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8/13/2019 Suraj It Basu

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ECOTECHPRESENTS

FLY SH BRICK N ENTREPRENEURSPPRO CH

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 complexcomposite, arising out of in-built

judgment in orienting the

characteristics and constituents ofvarious products to serve the human

race; and depending on the natures

gift, tapping the same for theapplication of human need.


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Bricks made out of clay is one such product

which proved its credence since the dawn ofcivilization. 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 vaststretches of erstwhile fertile land. Added

to that, soil degradation and disturbances

in ecology are threatening the veryrudimentary pillars of welfare.


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In countries like India, where about 65%

of the population is still living ineconomically 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 brickmanufacturers stands at around 8,000 in numbers. There isalmost an equal number of unregistered brickfields taking the

State level aggregate to approx. 15,000 brickfields.Considering that the minimum annual production of abrickfield is around 30,00,000 pieces, the total clay brickproduction of the State works out to approx. 4,500 Crorepieces.

Taking into account that 10% of this production is carried outusing silt available along the river banks, approx. quantity ofclay bricks manufactured through excavation of top soil maybe assumed at approx. 4,000 Crore pieces, which destroys9.77 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, theminimum quantity of flyash required annually would work

out to :-

4000 Crore pcs x 0.0033 MT/brick x 50% (by weight) = 6.60Crore MT

Therefore, daily requirement of flyash is envisaged at =1,80,000 MT

So, even theoretically, most of the flyash can be recycled bybrick manufacturers, which in turn would save precious topsoil as well as abate carbon di-oxide emission, the processbeing devoid of sintering.


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DISTRICT WISE

ESTIMATED NO.

OF FLYASH

BRICK UNITS IN

WEST BENGAL

40 Units

12 Units

5 Units

2 Units

15 Units

7 Units

5 Units

8 Units

10 Units

15 Units

10 Units

5 Units

4 Units

2 Units

ESTIMATED TOTAL NO. OF UNITS = 140


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2 6

35

140

0

20

40

60

80

100

120

140

160

2000 2005 2010 2012

Estimated No. of Units in West Bengal

Estimated No. of

Units


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1% 3%

19%

77%

Estimated No. of Units in West Bengal

2000

2005

2010

2012


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Properties of Fly Ash brick / block

Compressive strength : 50 - 160 kg/sq.cm.

Water absorption : 1015 percentDensity : As pure mix : 1.4 gm/cc.

As mortar brick: 1.61.8 gm/cc.

Coefficient of softening (depending

on water consistency factor) : 2 -15 percent


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Durability

Once the hydrated compounds and related mineralogiesform 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 ofpozzolanic products.

Pozzolanic applications have been well established as

durable materials of construction for the last 2 3millennium 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 rawmaterial 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?

a) 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 engineeringproperties 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 : 14

th

. September, 1999 ?

Whereas it is necessary to protect the environment,conserve top soil and prevent the dumping and

disposal of flyash discharged from coal or lignitebased thermal power plants on land ;

And whereas, there is a need for restricting the

excavation of top soil for manufacture of bricks andpromoting the utilization of flyash in the manufactureof building materials and in construction activity.


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How flyash bricks and blocks are suitable alternativeto ordinary burnt clay bricks ?

The manufacture of flyash bricks and blocks does notrequire excavation of top soil and utilizes flyashgenerated by thermal power stations instead.

Flyash as all knows has its own problems of disposaland is otherwise a social menace with recycling

through production of building materials being thepreferred utilization.


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Flyash bricks and blocks being chemically

bonded does not require sintering anddispenses 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 responsiblefor global warming.


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Flyash bricks and blocks have the followingadvantages over ordinary burnt clay bricks :-

Better finishHigh 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 cultivationLower cost of bricks and blocks

Less mortar consumption


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Why is the flyash brick/block industry suffering in theState of West Bengal ?

The notifications published by the Ministry ofEnvironment & Forests, Government of India for 100%utilization of flyash bricks, blocks and tiles for allconstruction works within a radius of 100 kilometres

of a coal/lignite based thermal power plant is notbeing adhered to by both the Government andprivate construction agencies in the absence ofmonitoring by statutory authorities and/or impositionof penal provisions as provided by law. Even thermal

power plants generating the flyash do not use flyashbricks, blocks and tiles mandatorily in all itsconstruction works.


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The flyash bricks and blocks industry is

burdened with unfair tax regime vis--vis theclay brick manufacturers, who can get away

with evasion of VAT, Central Excise, ESI, PF

and other statutory duties or taxes inspite ofdoing 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-riseindustry in West Bengal are as under :-

a) Entrepreneurs are entering the business on

a hype of making fast money devoid ofknowledge 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 ofraw material cost of the product.


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Nature always summons for transformations in materialscience and that is how balance is atoned in resourceavailability to fulfill the varietal needs of human race.

Though talk of habits and attunements are populararguments, particularly in countries like India whileresponding to advent of innovative products, need forces tocompromise first and get appeased next.

The availability and use of clay is exactly at such crossroads.Lack of technological and material alternates held up clayusers all these years inspite of dire necessities andpressures. The profuse availability of fly ash on one handand FAL-G technology on the other have emerged to offer

respite on clay front. Hence it is time to say good-bye toclay bricks and welcome flyash brick manufacturing with abig hand for its techno-economic virtues.


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THANK YOU