Brick Making Machine

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ABSTRACT

The provision of shelter is one the most basic demand of a Man all over the World. It is
one the most important challenges a man faces in his life. The problem of good shelter varies
from place to place. A good shelter provides, first and foremost Security and Privacy. One of the
most important materials used for building of a shelter is block/brick, but majority of the people
cannot afford these materials (blocks or bricks) due high cost. Therefore, the production of high
quality and affordable blocks/bricks is paramount to solving housing problems in developing
countries. Thus, this project focused on fabrication of a multipurpose machine that produces high
quality blocks/bricks for low cost housing. That is, for low income communities/earners. In other
words, bricks or blocks produced by using this machine are relatively cheap and affordable for
those in the rural areas and for low income earners.

The machine parts were made of mild steel, because of its availability and versatile
machinability. The efficiency of the machine was examined using local clay. Water was added to
the clay after sieving to form a paste, and then packed into a mould box, before manually
rammed and compacted with the machine mould cover. This process allowed for the formation
of required shape. The machine is capable of producing one bricks at a time using the available
mould box.
CHAPTER 1

INTRODUCTION

Building construction has become complex and sophisticated nowadays. Early types of
construction provided minimal shelter from wind, fire attack and rain. Modern day housing
provides not just only shelter but a total internal environment where every aspect of security,
climate and lightning can be under finger-tip control. With this development, there is continuous
demand for improved, more efficient and economical as well as environmental friendly
construction materials such as baked clay bricks.

Bricks can be made of clay or a mixture of sand and cement, but the latter is widely used
for building houses. However, modern construction work, such as structural design and
construction, building, architectural design and some other industrial applications, requires
proper selection of materials. Hence, modern brickwork represents a highly complex undertaking
planned down to the last detail and completely rationalized in operation. This means that before
the realization of such project, careful planning is required to ensure profitability, proper
materials selection and operational efficiency in order to minimize investment risk.

As shown in Figure. 1.1, clay bricks may be arranged instacks in a building wall. They stand
better test of time and require even lesser amount of concrete mix than the conventional blocks.
They also require no plastering when used in buildings.

Figure 1.1: Brick wall used for construction


Clay bricks are generally stronger, more durable and are exceptionally less prone to fire attacks
all of which means they can withstand the most severe service conditions in building applications
and other engineering structures. Clay bricks can be used for external and internal load bearing
walls, partition walls, building foundations, floorings and construction paving’s, where they
could serve as suitable and even better replacements for concrete blocks. The use of clay bricks
for building and other general construction purposes in replacement of conventional concrete
blocks, which are more expensive and less protective against fire outbreak.

1.1 Concept of Interlocking Block


The block's sizes are modular and rectangular (250 mm length, 210 mm wide and125 mm
high) in shape. Corner or junction block is required to maintain right angle corner or a proper T-
junction. The interlocking block is different from conventional blocks or bricks since they do not
require mortar for its laying work. Because of this characteristic, the process of building walls
and other structures are faster as the blocks are laid dry and lock into place. Almost any type of
building can be constructed with interlocking blocks, which has projection and depression to key
each other. The toe blocks have flat bottom and partly projected top to properly rest on the base
mortar and at the same time receive the middle blocks to rest on it. The middle blocks have
bottom depression and top projection to receive subsequent middle blocks and finally the top
blocks. Before placing or forming the first course in a mortar bed, the blocks must be laid dry on
the foundation around the entire building (that is, the forming process), in order to ensure that
they fit exactly next to each other, the main design constraints being that the plan should be
rectangular and all wall dimensions and openings must be multiples of the length of the block
type used. All other principles of design and construction, such as dimensioning of foundations,
protection against rain and ground moisture, construction of ceilings and roofs, among other
things remains the same as in other standard buildings.
The concept of interlocking blocks is based on the following principles: (a) the blocks
were shaped with protruding parts, which fit exactly into recess parts in the subsequent lateral
blocks and blocks placed above, such that they are automatically aligned horizontally and
vertically respectively – thus block assembling is possible without specialized block laying skills
(b) since the blocks can be laid dry, no mortar is required and a considerable amount of cement
and cost of labour are saved (c) each block could necessarily be provided with vertical holes,
which serve four purposes - (i) to reduce the weight of the block (ii) to insert steel rods or bars
for reinforcement (iii) to act as conduit for electrical and water/fluid piping etc (iv) to pour liquid
mortar or grout into the holes, which run through the full height of the wall. Thus, sealing the
wall and making a permanent solid wall, increasing its stability otherwise could be solid
interlocking blocks without vertical holes which this research is particularly concerned with.
This work objectively aims at (i) the Construction of a dual mould interlocking block
machine with high compaction effort (ii) Sampling of soils from reliable burrow pit and various
laboratory tests on sampled soils so as to ascertain their properties for production of interlocking
blocks and (iii) Production of interlocking block with adequate compressive strength using
available local materials such as aggregates (stabilised lateritic clay, river sand, Bama or Madube
gravel), lime or Portland cement and water.

Therefore, first and foremost, there is need to develop a machine that will be relatively
in-expensive, easy to be maintained, easy to operate and, most importantly, has a good quality
control mechanism (such as compaction pressure control). Secondly, although the basic principle
of block/brick making whether concrete or earthen is the same, no commercially available
machines, that produces both concrete block as well as compress earth bricks. Thus, this research
seeks to address the aforementioned challenges.
1.2 Shapes and Sizes
A variety of interlocking blocks have been developed during the past years, differing in
shapes and sizes, depending on the required strengths and uses. The system developed has the
following shapes and forms:
(i) Full blocks (300 x 125 – 150 x 100 mm) for all standard walls (single or double block thick).
(ii) Half blocks (150 x 125 - 150 x 100 mm), which can be moulded to size, or made by cutting
freshly moulded full blocks in half.
(iii) Channel blocks, same sizes as full and half blocks, but with a channel along the long axis,
into which reinforcing steel and concrete can be placed to form lintels or ring beams.
(iv) The vertical sides of the blocks can be flat or have recesses, and the vertical grout holes can
be square or round.
(v) Inserts for electrical switch housing and conduits as well as water piping outlets can be
incorporated.
(vi) Special blocks for window sills.

1.3 Soil
Soil is a natural aggregate of mineral particles, sometimes including organic constituents;
it has solid, liquid and gaseous phases. Soil itself is defined as uncemented aggregates of
minerals grains and decayed organic matter with liquid and gaseous occupying the void spaces
between the solid particles. Soil is used as uncemented materials in various civil engineering
projects and it support the foundation of structures. Soil has been used for building in a great
variety of ways, which vary according to climate and type of soil available.
The properties and use of soil as a building material must therefore be studied by anyone
concerned with building materials. In recent times, the potential of soil as a building material has
been considerably underestimated. There seems to be two main reasons for this. Firstly, the
enormous variety of naturally occurring soils has made specification for any particular set of
property difficult, and engineers have therefore tend to prefer the more predictable manufactured
materials; secondly, many soils in their untreated states lack strength and dimensional stability,
this has led to the believe that soil is a generally inferior material of short life and requiring high
maintenance. The development of science of soil mechanics and other related testing and
classification of soil types has made possible the selection and specification of soil for building
purposes with some precision; and the techniques of stabilization, first developed for use in
roads, airfields and dams, can now be used to convert soil into a building material whose
properties are entirely adequate for most building purposes, and are often fully comparable with
other available building materials. If soil is to be used successfully, it is important, as with other
building materials, that its engineering properties should be clearly understood. These derived
from the origin and condition of formation of soils.

1.3.1 Formation of Soils


Soil is formed from the by-disintegration of parent rocks by weathering, which may be
stationary or transported to other places by ice, water, wind and gravity. There are three types:

(i) Residual Soil (topsoil, laterites and saprophyte):

The soils formed by weathered product at the place of origin are called residual soils. An
important characteristics of residual soils is the presence of fine grain soil at the surface, grain
sizes increases with depth down to the bedrock. At larger depth angular rock may be formed.
Laterites are formed by chemical weathering under warm, humid tropical condition when rain
water leaches out the soluble rock materials leaving behind the insoluble hydroxide and
magnesium given the characteristic reddish brown or dark brown colour. The lateritic
interlocking block was made from lateritic-clay and not lateritic-gravel.

(ii) Transported Soil (gravel, silt and clay):


This may be classified into several groups depending on their mode of transportation and
deposition such as: (a) Glacial soils: these are formed by transportation and deposition of glaciers
(b) Alluvial soils: these are transported by running water and deposited along the stream (c)
Marine soils: these are formed by deposition in the sea (d) Lacustrine soils: these are formed by
deposition of quiet lakes (e) Aeolian soils: these soils are formed by transportation and
deposition by wind (f) Colluvial soils: these are soils formed by the movement and deposition
due to gravity such as land slide from its original place.
(iii) Organic Soils:
These soils contain large amount of organic plants and animals matter. They are usually
dark in colour and give up a distinct odour. Deposit of organic silts and clays have usually been
created in river or lake sediments. Peat is a special kind of organic soil and is dark brown spongy
materials which almost entirely consist of light vegetable matter. It exits in one of the three
forms a) Fibrous b) Pseudo fibrous c) Amorphous. Taking them singly;
a.) Fibrous peat: - non-plastic with a firm structure only slightly affected by decay.
b.) Pseudo fibrous: - peat in this form still has fibrous appearance but it is softer and plastic than
fibrous peat. Their change is due more to prolong submerge in airless water than to
decomposition.
c.) Amorphous peat: - with this type of peat, decomposition has destroyed the original fibrous
vegetable so that it has virtually become organic clay.
Peat deposits occur extensively throughout the world (local examples; Lagos and Port-Harcourt
areas) and can be extremely troublesome when encountered in civil engineering works.

1.3.2 Types and Properties of Soil


(i) Sand and Gravel: - these are cohesionless aggregates of rounded, sub-rounded or angular
fragments of rocks or mineral grains. Particles of size from 0.06mm (or 0.075mm) to 2.0mm (or
4.75mm) are referred to as Sand and those with a size of from 2.0mm (or 4.75mm) to 60mm (or
76mm) as Gravel (ii) Cobbles: - are rounded or sub-angular stones of sizes between 60mm to
200mm (iii) Silt: - these are fine grain soils with little or no plasticity. Silt may be organic or
inorganic. Particle sizes ranges between 0.002mm to 0.06mm (iv) Clay: - this is an aggregate of
mineral particles of microscopic and sub-microscopic range. Particle sizes less than 0.002mm (v)
Inorganic clay: - is more plastic than organic clay. Organic clays are more compressive (vi)
Bentonite: - this is clay formed by the decomposition of volcanic ash with a high content of
montmorillonite (vi) Varved clay: - these clays are made of thin alternate layers of silt and fat
clays of glacial (moving ice) origin (vii) Kaolin: - this is a very pure form of white clay used in
the ceramics industries (viii) Peat:- this is a very compressible organic soil composed of fibrous
aggregates of finer fragments of decayed vegetable matter (ix) Loam: - this is a mixture of sand,
silt and clay (x) Black cotton soil: - the colour of this soil varies from dark grey to black. It is
characterised by its high expansive and shrinkage properties. This soil occurs locally in Borno
state (new Marte, Biu, Hawul, Gamboru Ngala), parts of Gombe state, Adamawa state (Numan),
as well as different parts of Africa and India (C. M. O. Nwaiwu, 2008).
As mentioned earlier, the soils used for this project are lateritic-clay, river sand and Madube
gravel as aggregates. How the soil of civil engineering materials will support the stresses upon it
or respond to movement in the course of engineering construction and under loading depends
upon its properties—
1. Index properties of soils: these include particles size distribution, water content, Atterberg
limits (liquid limit, LL; liquidity index, LI; plastic limit, PL; plasticity index, PI; shrinkage limit,
SL), relative density or specific gravity.
2. Internal friction: the resistance of a soil mass to sliding is inversely related to the amount of
moisture in the soil and, thus, is greater in sand and gravel than clay.
3. Cohesion: molecular attraction between soil particles, much higher in clay than sand or silt.
4. Consolidation: this is the process of reduction of soil mass in volume due to expulsion of pore
water under load.
5. Compressibility: the degree to which soil may be made denser by various means including
tamping and vibration, and thus able to support greater loads.
6. Elasticity: the ability of soil to re-expand after being compressed.
7. Permeability: is the degree to which a soil will conduct flow of water, that is, the property of
soil to permit the percolation of water through its pore space in soil.
8. Shear strength: is the maximum resistance to shearing stress.
9. Capillarity: the degree to which water is drawn upward from the normal water table.

1.3.3 Soil Stabilization Techniques


The soil properties can be modified by adding other material to improve its durability.
This process is called soil stabilization. Soil stabilization has been used widely since the 1920s
mainly for road construction and slope stability. When a soil is successfully stabilised one or
more of the following effects will be evident: (i) Increase in the strength and cohesion of the soil
(ii) Reduction in the permeability of the soil (iii) The resulting soil will be made water repellent
(iv) Increase in the durability of the soil (v) Less shrinkage and expansion of the resulting soil in
dry and wet conditions.
Soil Stabilization with Cement
The action of cement in soil-cement is precisely the same as concrete. It reacts with water
in the mixture to form an insoluble cementation colloidal gel, a material which is able to disperse
itself to fill the available pore spaces, where it sets and hardens, forms a continuous matrix of
great strength which surround the particles of the soil and bind them together. In fact, the
difference between concrete and soil-cement is that in concrete all materials that are finer than
0.1mm diameter are excluded, whereas in soil-cement they are tolerated. A small amount of clay
present in soil-cement is an aid to compaction, but also has disadvantages.
The clay particles are considerably finer than the cement particles, and they tend to form
a continuous matrix through the soil causing swelling and shrinkage. This tendency cannot be
completely counteracted without rather large amounts of cement, but can be limited to a tolerable
level with quite small quantities. The best soils for cement stabilization are therefore, those
which have only small clay content, and consist mostly of sand and gravel particles. The
properties of soil-cement are, of course affected by the type of soil, the compaction effort used,
the density of the soil-cement mixture and the proportion of the cement used. It is very important
to note that compressive strength depends on mixing methods (the more complete the mixing,
the higher the strength) and is also adversely affected by any delay between mixing and
compaction.

Soil Stabilization with Lime


The action of lime in a stabilized soil is very different from that of cement, since lime is
not itself a cementation material, and cannot therefore form a rigid skeleton with the soil. But a
reaction of the pozzolanic type can take place between lime and certain clay materials in the
presence of water, which forms an insoluble gel like that formed by Portland cement. The
reaction however, is slow, produces a cementation material of rather lower strength than Portland
cement and of course depends on the presence of a suitable soil mineral.
The best soils for stabilization with lime are therefore those with significant amount of
clay minerals, however, lime has an additional effect on the soil, by a process known as cation
exchange (the exchange of the metallic ions on the surface of clay particles which control the
water absorption tendency), it reduces the expansibility of the clay lattice and thereby lowers the
soil‘s liquid limit and plasticity, it makes the soil more suitable for compaction and increases its
compressive strength.

1.4 Composition of Interlocking Block


The composition of block depends on the availability of materials and its use. The major
components of interlocking block include:

Cement: Cement has the property of setting and solidifying upon mixture with water. Cements
are widely used in construction firms in design of structures, and having varieties, with Portland
cement as the most common type of cement in general usage. It is a basic component of
concrete, block, mortar or plaster. Cement consists of a mixture of oxide of calcium silicon and
aluminium. Portland cement is made by heating limestone (a source of calcium) with clay and
grinding this product (called clinker) with a source of sulphate most commonly called gypsum
(Niel Jackson and Ravindra K. Dhir).

Water: Water combines with cement and aggregates to begin the process of hydration, and
adequate water-cement ratio provides good consistency. The cement paste glues the aggregate
together, fills voids within it and allows it to flow more easily. The use of clean pure water is
always recommended for use in block production to prevent adverse harmful effect of salt,
turbidity and other impurities. Impure water used to make block can cause problem when setting
or in causing premature failure of interlocking block walls.

Aggregates: Fine and coarse aggregates made up the bulk of interlocking block mixture. Various
types were explained above under ‗properties and types of soil‘. It can occur naturally or made
artificially in industries (uncrushed or crushed). The size of aggregate affects the strength and
load bearing capacity of interlocking block.
1.5 Block Strength
The compressive strength of compressed stabilized soil blocks (CSSB) depends on the
soil type, type and amount of stabilizer and the compaction pressure used to form the block. The
maximum compressive strengths of the block are obtained by proper mixing of suitable materials
and proper compacting and curing. Thorough mix is essential in the production of uniformly
high quality block. Therefore, equipments and methods adopted should be capable of effective
mixture. However, hand mixing is likely to produce a block with lower strength than machine
mixed block of similar proportions.

1.6 Wall Construction


Before placing the first course in a mortar bed, the blocks must be laid dry on the
foundation around the entire building, in order to ensure that they fit exactly next to each other
(leaving no gaps). When laying the first course in the mortar bed, care must be taken that the
blocks are perfectly horizontal and in a straight line, or at right angles at corners and joints (T-
junction). Once the base course is properly hardened, the blocks are stacked dry, with the help of
a mallet to knock the blocks gently into place. Up to ten layers can be placed at a time.

The ring beam below window level, at lintel and below roof level is necessarily
constructed to enhance bonding of the assembled blocks. This can be achieved by the aid of
channel blocks placed around the building at positions where the ring beams are required for the
installation of ring beam, which enhance bonding of the assembled blocks. Interlocking blocks
are ideally suited for load-bearing wall constructions, even for two or more storey buildings.

1.7 Advantages of Interlocking Block


The advantages of interlocking Block are:
(i) Construction with interlocking block saves time and ample amount of mortar
concrete compared to conventional masonry block laid with mortar
(ii) Areas prone to earthquake uses hollow interlocking block with the strength
improved with grout and reinforcement throughout the height of the wall to
resist the effect of earthquake, thus, providing adequate structural stability
against collapse
(iii) Having formed the base course, other course can be assembled by unskilled
labour
(iv) Dismantling of the blocks in case of temporary structure does not incur much
damages as in blocks laid with mortar
(v) Cost of construction is relatively less.
1.8 Disadvantages of Interlocking Block

The disadvantages of interlocking block include

(i) A standard skilled masonry labour is required to ensure proper horizontal and
vertical alignment of the blocks, and that the corner and junction (T-joints) are
right angled, especially at the base course
(ii) Due to wind and rain seepage effect the block wall need be rendered
(iii) The mould, palettes groove or/and protrusion edge may affect the dimension of
the block; consequently hamper the alignment and stability of the wall, if not
adequately observed
(iv) It is difficult to maintain the required tight tolerances for accurate construction
of large walls or other structures through the moulding and cutting steps.
II. LITERATURE REVIEW

Ismail (2007) investigated the potential utilization of organic residues in clay bricks as sawdust,
tobacco residues and grass were mixed with clay at (0,2.5, 5, and 10) percent by weight.
Effects on shaping, plasticity, density, and mechanical properties were investigated. It was
observed that the fibrous nature of the residues did not create extrusion problems.
However, higher residue addition required a higher water content to ensure the right plasticity.
The organic residue can be utilized in an environmentally safe way as organic pore
-forming agents in brick clay.

Pitroda et al., (2013) analysed that, as the percentage of the glass fibre in brick increased the
compressive strength of the brick is also increased. In this experimental work 1% fibre addition
gives the maximum strength 5.86 N/mm2and water absorption 12.32%. He also recommends
that use of glass fibre increase the strength but at same time the cost is also increased.

Madurwar et al., (2014) studied the application of bio fuel by- product sugarcane bagasse ash
(SBA) as a principal raw material for the manufacturing of bricks was studied. The bricks were
developed using the quarry dust (QD) as a replacement to natural river sand and lime (L) as a
binder. The bricks with 20% addition of lime to SBA and quarry dust exhibited a compressive
strength of up to 6.59 MPa, which is almost double that of the conventional clay bricks (3.5
MPa). The optimum composition of SBA–QD–L brick is 15% and 25% lighter than the
commercially available burnt clay and fly ash–cement bricks respectively.

Niklesh et al (2017) studied that the commercial production of bricks from waste materials is
still very limited sot the possible reasons are related to the methods for producing bricks from
waste materials, the potential contamination from the waste materials used, absence of relevant
standards, improper guidance, lack of awareness, and the slow acceptance of waste materials-
based bricks by industry and public. For wide production and application of bricks from waste
materials, further research and development is needed, not only on the technical, economic and
environmental aspects but also on standardization, government policy and public education
related to waste recycling and sustainable development.
Indian Brick industry, the second largest producer of bricks in the world, is next to China
and commands 60.45% share in the net domestic product of the country, but is “clearly” away
from the ambit of state regulation and protection (Daniel.2009). Such informal, small-scale, often
unlicensed (unregistered) and unregulated brick kiln industries are running as unorganized
sector. (Daniel 2009, Maithel et.al2010).The industry has an annual turnover of more than Rs140
million, with an estimated coal consumption of around 25 million tons per year, as the third
largest consumer of coal after thermal power and steel sector of the country(Gupta and
Narayan2010).Indian brick industry, the second largest producer of bricks, run as a small sector
with more than 150,000 brick fields throughout the country, each unit manufacture on an average
between 10-100 million bricks per year.

Brick is the back-bone of construction activity In India, The Gangetic plain of north India
accounts for 65% of the total brick production. Punjab, Haryana, Uttar Pradesh, Bihar and west
Bangle are the major brick producing states in this region. Gujarat, Maharastra,
Orissa.Tamilnadu, Madhya Pradesh are the important brick producing states in the Peninsular
Plateau and coastal area of India (Gupta and Narayan2010). Bricks are prepared, processed and
baked in kiln at the cottage, village and rural enterprise level. Being situated in the remote
country side, the brick kiln industry portrays a unique model of industrial relations-
“Tripartism”(Iqbal2006).Brick making is a low technology industry which is characterized by
distinct division of labor, employing skilled and semi-skilled labor comprising men, women and
children during agricultural off season. The bricks are hand molded, sun dried and then fired in a
pit or clamp kiln. Complete mechanization in production is yet to be taken place in

India. In between the simple and the advanced methods of making bricks i.e. an 5
intermediate technology is most commonly used. Brick kiln industry is the second largest sector
after the construction sector with floating labor population; these workers are mostly seasonal
migrants. They belong to the poorest and weakest sections of the rural society and they migrate
to brick kiln industry in search of employment during the lean period of agriculture (Gupta
2003).
Migrant brick kiln workers belonged to low caste and tribal communities and migrate
with their family. The entire family lives on the site and work on one unit. (Kainth2009).Migrant
brick kiln workers who are semi skilled workers, are one of the most exploited, un-organized and
un-regulated labor force (Daniel2009).In the brick sector, labour is brought in through a
contractor a from distance place. Since, they are not regular labour and not directly appointed by
the owner, they are not covered under the current Labour Laws, like minimum wage act.

The characteristics of ‘Bonded Labor’’—restricted freedom, hiring workers against


advances, long working hours, under payment and physical and verbal abuse by contractors and
employers are very common in Indian Brick industries. Labors involved in brick industries are
bonded in the sense that they all take advance money and haveto work to repay their debt
(Bhukunth 2005).The brick kiln industry is a significant employer of women and children with a
piece-rate-wage system through sarder in an advance payment mode (Gupta 2003).Brick kiln
labours are paid on the basis of quantum of work and against completion of certain tasks such as
moulding of 1000 bricks, transportation of 1000 green bricks etc. The seasonal nature of brick
production generates employment for a limited period of 6-7 months in a year. Majority
ofworkers has no option, but to engage as labours (generally as agricultural labour) for the rest of
the year.
(Danieal, K.2009).The employers usually employ more casual labourers in order to avoid
the fixed cost of employing permanent workers. Such type of casualisation of workforce
becomes a remarkable features of unorganized sector,(unorganized sector implies insecure,
unprotected employment, labour-intensive output with poor value added production i.e. long
hours of works with little reward).(Bandyopadhyay,2003)
PROBLEM STATEMENT AND OBJECTIVES
Statement of the problem:

It is required to minimize the consumption of fertile land soil in manufacturing of


building bricks and finds the alternative for this problem and also it is necessary to increase the
utilization of fly ash in building brick so that we easily recycle the fly ash and protect our fertile
land soil from sulphur which is present in fly ash otherwise land will be barren when waste fly
ash spread all over the fertile land. To find the optimum material ratio composition of fly ash in
building brick, this will satisfy the level of strength properties well, according to market demand
and for specific situation like earth quack, after considering above valuable point it is necessary
that to produce an effective, feasible and remarkable common solution for society which cover
all the above point.
Economic Development is directly related to the continuous rise in demand for bricks.
Increasing per capita income also an indicator of rising demand for bricks as construction of
concrete houses increase the status of the owner and is considered a sign of being modern.
Besides it, local materials traditionally used for permanent construction like timber, bamboo &
thatch have become very scarce, while modern building materials are more expensive and have
to be imported from outside the state.
The brick making process mainly comprise two activities---
(a) Making of green bricks from good alluvial soil
(b) Burning of green bricks by highly energy intensive thermal energy from coal.
As fuel, coal is used continuously for almost 6 months, which may cause severe impact
on environment. The mushroom growth of brick kiln and brick field creates a threat to the social
and economic sustainability of the area (Patowary2010). All brick kiln units are operating in
cluster and cause substantial level of air pollution and land degradation in the locality.
Some environmental issues related with such activities as availability of good fertile
alluvial land which is one of the most important conditions for establishing a brick industry that
initiates the process of land degradation. As land is finite and fixed in an area, so loss of such
land used by some manmade activities has raised the question of sustainability (Singh and
Asgher2005).Ministry of Agriculture,
While exploring ways to ameliorate the performance of the industry, what is needed, is a
more dynamic approach to implement the available knowledge. The contribution of this industry
to the economy is largely positive. Significant progress could occur in national development,
which could result in the consolidation of small industrial base. This would require significant
efforts towards improving the management and technology.
Therefore, there is a growing need for information about detailed economic performance
of the industry to enhance productivity with less cost of production (both economic and social
cost).Research on this aspect is very limited, which creates the necessity of conducting research
on detailed economic indicators not only profitability, but also input ,prices factor market,
product market etc.
For this reason, this study will focus on in depth economic analysis in terms of cost, profit and
productivity in Brick kiln industry.

Objectives of the study


On the basis of the above discussion, the objectives of the study are stated below
(1) To required the present status of Brick Industry.
(2) Cost analysis of the brick industry.
(3) To study the pattern of employment and income generation of the industry.
(4) To examine the socio-economic conditions of the workers.
METHODOLOGY
1. SETUP OF PRODUCTION LINE

Once you have established where you are going to make your bricks, it is a good idea to set up
your production site in such a way as to have a free flowing production line in order to minimize
labour, time and cost.

It is a good idea to have your machine and mixing area all under some shade. We also want our
water supply at our place of mixing and curing – either by tap or water tank.

2. SOIL TYPE

When looking for the right soil type, we should use soil from the subsoil, so as to avoid any
organic matter. The best soil type is sandy loam (more sand than clay). Our optimum ration is
70% sand to 30% clay silt content. The reason for this is too much sand causes difficulties in
handling, and too much clay causes the brick to shrink and in doing so they crack. If your soil
has too much clay we can add sand to get the right ration.

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