Wienerberger

POROTHERM Walling Material For Next Generation

Kundan Dighe 10th March 2011

What is the Present Scenario ?

The Need for SUSTAINABILITY: Two Reasons

1) POPULATION GROWTH: INDIAS DEVELOPMENT DILEMMA

The Need for SUSTAINABILITY

2) GLOBAL WARMING: STRONGER, FASTER, SOONER

The Combination: A Great Future?

2050?

2020?

Can There Still be Doubt?

Number of peer-reviewed articles dealing with climate change published in scientific journals during the previous 10 years: Percentage of articles in doubt as to the cause of global warming:

928 0
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In 2007 the UN Intergovernmental Panel on Climate Change published a report that put the reality of human-induced climate change beyond any doubt!

How are we related to that?

Impact of Construction: A Double Whammy Production and Transportation of Construction Materials Low Energy Efficiency of Buildings / Structures

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Up to 30% of all raw materials used / steel and cement two largest green house gas producing industries in any country Up to 65% of a countries electricity consumption from buildings / up to 50% of carbon emissions
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The Indian Emission Scenario

80% of Indias Total Emissions

100km of transportation add another 10-15% of global warming potential to the production of building materials

Content
-Label Definition Resource
Efficiency Why Brick Industry think of Resource Efficiency ? Introducing POROTHERM HP as resource efficient bricks The Production Process of Ceramic Building Materials Product Benefits

Expectation from the Government & Industry

Definition Resource Efficiency

The efficient use of materials in design and construction (eg, design strategies that reduce material use or enable materials to be salvaged, reused, or recycled) Reduces the demand of Natural Resources Ensures sustainable growth & support from nature to inhabitants for generations

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Why do Brick Industry think of Resource Efficiency ?

1,000 Billion bricks are produced & consumed per year in Asian Countries, equivalent to 100,000 New York Empire State Buildings Each Asian Citizen consumes ~ 250 bricks Per Year Consumption of coal 110 million tons of coal per annum Up to 40% of this energy consumption can be saved by:

- Implementing energy efficient brick production

- Switching over from solid brick to HOLLOW Brick

Source Brick By Brick The Herculean Task of Cleaning up the Asian Brick Industry
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The Evolution of Ceramic Building Materials

1. Bigger 2. Lighter 3. Cooler 4. Cheaper 5. More Environmental

Friendly

6. Precise

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We look back at a great history

189 Years of History (founded 1819 - Vienna)

International World Exhibition, Paris 1867

The beginning, brick making for the emperor of Austria & Hungary
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Wienerberger Today
We are a leading international building materials group with headquarters in Vienna Wienerberger is # 1 worldwide in clay hollow bricks and bricks Present in 27 countries and 5 export markets

- 227 plants in Europe and North

America

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Arial Views of Wienerberger Factories

Belgium: Beerse TERCA Facing Bricks Plant

Czech Republic: Jerzernice POROTHERM Brick Plant

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Wienerberger - Product Portfolio

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POROTHERM HP Resource Efficient Brick

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POROTHERM HP Product Parameters

POROTHERM HP - Product Paramters

Name

Length (mm) Width (mm) Height (mm)

Weight (kg)

Density (kg/m3)

Compressive Strength (N/mm2)

Water Absorption (%)

Efflorescence

U-Value (W/mK)

Sound Insulation Rw (db)

Fire Resistance (min)

POROTHERM HP 200 POROTHERM HP 150 POROTHERM HP 100 POROTHERM HP 200H POROTHERM HP 150H POROTHERM HP 100H

400 400 400 200 200 200

200 150 100 200 150 100

200 200 200 200 200 200

11.1 8.8 6.3 5.8 4.2 3.1

694 733 788 Same as full bricks

3.5 Same as full bricks

~ 15 Same as full bricks

Slight Same as full bricks

1.1 1.2 1.7 Same as full bricks

46 43 40 Same as full bricks

240 120 90 Same as full bricks

POROTHERM HP - Tolerance
Name 400 200 150 100

Dimensions (mm)

Note : Compressive Strength value is based on testing procedure as prescribed in IS 3952 POROTHERM is manufactured using Natural Raw Materials, hence there could be variations in colour

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Wienerberger Factory at Kunigal

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Clay Quarry

Clay excavation done locally from water tanks close to the factory (De silting of tanks)
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Dosing of Raw Materials

Raw Material Feeders Primarily Clay & other filler materials Dosage of raw material controlled by feeders

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Clay Preparation

Feeders feed raw materials for preparation of clay (grinding, mixing, homogenization ) Pan mill grinds the clay
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POROTHERM HP - Extruder

Extrusion of clay bricks

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Automation of Production

Cutting Line for length Arranging bricks in dryer cars

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Automation of Production

Robots handle the bricks in Green State

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Dryer and Kiln Cars

Dryer - Dries the brick, prior to firing. Kiln Cars Ready to be loaded in kiln for firing
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Kiln For Burning Bricks

Fuel Injection Unit Pet Coke injection unit for high temp firing Tunnel Kiln - 160 Mtr. Long, Clay bricks are fired at temperature ~ 1,000C
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Laboratory

Testing Facility

- State of the Art testing equipments - Ensures quality of Raw Material and
finished products
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Factory Stock & Clay Storage

Adequate stock of finished products as well as of the clay (raw material)

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POROTHERM HP Product Advantages Construction

Bigger Size

- POROTHERM HP is same in size as that of concrete blocks - POROTHERM HP 200 = 9 Clay Bricks - Less mortar joints, hence less plumb & alignment - Faster construction
Light Weight

- Ease of handling, Transportation - Saves labor - Less dead load, Savings in Structural Cost
(Steel & Concrete) by 10 to 15%
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POROTHERM HP Product Advantages Construction

Perfect brick Size

- Savings on mortar - Line and leveled plaster surface

Low U Values 1.0 W/mK

- Better Thermal Insulation = less energy loss through walls - Savings on Energy consumption - Comfortable inside temperature

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U Value External walls

U Values of outer walls (200mm / 230mm):

- POROTHERM HP 200: - POROTHERM VP 200: - Solid Concrete block (8): - AAC block (8):

1.0 W/mK
6,00

1.3 W/mK 2.0 W/mK 0.7 WmK

5,00 4,00 3,00 2,00

POROTHERM VP has a higher U-Value than POROTHERM HP because the density is higher

1,00 0,00 Clear Float Glass Double Glazed Glass Concrete Blocks Hollow Clay Blocks AAC

Plaster has hardly any positive influence on the U-Value, because it is a solid material which conducts heat well

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Test Result Crushing Strength

POROTHERM HP 100 5.2 N/mm2

POROTHERM HP 150 4.3 N/mm2

POROTHERM HP 200 4.1 N/mm2

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IGBC POROTHERM HP
POROTHERM HP Clay Hollow bricks contribute to the rating system under

- Energy Efficiency: - Local Materials : - local raw materials

U-Value : 1.0 W/mK

- finished goods transported < 500km - Material with Recycled Content: -Raw Material used are (fly ash, rice husk,
saw dust, granite dust)

-In addition we use Desilted Clay

IGBC = Indian Green Building Council
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POROTHERM HP Applications

Cutting of Brick Masonry Plaster/ Rendering Door / window Fixation Chasing, Conduiting for Services Load Fixation (Mirror, LCD, Geysers, EWC etc)

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POROTHERM HP - Application Cutting of Brick

Masonry

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POROTHERM HP - Application Plastering/ Rendering

- Gypsum Plaster

- Sand Cement Plaster

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POROTHERM HP Door/ Window fixation

Conventional Method Hold fast

Anchor fixing Plastic sleeve anchors

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POROTHERM HP Applications

Conduiting for electrical, plumbing

- Chasing, Chiseling similar to other conventional bricks/
blocks

- To be filled with rich mortar - Plastered as a normal wall

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POROTHERM HP Application

Light Loads: To be fixed by wooden peg 100mm in length

Medium & Heavy Loads: To be fixed using Rack bolts or sleeve anchors

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POROTHERM HP Application

Hole for rack bolt

Cement mortar stuffed in hole

Rack bolt fixed

Load fixed

Practical Test

Rack bolt with load

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POROTHERM HP E.g. of Geyser Fixation

Branded Sleeve inserted Screws fixed in branded plugs

Geyser Plate fixed

Geyser fixed
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POROTHERM HP MTC -Trainings

Trainings to stake holders

- MTC Trainings in WB Factory

MTC Masonry Training Centre

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POROTHERM HP Site Trainings

Trainings to stake holders

- Trainings at project sites

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POROTHERM HP College Presentations

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Apartments

Architect: In house Builder : Ramaniyam Real Estate Location : Sholinganallur, Chennai

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Apartments

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Apartments

Architect: In house Builder : Ramaniyam Real Estate Location : Kazhipathur, Chennai

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Apartments Pebble Bay

Architect: Vijay Raheja Builder : The Advantage Raheja Location: RMV 2nd Stage, Bangalore Wall Area:7,00,000 sq ft - G+21 Floors
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ISB Housing Tower - Hyderabad

Architect : Inform Architects Floors: 16 Floors Location : Hyderabad Project Wall Area : 380,000 Sft
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Sydney Court

Architect: Thomas Associates Location: Lavelle Road, Bangalore Wall Area:30,000 Sft
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Legacy Dimora

Architect : DFA Architects Location : Bellary Road, Bangalore Project Wall Area : 130,000 Sft
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Introducing - POROTHERM VP

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Wienerberger India - Showroom in Bangalore

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Wienerberger India

Natural Comfort for generations!

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Many thanks

for your interest in Wienerberger!

Wienerberger Brick Industry Private Limited T +91 80 4149 1682 www.wienerberger.in

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