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WienerbergerPOROTHERM – Walling Material For Next Generation

Kundan Dighe10th March 2011

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What is the Present Scenario ?

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The Need for SUSTAINABILITY: Two Reasons

1) POPULATION GROWTH:

INDIA’S DEVELOPMENT DILEMMA

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2) GLOBAL WARMING:

STRONGER, FASTER, SOONER

The Need for SUSTAINABILITY

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2020?

2050?

The Combination: A Great Future?

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Can There Still be Doubt?

Percentage of articles in doubt as to the cause of global warming: 0

Number of peer-reviewed articles dealing with “climate change” published in scientific journals during the previous 10 years:

928

In 2007 the UN Intergovernmental Panel on Climate Change published a report that put the reality of human-induced climate change beyond any doubt!

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How are we related to that?

Impact of Construction: A Double Whammy

Production and Transportation of Construction Materials

Low Energy Efficiency of Buildings / Structures

+Up to 65% of a countries electricity consumption from buildings / up to 50% of carbon emissions

Up to 30% of all raw materials used / steel and cement two largest green house gas producing industries in any country

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The Indian Emission Scenario

80% of India’s Total Emissions

100km of transportation add another 10-15% of global warming potential to the production of building materials

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Content

-LabelDefinition – Resource Efficiency

Why Brick Industry think of Resource Efficiency ?

Introducing –POROTHERM HP as resource efficient bricks

The Production Process of Ceramic Building Materials

Product Benefits

Expectation from the Government & Industry

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Definition – Resource Efficiency

The efficient use of materials in design and construction (eg, design strategies that reduce material use or enable materials to be salvaged, reused, or recycled)

Reduces the demand of Natural Resources

Ensures sustainable growth & support from nature to inhabitants for generations

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Why do Brick Industry think of – Resource Efficiency ?

1,000 Billion bricks are produced & consumed per year in Asian Countries, equivalent to 100,000 New York Empire State Buildings

Each Asian Citizen consumes ~ 250 bricks Per Year

Consumption of coal – 110 million tons of coal per annum

Up to 40% of this energy consumption can be saved by:

- Implementing energy efficient brick production

- Switching over from solid brick to HOLLOW Brick

Source – Brick By Brick The Herculean Task of Cleaning up the Asian Brick Industry

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The Evolution of Ceramic Building Materials

1. Bigger

2. Lighter

3. Cooler

4. Cheaper

5. More Environmental Friendly

6. Precise

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We look back at a great history…

The beginning, brick making for the emperor of Austria & Hungary

International World Exhibition, Paris 1867

189 Years of History (founded 1819 - Vienna)

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Wienerberger Today …

We are a leading international building materials group with headquarters in Vienna

Wienerberger is # 1 worldwide in clay hollow bricks and bricks

Present in 27 countries and 5 export markets

- 227 plants in Europe and North America

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Arial Views of Wienerberger Factories

Belgium: Beerse – TERCA Facing Bricks Plant Czech Republic: Jerzernice – POROTHERM Brick Plant

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Wienerberger - Product Portfolio

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POROTHERM HP – Resource Efficient Brick

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POROTHERM HP – Product Parameters

Name Length (mm) Width (mm) Height (mm) Weight (kg) Density (kg/m3)Compressive Strength

(N/mm2) Water Absorption (%) Efflorescence U-Value (W/m²K)Sound Insulation

Rw (db) Fire Resistance (min)POROTHERM HP 200 400 200 200 11.1 694 1.1 46 240POROTHERM HP 150 400 150 200 8.8 733 1.2 43 120POROTHERM HP 100 400 100 200 6.3 788 1.7 40 90POROTHERM HP 200H 200 200 200 5.8POROTHERM HP 150H 200 150 200 4.2POROTHERM HP 100H 200 100 200 3.1

Name 400 200 150 100Dimensions (mm) ± 8 ± 4 ± 3 ± 2

Note :Compressive Strength value is based on testing procedure as prescribed in IS 3952 POROTHERM is manufactured using Natural Raw Materials, hence there could be variations in colour

POROTHERM HP - Product Paramters

Same as full bricks

Same as full bricks

Same as full bricks

Same as full bricks

Same as full bricks

Same as full bricks

≥ 3.5 ~ 15

POROTHERM HP - Tolerance

Slight

Same as full bricks

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Wienerberger Factory at Kunigal

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Clay Quarry

Clay excavation done locally from water tanks close to the factory

(De silting of tanks)

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Dosing of Raw Materials

Raw Material Feeders – Primarily Clay & other filler materials

Dosage of raw material controlled by feeders

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Clay Preparation

Feeders feed raw materials for preparation of clay (grinding,

mixing, homogenization )

Pan mill grinds the clay

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POROTHERM HP - Extruder

Extrusion of clay bricks

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Automation of Production

Cutting Line for length

Arranging bricks in dryer cars

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Automation of Production

Robots handle the bricks in Green State

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Dryer and Kiln Cars

Dryer - Dries the brick, prior to firing.

Kiln Cars – Ready to be loaded in kiln for firing

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Kiln – For Burning Bricks

Fuel Injection Unit – Pet Coke injection unit for high temp firing

Tunnel Kiln - 160 Mtr. Long, Clay bricks are fired at temperature ~ 1,000°C

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Laboratory

Testing Facility

- State of the Art testing equipments

- Ensures quality of Raw Material and

finished products

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Factory – Stock & Clay Storage

Adequate stock of finished products as well as of the clay (raw material)

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POROTHERM HP – Product AdvantagesConstruction

Bigger Size

- POROTHERM HP is same in size as that of concrete blocks

- POROTHERM HP 200 = 9 Clay Bricks

- Less mortar joints, hence less plumb & alignment

- Faster construction

Light Weight

- Ease of handling, Transportation

- Saves labor

- Less dead load, Savings in Structural Cost

(Steel & Concrete) by 10 to 15%

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Perfect brick Size

- Savings on mortar

- Line and leveled plaster surface

Low ‘U’ Values – 1.0 W/m²K

- Better Thermal Insulation = less energy loss through walls

- Savings on Energy consumption

- Comfortable inside temperature

POROTHERM HP – Product Advantages Construction

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0,00

1,00

2,00

3,00

4,00

5,00

6,00

Clear FloatGlass

DoubleGlazedGlass

ConcreteBlocks

HollowClay

Blocks

AAC

U Value – External walls

U – Values of outer walls (200mm / 230mm):

- POROTHERM HP 200: 1.0 W/m²K

- POROTHERM VP 200: 1.3 W/m²K

- Solid Concrete block (8”): 2.0 W/m²K

- AAC block (8”): 0.7 Wm²K

POROTHERM VP has a higher U-Value than POROTHERM HP because the

density is higher

Plaster has hardly any positive influence on the U-Value, because it is a solid material which conducts heat well

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Test Result – Crushing Strength

POROTHERM HP 100 – 5.2 N/mm2 POROTHERM HP 150 – 4.3 N/mm2 POROTHERM HP 200 – 4.1 N/mm2

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IGBC – POROTHERM HP

POROTHERM HP Clay Hollow bricks contribute to the rating system under

- Energy Efficiency: U-Value : 1.0 W/m²K

- Local Materials :

- local raw materials

- finished goods transported < 500km

- Material with Recycled Content:

-Raw Material used are (fly ash, rice husk, saw dust, granite dust)

-In addition we use Desilted Clay

IGBC = Indian Green Building Council

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POROTHERM HP – Applications

Cutting of Brick

Masonry

Plaster/ Rendering

Door / window Fixation

Chasing, Conduiting for Services

Load Fixation (Mirror, LCD, Geysers, EWC etc)

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POROTHERM HP - Application

Cutting of Brick

Masonry

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POROTHERM HP - Application

Plastering/ Rendering- Gypsum Plaster

- Sand Cement Plaster

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POROTHERM HP

Door/ Window fixation

Conventional Method – Hold fast

Anchor fixing – Plastic sleeve anchors

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POROTHERM HP – Applications

Conduiting for electrical, plumbing- Chasing, Chiseling similar to other conventional bricks/ blocks

- To be filled with rich mortar

- Plastered as a normal wall

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Light Loads: To be fixed by wooden peg 100mm in length

POROTHERM HP – Application

Medium & Heavy Loads: To be fixed using Rack bolts or sleeve anchors

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Hole for rack bolt Rack bolt fixedCement mortar stuffed in hole

Load fixed

Rack bolt with load

POROTHERM HP – Application

Practical Test

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POROTHERM HP – E.g. of Geyser Fixation

Branded Sleeve inserted Screws fixed in branded plugs

Geyser Plate fixed Geyser fixed

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POROTHERM HP – MTC -Trainings

Trainings to stake holders - MTC Trainings in WB Factory

MTC – Masonry Training Centre

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POROTHERM HP – Site Trainings

Trainings to stake holders- Trainings at project sites

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POROTHERM HP – College Presentations

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Apartments

Architect: In house

Builder : Ramaniyam Real Estate

Location : Sholinganallur, Chennai

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Apartments

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Apartments

Architect: In house

Builder : Ramaniyam Real Estate

Location : Kazhipathur, Chennai

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Apartments – Pebble Bay

Architect: Vijay Raheja

Builder : The Advantage Raheja

Location: RMV 2nd Stage, Bangalore

Wall Area:7,00,000 sq ft - G+21 Floors

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ISB – Housing Tower - Hyderabad

Architect : Inform Architects

Floors: 16 Floors

Location : Hyderabad

Project Wall Area : 380,000 Sft

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Sydney Court

Architect: Thomas Associates

Location: Lavelle Road, Bangalore

Wall Area:30,000 Sft

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Legacy Dimora

Architect : DFA Architects Location : Bellary Road, BangaloreProject Wall Area : 130,000 Sft

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Introducing - POROTHERM VP

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Wienerberger India - Showroom in Bangalore

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Wienerberger India

Natural Comfort for generations!

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Many thanks…

…for your interest in Wienerberger!

Wienerberger Brick Industry Private Limited

T +91 80 4149 1682

www.wienerberger.in