Operational Aspects of VSBK

Salient Features VSBK BTK

Construction

 Total Construction cost (Rs) 2.4 Millions 0.9 Million

 Total Construction Period 4 Months 2 Months
 Total Land Required (2 Shafts) 3 Kanals 5 Kanals
 
Daily Production
 
 2 Shafts 8,000 Bricks
 4 Shafts 16,000 Bricks 22,000 Bricks
(5,600,000 / Year) (5, 280,000 / Year)
 
Operational Days 350 Days 240 Days (8 Months)
 
Labor for Operation
 
 Fire Men / Fire Masters 8 (Two Shifts) 5 (Two Shifts)

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 Comparison

Salient Features VSBK BTK

Unloading Mechanism Screw Jack Manual / Donkeys
Unloading Trolley

 Temperature Control Dampers

Thermocouples
Fire position in Shaft Visual / Manual
Unloading Time

Fuel Consumption 130 gms / Brick 210 gms / Brick

(38% Saving)

A-Grade Bricks 95 % 70 %

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 Cost of IF VSBK Fired Brick
S.No. Description Breakup of cost Cost / Brick
Cost of IF GB making
60 trolleys @ Rs. 220/trolley + charges
1 Excavation and transportation of soil Rs.0.14
for making passage for excavator

2 Cost of Coal per Brick @ 105 g (internal) (Int ) 105 g per brick @ Rs.6/kg Rs.0.63

3 Coal/sand mixing cost with Trolley Rs. 250 / 1700 IFGB Rs.0.15

4 Coal crushing labour cost Rs. 20 / 45 KG Rs.0.050

Electricity cost for coal crusher & 12 hp power for water pump and crusher
6 Rs.0.073
water pump consuming 80 units.day @Rs.9/unit daily
7 Cost of molding GB Rs. 550 / 1000 Gb Rs.0.550

water 750g / brick (25% by weight of brick)

8 Cost of water for GB Rs.0.075
@Rs 500 / 5000 litres
11 Cost of nakasi of fired brick Rs. 75 / 1000 GB Rs.0.075

12 Releasing sand Rs. 200 / trolley for 6000 GB Rs.0.030

13 Plastic sheets for GB covering RS. 8000 / 100,000 GB Rs.0.080

Total IF GB making cost Rs.1.853

Cost of Firing
12 FMs @ Rs.7500/month each (using 30
1 Firemasters Salary Rs.0.39
days / month)

2 External coal @ 25g / brick (Ext ) 25 g per brick @ Rs.6/kg Rs.0.14

Total IF GB making cost Rs.0.530

Total IF GB making & Firing Cost per Brick Rs.2.38

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 GREEN BRICK MAKING
Soil Analysis

Soil Constituents Clay Silt Sand Silica Alumina Calcium

Recommended 30% 40% 30% 60% 25% <1%

Rawalpindi Soil 50% 30% 20% 55% 12% 7-9%

Coal
Analysis
Moisture
Ash Volatile Matter Fixed Carbon Sulphur C.V/ Btu
Coal Sample
(%) (%) (%) (%) per lb
(%)
Choa Saiden 8500 -
6-2 20-35 35-45 30-45 06-04
Shah 10,000
8100 –
VSBK Standard 2-1 25-40 15-20 35-40 <1
9900

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Quarry Site Selection
Stones +Sand Layer
 Right Quality
 Adequate Quantity Yellowish Clay
 Careful Quarrying
Red Clay

Soil Crushing

 Tractor
 Soil Crusher

Seasoning
 For 3 – 6 Months

Coal Crushing for IF GB

Mixing

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