What is a fly ash bricks project report?
A bricks from fly ash project report is a detailed project report (DPR) for a unit that presses fly ash with lime or cement, sand and gypsum into building bricks. It covers the process, machinery, raw materials, market, project cost, means of finance, five-year projections, DSCR and break-even that a bank or PMEGP office reviews before funding.
Entrepreneurs near thermal power plants use it to size a brick unit and apply for a term loan or PMEGP; lenders use it to judge whether brick sales can repay the loan.
Also known as: fly ash bricks project report, fly ash brick plant DPR, fly ash brick business plan, fly ash brick project report PDF.
What a bank checks in a bricks from fly ash project report
A fly ash brick unit earns a small margin on a very large number of bricks, so a lender looks hard at price, cement cost and repayment in the weakest year. These are the values in our sample report and why each one matters.
Banks compare it with what local dealers and contractors pay at the gate. A price taken from retail rates or another district inflates sales and DSCR.
Cement is the largest single item in the sample mix, so a rise in cement prices hits profit faster than any other cost. A good report tests it.
DSCR (debt service coverage ratio) is the cash available for each rupee of loan instalment. Lenders read the weakest year, not only the 1.63 average.
Builders and works contractors often pay late. Debtor days, plus 15 days each of raw material and finished brick stock, set the cash credit limit.
Values are the assumptions in our illustrative sample. Your report uses figures for your capacity, ash source and market.
Fly ash brick manufacturing plant cost in India
Cost depends mainly on the type of press. A manual or semi-automatic press needs more workers per brick, while a fully automatic line with batching and a loader needs fewer people but far more capital. The large tier is the unit modelled in our sample report; the other two are indicative ranges.
Small unit
₹20–45 lakh
About 3,000–10,000 bricks per day, manual or semi-automatic press
- Press and mixer₹8–20 lakh
- Shed, platform and curing yard₹6–15 lakh
- Working capital margin₹2–5 lakh
Fits PMEGP or Mudra, subject to limits
Mid-size unit
₹50–95 lakh
About 10,000–18,000 bricks per day, semi-automatic line
- Machinery₹25–45 lakh
- Land and building₹15–35 lakh
- Working capital margin₹4–8 lakh
MSME term loan, often with CGTMSE cover
Fully automatic unit
₹133 lakh
24,000 bricks per day, 72,00,000 bricks per year
- Plant and machinery₹66.53 lakh
- Land and building₹47.38 lakh
- Working capital margin₹5.56 lakh
Term loan ₹99.83 lakh (75%), promoter ₹33.28 lakh
Small and mid-size ranges are indicative and assume rented or owned land at rural rates. Press make, land price and distance from the ash source move them most.
Fly ash brick plant economics in our sample
The sample models a 24,000 bricks per day plant working 300 days a year. It starts at 60% of capacity and reaches 80% in Year 5, with 14 people on the payroll and bricks sold at ₹4.81 each.
| Land and site development | 25.48 |
|---|---|
| Building and civil works | 21.90 |
| Plant and machinery | 66.53 |
| Other fixed assets | 6.11 |
| Contingencies | 4.42 |
| Preliminary and pre-operative | 3.11 |
| Working capital margin | 5.56 |
| Total | 133.11 |
| Promoter's contribution (25%) | 33.28 |
|---|---|
| Term loan from bank (75%) | 99.83 |
| Cash credit limit (separate) | 16.67 |
| Total project cost | 133.11 |
Term loan at 10.5% with a 6-month moratorium and 54 monthly instalments. All figures are illustrative.
Bricks from fly ash manufacturing process
Fly ash bricks are pressed and water-cured, not fired in a kiln. The binder (lime with gypsum, or cement) reacts with the ash over the curing period, which is why yard space and water matter as much as the press.
- Receiving and storing ash
Dry fly ash arrives in tankers or covered trucks and is kept in a covered bay or silo, so it stays dry and does not blow around.
- Batching
Fly ash, binder, sand or stone dust and gypsum are weighed in the set proportion; weigh batching keeps every batch the same.
- Mixing
A pan mixer blends the batch with a measured amount of water to a semi-dry mix that holds its shape when pressed.
- Pressing
A hydraulic press compacts the mix in the mould and ejects green bricks onto pallets.
- Initial setting
Green bricks rest on pallets under shade for one to two days until they are firm enough to stack.
- Water curing
Stacked bricks are kept wet in the yard; our sample allows 14 to 21 days, while the Odisha pollution board guideline describes 10 to 14 days.
- Testing and dispatch
Sample bricks are tested for compressive strength, water absorption and efflorescence before lots are released to buyers.
Raw materials and mix for fly ash bricks
By weight, fly ash is most of the brick. The Odisha pollution board guideline gives a typical lime mix of about 70% fly ash, 10% lime, 5% gypsum and 15% sand. By cost the picture is different, because ash is cheap and binder is not. In our sample, cement is the largest item and ash, including its transport, is a quarter of raw material cost.
| Raw material | Share of cost | Year 3 (₹ lakh) |
|---|---|---|
| Fly ash (including transport) | 25% | 29.05 |
| Cement | 30% | 34.87 |
| Lime | 20% | 23.24 |
| Sand or stone dust | 20% | 23.24 |
| Gypsum | 5% | 5.81 |
| Total | 100% | 116.21 |
Check the ash before you fix the mix: ash from different units of the same power plant can vary in fineness and unburnt carbon. Bottom ash used in place of sand should have a loss on ignition of 12% or less. Lime should be class C hydrated lime with at least 40% CaO.
Fly ash brick making machine and other equipment
The press is the heart of the plant and the largest single cost. Everything else either feeds it a consistent mix or moves green bricks away fast enough to keep it running.
| Machine | What it does | Sample cost (₹ lakh) |
|---|---|---|
| Fully automatic hydraulic brick press | Presses and ejects green bricks | 29.94 |
| Pan mixer with weigh batching | Weighs and blends each batch | 9.98 |
| Wheel loader | Moves ash, sand and mix around the yard | 7.98 |
| Pallets and trolleys | Carry green bricks to the setting area | 6.65 |
| Belt conveyors and hoppers | Feed mix from mixer to press | 5.32 |
| Water storage and pumping system | Supplies mixing and curing water | 2.66 |
| Compressive strength testing machine | Tests bricks before dispatch | 2.00 |
| Electrical control panel | Controls press, mixer and conveyors | 2.00 |
| Total plant and machinery | 66.53 | |
Costs are the sample report's estimates for a 24,000 bricks per day line. Get current quotations before you finalise.
Market for fly ash bricks: who buys and how far they travel
Fly ash bricks compete directly with burnt clay bricks in walls. Builders choose them for uniform size, which cuts mortar and plaster, and public works departments in several states prefer or require fly ash products for buildings near thermal power plants.
Sales slow in the monsoon, when construction pauses, so the unit carries more finished stock for those months. Bricks are heavy for their price, which keeps most sales within a district or two of the plant.
- Builders and real estate developers
- Government, PWD and railway works contractors
- Individual house builders
- Building-material dealers
- Industrial and warehouse construction contractors
Where a new unit wins: between the power plant and the buyer. A site that is close to both keeps ash freight and brick freight low, which is usually the whole margin in this business.
Licences, BIS standards and GST for a fly ash brick unit
| Business registration | Udyam (MSME) registration and GST registration |
|---|---|
| Pollution board consent | Consent or registration with the State Pollution Control Board; Odisha lists fly ash brick and block units in the white category, but each state keeps its own list |
| Product standard | IS 12894 for fly ash lime bricks (classes from 3.5 to 30 N/mm², water absorption up to 20% for class 12.5 and below) or IS 16720 for fly ash cement bricks |
| BIS certification | A draft Fly Ash based Products Quality Control Order (2023) proposed making BIS marking compulsory for these bricks; check its status before you plan sales |
| GST | Heading 6815; 12% (6% central plus 6% state tax) from 22 September 2025, as of October 2026 |
| Fly ash supply | A written supply arrangement with a coal or lignite thermal power plant, covering quantity, price and lifting schedule |
Rules differ by state and change over time. Confirm current requirements with the pollution board, BIS and your tax adviser.
Mistakes that weaken a fly ash bricks project report
- Treating fly ash as free
Even when the ash costs little, trucking it from the power plant does not. A report without ash freight understates raw material cost.
- No allowance for broken and rejected bricks
Some green bricks crack in handling and some lots fail strength tests. Saleable output must be lower than press output.
- Too little yard for curing
Two to three weeks of curing means the yard holds weeks of production at a time. A small site caps output below the press rating.
- Running at full capacity all year
Monsoon months slow both sales and curing. Projections that assume the same output every month overstate cash flow.
- Skipping strength testing
Government and large builders ask for test results to IS 12894 or IS 16720. Without them the unit sells only to the lowest-price buyers.
How NPCS helps you set up a fly ash brick unit
- Site and ash sourceWeigh locations by distance to the power plant, to buyers and to water.
- Press and line selectionCompare manual, semi-automatic and fully automatic presses for your budget and output.
- Bank-ready project reportProjections, DSCR and working capital in the format your lender or PMEGP office wants.
- Layout and approvalsPlan the press shed, curing yard and storage, and list approvals for your state.
NPCS has prepared project reports and feasibility studies since 1994. Its published client list records 48 assignments in recycling and waste processing, including one for this product.
What's inside the fly ash bricks sample report
- Introduction
- Uses and applications
- Market potential
- Manufacturing process
- Raw materials
- Plant and machinery
- Land, building and utilities
- Manpower
- Licences and approvals
- Project cost and means of finance
- Working capital
- Projected profitability
- Cash flow statement
- Projected balance sheet
- Depreciation
- Term loan repayment
- Debt service coverage
- Break-even analysis
- Financial ratios
- Key assumptions
- Conclusion
- Monthly loan repayment schedule
18 pages, five-year projections, illustrative figures.
Open sample reportFree sample or a report for your project?
| What you get | Free sample | NPCS report for your project |
|---|---|---|
| Capacity and location | Typical unit | Your capacity, site and state |
| Figures | Illustrative | Built on current prices and quotations |
| Machinery suppliers and quotations | No | Yes |
| Market survey for your region | No | Yes |
| Bank or scheme format (PMEGP, term loan) | No | Yes |
| Use for a loan application | No | Yes |
Real NPCS fly ash bricks project reports
These are fly ash bricks project reports NPCS has prepared, with the plant capacity, total capital investment, rate of return and break-even worked out in each. Costs have moved since some were written, so we bring any of them up to date for your capacity and location.
| Project report | Plant capacity | Total investment | Rate of return | Break-even | Action |
|---|---|---|---|---|---|
| Bricks From Fly Ash | 250 Lacs Nos/Annum | ₹1.58 crore | 27.2% | 65.7% | Get this report |
| Bricks From Fly Ash | 83333 Nos./Day | ₹1.92 crore | 40.8% | 53% | Get this report |
| Bricks from Fly Ash | Fly Ash Bricks, 24000 Nos/Day | ₹1.94 crore | 25.9% | 59.3% | Get this report |
| Bricks from Fly Ash | Fly Ash Bricks: 24,000,000 Pcs/annum | ₹3.36 crore | 28% | 46% | Get this report |
| Bricks from Fly Ash | Bricks, 25,000 Nos. per day | ₹3.65 crore | 27% | 48% | Get this report |
| FLY ASH Bricks From Limestone | 12000000 Nos./Annum | ₹4.09 crore | 43% | 40% | Get this report |
Figures as worked out in each NPCS report. Total investment includes plant and machinery, land and building, and working capital.
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Fly Ash Bricks project report: frequently asked questions
What is the cost of a fly ash brick plant in India?
A small unit with a manual or semi-automatic press needs roughly ₹20–45 lakh. A semi-automatic line with a pan mixer costs about ₹50–95 lakh, and a fully automatic plant of around 24,000 bricks per day costs more than ₹1 crore. Our sample report models that last size at ₹133 lakh. These are indicative figures; land, press make and location change them.
Is the fly ash brick business profitable?
It can be, if ash is close by and the price holds. In our illustrative sample, a 24,000 bricks per day unit selling at ₹4.81 per brick earns a 19% return on investment in Year 3. It breaks even at 44% of capacity and pays back in about 4 years. Cement prices, ash freight and buyer credit decide the real margin.
Which machine is used to make fly ash bricks?
The core machine is a hydraulic brick press, available as manual, semi-automatic or fully automatic. A fully automatic line adds a pan mixer with weigh batching, conveyors, pallets and a wheel loader. In our sample the press costs ₹29.94 lakh of the ₹66.53 lakh machinery budget. Get two or three quotations, because output per hour varies widely between makes.
What is the mix ratio for fly ash bricks?
A common lime-based mix is about 70% fly ash, 10% lime, 5% gypsum and 15% sand, as described in the Odisha State Pollution Control Board guideline. Cement can replace lime and gypsum as the binder. The right ratio depends on the ash and sand you get, so test batches for strength and water absorption before you fix it.
Can I get a PMEGP loan for a fly ash brick unit?
Yes, if the project cost is within the PMEGP limit of ₹50 lakh for manufacturing. Subsidy on project cost ranges from 15% to 35% depending on your category and whether the unit is urban or rural, and the promoter puts in 5–10%. A fully automatic plant usually goes beyond this and takes an MSME term loan instead.
Fly ash bricks ka business kaise shuru kare?
Start by finding a thermal power plant within easy trucking distance and confirming that it will supply dry ash. Then pick a press size that matches local demand and arrange about half an acre for pressing and curing. Take Udyam and pollution board registration, and get a project report made for your bank or PMEGP application.
Is the sample report free and can I use it for a loan?
The sample is free to view and download. It is an illustrative report that shows the format and depth of an NPCS report. Its figures are representative and not based on a real project, so it should not be submitted to a bank. For a loan, NPCS prepares a report for your own capacity, location and loan scheme.
Sources and references
- Guidelines for fly ash bricksState Pollution Control Board, Odisha, checked Oct 2026
- White category industries listState Pollution Control Board, Odisha, checked Oct 2026
- IS 12894:2002 Pulverized fuel ash lime bricks: specificationBureau of Indian Standards, checked Oct 2026
- Draft Fly Ash based Products (Quality Control) Order, 2023: stakeholder consultationDepartment for Promotion of Industry and Internal Trade, checked Oct 2026
- State tax rate notification 14/2025 (fly ash bricks, heading 6815)Finance Department, Government of Karnataka, checked Oct 2026
- Prime Minister's Employment Generation Programme (PMEGP) guideDistrict Industries Centre, Ganjam, Government of Odisha, checked Oct 2026
The NPCS project team, led by Ajay Kumar Gupta
This page and its sample report are prepared and reviewed by the NPCS project team, which has written techno-economic feasibility studies and detailed project reports since 1994.
Ajay Kumar Gupta founded Niir Project Consultancy Services (NPCS) and leads the organisation. With 40 years of experience in MSME project consulting, he has built the team that has delivered more than 28,000 project reports for clients worldwide, helping entrepreneurs plan and finance profitable manufacturing businesses.
- Published
- Last updated
- Next review
- Oct 2027
- Reviewed by
- NPCS project team
This page is reviewed every 12 months, or sooner when scheme limits, GST rates, BIS rules or pollution categories change. The sample report is illustrative: its figures are generated from industry-typical ratios for a unit of this size, checked so every statement balances, and are not taken from any client project.