Fly Ash Bricks Manufacturing Process In Lahore, Pakistan

Novel Concrete delivers a wide range of precast concrete products including pavers, slab, and wall panels, paving stones and blocks, kerbstones and barriers, EPS panels, and pre-stressed structural elements.


The ban on the production and the use of fly ash bricks in Lahore and the persistent economic crisis in 2008, had affected the country’s real estate sector to a large extent, thus dampening the enthusiasm of investors and construction companies in the construction sector.

However, after the construction of the Lahore-Karachi motorway by NHA in 2013, the new transport and communication routes have gradually become more accessible, thus encouraging the investors and real estate developers to put up more projects at the most affordable prices.

Lahore Precast Concrete, being a well-known brand in the market for the past couple of decades, caters to the increasing demand for fly ash bricks from new real estate projects.

Why Fly Ash Bricks?

Placing fly ash and other waste materials in an effective and safe form makes them both a valuable asset as well as a source of renewable energy. According to studies, fly ash is the largest non-renewable source of renewable energy worldwide. With a density of 21 grams per cubic foot (g/cm3), it’s one of the most abundant lightweight materials in the world.

Most of the fly ash is located in its natural state in Tennessee, North Carolina, Ohio, and Pennsylvania.

These fly ash bricks are not only useful but also eco-friendly as they make up to 50 percent less carbon dioxide than cement bricks.

What’s the Difference between Normal Concrete and Fly Ash Bricks?

A fly ash block is constructed up of either mixed cement (50% of aggregate) or ferric oxide, a natural mineral.

Manufacturing Process

• Spray lime is applied to the fly ash bricks to make them ready for use

• It is then washed with water and allowed to dry.

• The end products are placed in a large mixing drum for sand and cement to be added.

• The mix is squeezed out between two industrial roller machines to extract the liquid contents

• The two liquids are combined in a mixer where the two liquids are pumped through a lime press, eliminating the lime dust.

• The powder is tumbled into dust form.

• The dry powder is placed into a bag for later packaging.

• The dry dust is crushed into fine particles

• The powder is placed into large diameter plastic bags for transport

• The bags are wrapped in two layers to ensure that the powder does not separate during transportation.


Heap-formed fly ash bricks and fly ash concrete manufacture in Pakistan is an appropriate and economical solution to construct multi-story residential complexes.

Pavements and slabs that are fabricated in a fly ash brick production plant are fired in a blast furnace and then sliced and machined to the desired shapes.


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