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Fly Ash Brick Making Machine
A fly ash brick making machine produces bricks using fly ash (a waste byproduct of coal power) as the primary raw material, along with cement, lime, water, and additives. The process typically involves mixing raw materials into a homogeneous slurry or semi-dry mix and then compressing them into brick shapes (often using a hydraulic press)
Unlike traditional clay bricks fired in a kiln, fly ash bricks cure at ambient conditions (or steam-cured) without firing, saving energy.
Type of Fly Ash Brick Making Machine
Fully Automatic: PLC-controlled, continuous brick making lines with conveyors, automatic dosing, and hydraulic presses (yielding thousands of bricks/hour).
Semi-Automatic: Machines where raw mix is fed manually or by screw feeder into a molding press; presses operate hydraulically with user control. Output is moderate (~500–3000 bricks/hour).
Manual Machines: For small workshops; manual loading of mold and manual press or small hydraulic press.
Machines are also classified by pallet size (mold dimensions) and output per stroke.
Applications in various Industries
Fly ash bricks are used in building construction (walls, partitions) similarly to conventional bricks. They have high compressive strength and good insulation. Large construction projects, government housing schemes, and infrastructure projects In Ghaziabad often use fly ash bricks to reduce reliance on clay. Globally, they are used in countries with coal industries (e.g. China, India) for sustainable building.
Material Selection Considerations
Key raw material is fly ash, which is low-cost and adds silica/alumina. Cement or lime is added as a binder. The machine’s mold and press are made of hardened steel or alloy to resist wear from abrasive mix. Corrosion is a factor: the brick slurry is alkaline, so mixing and molding parts are often manganese steel or coated to resist alkaline corrosion. Productivity (brick per minute) and brick quality (uniform density) depend on precise material control and high pressure (often 150–200 bar in hydraulic presses). Durability of machines is ensured through robust frames (welded steel) and heavy-duty hydraulic systems.
FAQ's
How do you make fly ash? Fly ash is produced by coal-fired electric and steam generating plants. Typically, coal is pulverized and blown with air into the boiler's combustion chamber where it immediately ignites, generating heat and producing a molten mineral residue.
What is the cost of fly ash bricks? While each fly ash brick costs around Rs 3.50-4, a clay brick of the same size costs around Rs 5-5.50 per bricks.
How do you make fly ash bricks? The mixing proportion is generally 40-50% Fly Ash, 50-40% Sand 10% lime and 4% water. Fly ash reacts with lime in the presence of moisture to form calcium silicate hydrate which is the binder material. The raw mix is molded in the machine, pressed under a pressure into bricks.
What is the use of fly ash bricks? Fly ash brick making machine is used to toughen the bricks. Since the concentration of calcium oxide is very high in Fly ash Bricks, the brick is described as self cementing.
