STAKEHOLDER WORKSHOP
ACTION PLAN TO DEVELOP THE MARKET FOR HOLLOW
AND PERFORATED FIRED-CLAY BRICKS
Sameer Maithel, Sonal Kumar & Ananth Krishnan
08th June 2016
Action Plan to Develop the Market for Hollow and Perforated Fired-Clay Bricks
OUTLINE
1. Project Background – Building Materials & Resource
Efficiency Concerns
2. How perforated and hollow bricks addresses resource
efficiency question ?
3. Current status of the production and market
4. Future demand projections, market potential and barriers
5. Action plan for accelerated market development
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Action Plan to Develop the Market for Hollow and Perforated Fired-Clay Bricks
BACKGROUND
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Action Plan to Develop the Market for Hollow and Perforated Fired-Clay Bricks
PROJECTED LARGE GROWTH IN NEW BUILDING
CONSTRUCTION
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13.4
53.6
0.75
9.6
0
10
20
30
40
50
60
2012 2047
Residential floor space area (billion m2) Commercial floor space (billion m2)
Source: India Energy Security Scenarios, NITI Aayog (2015) estimates based for 7.4% CAGR in GDP
The building floor area is expected
to increase 4X by 2047
Action Plan to Develop the Market for Hollow and Perforated Fired-Clay Bricks
NEW HOUSING - LARGEST CONSTRUCTION
CATEGORY
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Source: Funding the vision — Housing for all by 2022, KPMG in India, 2014
19
40
5926-29
23-25
49-54
0
20
40
60
80
100
120
Urban (million housing units) Rural (million housing units) Total (million housing units)
Housing Forecast
Current housing shortage Required housing units by 2022
45-48
63-65
108-113
To provide “Housing for All” by 2022-more than 10 crore houses needs to be constructed.
Action Plan to Develop the Market for Hollow and Perforated Fired-Clay Bricks
LARGE INCREASE IN THE CONSUMPTION OF
CONSTRUCTION MATERIALS
Demand for
construction
materials
2012 2047 % Increase
(2012-2047)
Steel 80 MT/year 654 MT/year 820%
Cement 246 MT/year 1042 MT/year 425%
Walling
materials
200-300 billion
bricks/year
~1000 billion
bricks/year
400 -500 %
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Source: India Energy Security Scenarios, NITI Aayog (2015) estimates based for 7.4% CAGR in GDP for cement &
steel; GKSPL estimates for walling materials
The annual consumption of construction materials to increase by 400% or more.
Action Plan to Develop the Market for Hollow and Perforated Fired-Clay Bricks
ENVIRONMENTAL IMPACTS – WALLING MATERIALS
Life Cycle of Walling Material
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Mining/Extraction
Large scale extraction: 0.7-1.0 billion tons/year of fresh raw material
Possibility of using available waste material e.g. flyash, agri waste,…
Production
50-70 million tons of CO2/ year
Important source of PM & black
carbon emissions
Transport
CO2 emissions and air
pollution in transport
60-100 billion ton-kilometer/
year of road transport of raw
material and finished
walling materials
Building Construction &
Operation
Buildings consume 31% of
India’s electricity
Air-conditioning energy
increasing rapidly, thermal
properties of walling
material influences the
operational energy
Demolition/ End of Life
Waste generation
Reuse, recycle and disposal
Action Plan to Develop the Market for Hollow and Perforated Fired-Clay Bricks
PERFORATED & HOLLOW BRICKS – HOW THEY
ADDRESS RESOURCE EFFICIENCY CHALLENGE?
Life Cycle of Walling Material
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Mining/Extraction
Production
TransportBuilding Construction
& Operation
Demolition/
End of Life
Low freshly mined raw material content (kg/m3)
Low primary energy for manufacturing (MJ/m3)
Low CO2 emission for manufacturing (T CO2 /m3)
Low Thermal Conductivity
Action Plan to Develop the Market for Hollow and Perforated Fired-Clay Bricks
BURNT CLAY HOLLOW BLOCKS
• Burnt clay hollow bricks and
blocks for Walls and Partitions (IS
3952: 2013)
• Holes passing through the block
exceed 25 % of its volume and
the holes are not small.
• The hollows may be at right
angle or parallel to the bearing
surface.
• Minimum Average Crushing
strength: 3.5 N/mm2
• Water absorption shall not be
more than 20 %
• The thickness of any shell shall
not be less than 11 mm and that
of any web not less than 8 mm.
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Action Plan to Develop the Market for Hollow and Perforated Fired-Clay Bricks
BURNT CLAY PERFORATED BUILDING BRICKS
• Burnt clay perforated building bricks IS
2222:1991
– The area of perforation shall be
between 30-45 % of the total area of
the corresponding face of the bricks.
– Minimum Average Compressive
strength: 7 N/mm2
– Water absorption shall not be more
than 20 %
– The shorter side of the perforation shall
be less than 20 mm in case of
rectangular perforations and less than
25 mm diameter in case of circular
perforations. The area of each
perforation shall not exceed 500 mm2.
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Action Plan to Develop the Market for Hollow and Perforated Fired-Clay Bricks
MARKET ASSESSMENT STUDY
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Action Plan to Develop the Market for Hollow and Perforated Fired-Clay Bricks
METHODOLOGY FOR THE STUDY
Action Plan For Accelerated Market Development
Demand Projection
Key InformationProduction data Market (type of building, regions, advantages) Barriers
Survey & VisitsManufacturer (15 nos) Users (Architects, Builders, etc) - 30 nos
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Action Plan to Develop the Market for Hollow and Perforated Fired-Clay Bricks
SURVEY
RESPONDENTS
LOCATIONS
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Action Plan to Develop the Market for Hollow and Perforated Fired-Clay Bricks
PERFORATED BRICK PRODUCTION: 2011 & 2015 (STANDARD MILLION BRICKS/YEAR)
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14.4 13.5
5.0
26.8
0.0
5.0
10.0
15.0
20.0
25.0
30.0
35.0
40.0
45.0
2011 2015
UNDP Other
19.4
40.3
• The production of perforated bricks has doubled during 2011-2015.
• Most of the increase is from the new units that have been set-up.
Action Plan to Develop the Market for Hollow and Perforated Fired-Clay Bricks
1.9 9.2
98.6
150.2
0.0
20.0
40.0
60.0
80.0
100.0
120.0
140.0
160.0
180.0
2011 2015
UNDP Other
HOLLOW BRICK PRODUCTION – 2011 & 2015 (STANDARD MILLION BRICKS/YEAR)
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100.5
159.4
• The production of hollow bricks has increased 150% during 2011-2015.
• Weinberger alone constitutes ~ 90% of the production.
• Hollow blocks production in several existing units has increased.
Action Plan to Develop the Market for Hollow and Perforated Fired-Clay Bricks
SURVEY: KEY ISSUES OF PRODUCERS
• Technological issues
– Most of the units do not have complete integrated technology production line
– Shortage of drying facilities, seasonal operation of kilns, technical problems in extruders - limits the production
• Regulatory issues
– Uncertainty over clay supply and availability due to environment regulations (highlighted in Kerala) adversely impacts production and expansion plans
• Market
– In new markets, creating consumer awareness is a slow process and hence slow growth of the market. Production intermittent – high cost.
– Lack of recognition by the government as resource-efficient product and providing preference in procurement
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Action Plan to Develop the Market for Hollow and Perforated Fired-Clay Bricks
MARKET OF WALLING MATERIALS - TYPES OF
BUILDINGS
New Construction
Residential
Rural
EWS
LIG/ MIG/ HIG
Urban
Low-rise
EWS/ LIG
MIG
HIG/ Luxury
Mid/ High-rise
EWS/ LIG
MIG
HIG/ Luxury
Non-Residential
Commercial
Educational Institute
Office
Retail/ Shopping
Hospital
Hotel
Public
Office
Hospital
Educational Institute
Airport/ Railway
Industrial
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S
P
G
Self-constructed
Private Sector Builder
Government Program/Public Sector
GS
G
P
S
P
S
P
G
S
P
G
S
P
P
P
P
P
P
P
P
P
G
G
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Action Plan to Develop the Market for Hollow and Perforated Fired-Clay Bricks
MARKET OF WALLING MATERIALS - TYPES OF
BUILDINGS
New Construction
Residential
Rural
EWS
LIG/ MIG/ HIG
Urban
Low-rise
EWS/ LIG
MIG
HIG/ Luxury
Mid/ High-rise
EWS/ LIG
MIG
HIG/ Luxury
Non-Residential
Commercial
Educational Institute
Office
Retail/ Shopping
Hospital
Hotel
Public
Office
Hospital
Educational Institute
Airport/ Railway
Industrial
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S
P
G
Self-constructed
Private Sector Builder
Government Program/Public Sector
GS
G
P
S
P
S
P
G
S
P
G
S
P
P
P
P
P
P
P
P
P
G
G
G
Market for perforated and hollow bricks is limited to certain market segments.
Action Plan to Develop the Market for Hollow and Perforated Fired-Clay Bricks
MARKET – BURNT CLAY HOLLOW BLOCKS
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SOURCE: LIVING WALLS-VDB INFRA & REALTY PVT. LTD.-BANGALORE
Key benefits as perceived by the users• Faster construction• Good insulation• Reduction in dead load
Individual MIG/HIG Housing Mid/High-Rise MIG/HIG Housing
SOURCE: AR K.S. CHETAN- KHAM DESIGN
Action Plan to Develop the Market for Hollow and Perforated Fired-Clay Bricks
MARKET - PERFORATED CLAY BRICKS
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SOURCE: MAHALUXMI BRICKS SOURCE: JINDAL MECHNO BRICKSSOURCE: ADALAKHA ASSOCIATES
Key benefits as perceived by the users• Aesthetics – possibility to use as facing bricks• High compressive strength – possibility of load-
bearing structure• Uniform shape and quality – better finish of walls,
reduction in plastering
Low rise EWS/LIG Mass Housing Individual HIG Housing Institutional buildings
Action Plan to Develop the Market for Hollow and Perforated Fired-Clay Bricks
MARKET – KEY ISSUES AS PERCEIVED BY USERS
1. Unavailability of skilled workers for construction with
perforated and hollow bricks - problems during construction
like laying of pipes and conduits
2. Limited availability of hollow/perforated clay products and
higher price for these products
3. Suitable for specific applications and type of buildings
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Action Plan to Develop the Market for Hollow and Perforated Fired-Clay Bricks
ACTION PLAN FOR ACCELERATED MARKET
DEVELOPMENT
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Action Plan to Develop the Market for Hollow and Perforated Fired-Clay Bricks
PERFORATED & HOLLOW CLAY BRICK
PRODUCTION: DEMAND PROJECTION
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40 144403
159
358
1594
0
500
1000
1500
2000
2500
2015 2022-Business as Usual 2022-Accelerated Growth
Perforated Hollow
~200
~500
~2000
• In the BAU scenario, the production of perforated and hollow bricks is expected to increase from 20 crore/year (2015) to 50 crore/year (2022). These bricks constitute only 0.1% of the total walling material market.
• The potential market for these bricks could be huge, given their suitability for different kinds of housing. If a 10 times increase is targeted, then the projected production in 2022 will be 200 crore bricks/year.
Action Plan to Develop the Market for Hollow and Perforated Fired-Clay Bricks
THE WAY FORWARD
• The efforts made by the ongoing relatively small MoEFCC-
UNDP-GEF project and the existing perforated and hollow
brick producers, has laid a solid foundation in the form of
revised IS standards, PWD schedule of rate in a few states,
quantifying benefits, development of niche markets, etc.
• There is a scope to scale-up the efforts in coming years in
the form of a “National Resource Efficient Brick Mission”, to
promote perforated and hollow bricks along with other
resource efficient options.
• These bricks can play an important role in the “Housing for
All” and “Make in India” initiatives of the GoI.
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Action Plan to Develop the Market for Hollow and Perforated Fired-Clay Bricks
WHAT NEEDS TO BE DONE ?
Actions for Accelerated
Market Development
Increase Supply
Increase Demand
Develop Human
Capacities
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Action Plan to Develop the Market for Hollow and Perforated Fired-Clay Bricks
MEASURES TO INCREASE SUPPLY
1. An action plan aimed at increasing the utilization of the installed capacity of machines to increase the supply and reduce the cost of burnt clay perforated and hollow bricks– Around 25 enterprises are producing perforated and hollow bricks but plant
utilization factor is low.
– There are >100 other enterprises who have some basic machinery (extruder), and can potentially produce perforated/hollow bricks
Actions to create awareness, provide technical support, access to finance and assistance in market creation can help in expanding the production with small investment and in short time.
2. Making available cost-effective integrated technology package(s) for the production of perforated and hollow bricks– Brick dryer
– Tunnel kiln
– Material transfer
– Clay preparation and shaping
This would involve work in developing standard specifications as well as pilot testing of certain technologies.
3. Clay and other raw materials– Resolving the issues regarding the environment clearance for clay mining
– Systematic clay resource assessment and mining
– Utilization of waste materials2608-06-2016
Action Plan to Develop the Market for Hollow and Perforated Fired-Clay Bricks
MEASURES TO CREATE DEMAND
1. Recognition as a resource efficient product through
certification by government agencies (e.g. BMTPC) and by
independent green building product ratings (GRIHA, IGBC,
GBCI).
2. Inclusion in the schedule of rates by CPWD and various
PWDs
3. Targeted awareness creating campaign for end-users
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Action Plan to Develop the Market for Hollow and Perforated Fired-Clay Bricks
MEASURES TO BUILD CAPACITIES
• Development of human capacities
– Manufacturing, service and operation of machines to produce
hollow and perforated bricks (Technical training of technicians
and engineers)
– Application of perforated and hollow bricks in buildings
(Training of masons, contractors, architects, etc.)
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Action Plan to Develop the Market for Hollow and Perforated Fired-Clay Bricks
CONCLUSIONS
• Through the efforts of MoEF-UNDP-GEF and brick industry, useful work has already been done to establish perforated and hollow bricks in some markets in India.
• A large potential exists for accelerated development of the market for these products given their specific application in residential buildings and in the context of “Housing for All” initiative.
• A “National Resource Efficient Brick Mission” which promotes perforated and hollow bricks along with other resource efficient walling materials is needed. Specific actions are required
– Increase supply or support manufacturing industry
– Create demand
– Capacity building
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www.gkspl.in
THANK YOU !!!
Contact: Sameer Maithel
Email: [email protected]
Mobile: +91 98113 92256
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