Summer Internship Report

On
Ayodhya brick field industry

Submitted Toward the Partial Fulfillment of the Requirement for the

Award of the Degree of

Bachelor’s of Business Administration (core)

Under the Guidance of

Dr. Saiffudin Ahmad
ASSISTANT PROFESSOR

Submitted By
Submitted To
Respected Course Incharge
Dr. Saiffudin Ahmad Name : Avanish Pal
Class BBA CORE
Roll No.:2110012035337
Batch : 2021-2024

Institute of Management Sciences

University of Lucknow (New Campus)
Lucknow.

Page 1
Page 2
 DECLARATION

I, Avanish Pal declare that the Summer Training project Title “Sales and
manufacturing in Ayodhya brick field” submitted to the INSTITUTE OF
MANAGEMENT SCIENCES, UNIVERSITY OF LUCKNOW is a record of
an original work done by me under the guidance of DR. SAIFFUDIN AHMAD
Project Guide, INSTITUTE OF MANAGEMENT SCIENCES,
UNIVERSITY OF LUCKNOW and this project work has not performed the
basis for the award of any Degree or diploma and similar project if any.

Place: LUCKNOW

Date:

Avanish Pal
BBA 3rd Year/5th Sem.

Page 3
 ACKNOWLEDGEMENT

I have been fortunate enough to get good timely advice and support from a host
of people to whom I shall remain grateful I take this opportunity to express my
heartfelt thanks to Head Department of MANAGEMENT. INSTITUTE OF
MANAGEMENT SCIENCES, UNIVERSITY OF LUCKNOW, for his support
and cooperation to undertake and complete the project work.

I acknowledge the insights provided by MR. Vivekanand Pandey (External

Guide) (MANAGER), Ayodhya brick field , & DR.

SAIFFUDIN AHMAD (Internal Guide). Which helped me to a great extent in

completion of the project work.

I am extremely thankful to my Internal Guide, DR. SAIFFUDIN AHMAD ,

Institute of management sciences, Lucknow University for his advice and support
throughout the completion of the project work. And finally, there is deepest of
thanks for the patience and cooperation of the family and friends, without whom
the endeavor would not have been possible.

Avanish Pal

BBA 3rd Year/5th Sem.

Page 4
Sl.no Particulars Page. no

1 Introduction 5 – 11

2 Company Profile 12 - 14

Manufacturing and
3 15 - 45
Marketing Profile
Data Analysis and
4 46 -54
Interpretation
5 SWOT Analysis 55 – 58

Recommendations and
6 59 – 62
Conclusion

7 Bibliography 63

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 EXECUTIVE SUMMARY

No construction is possible without bricks. Since many centuries

brick making has been practiced by human beings. Presently, bricks are
easily made by using machines using new technologies. Generally two
types of bricks are manufactured by using machines that are concrete
block machines and clay brick machines. Different types of automatic
machines use different techniques to make bricks. The raw materials used by
the machines for making interlocking bricks are fly ash, sand lime, iron
oxide, lime sludge, quarry wastes etc.

The focus of this project is on the production of concrete bricks,

specifically interlocking bricks which offer a speedier, cost effective,
environmentally sound alternative to conventional walling materials. It
is based on the principle of densification of a lean concrete mix to
make a regular shape, uniform, high performance masonry unit. Concrete
Block Technology can be easily adapted to suit special needs of users
by modifying some design parameters such as mix proportion, water to
cement ratio and type of production system. It is an effective means of
utilizing wastes generated by stone crushers, quarrying and stone
processing units. The technology has high potential in areas where raw
materials are easily available. The new technique in producing this
interlock brick can generate a highly profitable business for micro and
small scale building material producers and construction companies. The
market for this type of brick in Malaysia is not yet growing at a rapid
rate, even though there are demands in construction industries due to low
production rate which reflect the cost of brick itself.

The AYODHYA BRICK FIELD bricks industry also started to

provide a good and efficient bricks for the citizen of Barabanki and
surroundings with a motivation and a small capital of 2 lacs. But the response
was good so the industry begins and developed well. Now they are even not
able to meeting their demand because of good production.

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 Topic of the study

“A study on manufacturing process and sales of fly ash bricks in

AYODHYA BRICK FIELD bricks industry”

Objectives of the project

➢ To study the importance of bricks industry

➢ To study the demand for bricks in barabanki
➢ To study the process involved in bricks making
➢ To study the bricks industry, its structure and operations

Methodology:

➢ Collection of data from Primary and Secondary source

Primary Source

➢ Questionnaire
➢ Personal interaction
➢ Observation
➢ Work involvement

Secondary Source

➢ Related information from net

Measurement and analysis technique

➢ Graphical representation using data coding sheets

➢ Applying various mathematical calculation

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 CHAPTER - 1

INTRODUCTION

Page 8
 1. Introduction

T he construction sector is an important part of the Indian economy with the

contribution of 10% in the GDP and is registering an annual growth of 9%. Clay
fired bricks are the backbone of this sector. The Indian brick industry is the
second largest producer of bricks in the world after China. India is estimated to
produce more than 14000 crores of bricks annually, mainly by adopting age-old
manual traditional processes. The brick sector consumes more than 24 million
tonnes of coals annual along with huge quantity of biomass fuels. The per annum
CO2 emissions from Indian brick industry are estimated to be 42 million tonnes.
Due to large scale construction activities in major towns and cities, a number of
brick plants have been set up on the outskirts of these cities. These clusters are
the source of local air pollution affecting local population, agriculture and
vegetation.

For the production of clay bricks, top soil to the extent of 350 million tonnes is
used every year, which is a reason for concern. Since this brick sector is labour
intensive, it limits its capacity to produce any other type of bricks. With the
introduction of NREGA scheme in various states, these labour intensive
industries are facing the shortage of manpower. Thus the brick industry has
started exploring other options like introduction of partial/full-scale
mechanization in this sector.

While studying the market in the developed countries, it has been observed that
they have completely switched over from solid brick to other resource efficient
products like perforated bricks and hollow bricks. These products consume less
fuel(coal, biomass etc.) and raw material (fertile top soil) for their production and
have better insulation properties during its usage.

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Brick industry in India

Fired clay brick is one of the most popular building material in India. More than 1,00,000
enterprises produce nearly 100 billion bricks per year. The main features of brick industry in
India are:

• It is a traditional industry,

• Has decentralized production mainly through small and medium scale enterprises that
operate only during dry season (5-6 months in a year),

• Has low level of mechanization and a high labour intensity (employing more than 5
million workers),

• Brick firing is an energy intensive process as a result brick industry is the third largest
consumer of coal in the country with coal consumption of around 15-20 million tones
per year, and

• Brick industry is a source of air pollution in the form of GHGs (mainly carbon dioxide),
particulate matter, sulfur oxides, carbon monoxide etc.

History of Brick Making

A brick is a block made of clay burnt in a kiln. It is one of the primary building
materials known to mankind. Over time, bricks have appeared, gained
prominence, lost importance and then come to the forefront again with various
styles of architecture. Burnt bricks were used in ancient Indian, Babylon, Egypt
and Roman civilizations. They are still being used as filler materials for
framework structures as well as to construct load bearing structures. Down the

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ages, there have been various interesting historic and cultural references to
bricks.

• Bricks find mention in the Bible; the tower of Babel was built with burnt
bricks.

• Bricks were predominantly used in the Indus valley civilisation. In fact, the
civilisation was first discovered when; ancient bricks being used to build railway
ballast came to the notice of a passing archaeologist.

• While the Taj Mahal was built in white marble, it had extensive scaffolding
made entirely out of brick, which was pulled down after completion.

Making the Brick

The process of making a brick has not changed much over the centuries or across
geographies. Traditionally the main steps followed to make a brick are explained
below.

1. Material Procurement: The clay is mined and stored in the open. This
makes the clay soft and removes unwanted oxides.
2. Tempering: This clay is then mixed with water and ash to get the right
consistency for moulding. Mixing is done manually with hands and feet.
Sometimes and in certain areas, animal driven pug mills are used.
3. Moulding: A lump of mix is taken, rolled in sand and slapped into the
mould. Initially moulds were made of wood, now metal moulds are used.
Sand is used so the brick does not stick to the mould.

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4. Drying: The mould is emptied onto the drying area, where the bricks are
arranged in a herring bone pattern to dry in the sun. Every two days they
are turned over to facilitate uniform drying and prevent warping. After two
weeks they are ready to be burnt.
5. Firing: The green bricks are arranged in a kiln and insulation is provided
with a mud pack. Fire holes left to ignite the kiln are later sealed to keep the
heat inside. This is maintained for a week. Firing like other operations also
depends on the knowledge and experience of the brick maker.
6. 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.

Tempering Moulding

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 Drying Sorting

Though the overall method remains the same, there are certain regional
variations considering the local soil 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. In Africa and South America, a massive fire using wood fuel is built,
and insulated with mud or grass. In India and Mexico, they fire large volumes
together and the volume itself acts as an insulator to prevent escape of heat. Fuel
ranges from wood to coal to biomass to even garbage and trash in the absence
of others.

Brick Kilns

Brick Kilns can be classified as intermittent and continuous. Clamps, Scotch,

Scove and Downdraft kilns are intermittent while the Bull Trench (BTK), Zig-
zag, Tunnel and Vertical Shaft Brick Kilns (VSBK) are continuous. The
continuous kilns are more efficient as they have heat recovery features from both
the heat in fired bricks and flue gases unlike the intermittent ones.

Intermittent Kilns

The oldest kiln is the clamp. Invented in 4000 BCE, these are still very
common in India. Clamps are temporary constructions made of green bricks or
clinker. The clinker can be reused while the green bricks are sold. A slight
variation is the Scove with a pile of dried bricks with tunnels at the bottom
allowing heat from fires to pass through and upward in the pile of bricks. It is
plastered with mud (scoved) to insulate it. Certain brick makers use permanent
clamps made of refractory bricks. Two basic variations of kilns are the updraft

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and the downdraft kilns, named after the direction of heat movement.
The updraft ones or Scotch have flues running through the floor of the kiln
with spaces between the stacks of bricks to allow heat to circulate, while the top
is covered for insulating the kiln. The downdraft ones are circular with the flue
running from the floor to the chimney stack. The hot air is then directed
downwards from the dome through the stacks of bricks.

Continuous Kilns

Continuous Kilns can be based either on the principle of moving fire or on

moving ware. The Hoffman, BTK and Zig-zag work on the principle of moving
fire. In the Tunnel and VSBK, the firing zone remains constant while the bricks
move.

The Bull Trench Kiln (BTK), which is very popular in the Indian sub continent,
is an arch-less modification of the Hoffman’s kiln. It is circular or elliptical in
shape. Bricks to be fired are arranged in a trench and tall movable metal
chimneys are placed on the brick setting. They are moved as the firing
progresses.There are also modifications of the BTK which have a permanent
fixedchimney.
.

The Vertical Shaft Brick Kiln (VSBK) is a Chinese technology based on the
traditional updraft intermittent kiln. The kiln consists of one or two shafts in a
rectangular structure insulated with agriculture residue and clay. The shaft is
loaded from the top in a pre determined pattern. After being fired in the shaft
they are removed batch wise from the bottom via an unloading tunnel. It is well
suited to the context of the South Asian brick sector.

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 CHAPTER – 2

COMPANY PROFILE

Page 15
 2.0 COMPANY PROFILE

COMPANY NAME : Ayodhya Brick field Industry

Barabanki, Tasipur, kotwadham UP

NATURE OF
BUSINESS : Mfg / selling based small scale industry.

OWNER : Vivekanand Pandey

TYPE OF
OWNERSHIP : Small scale industry with sole entrepreneaurship.

TEL-NO : 9452001514

RAW MATERIAL : Clay

Solvent Ash
Coke powder
Rice husk
Fire wood
FINISHED
PRODUCTS : Fly ash and clay Bricks.

TOTAL INITIAL

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INVESTMENT : 5 lacs

Why AYODHYA BRICK FIELD Bricks?

Infrastructure :

Ayodhya brick field has established state-of-the-art infrastructural base, fully

supported by advanced manufacturing unit. They have all the latest infrastructure and
furnaces required for the manufacturing of products that can meet the demands of the
client. They are able to fulfil the precise demands of the clients with accuracy, that too
within stipulated time frame.

Team:

They have a pool of good workers and they are competent enough to perform
their jobs and ensure complete customer satisfaction. They work hard and provide
production quality as well as service as per customer need. They also makes the
production continuous for meeting demand.

Quality Assurance :

Their customers judge them on the basis of quality offered by them, therefore,
they are committed to achieve the highest levels of quality and excellence in every
aspect of production. For maintaining the same, vigorous inspection process takes place
at different levels of production.

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 CHAPTER – 3
MANUFACTURING AND MARKETING PROFILE

- MATERIAL AND MANGEMENT

- MANUFACTURING PROCESS

- MARKETING

Page 18
 1. MATERIALS AND MANAGEMENT

2. Minimum Conditions Necessary To Produce Fired Clay Bricks

Many countries have an abundance of the natural elements needed to produce

bricks, but there are usually few areas which have all the necessary conditions
within a 15 km radius of the brick site. It is essential to verify before beginning to
establish a small brick production centre that all these conditions do exist. If the
planned brick site lacks even one of the minimum conditions listed here, it
is not advisable to establish a production centre at that site

The ten minimum conditions that a first-time producer needs to examine very
closely are:

1. Fly ash
2. Clay
3. Water
4. Sand
5. Fuel (firewood or coal)
6. Space
7. Transportation
8. Motivation
9. Management
10.Tools and Equipment
11. Assistance

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1. Fly ash
Fly Ash is the inorganic residue obtained after burning of coal/lignite in the
boilers. Fly Ash is that portion os ash which is collected from the hoppers
of ESP’s and pond ash is collected from the ash ponds.

2. Clay

A production unit needs to have good quality clay to produce a strong brick that
can be used in construction. Certain types of clay are not good for making fired
bricks. For example, the clay used by a potter to make bowls and cups is not
good for making because it has high shrinkage rate which causes the bricks to
crack during drying.

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3. Water
To produce bricks there must have water available in sufficient quantity. If they
plan to make bricks During the dry season means scarcity of water and it is little
difficult to providing the water in sufficient manner. To produce 1,000 bricks per
day, at least 600 litres of water will be needed. There is also a container to store
that water in; three empty fuel drums, each with a 200 litre capacity, are ideal.

4. Sand

Sand is used as a releasing agent during the moulding of a brick . It prevents the
wet clay from stick ing to the sides of the mould. It is also sometimes used as a
stabilizer and mixed with very clayey soils to prevent the bricks from cracking
when drying.

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5. Fuel (firewood or coal)

To fire the bricks well, you will need sufficient amounts of fuel; either firewood
or coal. If they fire bricks with coal, It will need 1 1/8 sacks of coal and 1/2 sack
of cinders for every 1,000 bricks. For example, to fire 20,000 bricks, you will need
22.5 sacks of coal and 10 sacks of cinders.

If they fire bricks with wood, they will need one ton or 3m3 of firewood for
every 1,000 bricks. For example, to fire 20,000 bricks you will have to gather
60 cubic metres of firewood

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6. Space
Every Brick Industry will need sufficient space to mould and dry the bricks. The
site should be smooth and level. A brick unit producing 1,000 bricks per day will
need an area from 600 to 1000 square metres.

7. Transport

It is essential that a brick producing unit has some type of transport to fetch
firewood or coal and possibly deliver the finished bricks to the customer. The
transport used could be trucks, tractors with trailers, or oxen with suitable carts.
The important point to remember, especially if the vehicles are borrowed or
rented, is that the brick unit will need regular access to this transport. The amount
of tune which is involved can be quite substantial, so this part must be well planned

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8. Motivation

The production of hand-made bricks is exhausting, tedious and dirty work .

Therefore, in order for a brick production unit to succeed, the workers must be
motivated or want to produce the bricks. They have to feel that the making of
bricks will either benefit themselves personally by earning them a fair and just
salary from the sale, or benefit their village by using the bricks in the construction
of a public building such as a school or clinic.

9. Management

As with any production unit or business, good management is essential.

Unfortunately this aspect is often ignored or forgotten because brickmaking is
considered to be a "low" or relatively simple technology. Remember that a brick
production unit cannot withstand more setbacks and difficulties than a normal
commercial business would be expected or prepared to tolerate.

Management of a brick unit means planning, organizing, staffing and controlling

the production in
order that the bricks can be produced within budget and sold at a reasonable price.
This includes ensuring that:

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- Adequate supplies of raw materials are obtained;
- The equipment is maintained;
- Suitable production facilities are available for the workers to work in safety and
comfort, at a reasonable pace and for the hours allotted for the tasks;
- The quality of the product is checked regularly;
- There is a smooth flow of production;
- Adequate financial arrangements are made for wages and general purchases
(with a good bookkeeping system);
- Suitable skilled personnel are recruited and trained; and
- The staff have specific tasks or roles and have the necessary tools and
information to do the job.

10. Tools and Equipment

A brickmaking unit will need basic tools in order to make bricks. A group of 15
people producing 1,000 bricks per day will need the following minimum
equipment:

6 hoes
2 pick axes
4 shovels
4 axes
4 machetes
2 wheelbarrows
3 empty fuel drums, each with a 200 litre capacity
7 buckets or pails, each with a 20 litre capacity
6 hinge moulds
2 moulding tables

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4 bow cutters
8 pallets
4 carrying boards

11. Assistance

Financial Assistance: The time between preparing to make the first brick and
selling it can be very
long; this period can often be between 3 to 6 months. For this reason they have to
plan how the
workers' salaries and general expenses will be paid. You may have to borrow
money from the bank.
If they do, plan on at least 3 to 6 months of no earned income. Remember too that
if they borrow, this
money is not a gift and must be paid back to the bank.

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Technical Assistance: All brickmaking units need technical assistance to
continually improve their
methods of selecting and preparing the clay, moulding the bricks, and firing them
in a kiln.

3. Standardization

Introduction

Standardization is an agreement between a group of producers or manufacturers

stating that the product which each one produces will have the same
characteristics.

For example, a person who owns a small portable radio can purchase batteries for
it made in Europe, Africa or Asia and know that the batteries will fit in the radio.
This is because the size, shape and power of the batteries have been standardized.

It is also important to standardize the characteristics of bricks made in an area.

These characteristics are:

1. Form
2. Size
3. Strength

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The Benefits of Standardization

Many builders and contractors do not like to use bricks made by small independent
producers because the bricks can vary a great deal in form, size and quality. For
example, one producer may make a brick 240 mm x 115 mm x 77 mm and another
in the same area may make a brick 220 mm x 100 mm x 65 mm. Because the sizes
differ, it is difficult for a builder to mix these bricks when building a wall. A large
contractor may need 500,000 bricks annually, yet many small producers will only
have 100,000 bricks available to sell each year. If the contractor bought 100,000
bricks from 5 different producers who each produced a different brick, it would
cause many problems for the builders.

Another advantage of standardizing the bricks is being able to accurately calculate

the number of bricks needed to construct a building. It also means that the size of
the openings (e.g. doors and windows) can be calculated and can be made before
the building is built.

Form

Clay with Ash bricks are better for a small rural producer to make because:

The form is simple. It is much easier to make the mould and easier to mould the
brick so there is less chance of a poorly formed brick.

You do not need a permanent kiln. It is possible to build and fire a simple clamp
or field kiln

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The bricks have good strength and can carry the weight of a heavy roof without
steel and concrete reinforcement.

They can be used to build arches.

If the bricks are made and fired well, it is not necessary to render or plaster the
wall, and therefore building materials are saved.

Size

A brick has a length, width and height. The size or dimensions of a brick are
determined by how it is
used in construction.

Possible Brick Sizes

Length Width Height
240 mm 115 mm 73 mm
230 mm 110 mm 70 mm
220 mm 105 mm 67 mm
215 mm 102 mm 65 mm
210 mm 100 mm 63 mm

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Minimum and Maximum Dimensions

Each fired brick will not be exactly the same size; they will vary a little for
many reasons. Ideally, these variations in dimensions should be limited because
many contractors prefer to have a guarantee that the bricks they buy will be
between certain predetermined limits.

The bricks manufactured in rural areas should have a tolerance of approximately

5%. This means that if the brick size is 240 mm x 115 mm x 73 mm, the length of
the brick should fall between 235 mm and 245 mm. The width should be between
112 mm and 118 mm and the height between 71 mm and 75 mm. Bricks with
dimensions outside of this 5% limit should be set aside and not sold.

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Strength

Bricks must have enough strength to carry the weight of the roof. If bricks have
been well- made and well-fired, you will hear a metallic sound or ring when they
are knocked together. If they make a dull sound, it could mean that they are either
cracked or under fired.

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 PRODUCTION PROCESS

Production of flyash bricks includes lots of manual processe. All steps are listed
below.

Clay Preparation
To make good quality bricks, the dry lumpy clay soil has to become a smooth,
soft, moist mixture containing no hard lumps of soil or stone. To obtain this
mixture, the clay soil is treated in two different steps:

1. Tempering, and
2. Mixing

Tempering:

First of all Soil or clay and fly ash is mixed in the ratio 50:50

Tempering is the process of adding water to the clay and fly ash mixture and
allowing it to stand undisturbed for a few days before mixing occurs. This will
begin to soften and break down the lumps of clay making the mixing process
easier.

At some brick sites, the producers flood the hole or pit where they are digging
with water because it makes the digging or extracting of the clay easier. This
method is not recommended because far too much water tends to get mixed into
the clay which results in lower quality bricks.

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It is better to dig or extract the dry clay and bring it to a special pit or tempering
tank and mix with fly ash where you can add water in exact proportions. This
tempering tank should be located close to the place where you mix the clay and
mould the bricks.

In the tempering pit or tank, the clay and fly ash is moistened with the correct
amount of water. In general, for every three buckets of dry clay soil and fly ash,
you will add one bucket of water. The amount of water can vary and will depend
on the type of soil and how damp it is. The dry clay soil and ash should be in
powder form or only small lumps before the water is added. This is to help the
clay absorb the water quicker. The ratio of three buckets of soil to one of water is
much less than what many producers are used to. It may seem slightly more
difficult to mix the clay when using this ratio but the results will be far better with
a stronger brick and a much lower breakage rate during drying.

Note: It is true that some very experienced people can judge the correct amount of
water without measuring, but this is not recommended for first time producers.
Because more water makes mixing easier, most people "forget" that the bricks will
be a poorer quality and tend to add more and more water to make their work easier.

The clay and ash is left in the pit to temper for one to five days (the time will
depend on the type of clay). During this tempering time, the water will enter the
clay particles or lumps and begin to soften them.

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 Mixing
After the soil and fly ash has been tempered well, it needs to be mixed and
kneaded. The purpose-of mixing is to ensure that the clay and ash is a smooth,
soft, homogeneous mixture that contains no hard lumps.

There are various methods of mixing tempered clay for small-scale brickmaking.
One system uses a simple mechanical mixer that uses an empty 200 litre fuel
drum with a mixing paddle built into it. The mixing paddle is connected to a tractor
and handled by a worker and mixed it 5 to 6 hours. The tempered clay is put into
the top of the barrel and the paddles mixes and pushes the clay out a hole cut in
the side of the drum. This method is very good for mixing but for some brick units
obtaining the materials for building it or the animal to operate it can be difficult.

Clay and Fly ash mixing unit

Page 34
 Moulding

Moulding is the art of giving shape to the brick according to the preferred size and
dimensions.

AYODHYA BRICK FIELD Bricks Industries have their own moulds. Works make the soil
and fly ash mixture which is called as wedge and that wedge will be thrown into mould. After
2 to 3 min they removes the mould and the moulded raw brick is ready.

Mould has a particular size to make a brick particular size and standardized one.

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 DRYING

Drying is the process where raw bricks after moulding it is kept in a particular place that has
been prepared for drying the raw bricks. These bricks are drown for 15 days after that the bricks
are again turned and again drown for 15 days. And after 15 days a group of 3 to 4 bricks are
made by keeping them one on one and leaved for drying for 15 days after it again 10 – 15
bricks are made as group and again drown for 15 days. This is the last process that after all that
the drown bricks are taken to the kiln place for firing it.

Group of raw bricks arranged for drying

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 Field Kiln

Field kiln is a place where the raw bricks are burnt and made them as a finished bricks that is

used for construction. Here in the AYODHYA BRICK FIELD industry they have their own

well built kiln and their capacity is of 100000 bricks. That 100000 means can be burnt at a

time.

As like that kiln they have another kiln also the capacity also same as the first one.Here the

Raw bricks are burnt by using the fuels like fire wood and some industries use coal as a fuel

for burning the bricks.

Page 37
Field Kiln in AYODHYA BRICK FIELD Bricks Industry

Page 38
 Firing The Field Kiln With Firewood

The firing of the field kiln is the last step in making the bricks and is the most
important. If the bricks are fired well, they will be of a good quality and an ideal
building material for building permanent structures such as schools, homes and
clinics. If the kiln is not fired well or if done without sufficient care and caution,
you can lose the majority of the bricks in a kiln and all the time, effort, energy,
firewood and resources that went into it will have been wasted.

Firewood

The firing of the field kiln is the most important phase in the production of bricks
and to obtain a good firing, it is essential that the correct size and quantity of
firewood is cut and brought to the kiln site. It is also very important that there is a
sufficient quantity of firewood to supply the brick site.

Quantity of Firewood

The general rule for estimating the quantity of firewood is that for every 1,000
bricks which you wish to fire, one ton or three cubic metres of cut and stacked
firewood will be needed.

Page 39
If less than this quantity is used to fire the bricks, the bricks will be under fired
and therefore weak and will probably not be suitable for use in construction

The Workers

Number: Depending on the size of the field kiln, you will need from 12 to 20
people to tend the fires during the firing stage which lasts from one to two weeks.
The workers should be divided into two groups of 6 to 10 people. The first shift
will work during the day from 06:00 hours until 18:00 hours and the second will
work during the night from 18:00 hours to 06:00 hours. At no point during the
firing should the kiln be left unattended. A general rule is that you will need at
least one person per tunnel at all times during the firing of the kiln.

The Firing Process

When bricks are heated to a high temperature, a chemical reaction occurs in the
clay which makes the brick permanently hard, durable and resistant to weather
and water.

When a brick is heated to a temperature between 20°C and 150°C, it loses most
of the water added to the clay during the preparation phase.

When heated from 150°C to 600°C, the clay brick loses its remaining water. When
firing a kiln, there will be a white vapour or steam coming from the top of the kiln
during these first two phases. If they were to stop the firing process at 600°C, the
bricks in the kiln would be useless for building purposes since they would not be
stabilized and would easily be worn down by wind and rain.

When the temperature starts to rise over 600°C, chemical changes begin to occur
in the clay which give the brick colour, hardness and durability. Temperatures of
900°C and above cause vitrification to occur. This means that a small quantity of
glass-like material forms which helps glue all of elements in the clay together. It
is after this point of vitrification that the brick will be at its hardest and most
resistant and will be ideal for construction.

The final quality of the brick will depend on the amount of vitrification which

Page 40
occurs. It therefore is essential that the temperature of the kiln rises to well above
900°C in order to obtain a well-fired brick.

Summary Of Firing Stages

1. Preheating

2. Main Firing

3. Soaking Stage

4. Closing the Field kiln

5. Cooling

6. Opening of the Field Kiln

1. Preheating

Begins firing the kiln with a small gentle fire with low heat in the centre of each
tunnel. The objective of this phase is to drive off all the water or moisture in the
bricks. During this stage there will be a white vapour or steam rising from the top
of the kiln; this is the water being released from the bricks.

The small fires are maintained until the white vapour or steam is no longer seen
coming from the top of the kiln. If the vapour is difficult to see, worker will climb
the top of the kiln using a ladder and simply feels with their hand whether the heat
coming off the top of the kiln is moist or not. This stage of firing lasts for two days
or more, depending on the size of the kiln and the moisture content of the bricks.
At the end of this phase, the temperature of the kiln will . have reached
approximately 150°C.

Page 41
2. Main Firing

Once the preheating phase has been completed, the main firing begins and will
take a total of four to six days to complete. The objective of this stage is to bring
all parts of the kiln up to the correct firing temperature of approximately 950°C.

On one side of the kiln, all tunnel openings are blocked up completely with bricks
and mud mortar. On the other side of the kiln, firewood is fed into the tunnels to
build up a large hot fire. The firewood is pushed down as far as possible into the
tunnels. This first Dart of the main firing will last about two
to three days or until the bricks in the tunnels begin to glow red. (This colour
indicates a temperature of between 600°C and 800°C.)

When the bricks in the tunnels are glowing red, the tunnels which were open
during the first two or three days of the main firing are blocked up with brick and
mud mortar and the ones which were initially blocked are broken open. Firewood
now continues to be fed in from the open side until the bricks in the tunnels are a
glowing yellow-orange colour. (This colour indicates a temperature
between 900°C and 1,100°C). This second half of the main firing stage will lasts
another two or three days depending on how well the fires are fed and the size of
the kiln.

3. Soaking Stage

It is important to maintain the fire and temperature of 900°C to 1,100°C inside the
kiln for another 12 to 24 hours. This period is called the soaking stage and is very
important because the heat enters into the centre of the brick and the brick gains
its greatest strength. The fires should not be allowed to go down at this point.

4. Closing the Kiln

Page 42
In this phase the top of the kiln is covered with 100 to 200 mm of sand or soil and
the tunnels are filled one last time with firewood before being blocked up with
brick and mud mortar. This is done to keep the heat in the kiln from escaping and
to permit the kiln to cool as slowly as possible.

5. Cooling

It is important that the field kiln is allowed to cool down as slowly as possible.
This means that the kiln should not be opened for at least two weeks and preferably
four weeks after the kiln has been completely sealed. If it is opened too soon, some
of the brick s may be cracked by the cool air rushing into the kiln. The bricks will
obtain a higher strength if the kiln was fired and sealed well and allowed to cool
slowly and naturally.

6. Opening of the Kiln

Once the kiln has cooled, it can be opened and dismantled. there will be 10% (or
10 bricks out of every 100) of the bricks removed from the kiln are either cracked,
broken, underfired, or unsaleable. This is normal for any field kiln of this type. If
however more than 20% are cracked, broken, or underfired, this indicates that the
type of clay used to make the bricks was not the correct
type or that the kiln was not fired properly.

Page 43
 WHY FLY ASH BRICKS INSTEAD OF CLAY BRICKS?

These are highly strong, durable and are extremely useful in construction.
AYODHYA BRICK FIELD fly ash bricks are in high demand due to the
user friendliness, easy handling and protection from fire feature. These
are of robust build and give an even and strong structure. Customized
sizes ensure less need of many layers of plastering

Features

• Good earthquake resistance features

• Fire resistant

• Easy handling / faster construction

• Excellent acoustic barriers

• Reduction in plastering due to even walls

Technical Specifications

• Sizes available :230x110x70 mm

• Raw Material Used : fly ash, sand, grit,

• Uses : constructions of walls

• Colors & packaging available : light grey, minimum 1 load truck can
be delivered

Uses

• Construction of malls

• Commercial buildings

• Residential buildings

Page 44
 MARKETING

Introduction
Marketing is a very important component in any commercial venture. This has
to be carefully planned so as to gain the optimum profit. Marketing strategies
include assessment of the demand position, fixing the target buyers, gaining
advertisement, pricing of the product, using the intermediaries for sales
promotion, maintaining a good relationship with the customers and gaining
knowledge about the Government latest regulations and the schemes meant
for the brick industry.

In the present chapter, the researcher compares and analyses the marketing
performance of brick works in Tirunelveli and Thoothukudi districts, by virtue
of the product, physical distribution and promotional activities, price,
marketing cost, buyer behaviour and problems in marketing of bricks.

In the present chapter, the researcher compares and analyses the marketing
performance of brick works in Tirunelveli and Thoothukudi districts, by virtue
of the product, physical distribution and promotional activities, price,
marketing cost, buyer behaviour and problems in marketing of bricks.

There are four elements or sub mixes which should be taken as instruments,
by the marketer when formulating marketing plans. As such, the marketer
should have a thorough knowledge about the four elements popularly known
as four Ps namely Product, Promotion Physical Distribution and Price.

Product

The term product combines the physical product, branding and packaging.
Hence, in the present study various aspects relating to product such as
physical product, product services, branding and packaging are compared and
analysed.

Page 45
Brick – As a Physical Product

In the present study, the physical product is ‘brick’. They are clamp kiln
bricks, Bull’s Trench kiln bricks, hollow blocks and fly-ash bricks. Brick is
the core-product which has certain immediately identifiable characters such as
shape, design, colour, height and weight.

All the types of bricks under study in AYODHYA BRICK FIELD bricks
industry are rectangular in shape. No specific design is used to highlight
the product. Well-burnt clamp kiln bricks and Bull’s Trench kiln bricks are reddish
in colour, hollow blocks are in gray in colour (as cement is the major raw
material) and fly-ash brick is in ash-colour (as fly-ash is the major raw material).

An ideal clamp kiln brick, Bull’s Trench kiln brick and fly-ash brick should
be of three kilograms in weight. Hollow block should be six kilograms. The
size of an ideal clamp kiln brick should be 8. 75”x 4”x 3” (lxbxh); (lxbxh),
hollow block should be 18”x 6” x 8” (lxbxh) or 18”x 4” x 8” (lxbxh)
or18”x 8” x 8” (lxbxh). The hollow blocks popularly manufactured and bought
in the study areas are of 18”x 6” x 8” (lxbxh) in size.

The quality of all types of bricks could be checked by dropping it from a

height of five feet to check its non-breakage capacity, dipping the bricks
into water for several hours to check its water absorption capacity and tilting
the bricks to check its quality by hearing a metallic sound. More experienced
buyers could check the quality of bricks by just seeing it and by just touching the
bricks.

Branding

Branding not only facilitates identity for promoters but also it builds up
image of the industry. So long as the standard of quality is maintained. The
brand name itself will take care of the marketing aspects of the bricks.
Hence, many brick units engrave the brand names on the bricks.

Packing, Labelling and Grading

Since the bricks need not be packed or labelled, none of the sample industries
in Barabanki and surroundings packed or labelled their products.

Page 46
Physical Distribution

A channel of distribution for a product is the route by which the title to

goods moves from the producer to the ultimate consumer or industrial user.
Physical distribution is a process in which many means and channels are
involved. But here the buyer directly meets the seller due to their higly stable and
good quality bricks. Hence there is need not be a middleman or a channel to
distribute the product.

Storage and Transportation

Physical transfer of goods from the manufacturer to consumers takes place

by means of storage and transportation. Physical goods need to be stored,
insured and transported whether the channel is direct or indirect. As such,
bricks should be stored, insured and transported.

The fired clay bricks do not require any special provision for storage. They
keep the bricks in the open space as rain water is an additional advantage
for enhancing the quality of fired bricks.

In case of hollow blocks and fly-ash bricks, tarpaulin is used to cover the
semi-finished goods. Finished hollow blocks are kept in the open space as
rain water is an additional advantage for curing the bricks.
This industry has a tractor to transport their bricks to the customer but in case of more
transportation separate vehicles are hired and the same charge will be paid by the buyer.

Cost of Marketing

A major determinant in fact, the limit to marketing is the marketing cost. It is

important for the marketers to estimate the cost of marketing the product. It
is also important to know how costs behave over a period of time.

Price

The price of bricks has a direct impact on the volume of sales of bricks. The
factors influencing the pricing of bricks are cost of production, demand in the
market, competition, Government regulations, supply of raw materials and
the buyers’ behaviour.

Page 47
Price Analysis

Brick, being an indirect essential commodity, the price always depends

upon the demand and supply position. As production and supply largely
depend upon the erratic climatic conditions, the prices of bricks always do
fluctuate.

Price Concession to Brick Buyers

AYODHYA BRICK FIELD bricks industry provides some concessions to their

regular buyers and also for new customers if they buys more than 5000 bricks.
Credit sales also available only to the reputed customers and one who have the
credit worthiness.

Buying Decision Behaviour

Buyer’s motivation includes all the impulses, desires and considerations of

the buyer which induce a buyer to purchase a given product. The major
factors that influence buying behaviour are information, socio-cultural factors,
status of the buyer, group influences and psychological factors.

Page 48
 CHAPTER – 4
DATA ANALYSIS AND INTERPRETATION

Page 49
 1. Table showing sales turnover of different years

Year Sales (in units) Sales Turnover (in ₹)

2008 150000 600000

2009 200000 800000

2010 175000 700000

2011 250000 1000000

2012 280000 1260000

2013 330000 1485000

Graph showing increase of sales turnover year to year

Sales Turnover
1600000

1400000

1200000

1000000

800000 Sales Turnover

600000

400000

200000

0
2008 2009 2010 2011 2012 2013

Page 50
Interpretation:
From the above table and graph we can easily understand that there is
increase of sales turnover year by year. This is a good sign for the industry but the
increase by year to year is only of small difference so the industry must concentrate on
it for producing more and selling them. If we see the 2010 sales turnover it is down
compared to the previous year because of some competitiveness and less production.
Overall the company is in good position and the same should be continued by the
company for the good results in future.

If we go through sales the sales also increased year to year except in 2010. This shows
a good sign for the industry.

2. Table showing market acquisition of different bricks industry

Industry Market acquisition (in %)

AYODHYA BRICK FIELD bricks 30

RMB bricks 20

MSN bricks 15

AVP bricks 15

Others 20

Page 51
 Graph showing market acquisition of AYODHYA BRICK FIELD

Market Acquisition

KTC bricks 30%

RMB bricks 20%
MSN bricks 15%
AVP bricks 15%
Others 20%

Interpretation:
From the above table and graph we can interpret that the market
acquisition of AYODHYA BRICK FIELD bricks in Barabanki and surroundings is well
because market of 100%, 30% is acquired by the AYODHYA BRICK FIELD bricks
industry. This is a good sign but as we seen in the industry and referring to the
respondents told that they are not meeting the supply for the demand. Because of lack
of production the supply is not meeting the demand. Not only in Barabanki AYODHYA
BRICK FIELD sometimes supplies its bricks to the outer state also.

Page 52
 3. Table showing production of bricks per year

Year Production

2008 160000

2009 210000

2010 180000

2011 255000

2012 283000

2013 340000

Graph showing brick production every year

Sales

400000

300000

200000

100000 Sales

0
2008 2009
2010 Sales
2011
2012
2013

Page 53
Interpretation:

From the above table and graph we can easily understand that there is
increase of sales turnover year by year. This is a good sign for the industry but the
increase by year to year is only of small difference so the industry must concentrate on
it for producing more and selling them. If we see the 2010 sales turnover it is down
compared to the previous year because of some competitiveness and less production.
Overall the company is in good position and the same should be continued by the
company for the good results in future.

If we go through sales the sales also increased year to year except in 2010. This shows
a good sign for the industry.

4. Table Showing the types of bricks produced per year

Type of Brick
Year
Fly Ash Bricks Clay Bricks

2008 160000 200000

2009 210000 220000

2010 180000 150000

2011 255000 180000

2012 283000 200000

2013 340000 250000

Page 54
 Graph Showing different bricks that are manufactured per year

350000
300000
250000
200000
150000 Fly Ash Bricks

100000 Clay Bricks

50000
0
Clay Bricks
2008 2009 Fly Ash Bricks
2010 2011 2012 2013

Interpretation:
From the above table and graph we can easily understand that there is
increase of sales turnover year by year. This is a good sign for the industry but the
increase by year to year is only of small difference so the industry must concentrate on
it for producing more and selling them. If we see the 2010 sales turnover it is down
compared to the previous year because of some competitiveness and less production.
Overall the company is in good position and the same should be continued by the
company for the good results in future.

If we go through sales the sales also increased year to year except in 2010. This shows
a good sign for the industry.

Page 55
 5. Table Showing the types of bricks sold per year

Type of Brick
Year
Fly Ash Bricks Clay Bricks

2008 150000 190000

2009 200000 215000

2010 175000 148000

2011 250000 180000

2012 280000 195000

2013 330000 250000

Graph Showing different bricks that sold per year

350000

300000

250000

200000
Fly Ash Bricks

150000 Clay Bricks

100000

50000

0
2008 2009 2010 2011 2012 2013

Interpretation:
Page 56
 From the above table and graph we can easily understand that there is
increase of sales turnover year by year. This is a good sign for the industry but the
increase by year to year is only of small difference so the industry must concentrate on
it for producing more and selling them. If we see the 2010 sales turnover it is down
compared to the previous year because of some competitiveness and less production.
Overall the company is in good position and the same should be continued by the
company for the good results in future.

If we go through sales the sales also increased year to year except in 2010. This shows
a good sign for the industry.

Page 57
 CHAPTER - 5
SWOT ANALYSIS

Page 58
 Strengths

• Ayodhya Brick field industry is the major Bricks industry in the

surroundings of barabanki.

• AYODHYA BRICK FIELD provides Better Quality of Products

• AYODHYA BRICK FIELD provides the door delivery facility with no extra

cost

• AYODHYA BRICK FIELD provides in time delivery

• AYODHYA BRICK FIELD is the Quality brick maker industry in the

surroundings of Barabanki.

• AYODHYA BRICK FIELD provided more and more employment for

unemployed persons

• AYODHYA BRICK FIELD having a good brand and image

• AYODHYA BRICK FIELD having a good labour relationship

Page 59
 Weaknesses

• No Regularity In Production

• They doesn’t provides continuity

• Lack of transportation facility with them

• Lack of Labourers

• Lack of production

• Lack of supply

• Sometimes Rain will destroy their production

Page 60
 Opportunities

• They having a good name and image so they can produce more and make
their sales even more

• They having a good resource to compete with other industry.

• There is a lack of brick production in Barabanki so they can take advantage

of this and make their production more

• They can purchase own vehicles for delivering the bricks

• They can start their another unit because they have vast own land

Threats

• More and more competitors are rising day to day

• Lack of supply leads to a big loss

• Other industries are producing more bricks hence they may cause a threat

to this industry

• There is a lack of labourers

Page 61
 CHAPTER - 6

RECOMMENDATIONS
CONCLUSION

Page 62
 SUGGESTIONS

• They can make production faster by using more land and new technology

• They can increase their production by purchasing more and more raw materials

• They can employ workers from other villages

• They can start some more units as branches

• They can provide some place for halting of labourers that the production will fast

if the halting place is near to the work place.

• They can make advertisements about their bricks

• They can make their own vehicles for delivering the bricks to the ordered place

Page 63
 CONCLUSION

• As we reached first at the industry we shocked to see because the industry is like

huge. Because it is very well organised industry that I have never seen in

Barabanki surroundings.

• This is a big bricks industry and it is maintaining its standards towards

manufacturing their product (i.e. Bricks)

Page 64
 CHAPTER - 7
BIBILIOGRAPHY

Page 65
 BIBILIOGRAPHY

WEBSITES:

www.wikipedia .org
www.resourceefficientbricks.org
www.slideshare.net
www.scbrid.com

Other Information given by the owner of the industry:

Vivekanand Pandey

Page 66
 QUESTIONNAIRE

Dear Sir/ Madam

I am Avanish B. administrative Student undertaking on “A study on

manufacturing process and sales of bricks in AYODHYA BRICK FIELD
industry” with special reference to AYODHYA BRICK FIELD. I request you to
spare sometime to fill this questionnaire. Your response will be kept strictly
confidential.

Thanking you

Yours faithfully

Avanish

1. Name of the owner:___________

2. Age :____________

3. Annual turnover:_____________

4. What is your sales turnover per annum?

a) 200000 b) 300000
c) 400000 d) 700000

Page 67
5. What is your position in manufacturing bricks compared other industry?

a) Poor b) Good
c) Better d) Far Better

6. What is your current market acquisition?

7. How often do you produce bricks in a year?

a) 2 times b) 3 times
c) 4 times d) 5 times

8. How many bricks do you burnt and prepared at a time?

a) 10000 b) 50000

c) 75000 d) 100000

9. Which bricks do you produce more?

a) Fly ash Bricks b) Clay Bricks

10. Which bricks do you sell more?

a) Fly ash Bricks b) Clay Bricks

Page 68