Now let ’ s talk about Flyash & Other Environment friendly products in Construction …

1. Now let’s talk about Flyash & Other Environment friendly products in Construction… Knowledge Hub… We at OxyGreen believe in sharing knowledge as well learning anything and everything that is innovative & helpful to the field of Construction as well a hand to save our Mother Earth.

2. Now let’s try & understand this much talked about Flyash in Construction

3. What is Flyash? Fly ash closely resembles volcanic ashes used in production of the earliest known hydraulic cements about 2,300 years ago. Those cements were made near the small Italian town of Pozzuoli - which later gave its name to the term "pozzolan.“  A pozzolan is a siliceous or siliceous / aluminous material that, when mixed with lime and water, forms a cementitious compound. Fly ash is the best known, and one of the most commonly used, pozzolans in the world. Instead of volcanoes, today's fly ash comes primarily from coal-fired electricity generating power plants. These power plants grind coal to powder fineness before it is burned. Fly ash - the mineral residue produced by burning coal - is captured from the power plant's exhaust gases and collected for use.Fly ash is a fine, glass powder recovered from the gases of burning coal during the production of electricity. These micron-sized earth elements consist primarily of silica, alumina and iron. The difference between fly ash and Portland cement becomes apparent under a microscope. Fly ash particles are almost totally spherical in shape, allowing them to flow and blend freely in mixtures. That capability is one of the properties making fly ash a desirable admixture for concrete.

4. Features of Flyash • Spherical shape : Fly ash particles are almost totally spherical in shape, allowing them to flow and blend freely in mixtures. • Ball bearing effect :The "ball-bearing" effect of fly ash particles creates a lubricating action when concrete is in its plastic state. • Higher Strength : Fly ash continues to combine with free lime, increasing structural strength over time. • Decreased Permeability : Increased density and long term pozzolanic action of fly ash, which ties up free lime, results in fewer bleed channels and decreases permeabilityIncreased Durability. Dense fly ash concrete helps keep aggressive compounds on the surface, where destructive action is lessened. Fly ash concrete is also more resistant to attack by sulfate, mild acid, soft (lime hungry) water, and seawater. • Reduced Sulfate Attack : Fly ash ties up free lime that can combine with sulfate to create destructive expansion. • Reduced Efflorescence : Fly ash chemically binds free lime and salts that can create efflorescence and dense concrete holds efflorescence producing compounds on the inside. • Reduced Shrinkage : The largest contributor to drying shrinkage is water content. The lubricating action of fly ash reduces water content and drying shrinkage.  • Reduced Heat of Hydration :The pozzolanic reaction between fly ash and lime generates less heat, resulting in reduced thermal cracking when fly ash is used to replace port land cement. 

5. Features of Flyash Contd… • Reduced Alkali Silica Reactivity: Fly ash combines with alkalis from cement that might otherwise combine with silica from aggregates, causing destructive expansion. • Workability: Concrete is easier to place with less effort, responding better to vibration to fill forms more completely.Ease of Pumping. Pumping requires less energy and longer pumping distances are possible. • Improved Finishing: Sharp, clear architectural definition is easier to achieve, with less worry about in-place integrity. • Reduced Bleeding: Fewer bleed channels decreases porosity and chemical attack. Bleed streaking is reduced for architectural finishes. Improved paste to aggregate contact results in enhanced bond strengths. • Reduced Segregation: Improved cohesiveness of fly ash concrete reduces segregation that can lead to rock pockets and blemishes. • Reduced Slump Loss: More dependable concrete allows for greater working time, especially in hot weather.

6. Flyash-Sand-Lime-Gypsum Bricks Use For walls in housing & all types of building construction as well boundary walls. Salient Features • Environment friendly • Accurate dimensions & excellent surfaces finish • Excellent strength • Quick drying of bricks • Reduce water absorption & shrinkage • Reduction in mortar consumption • Utilization of industrial wastes (ashes/sludge’s) & volcanic ash

7. Compressed Earth / Fly Ash Sand Lime Gypsum Blocks (Interlocking Type) Use For walling compressed earth / fly ash sand lime gypsum blocks. Salient Features • The interlocking blocks required minimum quantity of mortar, plaster in the masonry work • Faster masonry • Improved performance of masonry because of less number of joints • Environmental friendly, energy efficient technology with very low consumption of energy • The production plant can work on electrical or diesel • Machines utilized for manufacturing blocks are mobile and can be shifted from site to site, either near the raw material source or near the construction site. • The product can be designed for use in earthquake / cyclone prone region • Volume of 1 block is equivalent to 3 standard size bricks • Use of marble powder / stone dust is possible

8. Compresses Earth Bricks / Blocks Use Can be used, in walling in a variety of ways, to construct buildings that are aesthetic, efficient & easy to build. Particularly, for rural areas. Salient Features • Energy efficient, eco-friendly technology • Bricks produced are of accurate dimensions & excellent surface finish • Better thermal insulation • Cost effective technology • External & internal plastering not essential

9. Clay Flyash Burnt Bricks Use For walling in the same manner as conventional burnt clay bricks Salient Features • Environmental friendly & energy efficient technology • Un-burnt carbon present in Flyash helps in reduction of fuel consumption • Reduction in drying shrinkage & efflorescence as compared to clay bricks • Reduction in weight • Better thermal insulation • Less reduced emissions from kilns • Percentage of 1st class bricks • Consumption of coal is 50% less than conventional kiln • Kiln used is a covered kiln therefore can work throughout the year & is not weather dependant

10. Marble Slurry Bricks Use For waling, as an alternative, to conventional clay bricks. Salient Features • Environment friendly & energy efficient technology • High volume utilization of waste • Saves construction cost & time • Much stronger than clay bricks • Good heat & sound insulation • Fire resistant technology • 28% less consumption of mortar • 32% less consumption of labour • Plastering can be avoided • High load bearing capacity

11. Solid / Hollow Concrete Blocks Use For walls in housing & building construction as substitute to bricks. Salient Features • Cost effective option • Environment friendly energy efficient • Simple manufacturing process • Industrial wastes like Flyash, Blast Furnace Slag etc. can be utilized • Less consumption of mortar • Leaner mix for production of blocks • Faster masonry

12. Cellular Light Weight Concrete Use In building construction as substitute to conventional bricks / blocks particularly in multi-storey building as it helps in substantial reduction of dead weight leading to reduction of cost of foundations. Salient Features • Environment friendly • Make use of Flyash / Volcanic ash as one of the major constituents • Depending upon the application the density can be designed • Being light weight material, reduces dead load which results in saving of steel inb structure & foundation • High thermal insulation – particularly suitable to air-conditioned buildings • Less consumption of mortars as compared to brick masonry • Energy efficient • The components can be manufactured at site • Substantial material saving

13. Ferro cement Wall Panels Use For walling particularly suitable where speedy construction is required. Salient Features • Cost effective technology • Energy efficient • Dimensional regularity in shape & size • Reduction in construction & finish time • Components can be retrieved for construction on other sites

14. Rat Trap Bond Brick Masonry About the Rat Trap Bond Bricks placed on edge in 1:6 cement sand mortar as shown is a rat trap bond wall. Use For walling as an alternative to conventional English / Flemish Bond Salient Features • Reduction in consumption of bricks by 25% as compared to 230 mm thick solid brick wall • Reduction in mortar consumption • Reduction in load of walls in foundation as Rat Trap Bond load is 80% of solid walls • Good Thermal insulation • Equal strength compared to other conventional bonds • Same stability as that of solid walls • No need of plaster in wall surface • Considered as Earthquake Resistant Technology • Labour intensive technology • Up-to 3 storeyed buildings can be constructed with this bond

15. Micro Concrete Roofing Tiles Use Cladding for slopping roofs of different types of buildings, as an substitute to country tiles, asbestos & other corrugated sheets Salient Features • Highly cost effective • Production under controlled conditions • More durable and strong in different climatic conditions • Can be colored to specification • No noise during rain • Decentralized production makes it more energy effective • Manageable tile size make the structure relatively lighter • Reduction in construction & finishing time

16. Ferro cement Roofing Channels Use For roof & intermediate floor construction as a substitute to RCC slabs particularly suitable for large spans as required in schools, health centre’s, community halls etc… Salient Features • Speedy installation – No shuttering required • 30% cost saving over RCC roofing • Lower dead load on walls • Usable as an intermediate floor • High strength to weight ratio • Elegant profile and unique size • Large span up to 6.1 meters • Light weight, slender element & shell structure

17. RCC Planks & Joists Use For structural roofing in load bearing structure & framed structures. Salient Features • Sturdy & higher strength • Dimensional regularity in shape & size • Saving in time, energy resources • Cost effective roofing option • No shuttering required

18. Reinforced Brick Panels & Joists Use For roofing as an alternative to conventional RCC Slab Salient Features • Economy in steel, cement, labour, time & cost • Simple technology • No shuttering is required • Same structural stability & durability as that of conventional RCC Slab • Suitable for rural areas

19. Precast Concrete L-Panels Use For sloping roofs as an alternative to conventional RCC Slab, particularly suitable for coastal areas prone to cyclone / hurricanes. Salient Features • Reduction in both live & dead load resulting in an economic design of foundation & other supportive structure • Easy to construct a roof • More durable • Also suitable for temporary construction • Cost effective • L-Panels can be used in high rainfall areas • Suitable for rural areas & creating employment

20. Ferro Cement C-Beams / Rafters Use For structural application as beams in roofing. Salient Features • Cost effective prefab technology • Dimensional regularity in shape & size • Reduction construction time • Simple technology • Two C-Beam joined in opposite direction makes an I – Beam

21. Precast Concrete Door / Window Frames Use For all applications where standard door & window openings are provided as a substitute to wood Salient Features • Environment friendly • Termite proof & rot free • Fire & water proof • High quality & long life • Produced with a moderate level of skill and a simple technology • In-built provision for hinges, locks, tower bolts & other hardware

22. Concrete Paving Blocks Use For paving of roads, pavements, driveways, streets, platforms, etc… Salient Features • High compressive strength • Good abrasion resistance • Flexible design of shape & size • Interlocking provides variety of patterns • Re-usable

23. Mosaic & Checkered Flooring Tiles Use Mosaic Tiles: For flooring in housing & building construction Checkered Tiles: For pedestrian pathways, garage, ramps of houses etc… Salient Features • High abrasion resistance • High impact strength • Speedy construction • High quality

24. Bamboo Mat Corrugated Roofing Sheets Use For roofing as an alternative to Galvanized Iron / Asbestos Corrugated Sheets Salient Features • Environment friendly roofing alternative • Light but strong & posses high resilience • Good thermal insulation • Low cost of understructure due to its light weight • Load bearing capacity is comparable to Galvanized Iron / Asbestos Corrugated Sheets • Efficient use of renewable resources • Water proof & termite proof • Resistant to fire with desired fire rating • Aesthetically good • Also suitable for disaster prone & heavy rainfall areas • Very energy efficient roofing material

25. Bamboo Mat Boards Use For partitions, False ceiling, Door / Window shutters, Infill’s paneling, Partitions, Table tops, Cladding, Prefab huts as an alternative to commercial plywood Salient Features • Environment friendly & energy efficient technology • Compare favorably with plywood in terms of durability, stability & versatility • Highly resistant to water, termites, borer, insects, wood rotting fungi • More durable and able to withstand severe climatic conditions • More stronger than plywood

26. Coir Polymer Composite Boards & Ply Use Boards / Ply are ideal for door shutters, door inserts, false ceilings, Table tops, Partitioning, Furniture etc… Salient Features • Environment friendly technology • Has all properties of phenol bonded ply boards with added strength • Has both vertical & horizontal load bearing strengths • Natural, smooth, glossy finishes on both sides • Can be painted, polished or laminated • Low consumption of paint and varnishes • High degree of surface abrasion resistance • Termite / insect resistant • Fire retardant • Can be formed in virtually any shape • Can be nailed or screwed • Maintenance free

27. Flyash / Red Mud Polymer Doors & Panel Products Use A very good wood substitute for Doors, Windows, Ceilings, Partitions, Furniture etc… Salient Features • Environment friendly technology • Fruitful utilization of industrial waste such as Flyash, red mud • Energy efficient production technology • Products stronger than wood • Weather resistant & durable • Termite, fungus, rot & rodent resistant • Fire resistant • Cheaper than natural wood • Less maintenance cost

28. Glass Reinforced Polymer (GRP) Door Shutters & Frames Use For use in residential houses, offices, schools, hospitals, hotels, laboratories etc, as an substitute to wooden door shutters & frames Salient Features • Cost effective& environment friendly technology • Strong durable & impact resistant • Superior quality & finish • Moisture resistant • Boiling water resistant • No painting required for life • Provide Sound & Thermal insulation

29. Finger Jointed Lumber from Plantation Timbers Use To join smaller sections of plantation timber for bringing them up to useable length for paneling, partitions, panel doors, flush doors, furniture, etc… Salient Features • Utilization of plantation wood, thereby saving finger wood • Minimize wastage of wood • Reduced consumption of glue • Horizontal, vertical & inclined finger joints can be produced • High productivity • Joint strength up to 75% of original wood • Removal of defects & rejoining • Both soft & hard woods can be processed