Fly Ash bricks comply with the criteria for
  environmentally friendly products and eligible
  for Carbon Emission Reduction earnings in terms
  of Kyoto Protocol on account of the main raw
  material being an industrial by-product and the
  manufacturing process being devoid of sintering
  or auto-claving is totally energy conservative.

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• What made Fly Ash brick/block attractive?
• Fly Ash bricks do not lose strength unduly even
  on soaking in water continuously. Hence
  plastering is optional rather than necessary.
• b) On account of size accuracy, plastering can
  be rationalized adding additional savings on
  cement.
• c) Well cured fly ash bricks absorb 4 12 of
  water only.
• d) On account of less absorption,
  rationalization of plastering mortar, a
  finished fly ash brick wall is lighter and
  cheaper in comparison to finished clay brick
  wall.
• e) Fly ash bricks can be made to order with
  engineering properties comparable to cement
  concrete, befitting for specialized applications
  such as canal lining, dam construction, water
  tanks, etc.

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• Why the Ministry of Environment Forests,
  Government of India published the notification no
  S. O. 763 (E) dated 14th. September, 1999 ?
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• Whereas it is necessary to protect the
  environment, conserve top soil and prevent the
  dumping and disposal of flyash discharged from
  coal or lignite based thermal power plants on
  land
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• And whereas, there is a need for restricting the
  excavation of top soil for manufacture of bricks
  and promoting the utilization of flyash in the
  manufacture of building materials and in
  construction activity.

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• How flyash bricks and blocks are suitable
  alternative to ordinary burnt clay bricks ?
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• The manufacture of flyash bricks and blocks does
  not require excavation of top soil and utilizes
  flyash generated by thermal power stations
  instead.
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• Flyash as all knows has its own problems of
  disposal and is otherwise a social menace with
  recycling through production of building
  materials being the preferred utilization.
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• Flyash bricks and blocks being chemically bonded
  does not require sintering and dispenses with the
  need for coal a non-renewable fossil fuel.
  Further, as need for burning the bricks and
  blocks is absent, the manufacturing process is
  totally environment friendly and contributes
  substantially to reduction of carbon di-oxide
  emission - a harmful greenhouse gas which is
  responsible for global warming.
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• Flyash bricks and blocks have the following
  advantages over ordinary burnt clay bricks -
• Better finish
• High Strength
• Less water absorption
• No efflorescence
• Lower unit weight and less load on foundation
• Reduced energy consumption
• No excavation of top soil which is otherwise
  suitable for cultivation
• Lower cost of bricks and blocks
• Less mortar consumption

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• Why is the flyash brick/block industry suffering
  in the State of West Bengal ?
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• The notifications published by the Ministry of
  Environment Forests, Government of India for
  100 utilization of flyash bricks, blocks and
  tiles for all construction works within a radius
  of 100 kilometres of a coal/lignite based thermal
  power plant is not being adhered to by both the
  Government and private construction agencies in
  the absence of monitoring by statutory
  authorities and/or imposition of penal provisions
  as provided by law. Even thermal power plants
  generating the flyash do not use flyash bricks,
  blocks and tiles mandatorily in all its
  construction works.

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• The flyash bricks and blocks industry is burdened
  with unfair tax regime vis-à-vis the clay brick
  manufacturers, who can get away with evasion of
  VAT, Central Excise, ESI, PF and other statutory
  duties or taxes inspite of doing enormous harm
  to the environment through excavation of top
  soil, consumption of non-renewable coal and
  emission of carbon di-oxide.

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• Some other bottlenecks that are acting as hurdles
  to the development of this sun-rise industry in
  West Bengal are as under -
• a) Entrepreneurs are entering the business on
  a hype of making fast money devoid of knowledge
  about the process technology and marketing
  constraints.
• b) There is less consciousness and focus on
  product quality leading to a wide variation in
  attributes amongst different manufacturers.

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• c) Cannibalisation amongst manufacturers due to
  inadequate demand for the product and very slow
  evolution of market in absence of use by
  Government departments and agencies under their
  control.
• d) Buyers need to be realistic while drawing up
  specification and price so that manufacturers are
  not compelled to compromise on the binder, which
  constitutes 60 70 percent of raw material cost
  of the product.

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• Nature always summons for transformations in
  material science and that is how balance is
  atoned in resource availability to fulfill the
  varietal needs of human race. Though talk of
  habits and attunements are popular arguments,
  particularly in countries like India while
  responding to advent of innovative products, need
  forces to compromise first and get appeased next.
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• The availability and use of clay is exactly at
  such crossroads. Lack of technological and
  material alternates held up clay users all these
  years inspite of dire necessities and pressures.
  The profuse availability of fly ash on one hand
  and FAL-G technology on the other have emerged to
  offer respite on clay front. Hence it is time to
  say good-bye to clay bricks and welcome flyash
  brick manufacturing with a big hand for its
  techno-economic virtues.

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• THANK YOU