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What are the Advantages, Uses & Manufacturing processes of Fly Ash Bricks?
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WHAT ARE FLY ASH CONCRETE BRICKS?
Concrete made of cellular lightweight bricks, or CLC, is also referred to as foam concrete. A type of lightweight concrete known as cellular lightweight concrete (CLC) is created in the same way as regular concrete under natural production conditions. CLC Bricks are a cement-bonded product created by mixing cement slurry. To create foam concrete, stable, pre-formed foam that is produced locally is injected into this slurry. Cellular lightweight concrete or foam concrete is used to make CLC bricks.
Fly ash is a fine, powdery substance that forms a material similar to Portland cement when mixed with water. Portland cement is created by mixing limestone and clay or shale that’s been finely ground or burned. Fly ash bricks tend to only come in small sizes, since they become less durable the bigger they get, and are more prone to fractures and cracking at larger sizes.
ADVANTAGES OF CLC CONCRETE BRICKS IN CONSTRUCTION
LIGHT IN WEIGHT
CLC bricks range in density from 600 to 800 Kg/cum. This costs almost three times as little as the standard clay or fly ash bricks.
REDUCED CONSTRUCTION COST
When CLC bricks are utilized in construction, the overall dead load of the structure is reduced. House owners can save money on expensive construction materials like cement and steel by optimizing the design appropriately.
ECO-FRIENDLY
Materials like fly ash and other industrial wastes are used to make CLC bricks. There are no toxic effluents released during the CLC block production process that could influence the ground, water, or air.
SOUND AND THERMAL INSULATION
CLC Bricks are good for insulating against heat and sound. As a result, the energy used to heat and cool homes is reduced, which lowers the cost of power for homeowners.
LOWER WATER ABSORPTION
The water absorption of CLC bricks is significantly less than that of other materials because they contain air spaces that are not connected to one another. This contrasts far better than concrete, which absorbs water to the tune of 50% to 80%, and regular brick. The reduced water absorption of these bricks will aid in minimizing wall fractures.
FIRE PROTECTION
Bricks made of foam concrete are fire resistant. With a wall that is only 100mm thick and has a density of 1000 kg/m3, it can withstand a fire for 4 hours while still transmitting heat without releasing any poisonous gases.
EASE TO HANDLING
Construction costs are reduced since CLC bricks are lightweight and simple to handle and install. They also use less cement and sand for bonding during construction.
WHERE ARE FLY ASH BRICKS USED?
- Acoustic construction
- Precast exterior walls
- Roof insulation and waterproofing
- Green construction
- Additional floors to an existing structure
- The building material for high-rises
- Air-conditioned buildings
- Subways
MANUFACTURING PROCESS OF FLY ASH BRICKS
- Approximately 5 Bags of OPC 53 Grade Cement and 500 Kg of Fly ash are put into a mixer to make 1 Cum of CLC bricks.
- 30 Ltrs of water and approximately 1.2 kg of a foaming agent are added and properly combined.
- By allowing air to enter the mixture, the foaming agent makes the slurry lighter in weight.
- The mixer’s slurry is removed, and one liter of it is weighed to determine its density. The slurry is drained into trollies if the requisite density is attained.
- The slurry is then applied to brick molds that have been built to the necessary dimensions, and it is left to set for 18 to 24 hours.
- The completed CLC bricks are transported to the curing area and left there for 28 days to cure. Bricks with good curing have the strength and dimensional stability.
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