Fly ash bricks are made through a simple but precise process. Here’s a step-by-step guide on how they’re manufactured:
1. Raw Material Collection: The primary raw materials include fly ash (an industrial waste from thermal power plants), sand/stone dust, lime sludge, and often, cement1. These materials are gathered in the right proportions for the production of the bricks.
2. Mixing: The collected raw materials are then mixed thoroughly to achieve a uniform consistency. This is usually done in a pan mixer.
3. Moulding: The mixed material is transferred into a moulding machine, where it’s compressed at high pressure to form the shape of the brick.
4. Curing: The moulded bricks are then kept in a water tank for curing. This process, which can last about 14-21 days, allows the bricks to harden and gain strength.
5. Drying: After curing, the bricks are left to dry in the open air. This step helps to remove any remaining moisture and further hardens the bricks.
6. Quality Check: Finally, the bricks undergo a quality check to ensure they meet the required standards. This involves testing their dimensions, strength, and weight
It’s important to note that the manufacturing process of fly ash bricks is eco-friendly, as it uses industrial waste and doesn’t require kiln firing like traditional brick making.