Renewable cold process bricks and panels from waste and clay

Roy Research and Technology has developed a unique process to use bio-char and fly-ash for lightweight panel, building blocks, bricks etc. Through its proprietary eco-bonded binding technology with double bond carbonated poly calcium silicate formation. This technology eliminates toxicity and breath-ability factor. Thus having the potential as a good building material, while offsetting about millions tones of bio-char from bio-char culture, pulverized ash annually produce in India by the numerous thermal power station, also from other agro-waste.

This technology allows various type of clays, soils, agro waste based bio-char ash lignin etc. to make green building blocks bricks and panels. The technology proves not only scope of utilization of huge volume of various grades of fly-ash but also reduces precious agricultural top soil and consumption of coal in making conventional clay bricks. Also, this eliminates the drying system of bricks through brick kilns.

Panels, blocks, bricks have gotten pleasing bright gray colors and other Eco-friendly color can be cooperated.   Also they are uniform in shape and smooth in finish. Also they require no plastering. They are of dense composition uniformly shaped. They are lighter in weight than the conventional one and less porous too and total replacement of conventional brick.

So far the brick making is concerned, a continuous unit of 10,000 – 50,000 bricks production per day per shift with 65% to 70% *bio-ash loading with average weight approximate 2.0 Kg to 2.5 Kg. R & D and also infrastructure are extra. Regarding block with male / female grove which is larger than conventional brick will weight around 3 Kg. Single Block making machine through the internal combustion engine without electric facility can produce1500 – 2000 blocks per day per shift with 70% – 80% bio-ash loading factor.





Typical observation test data of blocks and bricks based on poly fly ash as following:





Blocks weight

5 – 7 kg either with 1. Fly ash extended 2. Red soil extended 3. Fly ash and bio char extended.

Serial No. Sample Reference Average Dimension

L X B X H in mm


Load in KN

Area in mm2

2 X L X B

Compressive strength in




In %

Note: This is to note that the crushing strength of interlocking blocks aided by modified Co-bond is on an average 230.76 Kg/cm2 after a 28 day cure.

The standard building requirement is 125 Kg. per m.

The blocks are made by incorporating fly ash along with modified co-bonding within 24 hrs. The strength becomes 27 Kg. per Sq. cm. in 28 days.

1 2 3 4 5 6 7
1. MIX – 1

CO – 001


S – 1

225 X 50 X 116 123 22500 12.5 2.25
2. MIX – 1

CO – 001


S – 1

225 X 50 X 116 133 22500 12.5

Avg. 12.5


Avg. 2.73