• aac plant manufacturers visakhapatnam india



Fly-Ash, an indispensable by-product of Thermal Power Plants, is an environmental threat across the globe. Power plants are facing an ever increasing challenge disposal of this polluting agent. This unit is proposed to manufacture FAL-G Bricks & Blocks by consuming the Fly-Ash as one of the prime raw material. Secondly, it also helps environment by saving the invaluable top soil by not using them in brick making like conventional brick making. Thirdly, they need no burning, thus further enhancing their Eco-Friendly Brand. This is the reason these bricks are also referred as Eco Bricks or popularly Green Bricks, (though the color is gray).

Fly-Ash Bricks and Blocks are largely used in various constructions, such as load bearing and pillar structure Buildings, Boundary walls, Roads, Culverts, Pavements, and wherever conventional bricks can be used. The general Fly ash bricks fall in the strength zone of 60-250 Kg/Cm2, thus is much stronger then conventional Bricks. These bricks gain strength over a period of time up to 2 years, where as the conventional bricks tend to lose strength over a period of time. Because of this strength, the same mix can be also be used to make the Paver Blocks in the same casting machine with interchanging the moulds. These green bricks can attain very regular and uniform shapes. As no burning is involved, so the shape also remains unchanged. As a result, the final Brick work with these green bricks consumes less mortar to build, less mortar to plaster. Further, the FAL-G being artificial cement itself, it forms a more uniform bond with cement, giving almost a homogeneous structure. Not only this, even exposed brickwork (without plastering) is a good durable structure. So people prefer to leave the Green Bricks Brickworks in garages, boundary walls etc. un-plastered.


Shelter is third skin, according to a German Concept, which implies it’s importance next to human Skin and Clothing. This also shows the attachment of human race to this fundamental requirement. Building Material accounts for major component of the construction cost. Depending on the location they can contribute to 60 - 70 % of the cost of construction. With the ever increasing population, the demand for housing increases. This directly creates demand for this prime commodity of building. Add to the above fact the area under discussion and its surrounding area is undergoing a major infrastructure revolution. As Residential, Commercial, IT companies, and Industrial establishments are coming in, we can conclude that the Bricks unit will prosper and flourish in this environment. There is a central government gadget notification mandating government departments and CPWD to use 100% Fly Ash Bricks in their all constructions- directly of through contractors. This factor will help the marketability of this product immensely. Fly Ash policy of the Government also mandates that 20% of Fly ash Generated by a power plant must be given free of cost to SME sector on a priority basis.



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S.No Plant Model No Block Sizes Production Capacity (Blocks/Hr) Plant Capacity (Total Blocks/Day) Power Required for Total plant (in HP) Land Required
(in acres)
Shed Area Required
(in acres)
1 FAL-G 400X150X200 300-500 Blocks 2400-4000 15 0.5 min -
2 IFM-1 400X150X200 450-600 3600-4800 20 0.5-1 min 1000SFT
230X100X75 2000-2500 16000-20000
3 IFM-2 400X150X200 600-700 4800-5600 25 0.5-1 min 1000-1200SFT
230X100X75 2500-3000 20000-24000
4 IFM-3 400X150X200 750-800 3500-4000 40 1 min 1500-1800SFT
230X100X75 6000-6400 28000-32000
5 IFM-4 400X150X200 1000-1200 4500-5000 60 1.5 min 2000-2500SFT
230X100X75 8000-9600 36000-40000

Advantages of using Fly- Ash Bricks

  • Environmental friendly : Consumes Fly ash
  • Environmental friendly : Saves invaluable top soil
  • Environmental friendly: needs no burning/backing
  • Strength: Higher Strength Bricks
  • Uniform Shape: Easier and faster Brick working
  • Uniform Shape: Less Mortar in Brick work
  • Uniform Shape: Less Mortar in Plaster
  • Artificial Cement: Gains strength over time.
  • Artificial Cement: Walls can be left exposed/un plastered
  • Better heat & sound insulation compared to red Bricks
  • Far Lesser brakeage during handling & transportation
  • Better Vibration resistance compared to red Bricks


  • Land required mentioned is approximate. 75% of land required is for storage of Finished Products.
  • The project can be started at a smaller land , if there is a good management practice of marketing as per the prevailing orders. This helps holding a slim stock.
  • Fly to be provided free of cost by power plants. Only transportation to be arraigned by Project. All raw material prices assumed is landing price at project site.
  • The Unit aims for optimal fly ash utilization.
  • Production is estimated at moderate capacity, 1 shifts a day. for ratios analysis
  • 300 working days is considered in a year during the first year.
  • Boundary wall to be constructed from trail production bricks of Unit.
  • Sale price at site is estimated as per existing market Price.
  • Bricks of all sizes will be manufactured according to the market requirement, though mainly 230mm x 110mm x 70mm are the major concentration area.


  • Loading of Raw materials- Materials are loaded onto PAN MIXTURE. There is a provision to fit a BATCHING PLANT in future and loading can be done by the Mini Loader
  • Automatic Batching – In case a batching plant is fitted, The Raw materials are automatically weighed as per the preset weights by means of Load cells and its control circuit. At present, the loading is done by volumetric proportions directly into PAN mixture
  • Mixing - From the batching plant the mixture hopper pulls the materials and then the mix is blended homogenously and intimately in a semi wet form in a Twin shaft mixture.
  • Carrying to Brick machine - The mix is carried to the casting machine by means of conveyer belt.
  • Automatic Brick Making- there are a series of operations which is achieved by automatic PLC system. Pallet is pulled into the Machine. The mix is then collected fed into the machine moulds.. Automatic PLC controlled Vibration and hydraulic pressure is given for a while and bricks are cast on the pallets. The dual application of Pressure and vibration ( in a patent pending micro-sequence application ) ensures perfect compaction with best quality of bricks
  • Automatic Stacking – The machine has a provision to fit a stacker in future. The pallets along with the freshly cast bricks are rolled on a roller platform to the pallet stacker. The Pallet stacker stacks the pallets along with the bricks automatically and the
  • Brick shifting– in the absence of a stacker, the bricks are rolled into the specially provided trolley and they are shifted to the drying yard. If a stacker is present, then the stack is removed by Manual Hydraulic traulley or a mini forklift
  • Curing - Soon after the initial setting of one day, the Blocks/ Bricks are stacked for curing in layers. The layers are stacked in a way to enable water and air to go all around, to ensure proper curing and drying. The curing process is continued for 7 days. The blocks are allowed to normally dry for a day. Now they are ready for dispatch.
    Alternatively, the blocks/bricks can be steam cured for 8 hours or mist cured for 24 hours immediately after production, and made ready for dispatch immediately.
  • Dispatch - the cured bricks can be dispatched to market. The fnal strength of bricks will be around 80 to 120 Kg/Cm2 , water absorption of 6 to 10% and around 1.5 to 1.7 Gms/CC Density.

Quality Control

  • Moisture Content in Fly Ash should not be more than 5%
  • The color of Fly Ash should be either Light Steel or Smoke Gray.
  • It should never contain un-burnt Carbon by not more than 5%
  • Phospho Gypsum should better be made acid free by washing, if it is acidic
  • Special emphasis should be given to curing.
  • Proper stacking and layering can greatly enhance the quality of Bricks & Blocks.
  • Fresh Laid bricks to be protected from rain showers by Polythene Sheets
  • Fresh Laid bricks to be protected direct heavy sun drying by Polythene Sheets
  • Controlled drying under PVC covers of Fresh Laid bricks is advisable.
  • Stacks should not be allowed to fully dry at any time (within first 6 days).

Pollution Control Needs

  • There are no solid or liquid effluents out of this plant.
  • The unit is a Green unit as it consumes Fly-ash, saves fertile top soil and earns CER
  • Workman working in the Bricks production Unit to be provided with protective equipments like dust masks, safety goggles, Gum Boots, Gloves etc.

Energy Conservation needs

The management has to be vigilant in ensuring higher productivity by the optimal utilization of man and machine hours. Periodic checks on working stages, functioning of machinery, their preventive maintenance and timely repairs will help in energy conservation.