Fly Ash Bricks
| Product Code | N.A |
| Quality and Standards | IS 12894:1990 |
| Uploaded on | May 2007 |
Introduction
Fly Ash bricks are made of fly ash, lime, gypsum and sand. These can be extensively used in all building constructional activities similar to that of common burnt clay bricks. The fly ash bricks are comparatively lighter in weight and stronger than common clay bricks. Since fly ash is being accumulated as waste material in large quantity near thermal power plants and creating serious environmental pollution problems, its utilisation as main raw material in the manufacture of bricks will not only create ample opportunities for its proper and useful disposal but also help in environmental pollution control to a greater extent in the surrounding areas of power plants. In view of superior quality and eco-friendly nature, and government support the demand for Fly Ash Bricks has picked up.
Market Potential
The country consumes about 180 billion tonnes bricks, exhausting approximately 340 billion tonnes of clay every year and about 5000 acres of top soil land is made unfertile for a long period. The Government is seriously concerned over soil erosion for production of massive quantities of bricks, in the background of enormous housing needs.
The excellent engineering property and durability of fly ash brick enlarges its scope for application in building construction and development of infrastructure, construction of pavements, dams, tanks, under water works, canal lining and irrigation work etc. Enormous quantities of fly ash is available in and around thermal power stations in all the states. The demand of bricks could be met by establishing small units near thermal power stations and to meet the local demand with less transportation costs.
Basis and Presumptions
- It is assumed that the unit will operate on single shift basis for 300 working days in a year.
- The salary and wages for staff and labour has been taken into consideration on the basis of prevailing market rates.
- To reach the full plant capacity, it requires 1 year after trial production.
- Interest rate at 13% is considered in the project profile for both recurring and nonrecurring investment.
- Margin money will vary from 10- 25% depending upon the location and scheme adopted by the entrepreneur.
- Operative period of project is around 10 years considering technology obsolescence rate and period of repayment of loan.
- The costs of land, construction charges, machinery and equipment, raw materials, and consumables, other contingent expenses etc. indicated in the scheme are based on the prices, prevailing at the time of project preparation. Therefore, these are subject to necessary changes from time to time based on the local conditions.
Implementation Schedule
Activity |
Period Starting |
Period Completion |
| Survey of collection of data in respect of demand, availability of technology, power, land and clearance from State Pollution Control Board | 1day to | 2nd month |
| Arrangement for margin money | 2nd to | 3rd |
| Preparation of project report and registration | 2nd to | 3rd |
| Finance assistance | 2nd to | 4th |
| Development of Site and construction of building | 5th to | 7th |
| Machine purchasing and installation | 5th to | 8th |
| Trial production | 8th month | |
Technical Aspects
Process of Manufacture
Fly ash, lime sand and gypsum are manually fed into a pan mixer where water is added in the required proportion for intimate mixing. The proportion of the raw material is generally in the ratio 60-80% of fly ash 10-20% lime, 10% Gypsum and 10% sand, depending upon the quality of raw materials.
After mixing, the mixture is shifted to the hydraulic/mechanical presses. The bricks are carried on wooden pellets to the open area where they are dried and water cured for 21 days. The bricks are tested and sorted before despatch.
Quality Control and Standards
The Bureau of Indian Standards has formulated and published the specification for maintaining quality of product and testing purpose.
IS 12894:1990.
Production Capacity (Per year)
| Quantity (Nos.) | : 60 Lakhs bricks | |
| Value | ||
| Motive Power | 30 KW. | |
Pollution Control
The technology adopted for making fly ash bricks is eco-friendly. It does not require steaming or auto calving as the bricks are cured by water only. Since the firing process is avoided, there are no emissions and no effluent is discharged. On the other hand, it solves the problem of fly ash disposal.
Energy Conservation
General precautions for saving electricity are required to be followed by the unit by adopting energy conservation techniques not only to conserve the power but also to save considerable expenditure in their own and also in the interest of the nation as a whole.
Financial Aspects
A Fixed Capital
Land and Building
(Rs.) |
|
| Land 1 Acre @ Rs. 1200000 | 1200000 |
| Building Area 165 sq. mt. @ Rs. 5000 per sq mt. | 825000 |
| Working Shed 150 sq. mt. @ Rs. 4000 per sq. mt. | 600000 |
| Boundary Wall, Gate L.S. | 112519 |
| Fly Ash Pond and Curring Tank L.S. | 200000 |
| Total | 2937519 |
Machinery and Equipments
Description |
Ind./ Imp. |
Qty. |
Price (Rs.) |
| Pan mixer (run by 20 HP motor) | Ind. | 2 | 200000 |
| Gauge winding machine | Ind. | 2 | 450000 |
| Belt Conveyor (Run by 3 HP motor) | Ind. | 1 | 100000 |
| Deep Tube Well | Ind. | 1 | 80000 |
| Generator | - | 1 | 250000 |
| Steel Plates and Extra Moulds | - | L.S. | 150000 |
| Trollies | - | L.S. | 60000 |
| Office, Furniture and Equipments | - | L.S. | 60000 |
| Installation and Erection charges | - | L.S. | 70000 |
| Total | 1420000 | ||
Working Capital (Per Month)
Staff and Labour (per month)
Designation |
Nos. |
Salary |
Total Salary (Rs.) |
| Manager | 1 | 15000 | 15000 |
| Production Engineer | 1 | 12000 | 12000 |
| Skilled workers | 5 | 6000 | 30000 |
| Un-skilled workers | 10 | 4000 | 40000 |
| Chowkidars | 3 | 3000 | 9000 |
| Peons | 2 | 3000 | 6000 |
| Cashier-Cum-Clerk | 1 | 6000 | 4000 |
| Total | 116000 | ||
| Add Perquisites @ 22% | 25520 | ||
| Total | 141520 | ||
Raw Materials (per month)
Description |
Ind./ Imp. |
Qty. (Ton.) |
Rate (P.Ton) |
Value (Rs.) |
| Fly Ash | Ind. | 1000 | 120 | 120000 |
| Lime | Ind. | 1100 | 112000 | 275000 |
| Sand | Ind. | 120 | 35000 | 15000 |
| Gypsum | Ind. | 1100 | 40000 | 137500 |
| Total | 547500 | |||
Utilities (per month)
(Rs.) |
|
| Power | 30000 |
| Fuel | 20000 |
| Total | 50000 |
Other Contingent Expenses (per month)
Particulars |
(Rs.) |
| Postage and Stationery | 2000 |
| Telephone | 4000 |
| Transportation | 10000 |
| Insurance | 5000 |
| Repair and Maintenance | 5000 |
| Advertisement and Publicity | 2500 |
| Misc. Expenditure | 5000 |
| Total | 33500 |
| Total Recurring Expenditure (per month) (i+ii+iii+iv) | 772520 |
| Total Working Capital (for 2 months) | 1545040 |
Total Capital Investment
| Fixed Capital | 4345000 |
| Working Capital | 1545040 |
| Total | 5890040 |
Financial Analysis
Cost of Production (per year)
Description |
Value (Rs.) |
| Total Recurring Cost | 9270240 |
| Depreciation on Building at 5% | 141250 |
| Depreciation on Machinery and Equipment @10% | 136000 |
| Depreciation on Office equipment @ 20% | 12000 |
| Interest on Total Capital Investment @ 13% | 765705.2 |
| Total | 10325195.2 |
Turnover (per year)
Qty. |
Rate |
Value (Rs.) |
| 60 Lakhs Bricks | 2 per bricks | 12000000 |
Net Profit (per year)
| Turn Over – Production Cost | |
| Rs. 12000000 – 10325195.2 | |
| 1674804.8 | |
Net Profit Ratio
Net profit x 100 Total Turnover |
||
1674804.8 x 100 12000000 |
||
| 13.96% |
Rate of Return
Net Profit (per year) x 100 Total Investment |
||
1674804.8x 100 5890040 |
||
| 28.43% |
Break-even Point
Description |
(Rs) |
| Depreciation on building @ 5% | 141250 |
| Depreciation on Machinery and Equipment @ 10% | 136000 |
| Depreciation on Office Equipment @ 20% | 12000 |
| Interest on Total Capital Investment @ 13% | 765705.2 |
| Insurance | 60000 |
| 40% of Salary and Wages | 679296 |
| 40% of Other Contingent Expenses (excluding insurance) | 136800 |
| Total | 1931051.2 |
| B.E.P | Fixed cost x 100 Fixed cost + Profit
|
|
1931051.2 x 100 1931051.2 +1674804.8
|
||
53.55%
|
Addresses of Machinery and Equipment Suppliers
- M/s. Jindal Hydraulics
D-203, Sector-10,
Noida (UP) - NTPC's and Thermal Power Plants for Fly Ash.
- M/s. Stark and Co.
17, Najafgarh Road,
Near Jakhira Chowk,
New Delhi - 110015 - Central Building Research Institute
Roorkee - 247 667 (U.P.) - National Council for Cement and
Building Materials
KM Stone, Delhi - Mathura Road,
Ballabhgarh - 121 004
Distt. Faridabad (Haryana) - Institute for Solid Waste
Research and Ecological
Balance, Vishakhapatnam.
Raw Material Suppliers
Technology
For further information please contact
Information Manager
TIMEIS Project
E-mail: timeis@ficci.com
