How Fly Ash Bricks Are Made?

fly as brick making machine process (1)

Fly Ash Bricks Manufacturing Process

Fly ash bricks are produced using a combination of fly ash, sand, lime, and gypsum. These materials are mixed thoroughly, shaped in moulds, and then cured by heating in a kiln. This process utilises waste materials and consumes less energy compared to traditional methods, making fly ash bricks an environmentally friendly alternative to clay bricks.

Bricks have long been valued in construction for their versatility, durability, and ease of use. Over the years, brick manufacturing has evolved significantly with new technologies aimed at improving quality and sustainability. 

A notable advancement is the production of fly ash bricks, which use fly ash—a by-product from coal-fired power plants. By repurposing bricks making machine we provides an eco-friendly waste disposal solution. 

Fly ash bricks have gained popularity in construction due to their cost-effectiveness and sustainability. Understanding their production is essential for construction professionals and anyone interested in eco-friendly building materials.

What are Fly Ash Bricks?

Fly ash bricks are created by combining fly ash, cement, sand, and water. Fly ash is a fine powder generated by coal combustion in power plants. It is captured by pollution control equipment, preventing it from polluting the air. Using fly ash to produce bricks reduces the environmental impact of coal plants and conserves natural clay resources.

Raw Materials Used in Fly Ash Brick Manufacturing

The production of fly ash bricks involves carefully mixing several materials:

  1. Fly Ash: Main ingredient sourced from coal-fired power plants.
  2. Sand: Enhances strength, stability, and the brick’s appearance.
  3. Sludge Lime: Waste product from wastewater treatment, improves strength and durability.
  4. Gypsum: Regulates curing time and enhances brick quality.
  5. Grit (4-8mm): Adds surface texture and improves structural integrity.
  6. Crusher Dust (0mm): By-product of stone crushing; contributes strength and durability.
  7. Cement: Acts as a binder, enhancing the bricks’ strength and durability.
  8. Water: Ensures adequate moisture, binding the mixture and allowing proper brick formation.
 

The proportion of these materials may vary depending on desired brick characteristics such as strength and texture.

Manufacturing Process of Fly Ash Bricks

The manufacturing process includes these steps:

  • Mixing Raw Materials: Fly ash, cement, sand, and water are blended in a pan mixer or batching plant and transferred to a brick moulding machine.
  • Moulding: The mixture is compressed into bricks using a hydraulic machine, ensuring uniform shape and size.
  • Curing: Bricks are placed on wooden pallets and kept wet for 7-14 days, enhancing durability and strength.
  • Drying: Post-curing, bricks are dried in a dryer chamber maintained at 60-70°C to eliminate excess moisture.
  • Sorting and Stacking: Bricks are inspected for quality and strength, sorted, stacked, and prepared for dispatch.

Advantages of Fly Ash Bricks

Fly ash bricks offer numerous advantages:

  • Eco-friendly: Made from waste material, reducing environmental impact.
  • Cost-effective: Less expensive than traditional clay bricks.
  • High Strength and Durability: Possess higher compressive strength and longevity.
  • Better Insulation: Offer superior temperature regulation and energy efficiency.
  • Low Water Absorption: Reduced susceptibility to water damage.
  • Uniform Size and Shape: Manufactured precisely, simplifying construction and reducing waste.
  • Consistent Availability: Fly ash supply is stable, making these bricks readily accessible.

Disadvantages of Fly Ash Bricks

Despite their benefits, fly ash bricks have some drawbacks:

  • Limited Raw Material Quality: Fly ash quality may vary, impacting brick strength.
  • Strength Variability: Inconsistencies in fly ash purity and production methods can result in variable strength.
  • Quality Control: Newness of technology means quality standards may still be developing.
  • Water Absorption Issues: Improper curing and drying can increase susceptibility to water damage, affecting durability.

Why is Revomac Industries the best manufacturer of fly ash brick making machines in India?

Revomac Industries is a leading fly ash brick making machine manufacturer in India. Established in 2010, the company offers a range of machines, including the MAC Smart, Premium, and Robotic series, designed for high efficiency and precision. These machines are capable of producing various concrete products like bricks, blocks, and pavers, catering to diverse construction needs.

MAC Smart Application

Fly ash bricks
(without Frog)

Size: 230 x 75 x 110 (20)
Pcs/Hour: 4,800
Pcs/Shift: 38,400
MAC Premium Application

Fly ash bricks
(with Frog)

Size: 230 X 110 X 75 (12)
Pcs/Hour: 2,880
Pcs/Shift: 23,040
Robotic-application

Fly ash bricks
(without Frog)

Size: 230 X 110 X 75 (35)
Pcs/Hour: 8,400
Pcs/Shift: 84,000