Brick Manufacturing in Nepal. William S. Carter, Ph. D. CIH CET Emeritus Professor The University of Findlay

Transcription

1 Brick Manufacturing in Nepal William S. Carter, Ph. D. CIH CET Emeritus Professor The University of Findlay

2 Nepal

3 Steps in Brick Manufacturing Step One: Prepare the Clay Step Two: Mold the Clay into Balls Step Three: Press the Ball into the Mold Step Four: Remove the Brick from the Mold Step Five: Dry the Bricks in the Sun and Stack Step: Six: Transport the Bricks to the Kiln Step Seven: Load the Bricks in the Kiln Step Eight: Fire the Bricks Step Nine: Unload the Bricks from the Kiln Step Ten: Stack the Bricks for Storage or Sale

4 Digging and Transportation Technology

5 Improved Brick Kilns used in Nepal Continuous kilns a. Moving fire annular kilns i. Bull s trench ii. Hoffmann iii. Zigzag: Habala, high draught b. Moving ware kilns i. Tunnel ii. Vertical shaft

6 Bull Trench Movable Chimney Kiln Chimney Bhatta Kilns are of oval shape with two movable chimney-stacks. The kilns are constructed, usually on leased land, at the beginning of the season The production capacity of a kiln is dependent on cross-sectional area of the trench. The height and base are constructed, based on the trench size. The exhaust gases are drawn through movable sheet metal chimneys

7 Chimney Batta Operation Brick, ash and rubble form the top of the kiln. The chimneys are bout 16 meter high and have a wide base that fit over the open vent holes set in the top of the kiln. The pair of chimneys are positioned ahead of the fire, suck in the kiln gases from the entry point and creates a draught through the fire and the bricks. Daily the chimneys are moved by 10 to 15 people and held by steel cables The fired bricks are allowed to cool and then removed. Green bricks are set up at the other end of the kiln while the brick firing is in progress. The fuel, generally a mixture of crushed coal and sawdust (some kiln), is fed through the holes on the top. Depending on the size of the kiln, daily output ranges from 10,000 to 28,000 bricks.

8 Advantages and Disadvantages of the Movable Chimney Bull Trench The technology does not require complex machines or permanent structures It uses labor intensive brick making and firing process. Low capital investment The main disadvantages Only % production of No. 1 grade brick. Broken brick percentage is high. Fuel consumption is very high. OSH condition is very poor. Dust exposure to workers is very high. Overall efficiency of kiln is very low.

9 Hoffmann kilns are the most modern and expensive type of kiln used in Kathmandu Valley. They are oval in shape with multiple chambers for brick firing. The air is preheated by passing over cooling bricks in some chambers, and then the passes through firing zone. The cool bricks are removed from one side of the empty chamber; Green bricks are stacked on the other side. The fuel is fed from the top, through holes in the permanent arched roof. Hoffmann Kiln

10 Hoffmann Kiln Advantages Supply of bricks is continuous and regular Pre-heating of the bricks are done by hot gases before they escape into the atmosphere Fuel consumption and stack emission is low Bricks are burnt evenly and the quality of bricks is good Sufficient height of the chimney control flue gases Kiln is operational throughout the year. The main disadvantage associated with the Hoffman Kiln is the high capital investment.

11 Vertical Shaft Brick Kiln A Vertical Shaft Brick Kiln that offers a more energy efficient technology for the brick industry

12 Brick Making Industry in Nepal There are about 430 brick kilns in operation in Nepal and 120 in the Kathmandu Valley. Fixed Chimney Bull s Trench Kiln (FBTK s) is most common type of kiln. Vertical Shaft Brick Kiln (VSBK) and Hoffman brick technology also are used in a few cases. Coal and fire wood are the main fuel used. The coal consumption in FBTKs is 8-12 tons of coal/l100,000 bricks. Annual brick production in Kathmandu Valley is 900 million bricks per year. The coal consumption is around 100,000 tons per year.

13 Brick Makers Village Families live in the houses during Brick Making Season. The industry is seasonal and operates during the dry season from December to June. Workers working in brick kilns are generally migrant workers. Most come from rural areas of the country and some from India.

14 Better Brick Nepal Proposed policy developed to improve working conditions in Brick Kilns. Developed by Goodweave International. (Does that name ring a bell?) Objectives: Reduced forced, bonded and child labor on brick kilns. Improve working condition for all workers. Facilitate the development of a market-based model to certify bricks.

15 Better Brick Nepal Standard Criteria No child labor is allowed. No forced or bonded labor is allowed. Workplace safety and health standards implemented. Working hours specified. Remuneration and benefits specified. No harsh or inhumane treatment allowed.

16 Child Labor Requirements Children under 14 years not employed or allowed to work. Young workers 14 to 16 are allowed to work no more than 6 hours and not allowed to work on hazardous operations or dangerous equipment. Limit the weight 14 to 16 year olds can carry to 15 kg ( 33 lbs.). Not allowed to work at night or overtime. Limit the weight 16 to 18 year olds can carry to 25 kg for boys (20 kg for girls). Verify ages of all workers including contractors.

17 No Forced or Bonded Labor Employer does not use any type of physical or psychological measures requiring workers to remain employed. Terms and condition of work, such as prevailing piece rate, are defined. No documents of workers (such as passport) are withheld from worker. Workers are free to leave work premises after a standard work day. All earning are paid in full within seven days (less deductions of expense payments).

18 Work Place Safety and Health Maximum loads to be maintained for all workers. Living accommodations to be structurally safe with adequate ventilation and appropriate separate bathing facilities. Sanitary conditions including a single toilet for no more than 15 persons or 3 families. Toilet facilities must be easily accessible for workers in the workplace. Adequate potable water must be provided. Level pathways for routes where bricks are carried. First aid kit for each 100 workers.

19 Working Hours Document working hours for all workers. Overtime must not exceed 4 hours in a day or 20 hours for a week. Workers not compelled to work overtime.

20 Remuneration and Benefits Wages must not be less than legal minimum wages. No piece worker earns less than legal minimum wage. Records maintained for hours and days worked, production completed, and wages paid. Overtime to be paid at 150% of normal remuneration.

21 No Harsh or Inhumane Treatment Employer adopts zero tolerance towards harassment or abuse. Includes verbal, psychological, corporal, and sexual harassment or abuse. Employer appoints a senior management representatives, including at least one woman, to investigate and discuss grievances.