WienerbergerREB Production in India – Wienerberger Experience

Kundan Dighe25th August 2011

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Need for REB – Resource Efficient Bricks

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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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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

-Label� Definition – 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 worldwide market leader in clay bricks

�Presence in 27 countries

- 227 Factories 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 India - Product Portfolio

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POROTHERM HP – Resource Efficient Brick

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POROTHERM HP – Product Parameters

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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

- Savings on Energy consumption

- Comfortable inside temperature

POROTHERM HP – Product Advantages Construction

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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

- Solid Clay Bricks: 1.8 W/m²K

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

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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 De- silted 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,

Bangalore� Project Wall Area : 130,000 Sft

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Introducing - POROTHERM VP

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POROTHERM VP – Product Parameters

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POROTHERM VP – Product Advantages

� Eliminates Frame structure requirement (Load Bearing Construction)

� Savings on Steel and Concrete

� Faster Construction

� High Thermal Insulation

� Green Building Product

� Cost Saving

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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