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Fly Ash Bricks Soon Replace Clay Bricks Industry in Bihar

In the 19th century, the word fly ash bricks does not exist at that time. The mud houses were built mostly everywhere.

As time passed, people started building houses of red brick instead of clay.

This modern era is filled with technology. Today’s improvements in technology are being seen in our cities, neighborhoods, and almost every part of the country.

Such as skyscrapers, roads, vehicles, all these things are made faster by technological improvements.

Infrastructure is the most important aspect in GDP for every country. And along with GDP, it also affects the environment.

As I mentioned earlier, mud houses were built and then came the era of red bricks and is still going on.

But when mud houses were built, at that time the environment was not so polluted.

But since the red brick manufacturing started on a large scale, gradually it polluted the environment.

This does not mean that this is the only reason behind it. There are other reasons as well.

You must be thinking that,

How Will Red Brick Harm the Environment?

So let us tell you that while making clay bricks, nature is harmed in two ways.

First reason is the top layer of the land would have been fertile, by taking it out, we cannot cultivate that land.

This is a very big and serious reason; it has a lot of impact on the environment.

Another reason is that when clay is poured into a mould and shaped into a brick, then it is allowed to dry and heated in a kiln at a high temperature.

Due to this process, the smoke dissolves in the atmosphere, which is harmful for our health and also it affects the ozone layer.

Bihar Switched to Fly Ash Bricks

Nowadays, if someone wants to build with red brick, then he can do it and most places construction is being done with red brick.

But when it comes to Bihar, it is one step ahead. The Bihar government has decided that no construction work will be done with red brick.

This means that the Bihar government has completely banned the red brick.

The best thing is that, if a person wants to start a business related to the manufacturing of fly ash bricks, then he can establish the unit only after giving information to the department.

The government will support you in every way to start this business and free fly ash will be provided by NTPC Kahalgaon on demand.

The construction work done with fly ash bricks is strong as well as economical. Its use greatly reduces the cost.

More than six thousand red brick kilns and 400 fly ash brick units are operating in the state.

The minister said that red brick kilns cause a lot of pollution. For this reason, the Bihar government has directed the closure of the red brick kiln.

All red brick kilns in the state will not be closed simultaneously. The sudden closure of all red brick kilns will cause a lot of trouble to the common people.

Advantage of Fly Ash Bricks

That is why gradually by completely closing the red brick kilns, and the state government will promote the brick kiln of fly ash bricks. It comes under the category of white industry.

The pollution from fly ash bricks is very less. There is no need for any kind of license for this.

Fly Ash Bricks Home

Also, the Fly Ash Brick Making Machine comes with various capacities from 8000 to 30,000 bricks per shift.

In such a situation, the fly ash bricks industry will prove to be very effective in promoting employment.

The minister said that the details of red brick kilns available at all district and block level have been sought after that the required assessment will be taken. On this basis, gradually the red brick kiln will be closed.

Conclusion

Bihar has decided to completely ban red brick manufacturing for its better future.

Going forward, gradually every state can ban the production of red bricks. This will boost the business related to fly ash bricks.

And people will also like to make their house with this non-polluting fly ash brick because it is a very good option in every way.

With such changes, it can be said that our country is moving towards becoming a pollution free country. And it will make our future even better.

Best Business Ideas to Start Business in Construction Industry

India is a developing country and construction is vital part of it so there are lots of construction projects ongoing such as roads, bridges, buildings, schools and colleges, etc.

During the pandemic, the pace of construction slowed down, but if seen annually, more construction has been done according to percentage as compared to every year.

In this technological era, people want to try new ideas or something different and better.

As for construction, nowadays developers as well individuals have started using fly ash bricks, concrete bricks, and paver blocks for construction.

If you want to start your own business or searching for an idea for a business to begin, you can choose from a fly ash bricks, or concrete bricks, or blocks making.

It is a growing and most profitable business especially if you know how to set up or run the business.

Globally, this industry is hugely profitable. So, you can make a lot of profit in this businesses.

INDUSTRY OVERVIEW

The Indian construction industry plays an important role in the economy and contribute around 9% of India’s GDP.

Global Data’s ‘Construction in India – Key Trends and Opportunities to 2023’ report declare that India’s construction industry is presumed to grow at a compounded annual average of 6.44% to US$690.9 billion in 2023.

Also, according to a research by Global construction and Oxford Economics, India will become the world’s 3^rd biggest construction market by 2025, adding 11.5 million homes a year to become a $1 trillion a year market.

This is very encouraging for the entrepreneurs who will start a new journey in the construction industry in India.

In view of, this is the great time to begin your business. First, let’s take a look at Fly Ash Brick Making Business.

FLY ASH BRICK

The looks of fly ash bricks are very magnetic due to their pleasing color like cement, uniform size, and smooth finish.

It has high robustness, no breakages/wastages during transport and handling.

The heat passes ratio of fly ash bricks is 0.90 – 1.05 W/m2.

They soak up less heat and keeps your building cooler in summer makes it most appropriate for Indian climates.

These bricks are highly durable and less permeable. The lower permeability can efficacious decrease the effect of efflorescence on bricks.

These bricks are highly fire-resistant compared to normal clay bricks.

Fly ash bricks are environmentally friendly as they are made of Fly Ash which is a waste generated by burning of coal in thermal power plants.

These bricks have easy workability, sock up less water and cost is around 30% lower than clay bricks.

Because of its lightweight, these bricks are appropriate for multi-story structures. Fewer weight means fewer stress on the establishment.

If you are searching for a Swadeshi Business Idea, Fly Ash Bricks Manufacturing is a great idea.

Fly ash bricks are distinctive bricks manufactured from industrial wastes such as fly ash, water, quicklime or lime sludge, cement, and gypsum so, these types of bricks have gained popularity worldwide over clay bricks.

HOW TO START FLY ASH BRICK MAKING?

Area Requirement & Profit

In our country, 72% of Power plants based upon coal and they generate 40 million tons of fly ash per year.

According to a report of the Village Industries Commission (KVIC), the cost of starting this business is around 20 lakhs.

You require at least around 20,000 to 50,000 square feet of land and 15 to 20 worker and require fly ash brick making machine.

These Fly Ash Brick Making Machines have various models and capacities from 1000 to 10,000 bricks per hour.

The cost of this machine is according to production capacity which starts from 15 Lakhs.

Now take a look at Concrete Brick and Block Making Business.

CONCRETE BRICK AND BLOCK MAKING BUSINESS

Making Process of Concrete Blocks

It is a productive way to create a low-maintenance home in a high-moisture location.

It gives a natural level of fire resistance and materials can lower a homeowner’s energy usage.

Homes made from concrete brick and block are practically soundproof.

This material makes a fine home choice for many people.

The walls of a concrete brick and block home can manufacture off-site.

If a natural calamity strikes, then a concrete brick and block home is usually cheaper to rebuild.

A concrete brick and block business is significant to the building industry. This concrete brick and block business plan will be useful to you.

First you need to do a market research. A great business idea will let the entrepreneur see all the aspects about the business.

Today various types of concrete blocks available in the market.

Among them solid concrete blocks, hollow concrete blocks, concrete stretcher blocks, concrete corner blocks, concrete pillar blocks, jamb concrete blocks, partition concrete block, lintel blocks, frogged brick blocks, bullnose concrete block, etc.

The fully automatic concrete brick and block making machines are suitable for the manufacturing of high-strength Concrete Bricks and Blocks.

These automatic machines produce superior quality Concrete Bricks and Blocks, but it requires significant capital investment.

The manually operating machines are also obtainable and can even be install in the project area.

Moreover, the average initial capital needed for covering the costs of equipment, land purchase and employment is around 1 crore or nearby.

CONCLUSION

Fly ash brick, Concrete blocks, and Pavers can be useful for different location in various construction projects, whether you’re laying down a roadway, pathway, building load-bearing masonry walls, or creating partition walls.

This types of brick, block and paver manufacturing plant has huge potential in existing industrial market.

How Concrete Blocks are Made?

The concrete blocks or cement bricks are building material used to build walls in the building. It is also known as a concrete masonry unit (CMU). The concrete blocks are one of the precast concrete products used for construction. Precast is the blocks are formed and hardened before they reach the job site. There are various concrete blocks and have one or more hollow cavities and the side may cast smooth or with design. These blocks are stacked with concrete mortar to make a wall.

The concrete mortar was first used by Romans in 200 B.C. for binding shaped stone in the building. In the Roman emperor, Caligula in 37-41 A.D. the small blocks of concrete as construction material in modern-day Naples, Italy. The concrete technology develops by Romans is lost with the fall of the Roman empire in the fifth century. An English stonemason Joseph Aspdin develop Portland cement in 1824.

The first hollow concrete block is designed by Harmon S. Palmer in 1890 in the United States and after 10 years of research and experiment, he patented the design in 1900. The block developed by Palmer was 8 x 10 x 30 inches and heavy that the crane is used to move.

In this time there was an average 10 blocks made by one person and it was cast by hand. With modern-day machines and advanced technology, it is 2,000 blocks per hour.

Cellular Lightweight Concrete Materials

Which Raw Materials are used?

For making the concrete bricks or blocks the raw material like a mixture of powdered Portland cement, water, sand, and gravel is used. These raw materials together make a light gray block having a fine surface texture and have high compressive strength. The weight of a typical concrete block is 38-43 lb (17.2 to 19.5 kg). There is a higher percentage of sand and a lower percentage of gravel and water for the blocks. This made very dry, stiff mixture and hold shape when removing from the block mold.

Different types of Raw Material

The cinder block is made with granulated coal or volcanic cinders. This is a dark gray block with a medium to coarse surface texture, having good strength and good sound-deadening property with high thermal insulating than the concrete block. The typical cinder block weighs around 26-33 lb (11.8-15.0 kg).

If there is granulated coal or volcanic cinders are used instead of sand and gravel with expanded clay, shale or slate the lightweight concrete block is made. The expanded clay, shale, and slate are made with crushing the raw materials and heating up to 2000^o (1093^o)^. The material is bloat or puffs up as there is rapid a generation of gases caused by the combustion of small particles f organic material inside. The light-weight concrete block weighs around 22-28 lb (10.0 to 12.7 kg) use to build a non-loading bearing wall and other partitions. Also, the blast furnace slag and natural volcanic materials like pumice and scoria are used for lightweight blocks.

Along with basic components, there is concrete mixture is used to make blocks contains a chemical called admixture for altering curing time and it increases the compressive strength or to improve workability. There are pigments added into blocks for uniform color or make the surface of the block uniform. This also protects the surface of a block from chemicals. The glaze on the block surface is made with a thermosetting resinous binder, silica sand, and color pigments.

Design of the Concrete Blocks

There are standardized shapes and sizes for common concrete blocks for building construction. The common block size is 8 x 8 x 16, as 8 inch high, 8 inches deep, and 16 inches wide. This measurement is including the bead of mortar and block measure is 7.63 in (19.4 cm) high, 7.63 in (19.4 cm) deep, and 15.63 in (38.8 cm) wide.

Many block manufacturers offer variation in block to look it aesthetically look better for particular applications. Like there is one concrete bricks or blocks manufacturer who designs blocks especially for water resistance through exterior walls. There is a split-faced block with rough, stone-like texture on one face of the block then the smooth face. These concrete bricks give a nice look aesthetically.

Manufacturing Process of Concrete Bricks or Blocks

cement bricks

The concrete bricks manufacturing process consists of four steps: mixing, molding, curing, and cubing. There are concrete plants which only make concrete blocks while others produce a variety of precast products like blocks, flat paver, decorative pieces like lawn edging, concrete bricks, etc. With the advancement in technology some concrete brick making plants capable of making 2000 blocks per hour.

1.Mixing

Sand and gravel are stored in silos outside and then transfer through conveyor belt when needed and the cement is stored in silos to make it safe from moisture. When the mixing has started the sand, gravel and cement are coming out from silos via weighing batcher which weighs every material. The dry materials enter into a mixer where they are blended for a few minutes. There are mainly two types of mixers that use one is planetary or pan mixer also known as a shallow pan with a lid. The mixing blades are attached to a vertical rotating shaft with a mixer. Another type is a horizontal drum mixer. This is a coffee turned on the side and has mixing blades attach to the horizontal rotating shaft inside the mixer.

After the blending of dry materials, the small amount of water is added to the mixer. Now if the plant is located in warm places, the water is the first pass through heater or chiller to maintain the temperature. The mixing chemicals and color pigments added at this time and the concrete is mixed for six to eight minutes.

2. Molding

After the mixing, the concrete is dump into bucket conveyor and transported to an elevated hopper and the mixing cycle begins after the next load. After that, it is conveyed to other hoppers on the block machine at a controllable speed. Then concrete is downward to flow rate and it pours into molds. In the molds, there is an outer mold box that contains other mold liners. Liners have an outer shape of the block and inner shape of block cavities. There are 5 to 15 blocks are molded at one time depend on machine capacity.

After the mold filled with concrete, the hydraulic press compresses the concrete into the mold. The compression is complete by air or hydraulic pressure. Many of concrete bricks and concrete blocks machine uses vibration for completion of the process.

After that, the blocked are pushed out of the mold onto a flat steel pallet. The pallet and blocks are push out of a machine to the chain conveyor. Some of the machines have a feature of rotating brush and it removes the loose material from the top of the blocks.

3. Curing

Now the pallets of a block are conveyed to an automated stacker or loader and this places them in a curing rack. There are several hundred blocks on each rack. After the rack is full it is rolled onto a set of rails and then moved to a curing kiln.

This is the room having the capacity to hold several racks of the blocks at a time. There are mainly two types of curing is used. First is low-pressure kiln where blocks are held for one to three hours at room temperature to harden slowly. Then the steam is introduced at 60o F (16o C per hour) to raise the temperature for hardening. The standard weight blocks are cured at 150-165o F (66-74o C) and lightweight blocks are cured at 170-185o F (77-85o C). After reaching the temperature steam is shut off and blocks soaked the hot, moist air for 12-18 hours. The curing process takes about 24 hours.

The other type of kiln is high-pressure steam kiln it is also known as an autoclave. The temperature in this kiln is 300-375o F (149-191o C) and the pressure is 80-185 psi about 5.5 to 12.8 bar. The blocks are held for 5 to 10 hours. The pressure is vented and blocks release the moisture inside. The autoclave curing process is using more energy and also more expensive but it produces more blocks in less time.

4. Cubing

Racks of the cured blocks are then rolled out the kiln and the pallets of a block are unstacked and place on a chain conveyor. After that, the blocks are pushed off the steel pallets and the empty pallets are fed back to the block machine for new blocks.

If there is a split-face block, it first molded as two blocks joined. After the curing completed of double blocks, it passes through a splitter, and the heavy blade strikes between two halves.

The concrete bricks and blocks are pass through a cuber that aligns each block and stacks them into cube three blocks by six blocks deep by three or four blocks high. Then the cubes are carried outside with a forklift and store for dispatch.

Quality

Manufacturing of the concrete bricks and blocks are required to constant monitoring for producing the blocks for required properties. Raw material weighed electronically before goes to mixer. The water content in sand and gravel measured by ultrasonic sensors and how much water is required to measure automatically. For cold and warm conditions, the water has to pass through a chiller or heater before use.

After coming out of the machine the height of the block should check with laser beam sensors and in the curing chamber the temperature, pressure, and cycle time should be check properly and record automatically to ensure that the blocks should cure properly for maximum strength.