2012

Status of Brick Sector In The

State of Bihar
- A baseline study

Page 1 of 43

Page 2 of 43

Status of Brick Sector In The State of Bihar

- A Baseline Study

Prepared by:
Development Alternatives, New Delhi, India

Supported by:
Shakti Sustainable Energy Foundation, New Delhi, India
April 2012

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Acknowledgement

Development Alternatives would like to take this opportunity in expressing sincere thanks
and gratitude to KIIT School of Rural Management, Bhubaneswar for undertaking the task of
preparing this baseline study of the Brick Sector through placement of extremely competent
and enthusiastic interns. We would like to take this opportunity in expressing our sincere
thanks to Amit Kumar Singh of KSRM who undertook this important study.
Thanks are also due to Prof. L.K. Vaswani, Director KSRM for his continuous guidance, Prof.
Nandini Sen for her critique and contribution in steering the study towards its goal and Dr.
Prasun Kumar Das, Coordinator MTS for selecting appropriate interns suitable for the
assignment.

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Executive Summary

Status:
The state of Bihar is developing rapidly. In the five year period from 2004 to 2009 Bihars
Gross Domestic Product (GDP) has grown by 11.03% and between 2001 and 2011 there has
been a significant increase in urbanization with the number of towns increasing from 120 to
213 according to the latest census. This has been possible through investment in various
sectors, especially the construction sector. If this growth rate needs to be sustained, the
demand for quality building materials will increase manifold. In rural areas too, Bihar faces
challenges with the need for over 7.5 billion bricks over the next five years to meet the rural
housing gap.
A field study was conducted in 5 districts on Bihar to understand the present scenario of the
brick industry and to assess the market potential and barriers for introducing energy
efficient technologies for walling materials. The major brick producing districts of Bihar are
situated in the Northern and Central part comprising of Patna, Nalanda, Siwan, Muzaffarpur,
Sitamarhi, East and West Champaran, Darbhanga, Samastipur and Madhubani. With over
5,700 authorized brick kilns the state produces around 17 billion bricks per year.
The brick sector in Bihar is growing at a rate of 9%, however it continues to be dominated by
traditional technology - the Fixed Chimney Bulls Trench Kiln (FCBTK). Unlike the rest of India
(except Punjab, Haryana, Uttar Pradesh and West Bengal) the state of Bihar is the only state
which has transformed the brick firing technology from movable to fixed chimney. All this
has been done through own investment without any technical or financial support from the
Government. The FCBTK is comparatively resource and energy intensive as compared to
newer technology alternatives. The main fuel used for firing bricks in the Fixed Chimney Kilns
is coal. However the use of firewood has also been observed in some instances especially
during the initial firing period. Coal consumption is in the range of 20-25 ton/lakh bricks
produced and on an average, breakage losses are greater than 10%. However the overall
green and fired brick losses are around 30%. This is due to the open nature of the business
disrupted due to unseasonal rains especially during the peak summer season.
It was observed that the major raw material used in brick making is soil consuming around
16,500,000m3 of soil per year. No instances of alternate materials and products were
prevalent in Bihar. 90% of the brick making soil is procured from agricultural land with only
10% from river bed. This rampant use of agricultural soil is leading to a loss of around 5,500
acres of fertile agricultural land per year. This land otherwise would have supported the
production of 7,000 tons of rice. Thus use of brick making through agricultural soil is making
1,10,000 people suffer due to loss of food grain. Thus this type of uncontrolled soil use will
lead to a famine like situation in the near future if alternate methods not adopted
accordingly.
One of the major issues in Bihar is the non existence of alternate technology e.g. VSBK, High
draught or fly ash. There are some sporadic instances of High draught and VSBK but they are
not the choice of most entrepreneurs. This is mainly due to lack of awareness on its

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existence and demonstrated advantage. Although there are thermal power plants in the
state, no commercial fly ash units have come up yet. The major reason is the availability of
fly ash from thermal power plants to entrepreneurs. The common answers by the power
plant authorities are that there is no demand. On the other hand entrepreneurs complain of
lack of raw materials availability. To break the impasse no initiative has yet been taken by
the State Government on promoting the same with increased awareness and demonstration
of its use on public buildings to create confidence amongst users.
The Bihar brick sector is also characterized by high levels of pollution. Calculations show that
the specific energy consumption in fixed chimney kilns is around 1.59 MJ/kg. This leads to a
consumption of around 4 million tons of coal responsible for releasing high levels of
suspended particulate matter. This amount of coal when burnt in FCBTK technology is also
responsible for releasing around 12 million tons of carbon dioxide making it the highest GHG
emitter in Bihar in the entire industrial sector.
However the state of the Bihar brick industry is in a state of transformation. With increasing
coal prices and depleting profits, entrepreneurs are increasingly looking at ways and means
to reduce spiralling energy costs.

Proposed interventions:
Many organizations have been working towards improvement of the existing brick sector in
India and Asian countries. Successful initiatives have been launched towards improvement
of existing brick production practices. Incremental improvements in green brick making, use
of body fuel, better feeding/firing practices and design changes have ensured a substantial
reduction in anthropogenic emissions. Energy savings through arrestation /reduction of heat
losses have resulted in substantial profitability also. Improved product quality has also
increased earnings. Thus it has created a win-win situation for all. Introduction of new
technologies have also started, creating a basket of choices for an entrepreneur to adopt
and practice environment friendly brick making options. Initiatives have already been taken
up in introducing new initiatives in Bihar through the introduction of Vertical Shaft Brick
Kilns. Response has been slow due to high capital requirement. However improvement of
existing technologies has been overlooked till date. It has substantial potential of replication
since capital investment is low and does not require total transformation in the existing
practice of brick making and firing.
It is proposed to initiate interventions in improving the existing brick industry in Bihar. A two
pronged approach is hereby proposed:
1. Improvement of existing technologies
In this approach the existing FC BTK technologies will be encouraged to use internal
fuel in green brick. This will reduce both external fuel consumption, resulting in
energy savings and also improve upon the environmental emissions.
2. Introduction of new technologies
Sensing improved profitability, there will be new entrepreneurs willing to invest in
the brick business. They should be encouraged to adopt new technologies e.g. fly
ash block making technology, hollow brick making and Vertical Shaft Brick Kiln
Technological interventions will be based on Appropriate Technology and its Transfer
building on the indigenous knowledge and skills with the participation of the brick
entrepreneurs and the community. A carrot and stick approach is proposed involving

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strong policies and its implementation supported by favourable financial incentives based
only on performance.

Recommendations:

Extensive awareness generation and demonstration of eco friendly brick production

technologies.
Extensive capacity building for workers, and service providers to create a pool of
trained manpower to service the brick industry.
Capacity building of policy makers to create an enabling environment for adoption of
environment friendly technologies.
Brick sector should adopt methods and clean technologies which would lead to
improvements in quality and fulfillment of need of good quality construction
material market.
Review of existing policies and formulation of new policies related to energyresource efficient brick production to create a preferential regime for cleaner brick
production technologies.
State and Central government should give more attention in technology adoption as
well as in energy efficient brick production by setting examples in the use of green
building materials in public construction.
Financial institutions should be sensitized to support financial needs of credit worthy
brick kiln entrepreneurs. Additionally, other modes of financing other then loans and
subsidies need to be considered.
Steps need to be taken to enhance public awareness on cleaner brick usage; this
includes information on various technology choices, details of service providers,
financing options and how to avail finance.
Since there are a number of stakeholders involved to enable a transformation in the
brick sector, multi stakeholder processes for the tracking of the brick sector need to
be put in place to undertake short term and long term measures for ensuring the
brick sector is put on a low carbon path.

Impacts:
It is envisioned that even if 50% of the existing units in the state of Bihar adopt appropriate
technology on improvement of existing brick production practices, the result will be a:

Recurring saving of 250,000 300,000 tons of coal annually

Recurring saving of 750,000 900,000 tons of CO2 annually

Recurring earning of Rupees 396 - 475 million from sale of carbon credits annually

Reduction of black carbon (soot) resulting in abatement of global warming

The savings alone from CO2 will result in a generation of a substantial amount from sale of
CERs only each and every year. This - if judiciously used can be a trigger point for Greening
the Brick Industry of Bihar.

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Table of Contents

Acknowledgement

Executive summary
Chapter 1: Introduction

1.1.
1.2.
1.3.

Background
Indian brick sector
Baseline study area

1.4. Objectives of the baseline study

1.5. Methodology followed
Chapter 2: Technologies being practiced

9
9
9
10
10

2.1.
2.2.
2.3.

Brick making process

Common building material products
Technology used for brick production in Bihar

12
13
14

2.4.
2.5.

Raw materials for brick production

Potential raw materials for brick production

18
20

2.6.
2.7.

Mechanization used
Brick quality mapping

21
21

Chapter 3:

Energy and environmental status

3.1.
3.2.

Energy consumption and environmental status in the brick sector

Trend in coal price

22
22

3.3.

Diesel consumption details

23

3.4. Environmental issues

Chapter 4: Awareness issues
4.1.

Awareness and inclination to change

4.2. Brick sector clearances

Chapter 5: Market and financial trends
5.1.
5.2.
5.3.

Annual turnover
Trend in production cost
Trend in selling price

23
25
25
27
28
28

5.4. Trend in profit

5.5. Financial trend in the brick sector
Chapter 6: Social mapping of the brick sector

28
29
30

Chapter 7:
Chapter 8:
Chapter 9:

32
34
35

Key issues in Bihar brick sector

Key barriers for acceleration
Role of key stakeholders

Chapter 10: Recommendations

38

References

39

Annexure 1: Survey questionnaire

Annexure 2: List of entrepreneurs surveyed

40
43

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Chapter 1

Introduction

1.1. Background
The construction sector is an important part of the Indian economy with a contribution of
10% in GDP and registering an annual growth of 9%. The Indian brick industry is the second
largest producer of bricks in the world after China. The brick production in India is estimated
at 140 billion bricks, consuming 24 million tonnes of coal along with huge quantity of
biomass fuels. The total CO2 emissions are estimated at 41.6 million tonnes accounting for
4.5% of total GHG emissions from India. Brick production in India takes place in small units,
using manual labour and traditional firing technologies. Large demand for bricks in urban
centers has resulted in mushrooming of brick kiln clusters at the outskirts of major towns
and cities. These brick clusters are important source of local air pollution (SPM, SO2, fugitive
emissions, etc) affecting local population, agriculture and vegetation. Apart from air
pollution, brick industry also consumes good quality top soil for brick making. The industry is
estimated to consume 350 million tonne of top soil every year. There are several
opportunities exist in Indian brick industry to improve resource efficiencies and promote
production of resource efficient bricks such as perforated bricks, hollow blocks and fly ash
bricks.

1.2.

Indian brick sector

Bricks are one of the most important building materials used in India. The Indian brick kiln
industry, which is the second largest producer in the world, second only to China, has
more than 100,000 operating units, producing about 140 billion bricks annually. Brick
making is a traditional, unorganized industry generally confined to rural and peri-urban
areas. The Gangetic plain of North India accounts for about 65% of the total brick
production. Punjab, Haryana, Uttar Pradesh, Bihar and West Bengal are the major brick
producing states in this region. The availability of good fertile alluvium soils in North India
makes the fringe areas of North Indian cities dotted with brick kilns and consequently this
has become one of the major forces in bringing about land use/land cover changes around
cities.

1.3.

Baseline study area

The base line survey of Bihar brick sector was conducted in 6 different districts. The area
covered in this project is mention below. Choices of districts were made on the basis of brick
production and various types of technologies presently being available. Focus was also given
on the selection of districts based on the growth potential. Details are given in Table 1.

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Figure 1: Map of Bihar showing the surveyed clusters.

Cluster 1
Cluster 2

Table 1:

Coverage of study area

Districts
Study Area
Cluster-1
Patna
Sahpur, Chitnava,
Bhojpur
Sohadiya, Sangpur, Danupura, Jamira, Kaimnagar
Cluster-2
Saharsa
Supaul
Madhepura
Katihar

1.4.

Sulindabad, Saharsa
Sokhpur, Belahi, Parsarma, Malhi
Bhantakthy, Mathahi, Chauk, Savela
Bagmara, Miyapur, Bauliya

Objectives of the baseline study

1.5.

To understand the present scenario of brick industry in Bihar.

To assess the market potential and business viability for ecofriendly brick
production in allocated cluster areas.

Methodology followed

Phase 1 (Survey design)

Survey design of the project consisted of the background study about brick sector in Bihar. It
included the following steps:

Understanding the Project

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Designing the Questionnaire: A structured Questionnaire was prepared for the

collection of primary data.

Phase 2 (Data collection)

Both quantitative and qualitative data were collected during project period. Quantitative
data includes soil and coal quantity in brick making, brick production capacity per day, cost
of technology and selling price of final products. Qualitative data includes brick making
process, soil and coal type, green and fired brick quality.
The required data was collected from both primary and secondary sources. Primary data was
collected from Brick entrepreneurs, Builders and Secondary data collected from District
Industry Centre (DIC), Khadi and Village industries Commission (KVIC), Directorate of
Industries, BIhar as well as from different web sites articles as mentioned in reference part,
The Energy and Resources Institute (TERI) and from Development Alternatives (DA) .
Phase - 3 (Consolidation and analysis)
Microsoft excel was used as a major tool for analysis of primary data.

Tabular analysis and Graphical representation

Sampling Technique
In this project the technique of sampling used was Judgment sampling. Judgment sampling
involves the choice of brick kilns that are most advantageously placed or in the best position
to provide the information required.
Sample Design and size
Size of the sample was 50 brick kiln units depending upon the technology used in different
locations. Table below gives details of the areas surveyed.

Table 2:

Details of survey sampling based on available technologies

District

FCKBTK

FLY ASH

CLAMP

VSBK

MCBTK

CLUSTER 1
Patna

Bhojpur

10

Total
CLUSTER 2
Madhepura

Saharsa

Supaul

Katihar

20

Total

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Chapter 2

Technologies being practiced

2.1.

Brick making process

The main steps followed to make a brick are given below.

Clay winning

Clay transportation

Clay grinding and ageing

Mixing of additives

Brick forming through moulding or extrusion

Drying

Firing

Stacking and despatch

Material winning:
Normally the clay is procured from agricultural land. In some cases clay is also mined from
river banks and river bed also. The clay is mined either manually or through mechanized
means by JCB. However in most cases the clay is mined from the area where moulding is
done.
Tempering:
This mined clay is then mixed with water and left to age for atleast 8-12 hours. Before
watering the required additives are also sprinkled on the top of the clay. Just enough water
is added to get the right consistency for moulding. Mixing is usually done manually with
hands and feet. Sometimes and in certain areas where the clay is plastic in nature motor
driven pugmills are used to mix the clay into soft dough. In some cases also soft mud
moulding machine are also used to mould green bricks.
Moulding:
A lump of mixed dough is taken, rolled in sand and put into the mould. Initially moulds were
made of wood, now metal moulds are used. Sand is used as a releasing agent so the brick
does not stick to the mould and can easily be demoulded.
Drying:
The green bricks are demoulded into an open area. For proper shape it is ensured that the
demoulding field is levelled and devoid of any foreign materials. After 24 hours when the
green bricks become leather hard they are stacked in various open patterns to ensure
enough airflow to dry the bricks. Every 2 days they are turned over to facilitate uniform
drying and prevent warping. After 1 to 2 weeks they are ready to be fired into final shape.

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Firing:
Various technologies are used for firing. In India normally green bricks are fired in
continuous or intermitted kilns. The technology of firing depends on the resource availability
and the green brick quality.
Sorting:
After the kiln is disassembled, the bricks are sorted according to colour. Colour is an
indication of the level of burning. Over burnt bricks are used for paving or covering the kiln
while slightly under burnt bricks are used for building inner walls or burnt once again in the
next kiln.
Though the overall method remains the same, there are certain regional variations
considering the local edaphic and climatic conditions. In different areas, different soil types
are used with respect to local situation. The three general approaches for firing bricks
include using a massive fire, a massive volume and insulation

2.2.

Common building material products

Red Brick
Common fired clay brick is one of the important
building materials in Bihar. Bricks are very traditionally
used as walling material in most residential and
commercial buildings. They are also used for other
applications, e.g. road and canal construction. The brick
size is generally 250mm X 120mm X 70mm. Throughout
the state the red brick is the only available and used
walling material.
Adobe
Although it was not observed during the baseline survey, however it was heard that in
remote rural areas of Bihar especially in the hilly regions people do still use mud plastering
as a major walling material. The mud plastering is given over a structure of bamboo or other
structures. In some cases adobes are also used as a preferred walling material especially in
the remote areas of North Bihar. The main reason of this type of walling materials is its
affordability.
Fly ash brick
It is reported that some fly ash bricks are used in
Bhagalpur region at NTPC Kahalgaon premises.
However these are used in own construction and not
for sale to common users. The brick size for fly ash
usually is 230mm x 115mm x 70mm compared to the
bigger size for burnt clay bricks.
The table given below shows that red brick is used
both urban and rural area as major walling material in
all the surveyed clusters. Instances of fly ash brick are rare.

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Table 3:

Common building material products being used district wise

Urban

Rural

Red
Brick

Fly Ash

Adobe

Concrete
block

Red
Brick

Fly Ash

Concrete

Adobe

Patna

Major

NA

NA

Occasional

Major

NA

NA

NA

Bhojpur

Major

NA

NA

NA

Major

NA

NA

Occasional

Madhepura

Major

NA

NA

NA

Major

NA

NA

Minor

Supaul

Major

NA

NA

NA

Major

NA

NA

Minor

Saharsa

Major

NA

NA

NA

Major

NA

NA

Minor

Katihar

Major

NA

NA

NA

Major

NA

NA

Minor

District
Cluster-1

Cluster-2

Source: Observation during primary survey

2.3.

Technology used for brick production in Bihar

In India the variants of the Bulls Trench Kiln is the most common brick firing technology
followed. Previously it was the movable chimney variant with two steel chimneys on an oval
base. After its ban by the Supreme Court, the movable chimney has been replaced by
various variants of the continuous brick firing technologies e.g. the fixed chimney BTK, zig
zag kiln with forced draught, the vertical shaft brick kiln. Despite the ban of movable
chimney BTK across the country, there are many states where it is still under operation.
Amongst all the states in India, Bihar is the only state where entrepreneurs have successfully
followed the conversion of movable chimney to fixed chimney BTK. This is attributed to the
strict enforcement of the same by concerned regulatory authorities and willingness of
entrepreneurs in moving to newer firing methods. Instances of alternate technology e.g. the
forced draught zig zag kiln and vertical shaft brick kiln are slowly gaining popularity. Fly ash
technology has yet not been a popular technology due to the absence of raw material
available within a profitable distance.
Technical details of the technologies are given below:
Fixed chimney BTK
In 1996, following a Government order to ban movable
chimney BTK and raise stack height to 100 ft, movable
chimney BTKs were to accommodate taller and
permanent fixed chimneys. Underground piping (gravity
settling chamber) was necessary to divert the flue gas to
the chimney. This also required extending the width of
the base. The taller chimney creates a stronger draft,
which improves combustion to some extent and enables
flue gas to be released at 100 ft, dispersing the
pollutants over a wider area. With the present form, it has a slightly improved energy
efficiency compared to movable chimney BTK.

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Main features of fixed chimney design

1.

Chimney height

2.

Chimney cross sectional area

3.

100 -120 ft

a.

Top opening

16 25 ft

b.

Bottom opening

225 ft

Flue duct cross-section area

4 ft x 4 ft

Principles of operation of fixed chimney kilns

The kiln can be divided into three zones; brick cooling, preheating and combustion zone. In
the cooling zone air picks up heat from the fired bricks while in preheating zone, green bricks
are heated by the hot combustion gases. In both cases the mode of heat transfer is
convection. Convective heat transfer depends on the temperature difference between the
gas and the solid as well as on the speed with which the gas passes the solid.

In combustion zone the fuel is fed from the top through the fire holes. Most of the solid fuel
drops down to the bottom of the setting and burns on the floor of the kiln. The combustion
of fuel depends on:

Properties of the fuel

Temperature and size of fuel particles

Availability of air for combustion

Fuel feeding rate

Control of air flow

The amount of air flow through a kiln controls both
the combustion as well as heat distribution in the kiln.
In general higher is the air flow rate higher is the fire
travel in the kiln. The air flow in the kiln is achieved
with the help of chimney. The hot gases inside the

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chimney are lighter that the ambient air outside the kiln. The difference in weight between
the hot air column inside the chimney and outside air produces a pressure difference which
is known as draught. This pressure difference results in air movement in the kiln. The setting
in the kiln provides resistance to air flow and therefore the quantity of air flowing through a
kiln depends both on the draught produced as well as resistance provided by brick setting,
flue ducts and chimney.
Cold air leakage is also an important parameter affecting air flow in kilns. The chimney puts
the kiln under suction and so cold air tends to be drawn through any cracks and fissures
within the kiln structure. Most of the cold air leakage takes place in the flue ducts through
the cracks in the temporary partition walls erected to seal the flue ducts not in use. Cold air
drawn in reduces the average temperature of the hot gases in the stack and so reduces the
static draught. In addition, energy is consumed in moving air unnecessarily through the kiln
and up the chimney.
Coal charging and coal properties
An area of concern in the kiln operation is the coal feeding
in fixed chimney kilns. Presently coal is generally fed
intermittently with intervals between two successive
feeding operations ranging from 20-30 minutes to even an
hour. At any given time coal is generally fed in 2-3 rows and
due to heavy charging of coal, thick black smoke can be
observed coming out during and just after the coal feeding
operation.
When a fairly large charge of coal is fed, smoking is liable to
occur for two reasons:
1. The coal bed is deepened and the diffusion of air
into the coal becomes difficult
2. Addition of cold fuel reduces the temperature of
the fuel bed resulting in incomplete combustion.
The other factor which affects combustion is the quality and particle size of coal. The time
for combustion of solid fuel depends on particle size. The present practice of feeding large
sized coal and lumps results in wastage.
High draught kilns
High draught kilns are normally termed in Asia
countries e.g. India, Nepal, Bangladesh as Zig-Zag
kilns. It should be mentioned here that Zig-Zag is only
a firing pattern followed in High Draught kilns.
In these type of kilns, the length of the kiln gallery is
increased by zig-zagging the chambers and the fire
follows a zig-zag path instead of a straight path
followed in BTK. At any point of time these type of
kilns were widely used in developed countries
particularly in Germany and Australia. In Europe, the
interior cross-section of the kiln used to be small in original zig-zag kilns (7.5 ft wide x 7.5 ft
high) and the kiln used to have 16-20 chambers each 20-25 ft long. Fan draught was
provided and the kiln operated on high draught at a very fast rate of fire travel (50-100 ft per

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day). The Habla kiln developed in Australia is a form of zig-zag without crown and in which
the division walls between chambers are made of green bricks. The top of the setting is
covered by a layer of two or three courses of bricks followed by a layer of ash.
The Zig-Zag firing concept in India is generally
introduced and followed in the form of a High Draught
(HD) kiln. The HD kiln has several similarities with the
Habla kiln. The kiln consists of a rectangular gallery
which is divided into 24 chambers by providing
temporary partition walls with green bricks. The wall
of each chamber runs along the width of the gallery
except one end, wherein a space of 60 to 65 cm is left
for communication to next chamber. Draught is
created by an induced draught fan with a 20-35 HP
motor for proper combustion of fuel. Depending on the design capacity of a kiln, a chamber
can hold 7,500 to 15,000 bricks. Normally two chambers are fired per day and a output of
15,000 to 30,000 bricks per day can be obtained. When brought to full firing, the kiln
operates on a draught of 50 mm HG. However several problems are being encountered in
the HD kiln in different countries:
1. Bricks remain too hot for handling at
unloading point.
2. Dampers in the flues provided in the inner
wall communicating with the main central
flue being too close to the firing floor, were
exposed to high heat resulting in rapid
deterioration.
3. As the draught and hence the negative
pressure in the kiln is several times more
than that observed in fixed chimney BTKs, the HD kiln is also more susceptible to
air leakage. Most of the leakage takes place through wicket walls and through
leaking valves and dampers.
Specific energy consumption of around 1.35 MJ/kg of fired bricks has been achieved in HD
kilns being operated under full capacity. However it is generally observed that due to
shortage of trained manpower and lack of exposure to proper operating practices the
performance of HD kilns are much below the expected level of performance. Moreover, in
most of the rural areas either electricity supply is not available at brick kiln sites or the
supply is not reliable. Therefore installation of a DG set for electricity generation becomes
essential with a High Draught kiln which further adds to the complexity of the problem.
Clamp
Clamps are used for smaller production levels. A
variety of fuels such as coal, firewood, various types
of agricultural residues and dung cakes are used in
clamps. Large variations are observed in the shape,
size, stacking of bricks and firing techniques in clamps.
Generally, energy efficiencies of clamps are lower.
The specific energy consumption of clamps ranges
between 1.5 and 3.0 MJ/kg of fired brick. In Bihar
Clamps are not used for commercial brick production

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and there is a limit of 1 lakh bricks on a clamp that is producing bricks for commercial
purposes.
VSBK
A Vertical Shaft Brick Kiln (VSBK) is an energy efficient
technology for fired clay brick production that
originated in China. The VSBK technology
considerably economizes on fuel cost, with savings of
between 30to 50% when compared with other
common firing technologies such as Clamps or Bulls
Trench Kilns. Pollution levels are extremely reduced
compared to other prevalent methods of brick firing.
Although no VSBKs were covered in the sample
survey, there is a VSBKs in Ara, Bhojpur district and
more bring set up in other districts of Bihar.
Fly ash brick making
The process comprises of mixing the raw materials
using the pan mixer for 4-5 minutes and then
transferring the material to press machine with the
help of conveyor belt. Next, the compressed blocks
are transferred to a curing yard with the help of
wooden pallets on which the blocks are pressed using
the press machine. The blocks are then water cured
for minimum 14 days. After 14 days of curing bricks
are kept for 7 days in dried place, after that it is ready
for sale. The composition of a typical Fly Ash Cement
brick is given as below

Fly ash - 40-50%

Sand - 40-45%

Cement/Lime/Gypsum - 8-12%

Fly Ash Brick making requires Fly Ash that is a waste material from Thermal Power Plants and
there are currently very few such plants in Bihar and thus this technology is only feasible in
areas where raw materials are available.

2.4.

Raw materials for brick production

The raw materials used for burnt clay brick production are soil and coal. Industrial wastes or
dust coal can also be used as internal fuel in green bricks. Apart from burnt clay fired bricks
lime or cement stabilized cured blocks can also be produced from a mixture of fly ash
(thermal power plant waste) and sand.
In Bihar the major raw materials used in burnt clay brick making is only soil and coal. This is
mainly due to the availability of good quality soil in Bihar. Majority of brick making activity is
from soil excavated from agricultural land. In some isolated cases soil is procured from river
bed. Aerial photos given below (Figure 2a,b) shows the effect of soil excavation for brick
making both from agricultural land and from river bed.

Page 18 of 43

Figure 2a. Google photo of brick kilns

situated in river banks near Patna

The graph given in Figure 3 shows the

approximate distribution of soil use in Bihar. It
can be seen that despite the availability of good
quality soil from river beds, more than 90% of
the soil used is from agricultural land.
It is estimated that brick making activity in Bihar
consumes approximately 16,500,000 m3 of soil
each and every year. With this soil quantity
approximately 5,500 acres of land is
transformed into barren land each and every
year. This is equivalent to the loss of around
7,000 tons of rice production each year
depriving 1,10,000 people from their daily food.

Figure 2b. Google photo of brick kilns

situated on agricultural land near Patna

10%
River bed
soil

Agriculture
land

90%

Apart from soil, the major raw materials used to Figure 3: Comparison of soil use in brick
fire the green bricks are coal and wood. In the making
state of Bihar around 60,000 tonnes of wood is
used in brick production each and every year. The wood is used primarily during the initial
firing to dry up excessive moisture. However most of the wood is sourced illegally from
nearby and adjoining forests. This amount of wood is equivalent to around 300,000 full
grown trees which takes around 20 years to grow. This type of rampant use of full grown
trees will certainly lead to uncontrollable deforestation depleting the forest cover of the
state of Bihar.
Apart from fuelwood, the entire coal used in the state comes from either Jharkhand or
Assam. The major area of coal procurement in Jharkhand is from Dhanbad, Jharia, Hazaribag.
In Assam majority is supplied from Guwahati and nearby areas. On an average 22-24 tons of
coal is used for firing a lakh of bricks. The price of coal from Assam is generally higher than
Jharkhand coal due to high transportation costs. Normally North Bihar uses coal from Assam
whereas Central and South Bihar uses coal from Jharkhand sue to proximity and lower
transportation costs. The prices of coal and usage are given in Table 4.

Page 19 of 43

Table 4: Coal price and usage pattern in Bihar

District

Rate
(Rs/Ton)

Cluster 1
Patna
Bhojpur
Cluster 2
Saharsa
Supaul
Katihar
Madhepura

2.5.

Coal consumption
(Ton/year)

Total coal expenses

(Rs. in lakhs)

5,600
6,020
Average

452
450
451

25.30
27.07
26.18

9,000
9,740
9,800
9,500
Average

450
520
520
660
537

37.70
50.91
49.20
62.50
50.08

Potential raw materials for brick production

For the state of Bihar the potential raw materials for brick making in the coming years will
still be common soil. It is a common belief that good brick cannot be made from normal river
bed soils. On the contrary apart from saving of agricultural soil, use of river bed soil will also
promote de-silting of the rivers thereby promoting flow of excess water arresting flood
during the rainy season.
Apart from soil fly ash brick will be the choice of brick makers in the immediate future. In
Bihar, there are currently very few thermal power plants from where fly ash can be made
available to brick makers. However there are several new plants that are in the process of
being commissioned by the year 2012 2013. The appropriate use of industrial wastes and
hollow bricks can also save top soil.
Currently Fly Ash technology is only being used on a pilot basis at National Thermal Power
Corporation (NTPC) in Kahalgaon, Bhagalpur district. Bricks are being used by NTPC itself in
their own construction and not being sold for private or public use. However there is further
potential for brick production in Kahalgaon as well as in other areas. The Thermal power
plants that can currently be tapped for use of fly ash in brick making are given in the Figure
4. Additionally, boiler ash from sugar mills can also be used as internal fuel in green bricks to
improve resource and energy efficiency. There are currently nine sugar mills operating in the
state. The availability of boiler ash is mapped in Figure 5.

Figure 4:

Potential sources of fly ash waste

Page 20 of 43

Figure 5:

2.6.

Potential sources of boiler ash from sugar industries

Mechanization used

In Bihar mechanization was seen in soil excavation and soil preparation. However no
mechanization was observed in green brick fabrication due to the easy availability on intra
state moulders.
The mechanization used for soil excavation is JCB machines. They are mainly used to stock
soil and age them. Moreover since soil is procured from outside thus use of JCB in digging
becomes feasible to reduce labour costs and increase productivity. However due to high
capital cost, (Rs. 20 lakhs) JCB is not owned by brick entrepreneurs. Instead they are rented
from external sources at a cost of Rs. 800 per hour. During a production of 8 hours, a single
JCB can dig soil equivalent to around 120 tractors (1 tractor = 80-100 cft) which is enough to
support production for a period of 5-7 days. Thus it is economically feasible to use a JCB.
Apart from JCB, the use of motorized pugmills was common to the entire surveyed areas.
Usually the pugmills are electrically driven or run by diesel engines. They are generally used
to uniformly process the silty and clayey soil procured in the area.
No other mechanization was observed during the survey. This might be due to the easy
availability of unskilled workers in Bihar unlike other states where the use and demand of
semi mechanized soft mud moulding machine was favoured.

2.7.

Brick quality mapping

Generally the brick quality in Bihar is excellent compared to other adjoining states. This is
due to the availability of silty soil. Normally fired brick strength of around 70-125 kg/cm2 has
been observed in the surveyed clusters with good metallic ring. However colour of the bricks
varies due to variation in the soil quality. Processing of soil by pugmill might be an additional
reason for getting good fired brick properties.

Page 21 of 43

Chapter 3

Energy and environmental status

3.1.

Energy consumption and environmental status in the brick sector

The dominance of FCBTK technology poses environmental threats and challenges in the
Bihar brick sector. Brick firing, especially in FCBKT is an energy intensive process. There are
alternative technologies available that are more energy and resource efficient and emit
lesser green house gases. For instance the Vertical Shaft Brick Kiln consumes 40% less
energy compared to FCBTK through the waste heat recovery system and emits almost 70%
less emissions. The fly ash cured block technology does not use fossil fuel and therefore has
no emissions.
Globally, most of the countries are shifting from FCBTK to more environment friendly
technologies. The most pioneering step has been taken by Bangladesh in banning FCBTK
technology which is the most dominant brick firing technology in the country similar to
Bihar. Nepal is also encouraging shift to more environment friendly technologies like VSBK.

3.2.

Trend in coal price

The annual estimated coal consumption by the brick industry in India is 24 millions tonnes,
which represents 8% of the total coal consumption in the country. Besides coal, the brick
industry also consumes a large quantity of biomass fuels. The share of fuel in the total
production cost of bricks is in the range of 60% to 65% and is increasing further.
Between the years 2010 to 2011 the price of coal in the state has increased drastically as
shown in Figure 6. The price of Dhanbad coal being used in Patna has increased from Rs.
4900 to Rs. 6020 per MT of coal; an increase of more than 20%. The price of Assam coal in
Madhepura increased from Rs. 8000 to Rs. 9500 per MT of coal; an increase of 18%. This is a
very serious concern for entrepreneurs all over the state that is having an impact on the
profitability of the brick sector.
Figure 6: Trend in coal prices in various clusters
10000

9000

Cost of coal (Rs.)

8000

7000

6000

5000

4000

Bhojpur
Patna
Saharsa
Madhepura
Katihar

3000

2000
2006

2007

2008

2009

2010

2011

2012

Year

Page 22 of 43

3.3.

Diesel consumption details

One of the major sources of energy prices in brick production cost is contributed from the
use of diesel. Due to shortage of electricity in the brick manufacturing areas diesel is
extensively used for any mechanization processes in the brick industry. In Bihar, diesel is
used in transportation, soil excavation, soil mixing and diesel pump sets for the extraction of
water. In the sample survey, on an average 6970 liters of diesel was used for one brick
season. The most diesel consuming areas are Patna and Madhepura because of higher levels
of mechanization as can be seen in the graph below. In terms of mechanization the soil
extraction process with the JCB consumes maximum diesel. Table 5 given below gives the
idea of diesel consumption in Bihar.
Table 5: Trend of diesel consumption in various steps of mechanization
Technology

Diesel consumption
(litre/hour)
5.0
1.5
1.0

JCB for soil excavation

Pug mill for soil mixing
Diesel pump for water

Figure 7 below shows the yearly expenses from diesel consumption in various districts from
FC BTK operation.

140,000

120,000

Yearly expenses in Rs.

100,000

80,000

60,000

40,000

20,000

0
Bhojpur

Patna

Saharsa

Supaul

Madhepura

Katihar

Figure 7: Yearly expenses from diesel consumption in various districts of Bihar

3.4.

Environmental issues

Brick making has been identified as one of the most polluting industries in the small scale
sector by the Central Pollution Control Board (CPCB). Brick kilns are estimated to emit 42
million tonnes of CO2 every year. Apart from air pollution the brick industry also
consumes large quantity of top soil, estimated at 350 million tonnes every year. The
graph given below (Figure 8) shows the CO2 emissions from various technologies being
used in other states. Thus, if adopted, there is a potential of CO2 reduction even in the
state of Bihar in the longer run.

Page 23 of 43

Figure 8: Total CO2e emission per brick from various technologies

0.9

Emission (Ton CO 2 per brick)

0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0

FCK

VSBK"

FLY ASH

In the Bihar brick sector, there are various source of energy consumption like soil excavation,
raw material transportation, brick making and firing, however firing consumes the most
energy. Emissions from soil excavation and raw material transportation are negligible.
Emissions are negligible in brick making for red bricks that are moulded by hand (Figure 9),
however in fly ash bricks, around 60 tonnes per 1000 bricks is emitted which can be
attributed to electricity and diesel use. In the case of firing in fly ash bricks there are zero
emissions and in FCBTK technology emission is around 630 tonnes per 1000 bricks but in
VSBK technology is around 180 gram per brick.
Figure 9: Total CO2e per 1000 bricks from various technologies

Page 24 of 43

Chapter 4

Awareness issues

4.1.

Awareness and inclination to change

The primary survey was used to assess awareness about new technologies available in
the market including mechanization. While 53% entrepreneurs were aware that new
technologies exist in the market, 47% were not aware.

Figure 10: Knowledge of eco-friendly

technology

Figure 11: Knowledge about new

technologies

Technology used in the state is predominantly the traditional Fixed Chimney Bulls Trench
Kiln, which is an energy and resource intensive technology. When asked about
information on eco-friendly technologies that can reduce coal consumption, there was
less information available among entrepreneurs. 60% of respondents were not aware of
any eco friendly technologies. In the survey, entrepreneurs had no inclination to modify
or switch to new technologies; only 23% respondents were willing to modify their
technology to make it more eco-friendly. This is obvious since no entrepreneur will be
willing to take risk with any new technologies which ahs not yet been heard of or can be
seen under operation in the state.

4.2.

Brick sector clearances

Figure 12: Willingness to modify

technology

Figure 13: Status of DIC registration

Page 25 of 43

District Industry Center (DIC) is the state government body which promotes small and micro
enterprises at the district level and provides access to various schemes like subsidy, pollution
control, registration etc. However, most of the entrepreneurs in the brick sector in Bihar
have not registered themselves with DIC. This is depicting the true rural and unorganized
nature of the brick business rampant in Bihar. It is surprising that these units have
themselves registered with Mining and Pollution Control Board. It is also contradictory on
the availability of State Pollution Control Board NOC, since without a valid DIC registration
NOC cannot be available. Only 10% of respondents surveyed had registered with the DIC.
This also can be attributed to a lack of financial incentives in terms of subsidies or innovative
schemes provided to entrepreneurs by the DIC.
Additionally, the brick sector remains
unorganized and it is difficult to monitor
individual brick entrepreneurs. Unlike several
other small scale industries, there is no
unified association in the brick sector in the
state of Bihar. Although 20% respondent
stated that they are members of a brick
association, this body operates sporadically
and is not officially recognized.

Figure 14: Member of brick association

Page 26 of 43

Chapter 5

Market and financial trends

Brick production in the state of Bihar depends on the plant capacity; which varies from 20
60 lakh bricks per year. It is also dependent on other factors such as availability of labour
and raw material and weather. The FCBTK runs for an average of 6 - 7 months a year, and
has to shut down production during the monsoon season. As can be seen from the graph
below, brick production ranges between 19.4 lakh in Supaul to 40 lakh in Madhepura with an
average production in the sample clusters of around 25 lakh per year.

Average brick production per year (lakh)

45
40
35
30
25
20
15
10
5
0
Bhojpur

Figure 15:

5.1.

Patna

Saharsa

Supaul

Madhepura

Katihar

Average brick production in surveyed districts

Annual turnover
45,000

Annual turnover (lakh Rs.)

40,000
35,000
30,000
25,000
20,000
15,000
10,000
5,000
0
Bhojpur

Figure 16:

Patna

Saharsa

Supaul

Madhepura

Katihar

Annual turnover from brick production in surveyed districts

Page 27 of 43

In Bihar, the demand of red brick is very high because of no alternative substitutes such as
fly ash, concrete block etc. Patna has the highest turnover within the brick sector bringing in
Rs. 39052 lakhs followed by Madepura. The turnover from Cluster 1 and 2 is over a 1000
crores. This shows that brick business is a high turnover business which should be an
attractive proposition for the finance sector.

5.2.

Trend in production cost

The production cost of brick production in the state is increasing and will continue to
increase mainly because of rise in coal prices every year. Between 2007 to 2011, in Bhojpur
district the coal price increased at compound annual growth rate (CAGR) of 9%. In Patna
district it was 6.6%. Graph below shows the growth rate of coal prices in the surveyed
clusters. In both the clusters the average CAGR of coal is around 8%. This is due to the
increase in price of coal and increase in transportation cost due to rise in diesel prices.
No definite production cost could be ascertained from surveyed entrepreneurs. This is
mainly due to reluctance of entrepreneurs in disclosing the same. Thus it is implied that brick
production is a profitable business since entrepreneurs would not like to disclose the same
in open.
It was derived that the production cost per 1000 bricks ranges between Rs. 3500 to Rs. 4000
in the surveyed districts. In the study the lowest cost of production was in Ara (Rs. 3400) and
the highest cost of production in Madhepura (Rs. 4060).
Figure 17:

Annual growth rate of coal prices

Annual growth rate (CAGR) of coal price

10.0
9.0
8.0
7.0
6.0
5.0
4.0
3.0
2.0
1.0
0.0
Bhojpur

5.3.

Patna

Saharsa

Supaul

Madhepura

Katihar

Trend in selling price

The selling price of bricks is also increasing but not proportionate to the increase in
production cost. Therefore profitability is decreasing. In cluster 1 the compound annual
growth rate of selling price is around 6.4% and in cluster 2 it is around 7%.

5.4.

Trend in profit

In the surveyed districts of Bihar, profitability is decreasing because of increased production

costs. In fact in cluster 1 the compound annual growth rate of brick is around -1%, indicating
decreasing profits. In cluster 2 it is around -3%. The highest compound annual growth rate is

Page 28 of 43

-6% is in Saharsa and followed by Katihar at -3%. In almost all the districts the profit ranges
between Rs. 500 to Rs. 780 per 1000 bricks.
Figure 18: Trend in selling price of bricks

Figure 19:

5.5.

Trend in profits from brick business

Financial trend in the brick sector

In the surveyed clusters of Bihar no instances of financing of brick kilns was observed. Upon
discussion with brick entrepreneurs it was learnt that they do not avail of any finance. The
reason was two folds. Most of the entrepreneurs are ignorant on the schemes and
availability of finance for manufacturing units. On the other hand the financial institutions
are averse to loaning (both for fixed and working capital) to brick entrepreneurs due to their
rural setting and nature of business. On the other hand these financial institutions (State
Bank of India, Punjab National Bank etc.) have and are willing to provide only capital loans
for movable properties e.g. vehicles, equipments etc.
Entrepreneurs are also ignorant about the various schemes and subsidies given by the
Government. This is derived from the fact that the flagship PMEGP scheme of the
Government of India is grossly under utilized compared to other states. Only about 30% of
the subsidies have been utilized by the State Government under this scheme. This under
utilization is also attributed to banks apathy to provide loans to the SME sector inspite of
loan securement of around 25-30% through the subsidy amount.

Page 29 of 43

Chapter 6

Social mapping of the brick sector

The brick sector is a major source of employment providing jobs for approximately 10 million
workers nationally. In Bihar, the brick sector finds it labour from within the State as well as
migratory labour from neighbouring Uttar Pradesh and Jharkhand. There are various
categories of workers on a brick kiln such as moulders, firemen, unloaders and managerial
staff.

Increasing labour cost

Labour costs in the state of Bihar are increasing and shortages of certain types of
labour are leading to pressure on the brick business. The total labour cost in the
production of a brick is Rs. 0.99. A description of the labour costs involved in the 2
clusters is given below.
Moulder:
There are currently serious problems being faced by the brick sector from the shortage of
skilled moulders. Moulders charge a high advance of Rs. 15,000 per moulder family.

Figure 20:

Distribution of labour expenses in brick production

In Cluster 1 (Bhojpur and Patna), there is an average of 45 moulder families in each kiln. The
average remuneration of moulder on 1000 bricks is Rs. 410. In Cluster 2, there is an average
of 55 moulders in each kiln and the piece rate per 1000 brick is Rs. 430.

Page 30 of 43

Loader:
Green bricks are left in the sun for approximately one week to dry. Then they are
transported to the kiln on animal driven carts or donkeys. This work is physically taxing and
carried out by men and boys. Once they reach the kiln, the brick are stacked in the kiln for
firing. The average wage of loader in study area, in district Bhojpur, was the highest i.e. Rs
245 per 1000 brick followed by Supaul at Rs. 190. The average cost of loader per brick is Rs.
0.17.

Fire men:
There are 4 to 5 fire men and a mistri involved in firing a kiln. In Bihar, the firemen
are migrant labour from Uttar Pradesh (two districts, Allahabad and Raebareli). This
migration is seasonal, from January to June. The advance payment to labour in the
districts is around Rs.10,000. Firemen have a fixed salary of Rs. 6000 per month. In
cluster 1 the average firemen on each kiln was 5. Thus the cost of firemen per brick
was Rs. 0.58. In Cluster 2 the average firemen on each kiln was 5, with an average
cost of firemen per brick being Rs. 0.60.
Permanent staff:
The management hierarchy in the brick sector industry includes site manager,
supervisor and some office staff which are permanently employed. In brick industry
the involvement of entrepreneur is very high and is responsible for all decisions. In
district Bhojpur the average permanent staff cost per brick ranges between Rs. 0.08
to Rs. 0.20.

Page 31 of 43

Chapter 7

Key issues in Bihar brick sector

Bricks are the main building materials used for walling and as fillers in the construction of
residential houses, commercial buildings, canals, dams etc. The brick sector in the country is
unorganized and polluting, thus often exempted from policy and financial incentives
provided to other small and medium industries. Although there are alternative technologies
available, which are more energy and resource efficient, traditional technologies such as the
Fixed Chimney Bulls Trench Kiln and Clamps are predominant, especially in the state of
Bihar.
A field study was done in 5 districts and 2 clusters in the state of Bihar to understand the
present scenario of the brick industry. The sector is dominated by one technology i.e. the
fixed chimney kiln. However there is potential to improve the existing technology as well as
introducing new cleaner production technologies to reduce pollution and mitigate
emissions. Some of the barriers are the lack of awareness amongst brick sector
entrepreneurs, lack of demonstration of such technologies in the state and scope in the
improvement of the policy and financial regime towards environmentally friendly brick
technologies.
To overcome these barriers, the state and central government have a role to play in terms of
ensuring the promotion of energy and resource efficient bricks and mainstreaming such
technologies.

Key issues in the brick sector

Energy intensive brick making technology:

The FCBTK is a resource intensive and energy intensive technology for brick making
and emits over 600 tonnes of CO2 per 1000 bricks in its firing processes, as compared
with alternate technologies that are upto 40% more energy efficient in their firing
processes. The brick sector in Bihar is dominated by the FCBTK technology, and
currently there are no cleaner and more resource efficient technology alternatives.

High level of pollution:

The brick sector is the most polluting sector among other small-scale industries.
Currently in Bihar because of a lack of clean technology, the brick sector not only
emits high amount of carbon emissions but also other harmful gasses such as
Sulphur Dioxide (SO2), Nitrous Oxide (NOx), Carbon Monoxide (CO) and particulate
matter that is harmful for health as well as surrounding agricultural land, orchards
etc.

Resource intensive:
Currently the sector depletes large amounts of coal, soil and wood. The cost of coal
has risen by almost 20% in areas of Bihar from 2010-2011 and will continue to rise.
This has raised the cost of production of bricks and reduced the profit margins for
brick makers. Clay required for brick making is obtained from land, which could
otherwise be used for agriculture. The loss of soil fertility and associated impacts of

Page 32 of 43

soil erosion are serious issues raised by the brick sector. Additionally, 60,000 tonnes
of wood per year are used for brick making in the state, causing deforestation in the
state.

No formal financial regime and poor markets:

There is a lack of access and tailor made financial instruments to finance the
modernization and upgradation of the brick industry. Additionally, because of a lack
of awareness, there are poor markets from new types of bricks such as fly ash bricks
or concrete bricks and a perception that bricks from alternate technologies are of
poor quality prevails.

Page 33 of 43

Chapter 8

Key barriers for acceleration

The barriers that are responsible for stagnation of the brick sector and inhibiting technology
up gradation have been detailed below:
Policy
The existing codes and specifications for building materials are based on traditional brick
making technologies and do not meet modern practices and technologies. With the
availability of new building materials, these codes and specifications need to be reviewed
and modified for large-scale production and use. Currently incentives to switch to cleaner
technologies in the brick sector are lacking both in terms of financial incentives as well as in
terms of a preferential regime for environmentally friendly brick technologies. In fact,
currently the mining royalty structure in Bihar is a compounded rate based on the average
consumption of clay by FCBTKs, although new technologies use less soil.
Financial
There is a lack of awareness and knowledge among brick entrepreneurs necessary to
prepare project reports/ documents for seeking loans from financial institutions/ banks. The
credit-worthiness of brick kiln entrepreneurs is not favorably viewed by banks. At present,
there is no tailor-made financial instrument available to brick kiln entrepreneurs for
investing in technology upgradation.
Business Skills
The majority of brick kiln entrepreneurs use traditional methods of green brick production,
brick firing and marketing. They lack capacities in regard to modern practices in marketing,
buisness opportunities and kiln management. There is also a lack of trained manpower to
cope with new technology changes.
Technology
There is limited availability of technology know-how for resource efficient bricks, as very few
technology providers are available in the country. With brick kiln operations in India
generally being carried out at the small scale level, individual brick kiln entrepreneurs find it
difficult to access such know-how.
Awareness barrier
The present level of awareness of entrepreneurs and end-users on modern technologies
(machineries) and building products is low. The benefits from the production of resource
efficient bricks - such as energy savings, reduction in top soil consumption and air pollution are also not well known to entrepreneurs.

Page 34 of 43

Chapter 9

Role of key stakeholders

A large number of stakeholders need to be involved in carrying out the objectives of policy
through various actions oriented initiatives. The stakeholders include individual brick
manufacturer / entrepreneur, brick industry associations at regional and national levels,
financial institutions, technology and equipment suppliers, market and policy enforcement
agencies, government (both state and central), NGOs, private and corporate agency,
research laboratories, international funding agency as well as the building industry and other
end users of the brick products.

Brick kiln manufacturer/entrepreneur

Individual brick kiln units are expected to take an active role in widespread
technology adoption, which would lead to the introduction of new and resource
efficient products in the market.
Implementation of improved firing technology as VSBK for reduction of CO2
emissions.
Use of Internal fuel such as fly ash, coal dust, rice husk in the process of brick making
for consumption of less fuel in firing practices.
Produce resource efficient brick to reduce the quantity of soil usage.
Improved kiln operation, particularly by increasing the draught, improving air control
and improving fuel feeding practices, the unburnt can be reduced to a large extent.
Make small improvement in kiln design, construction and operation which would
helps in reduced energy consumption.
Brick industry associations
District level industry associations will facilitate identification of potential brick kiln
units who can adopt technologies for production of resource efficient products
through accessing finance from commercial banks/ financial institutions.
Create awareness among brick kiln units on resource efficient products, and interact
with policy makers to influencing relevant policies to promote resource efficient
products on large scale.
Banks and financial institutions
Banks and financial institutions would be involved for providing suitable financing
mechanisms for technology up gradation.
Facilitate new and improve technology by offering financial incentives for application
of these practices.
Develop flexible, customized finance products that address the n=eeds of the
entrepreneur and facilitate easy repayment.
Adopt a more flexible and innovative approach in their credit appraisal norms and
encourage entrepreneur to take insurance cover.

Page 35 of 43

Policy enforcement agencies

Policy enforcement agencies can greatly influence the market transformation
process by providing support for resource efficient products, which would help in
conserving resources and reducing pollution loads.
Effectively enforce regulatory measures for planned development.
Technology and equipment suppliers
Technology and equipment suppliers should help for up gradation of traditional
technology and adoption of new technology.
Share information and technologies with the other stake holders and facilitate
awareness creation on new, innovative and sustainable methods of brick making.
Customize alternate technologies for larger application in locally.
Promote use of resource efficient brick as far as possible and reduced the use of
scarce resource, so that the stress on the natural environment is reduced.
State Government
Prepare policy guidelines related to energy, environment, natural resource and
employment.
Plan long term programmes and short term strategies to tackle problems in brick
sector.
Review the legal and regulatory regime to encourage increasing or improving
technology in brick sector.
State government should take initiative for utilization of energy efficient brick in
government sector through govt. agency.
Encourage partnership between NGOs/CBOs, private sector, PRIs and Microfinance
institution.
Facilitate training programmes for entrepreneur and workers.
Facilitates research and development activities through appropriate capacity
building programmes.
Ensure large scale dissemination of government schemes and set up structure for
accessing them.
States should ensure availability of their share in schemes sponsored by central govt.
If required, State government should make efforts to mobilize resources from
exclusively for brick sector development.
Central Government
Take steps to bring in planning, financial, regulatory, institutional and legal reforms.
Evolve plans, strategies and parameters for optimal use of available resources
including land for sustainable development.
Develop and enforce appropriate ecological standards to protect the environment
and provide a better quality of life.
Promote research and development on innovative building materials, transfer of
technology for energy efficient brick sector.

Page 36 of 43

Civil society
Facilitate exposure and access of innovative technological and institutional solution
for brick sector development.
A very important role of NGOs is to provide Capacity building and training
programmes.
Facilitate Panchayat to access foreign funds /grants and wherever required, provide
services for increased effectiveness and greater work efficiency.

Building industry
Building industry should use resource efficient brick in their construction work.
Building industry should help for promotion of resource efficient brick, fly ash brick,
and also create awareness among all users.

Page 37 of 43

Chapter 10

Recommendations

1.

Brick sector should adopt methods and clean technologies which would lead to
improvements in quality and fulfillment of need of good quality construction
material market.

2.

There should be a review of existing policies and formulation of new policies related
to energy-resource efficient brick production to create a preferential regime for
cleaner brick production technologies.

3.

State and Central government should give more attention in technology adoption as
well as in energy efficient brick production by setting examples in the use of green
building materials in public construction.

4.

Financial institutions should be sensitized to support financial needs of credit worthy

brick kiln entrepreneurs. Additionally, other modes of financing other then loans and
subsidies need to be considered.

5.

Steps need to be taken to enhance public awareness on cleaner brick usage; this
includes information on various technology choices, details of service providers,
financing options and how to avail finance.

6.

Since there are a number of stakeholders involved to enable a transformation in the

brick sector, multi stakeholder processes for the tracking of the brick sector need to
be put in place to undertake short term and long term measures for ensuring the
brick sector is put on a low carbon path.

Page 38 of 43

References

Books and Articles

Heierli, U. & Maithel, S. Brick by Brick: the Herculean task of cleaning up the Asian
brick Industry.
Maithel, S., Vasudevan, N., Johri, R. & Kumar, A. (2001). Pollution reduction and
waste minimization in brick making. TERI: New Delhi.
Iqbal, M. (2006). Bonded labor in the brick kiln industry of Pakistan. The Lahore
journal economics, 11.1, 99-119.
Panigrahi,A., Lokadrusti. Experiences and strategies to address the concerned of
seasonal migrant labour in India. Orissa
Akbar, S. & Ferdausi, S.A. Urban Air Quality, Climate Change, and Development: An
IntegratedApproach to Greening the Brick Industry in Dhaka, Bangladesh.
Vasudevan, N. (1994) Accelerating informayion dissemination in small scale brick
kiln units through local support and local NGOs..

Web sites

http://www.bihar.nic.in

http://www.weinerberger.com

http://www.vsbknepal.com

http://www.forest.mtu.edu.com

Page 39 of 43

Annexure 1

Survey Questionnaire

Questionnaire (Brick Kilns/ Fly ash units)

1

Name of the District-

Name of the Block-

1.11

Name of the Proprietor

1.12

Address & Mobile no.

1.13

Years of Establishment-

1.2

Operation Hours

1.21

Hour per day

1.22
1.3

Months per year

Technology Specification

1.31

Firing technology

1.32

Per Day Capacity

Yearly Capacity

1.33

% of breakages

No .of Shafts/chimneys/machines

1.34

Single pan/double pan mixer with capacity(FA)

1.35

Ease of use

1.36

Process followed-mixing,moulding,drying,firing

1.37

Per day Diesel Consumption

1.38

Rated power of motor in KVA or HP

1.39

Monthly electricity consumption in units

1.4

Equipment used

1.41

Technology Supplier

1.42

How do you know about Technology?

1.43

Costs of the tech.?

1.44

Service provided by Technology supplier

1.45

How much charge by tech. supplier in major machinery Problem ?

1.46

Why you prefer this technology?

1.47

Any Suggestions regarding Delivery?

2.1

Brick

2.11

Dimension

Weight

2.12

Strength

Brand

Years of OperationOperation days in month

Reason for variation

Page 40 of 43

Market & Economics(Costs involved)

3.11

No. of brick units in District

3.12

Total brick production in District P.A

3.13

Which have greater Demand fly ash/ red brick

3.14

Majority supply in which location ?

3.15

How far?

3.16

% of consumers bricks?
Pvt. Small EPs

Public Urban

, Med EPs

and
,Large EPs

Public Rural
, Individuals For House Construction

3.17

What is the increase of sales of your bricks compared to last year ?

3.18

What is the projected growth of sales for next YR.

3.19

Production Cost Per brick

3.2

Marketing Strategy adopted(sold through supplier or direct)

Finance

4.11

Total investment

4.12

If own investment , from whom with amount?

4.13

Amount of Capital exp.

Selling price Per brick

Own investment/ loan

Own equity amount
Debt amount
Own equity amount
Debt amount

4.14

Amount of Working Capital

4.15

If bank loan , how much amount ?

4.16

Bank interest rate

Bank branch/Distance

4.17

Repayment years

Duration

4.18

Documents submitted

4.19

Issues faced

,
,

If you take Debt from informal source what is the interest rate ?
What do you prefer financing or own investment
Reasons for financing/own investment
4.2

Subsidy

4.21

If subsidy, why you prefer subsidy?

4.22

Name of the Scheme

4.23

Amount

4.24

Duration

4.25

Issues

Environment & Policy

5.11

Do you Know about new technology for savings of energy

5.12

Do you know about eco-friendly Technology?

5.13

Do you want to Modification Of your existing technology ?

5.14

Pollution clearance obtained?

5.15

EM1 Obtained

5.16

Is the unit registered at DIC-Reasons

5.17

Any other clearance/ Documents

5.18

Tax to be paid ?

5.19

Service tax or VAT ?

5.2

Difficulties Faced

Agency
Process

YES/NO
YES/NO
YES/NO
YES/NO

YES/NO

EM2 Obtained

YES/NO

If yes how much ?

YES/NO

Page 41 of 43

Situation Analysis(past , present, future)

6.11

Situation on start

6.12
6.13

situation now
Challenges faced in social ,technical & financial aspects

6.14

Failures

6.15

Solutions for the failure

6.16

Future plans

6.17

Benefits of using clean Tech(VSBK/Fly ash)

Employment
Better social condition

7.11
7.12

Environment
Financial saving
Whether you have joined in any brick association or not
What type of benefit do You get after joined in association-

YES/NO

Page 42 of 43

Annexure 2

List of entrepreneurs surveyed

Sl.

District

Name of unit

Location of unit

Name of enterpreneur

1
2
3
4
5

Bhojpur
Bhojpur
Bhojpur
Bhojpur
Bhojpur

India itt bhatha

Swastik itt bhatha
Super itt bhatha
Sivam itt bhatha
Swastik itt bhatha

sohadiya
Sang pur
Danupura
Jamira
Kaim nagar

Samim Akhatar
Sanjay singh
Mahendra singh
Kamlesh singh
Ajay kumar singh

6
7
8
9
10

Saharsa
Saharsa
Saharsa
Saharsa
Saharsa

JBW itt bhatha

King bricks
U.K. itt bhatha
Bam bricks
KP marka

Sulindabad
Saharsa
Saharsa
Sulindabad
Sulindabad

Manoj singh
Amrit sharma
Umesh kumar
Bam yadav
Chandrma singh

11
12

Supaul
Supaul

GHB itt bhatha

SNS itt bhatha

Sokhpur
Belahi

Jamal khan
Sekhar kumar

13
14

Supaul
Supaul

SBC itt bhatha

BBC itt bhatha

Parsarma
Malhi

Mukesh kr singh
Balram singh

15

Supaul

SKS itt bhatha

Sokhpur

Satendra singh

16
17
18
19
20

Katihar
Katihar
Katihar
Katihar
Katihar

AMBA bricks
ARSH itt bhatha
JPC itt bhatha
BABA bricks
DEV bricks

Katihar
Miyapur
Bauliya
Boliya gumti
Bangmara

Deelip kumar jha

Brij narayan panday
Jyotsna & Priti singh
Subash chandra mandal
Vijay krishna

21
22

Madhepura
Madhepura

Shri itt bhatha

SNM bricks

Bhantakthy
Mathahi

Arun kumar
Alok kumar

23
24

Madhepura
Madhepura

Shri laxmi bricks

Om itt udyog

Mathahi
Savela chauk

Prabhat chand gupta

Viswa prakash bharti

25

Madhepura

KDB bricks

Mathahi

Duryodhan prasad yadav

26
27
28
29
30

Patna
Patna
Patna
Patna
Patna

Rajan bricks
Kamal bricks
Mamta itt bhatha
UMA bricks
Kamal bricks

Sahpur
Chitnava
Chitnava
Sahpur
Sahpur

Naval kisor prasad

Hareram singh
Ashok kumar singh
Baldev prasad
Sujeet kumar

Page 43 of 43