Z. .Z' iw " L-1 c k z - VY" 'V7 g owo 1 . 41 , g, N "ga A 17M 411 IT, 4'1,1' :.% I  F2 v j;p g 7sag A.- 4 - A AN AF. X2B, 4 -,* X-111 -AI^R K 13T.W. 2,11 1 R 1nl W71 WR 'kN .tF I ,l . VP C IN, V4_ 9" N 7, j4t, ni AW, 5 X, Li, 7,* V _fk Y Et Vx W-1-V -;:4N,`w -.4 t 14 M tv If 4MII 'k M T5 z w- -7 T. bl 1pl V! ke_iAil. 9N TV;i sr -gg S' X, - i6 4& i6 -VA U4, IX" I, -r, 0, F.7-- ,w4k -4 . ..... i'M "We" X4i , j u -xuo  I WN wl f2li Q11, WV, jw 10 -na ENERGY EFFICIENCY IMPROVEHENT IN THE BRICK AND TILE INDUSTRY MARCH 1989 ACROWYMS AND ABBREVIATIONS Acronyms EIL Experiment in International Living GOU government of Uganda IPF Indicative Program Funding KCI Kiteredde Construction Institute I4M Ministry of Cooperatives and Marketing mmWD Ministry of Housing and Urban Development MNO Ministry of Energy MOEPF Ministry of of Environmental Protection and Forestry WOIT Ministry of Industry and Technology MPED Ministry of Planning and Economic Development UNDP United Nations Development Programme Abbreviations kg kilogram m meter MJ megajoule mm millimeter N Newton RFO Residual Fuel Oil t metric tonne toe tonne of oil equivalent tonne metric tonne USh Uganda Shilling US$ U. S. Dollar CWRUCY EQUIVALETS (as of September 1987) USh 60 a US$1.00 ENERGY CONVERSION FACTORS 1 metric tonne (t) D 1,000 kilograms (kg) 1 tonne of oil equivalent (toe) - 10 million kilocalories (keal) 1 tonne of oil equivalent (toe) = 41.9 megajoules (MJ) 1 tonne of oil equivalent (toe) - 7.33 barrels of oil equivalent (boe) 1 kilocalorie (kcal) = 0.00419 gigajoules (GJ) 1 megajoule (NJ) - 1 million Joules (J) 1 megajoule (NJ) = 239 kilocalories (kcal) 1 aegajoule (NJ) = 0.0000239 toe FUEL CONVERSION FACTORS Density Fuel Unit as Used Lower Heating Value (kg/unit) (MJ/kg) Fuelwood m3 stacked 510 15.0 (air-dried Eucalyptus) Coffee Husk m3 stacked 410 15.5 Rice Husk m3 stacked 105 13.0 Papyrus Stalks m3 stacked 240 15.0 Residual Fuel Oil (RFO) litre 0.98 38.6 TABLE OF COUTES Page No. EXECUTIVE SUMMARY ............................. ..... ..... .. i Project Development .................................... 1 Objectives ..04.0.6.. ............... ........ ....... 2 Scope ..................****..*.***... 000000@40 ***,* 3 National Economy....................................... 4 Energy 8ector......................................... 4 III. THE BRICK AND TILE INDUSTRY............................... 6 Structure................................ 6 Ovrie........... 000*O*.. 0....0 6 Artisan P roducers.............................e.... 7 Small-scale, Semi-mechanized Producers... 7 Medium-scale, Mechanized Producerstucer.*****s.*. 7 Brick and Tile Deund... 7 7 Estm tio........................ 8 Brick and Tile S U P P 1 Y 8 OveViee r V i eW.................. 8 Artisanal Production ......9 Small Scale, Semi-mechanized Production ............. 10 Medium Scale, Mechanized Production................. 10 Future Production .... 4000000000000060000*090000000e 11 Supply/Demand Gap...................................... 11 energy Consumption in the Brick and Tile Industry......e 12 Overview .............................................. 12 Artisanal Producers ................................. 13 Small Scale, Semi-mechanized Producers .............. 14 Medium Scale, Mechanized Producers.................. 14 IV. PROPOSED MEASURES TO IMPROVE ENERGY EFFICIENCY ............ 15 Overview ................. ................. 0e*0**000000 15 Artisan Producers ..........5........ 15 Energy Efficiency Measures........................... 15 Implementation...................................... 16 Introduction of Brick and Block Standards........... 18 Potential Energy ...................... 18 Small Scale, Semi-mechani.ed Producers.. .............. 19 Energy Efficiency Measures.......................... 19 Potential Energy Savings............................ 21 Medium Scale Producers......... .. ................... 21 Sub-sector Status............0...................**. 21 Energy Efficiency Measures ........................* 21 Impleakentation ...............,4*o*,oo,,,o, 21 Potential Energy Savingso..........................* 21 ALternative Fuels .................. ..*.*eee*....4** * 22 V. PROJECT COSTS AND SCHEDULING .............................. 23 8ummarye o ............o..o.....o...... ..o......... ... 23 Artisan Producers...................................... 25 Small Scale, Semi-mechanized Producers*................ 25 Medium Scale, Mechanized Producers.....................* 25 VI. PROJECT BENEFITS, JUSTIFICATION AND RISKS................. 26 Project Benefitso...................................... 26 Direct Fuelwood Savings............................. 26 Improved Product Qualityo.........................+o 28 Project Justification.o........oooo.o..oo.o*. o.o..o... 28 Financial Analysisa........ ....**...00*.*00*0........ 28 Economic Analysis.....o l y si.o..oo...o..o...osooo.oo. 30 Project Risks 32 TABLEs 3.1 Classsfication of Brick and Tile Industry................. 6 3.2 Estimated Brick and Tile Demand ........................... 8 3.3 Estimated Brick and Tile Supply ........................... 9 3.4 Proposed Brick and Tile Plants ............................ 11 3.5 Brick and Tile Supply/Demand Analysis..................... 12 3.6 Current Energy Consumption in Brick and Tile Industries... 13 4.1 Potential Energy Savings in Artisanal Brick Manufacture... 19 5.1 Summary of Cost of Recommended Component .................. 24 6.1 Fuelvood Savings Due to Proposed Energy Efficiency Measures for Artisan and Small-Scale Producers at Various Levels of Production............................ 27 6.2 Financial Cost of Fuelwood................................ 29 6.3 Project Financial Rate of Return.......................... 29 6.4 Estimates of Marginal Economic Cost of Fuelwood Production............. . ..... ..... .... . ................. 30 6.5 Economic Value of Fuelwoode................................ 31 6.6 'roject Economic Rate of Return........................... 31 1 List of Institutions snd Individuals Contacted............ 33 2 Structure of the Brick and Tile Industry.................. 36 3 Estimation of Brick and Tile Demand....................... 39 4 Brick Making in Uganda.................................... 54 5 A Sample of Periodic Kilns................................ 55 6 Horizontal and Vertical Cross Sections of a Hoffman Ring Kiln.............................................. 56 7 Brick and Block withFrog................................. 57 8 Relationship of Output of Clamp Kiln to Kiln Size......... 58 9 Kiteredde Construction Iastitute.......................... 60 10 Proposed Dimensions of Standards Bricks and Block kseee... 63 11 Model Down-draft Kiln 64 12 Model Small-Scale, Semi Mechanized Brick and Tile Production Unit. ........... 000 00 .. 67 13 Blade-set Clamp Kilns in Indonesia......o...oeo...o....... 91 14 Estimated Costs of Efficiency Improvement Measures in Artiosn subsector o.......................e........... * 92 15 Cost of an Eight Chamber Down-draft Kil n 93 16 Pinancial Analysis of Artisan and Small Scale Producer Project Components * 94 17 Economic Analysis of Artisan and Small Scale Producer Project Cop to n e n t o 101 MAP IBRD 18540Bs Uganda gxCcuTIVE SUIQIARY 1. The availability of energy is an important determinant in Uganda's economic development, and measures for developing energy supply and managing demand need to be planned and implemented in order to prevent energy bottlenecks from restraining economic recovery. The 1983 Energy Assessment Report, prepared under the joint UNDP/World Bank Energy Assessment Program, outlined a number of issues which needed to be addressed to enable the energy sector to play an effective role in the economic recovery of Uganda. One of the issues was the need to improve anergy efficiency of rural industries to alleviate the pressure on existing fuelwood resources. Objectives 2. The overall goal of this ESMAP activity ia to identify and evaluate technically and economically feasible means for improving the energy efficiency of the brick and tile industry in Uganda. Reduction of fuelwood demand would be expected to directly contribute to stemuing the erosion of Uganda's wood capital. In addition, as fuelwood supplies to the brick and tile industry are obtained at significant financial cost, energy efficiency gains should translate into greater production at lower cost. Woodfuels Sector 3. Woodfuels account for 96% of Uganda's current energy consump- tion, including approximately 70P of commercjal energy. Current consump- tion is estimated to be around 18,00O,000 m of fuelwood equivalent, and is expected to rise to 27,500,0O0 m by the 2000. 4. Growth of the woodfuel economy has precipitated the development of a number of discrete areas where woodfuels have become in short supply, most especially in parts of West Nile, Soroti, Mbarara and Rakai districts. This trend is very likely to accelerate. Current annual production , woody biomass in Uganda is estimated to be around 15,600,000 mo of fuelwood equivalent; demand thus exceeds sustainable supply by around 171. This picture is ezpected to change dramatically over the next 15 years. By the year 2000, demand for woodfuel is expected to exceed the 1985 sustainable supply by nearly 80X. Of this estimated future demand, commercial woodfuels will account for 191, compared with 141 in 1985. Brick and Tile Industry Structure S. Brick manufacturing methods in developing countries range from traditional artisan production units to medium-scale, capital intensive plants. In Uganda, considering the scale and technique of production, the brick and tile industry could be classified into artisan, small-scale and medium-scale production units. Table I summarizes the production techniques used by the various producers. Table t- CLASSIFICATION Of BRICK AND TILE INDUSTRY Number of Scale of Bricks/day Production (overage) 0/ Process Used Market Area Artisan b/ 1,000 Hand-made, Rural villages clamp-fired Small 10,000 SemI-mechanized Near towns Medium c/ 40,000 Mechanized, extruded, Near industrial- wire cut continuous Ized areas of rln; kiln high demand a/ Annual production per unit depends on the number of days In operation considering weather conditions and other constraints. b/ Artisan producers are major suppliers of brick In Uganda. c/ Presently Uganda Clays Is the only medium scale brick and tile producer in Uganda. Brick and Tile Supply and Demand 6, The demand for building materials (e.g. bricks and tiles) is more complex than simply pressure from population expansion. Knowledge of Uganda's recent history emphasizes the importance of demand for bricks and tiles caused by a large backlog in housing stock, plus reconstruction and maintenance of damaged and neglected buildings. Simultaneously# after years of stagnation, the construction industry has enormous building material requirements for new construction, reconstruction and maintenance in the industrial, commercial, clerical, private and public sectors. 7. Even cursory analysis of supply and demand figures reveals that there is an extreme shortage of brick and tile in Uganda. At the current rate of production, the gap between supply and demand will continue to widen, resulting in higher prices for these products to final consumers. A summary analysis of the current supply/demand situation is given in Table 2. - iii - Table 2: BRICK AND TILE SUPPLY/DEMAND ANALYSIS (ptlIlons) Estimated Supply Supply/Demand Present 1987 e 100% Present Gap I 100% Supply/Demand Product/Scetwwlo Demand Capacity 1/ Supply Capacity Gap Br ickis Low Case 3S0 5B 23 292 327 Optimistic Case 1,821 58 23 1,763 1,796 TIles Low Case 97 a 0.1 89 97 Optmlistlc Case "1 8 0.1 493 501 a/ Including six plants proposed for estabilshment. 8. Since various type of fuels are used to fire bricks, energy consumption has been determined in terms of cubic meters of stacked firewood equivalent for all fuels used, including coffee and rice husk. Total energy consumption in the bribck and tile industry is determined using this equivalency as 73,000 m of firewood per annum at present production rates. Approximately 91% of this energy demand is met by firewood as opposed to agricultural waste substitutes. 9. The significance of total wood demand by the industry may be realized by noting that production as a level to mect maximum forecast demand would require a hundred-fold increase in brick and tile output. Scaled by this factor and converted into solid wood equivalent terms, the implied future wood demand is 4,380,000 a . While the estimates are proximate, this is roughly 281 of annual woody biomass production in Uganda. Ignoring residential backlog still results in a forty-fold increase over present supply to meet annual demand, requiring some 1 of national wood biomass production at present industry energy efficiency. Proposed Measures to Improve Energy Efficiency 10. Energy consumption parameters demonstrate that there is up to a 9:1 variation in the energy efficiency of brick and tile manufacture in Uganda. The few small and medium scale production units are functioning at 20-25 percent of their installed capacities, and, in the case of small scale plants, are highly energy inefficient. Consequently, the traditional artisan brick producing units are furnishing the bulk (7 times the output of semi-mechanized plants) of Uganda's burnt bricks. Unfortunately, these artisan production units are also using the bulk of the energy in the form of fuelwood, which is leading to national concern over deforestation. The country can ill afford continuing inefficiencies - iV - in brick and tile production at inadequate production rates. Yet, Uganda requires locally produced building materials to support any positive reconstruction effort. Possible energy solutions take two formst (a) Low-cost energy efficiency enhancements through improved kiln design, maintenance and operation; and (b) Substitution of available alternative fuels, especially agricultural residues, for firewood. 11. Artisan Producers. Artisan brick producers will remain the prime suppliers of brick to the residential andt often, the industrial and commercial sectors for the forseeable future. In view of the scale of future wood demand from this sub-sector and the magnitude of potential energy savings, a national dissemination/extension effort is warranted. A suitable program would incltue the following componentst (a) Research/Pilot Demonstration to test and adapt proposed energy conservation measures in optimized brick structure and composition, and improved kiln construction and firing; (b) Training to sustainably transfer the knowledge and potential benefits of the research component; and (c) Dissemination to ensure popularization of the improved techniques throughout Uganda. The first two make up the pilot phase activities which would be overseen by a steering committee sponsored by the Ministry of Energy and made up of interested governmental representatives. Assuming satisfactory results from the pilot phase, a 3 1/2 year country-wide dissemination program will begin. 12. The program should be targeted at traditional rural-based artisan brickmakers as well as those located in medium cities, rural towns and institutionally-sponsored integrated development programs. While the basic rationale for the effort is based on energy conservation, program goals should be extended to encompass the promotion of improved local materials and the upgrading of standards of basic building materials. Because of their extensive prior experience in training artisans for the construction industry in Uganda, it is recommended that the day-to-day implementation of the proposed program for upgrading artisan brick production methods be placed 'nder the supervision of the Kiteredde Construction Institute (KCI). Technical assistance, especially on administration and management aspects, should be provided to the KCI. 13. Small Scale, Semi-mechanized Producers. The small scale brick production units promise to be highly beneficial to the country's r..onstruction efforts. The semi-mechanized units require modest capital investment, can service specific markets without extensive transport costs and are of a scale that is relatively easy to manage. A program to address inefficlencies in management and fuel consumption while promoting pilot scale improved brick production is therefore recommended. Measures include improved kiln draft control, replacement of1 manufacturing equip- ment, and provision of spare parts. 14. The proposed assistance to the small-scale brick production sector would also be coordinated by the steering committee, in close collaboration with other local agencies such as the Uganda Development Bank, that have some in-house capabilities to assist prospective small- scale brick makers on a number of critical tasks. Such tasks would includet (a) expediting 'clearing house' types of operations, related specifically to identifying and arranging the procurement from abroad of spare parts and other accessories for their equipment (i.e., to reburbish or retrofit their plants); and (b) completing project feasibility and appraisal studies in respect f ventures to retrofit individual plants. 15. Medium Scale Producers. Uganda Clay Works, Ltd., a parastatal organization, produces the best clay masonry units and the only clay roofing tiles in Uganda at a rate of fuel consumption that is on par with more mechanized European plants. The factory is well located to major markets and has an order backlog of six months. Nevertheless, the plant is three decades old with severe needs for renovation and spare parts. Due to interrupted electrical service and lack of transport and spares, the plant is operating at 30-40% of installed capacity and is undoubtedly at a production cost disadvantage from the full payroll being carried. 16. If and when foreign exchange becomes available through the economic recovery program, Uganda Clay Works should be placed high on the list of critical industries. The longer term goal should be to increase Uganda Clay's production capacity through the addition of another production line to produce preferentially for the public sector. Initially, technical assistance will be needed to define and substantiate the amount of spare parts required. In later phases, expertise will be required to study the feasibility of adding a new production line. Project Costs 17. Implementation of the recommended action plans is estimated to cost a total of approximately US$2,900,000. These costs cover: (a) Establishment and operation of a research and training/ dissemination program for the artisanal sub-sector; (b) Establishment of a revolving fund for provision of spare parts to the small scale producer sub-sector; (c) Pilot installation of an improved downdraft kiln at Kizubi Brickworks, and follow-on extension to four other small scale producers; (d) Feasibility evaluation of the addition of a new production line at Uganda Clay Works, Ltd.; and - vi - (e) Provision of technical assistance to all th ee sb-sectors in kiln design and construction, firing techniques, fuel substitution, and enterprise management. About 701 of the total cost will be in foreign exchange and the balance in local currency. 18. In addition to these expenditures, the mission envisions in the longer term an investment of US$4 million for equipment, installation and technical services at Uganda Clays. The feasibility of the investment in the proposed new production line will be established in component (d) above. Project Benefits 19. Benefits of a project to improve the energy efficiency of Uganda's brick and tile industry take both direct and indirect forms. Efforts to improve energy efficiency through rehabilitation and training will have numerous spin-off benefits to the construction industry, such as reduced equipment down time and higher capacity utilization, increased operator skill levels, and improved overall management. These benefits should all favorably impact on productive efficiency, enhancing the industry's important role in supporting economic recovery. 20. The main quantifiable benefit of the proposed project is an expected major reduction in fuelwood demand by the brick and tile industry, both through gains in end-use efficiency and substitution of agricultural residues. The total fuelwood saviggs at present production levels is estimated as just under 40,000 m /year, fairly small in absolute terms relative to demand in the household sub-sector. However, given the great brick and tile supply/demand gap and the expansion potential of the industry, the 60Z economies achievable in the artisan and small scale sub-sectors are very significant. Project Justification 21. Artisan Sub-sector. Returns in the economic analysis shown in Table 3 are favorable for all but the most pessimistic brick production scenario, indicating ample justification for a national research and training/extension program targeted at artisan producers. 22. Small Scale, Semi-mechanized Subsector. Results of the economic analysis of the small scale producer component are also shown in Table 3. With returns averaging 20 percent across all kiln dissemination scenarios, the kiln replacemert program is similarly well justified. - vii - Table 3: PROJECT ECONOMIC RATE OF RETURN Sub-Sector/Scenarlo EIRR (S) Artisan No growth In current production 7 10% annual Increase In years 6-20 15 20% annual Increase In years 6-20 22 Small Scale, Semi-mechanized Replacement of 1 kiln 21 Replacement of 5 kilns over 5 years 19 Replacement of 5 kllns over 3 years 19 Replacement of 5 kilns over 2 years 20 Source: Annex 17. Project Risks 23. The major project risks rest primarily in the artisan sub- sector. As with any national training and extension effort, implementation is subject to delay or failure to reach target populations. Renewed deterioration of the security situation could compound these difficulties. The risk is minimized through careful choice of implementing agents and use of a two-phased pilot/wide-scale dissemination approach to project scheduling and oversight. 24. The second major risk is failure to obtain anticipated energy savings. Especially in the artisan sub-sector, this could be the result of producers failing to follow technical advice and new techniques. However, purchased fuelwood makes up a substantial portion of brick and tile production costs, so there thus appear to be adequate incentives for adoption. In addition, the training/extension design incorporates in- field, community-level demonstrations in order to illustrate the new techniques under plausible operating conditions. I. IN.RODUCTION Project Development 1.1 The availability of energy is an important determinant in Uganda's economic development, and measures for developing energy supply and managing demand need to be planned and implemented in order to prevent energy bottlenecks from restreining economic recovery. The 1983 Energy Assessment Report, prepared under the joint UNDP/World Bank Energy Assessment Program, outlined a number. of issues which needed to be addressed to enable the energy sector to play an effective role in the economic recovery of Uganda. l/ One of the issues was the need to improve energy efficiency of rural industries to alleviate the pressure on existing fuelwood resources. In 1984, a follow-up to the Energy Assessment carried out under the joint UNDP/World Bank Energy Sector Management Assistance Program (ESMAP) recommended that immediate steps be taken to improve energy efficiency in Uganda's brick and tile industry. 1.2 Following a request by the Ugandan Government, agreement was reached for an ESMAP technical. assistance and investment identification activity to: (a) assess fuelwood supply and consumption requirements in the country's brick and tile industry; (b) identify measures to improve energy efficiency in the industry focusing mainly on simple, inexpensive energy conservation measures; and (c) design a program of action to disseminate these measures on a nationwide basis. Funding for the ESMAP project was secured from UNDP country IPF resources, supplemented by internal ESMAP funds and in-kind contributions from the Government of Uganda (GOU). The Energy Department of the Ministry of Power, Ports and Telecommunications was designated as implementing agency. 1.3 An ESMAP mission consisting of a mission leader, a brick and tile production engineer and an extension specialist arrived in Kampala in mid-July, 1985, for a planned visit of four weeks. 2/ However, the mission's work was hampered by a worsening security situation and consequent restrictions on internal travel. The mission's activities had to be prematurely terminated and its members left Uganda as part of an official evacuation on July 31, 1985. 1.4 In order to complete the work of the above mission, a second ESMAP mission was fielded in September, 1987, with the cooperation of the 1/ Usanda: Issues and Options in the Energy Sector, Report No. 4453- UG, World Bank, July, 1983. 2/ The mission members were Messrs. Bernard Frueh (Mission Leader), J. Van der Velden (Consultant - Brick and Tile Production Engineer), and S. Davenport (Consultant - Extension Specialist) 2 - Ministry of Energy. 3/ The mission was able to successfully, both update and extend the findings of the 1985 visit during its three week stays This report thus represents the combined results of the original and follow-up missions. ObJectives 1.5 The overall goal of this 8SMAP activity is to identify and evaluate technically and economically feasible means for improving the energy efficiency of the brick and tile industry in Uganda. These measures include kiln and process modifications to reduce the consumption of fuelwood per unit product output, as well as substitution of low-cost agricultural residue fuels where readily available. Reduction of fuelwood demand would be expected to directly contribute to stemaing the erosion of Uganda's wood capital. In addition, as fuelwood supplies to the brick and tile industry are obtained at significant financial cost, energy efficiency gains should translate into greater production at lower cost. 1.6 Specifically, the activity aims to: (a) Identify the areas of concentration of brick and tile production as well as the organizational structure of this industrial subsector; (b) Estimate current and likely future levels of brick and tile production as well as the fuel requirements of the industry; (c) Assess the performance of the different type of kilns and firing techniques used in Uganda, especially to determine the scope for energy qavings; (d) Assess the scope for using alternative fuels on the basis of their adaptability to regional conditions and their economic and financial competitiveness; (e) Prepare an inventory of the various technical packages and managerial measures that could be used to improve the efficiency of energy use in brick and tile production; and 3/ The members of the mission which visited Uganda from August 31 to September 18, 1987 were Messrs. Reza Khonsary (Mission Leader), Jan van der Velden (Consultant - Brick and Tile Production Engineer), and Stanton Davenport (Consultant - Extension Specialist). The report was authored by Mr. Charles Feinstein (Energy Planner). Administrative support was provided by Ms. Evelyn Cortez-Pusco. -3- (f) Formulate a financially and economically justifiedt program of action to improve the efficiency of energy use in the brick and the tile industries of Uganda. Scope 1.7 During the field work in Uganda, visits were made to a number of mechanized, semi-mechanized and artisan brick and tile production units in Kampala, Entebbe, Jinja, Tororo, Mbale, Luwero, Mpigi, Masaka and Arua. The mission liaised with representatives of the Ministries of Energy (MOE), Planning and Economic Development (MPD ), Housing and Urban Development (MMUD), Industry and Technology (NOIT), Cooperatives and Marketing (MCM), and Environmental Protection and Forestry (MOEPP). In addition, the mission briefed officials of international and non- governmental organizations operating in Uganda, and met with owners/managers of private enterprises. A complete list of persons and institutions contacted appears as Annex 1. II. UlUUD National Economy 2.1 Uganda has substantial reserves of natural wealth, with especially favorable soils and climate for agricultural production and with a significant mineral base to support the industrial sector. At independence in 1962, Uganda's economy was strong, backed by excep- tionally skilled labor resources. The production of export crops, primarily cotton and coffee, was rapidly growing. The small industrial sector provided export and consumer goods, transport and communications were good, and an extensive hydroelectric-based electrification system was developed during the years just after independence. A steady annual CDP growth rate of 2Z was achieved until 1970. 2.2 The economy stagpated and per capita income fell in the suc- ceeding decade. Long years of neglect resulting from an inability to maintain and manage basic industrial, monetary and agricultural infras- tructures as well as the emigration of skilled manpower and expertise contributed greatly to accelerating the economic decline. The Ugandan economy also suffered greatly from the rise in international petroleum prices in 1973, and from the breakup of the East African Community in 1977. The period of decline reached its lowest point during the war in 1979, which resulted in widespread looting and in damage to the few remaining productive sectors of the economy. 2.3 In 1981, the GOU began a program to stabilize the economy by encouraging private investment, reviving agricultural and industrial productive capacities, and by reducing inflation. The strategy involved floating the Uganda Shilling (USh), introducing more realistic producer prices, dismantling the system of price controls, and returning nationa- lized industries to private ownership. Recovery programs were developed with the aim of increasing agricultural production and exports in part through this strategy and in part by targeting external assistance at the rehabilitation of the most promising sectors. These programs have been successful both in attracting foreign finance and in restoring the economy on an upward growth path. Energy Sector 2.4 During 1980, per capita energy consumption in Uganda is estimated to have been 0.35 toe, of which only 0.06 toe was commercial. 4/ This level of commercial energy consumption, while exceptionally low by world standards, is comparable to estimates for some 4/ Commercial energy is defined as all energy traded outside the subsistence sector. other low-income countries in Sub-Saharan Africa. Energy use is concentrated in the household sector (802 of total energy and 372 of commercial energy in 1980). 2.5 Woodfuels account for 962 of Uganda's current energy consump- tion# including approximately 702 of commerc al energy. Current consump- tion is estimated to be around 18,t00,000 m of fuelvood equivalent, and is expected to rise to 27,500,000 m by the year 2000. 2.6 Growth of the woodfuel economy has precipitated the development of a number of discrete areas where woodfuels have become in short supply, most especiallvr in parts of West Vile, Soroti, Mbarara and Rakai districts. This trend is very likely to accelerate. Current annual production of woody biomass in Uganda is estimated to be around 15,600,000 m' of fuelwood equivalent; demand thus exceeds sustainable supply by around 17X. This picture is expected to change dramatically over the next 15 years. By the year 2000, demand for woodfuel is expected to exceed the 1985 sustainable supply by nearly 801. Of this estimated future demand, commercial woodfuels will account for 192 or 5,225,000 m3, compared with 14X in 1985. 2.7 Commercial woodfuels are used primarily by the urban domestic sector and by a number of agroindustries. The tea, tobacco and brick- making industries are greatly dependent on fuelwood for drying, curing, and burning their products, respectively. Aggregate demand by these industries totaled about 230,000 m (solid) in 1985. The ability of the tea, tobacco and brick and tile industries to expand may be severely constrained unless steps are taken on both the demand and supply sides. -6- III. THE BRICK AND TILE INDUSTRY Structure Overview 3.1 Brick manufacturing methods in developing countries range from traditional artisan production units to medium-scale, capital intensive plants. The choice of brick making technology is mostly a function of market demand (i.e. scale and location of demand, and required or minimum acceptable quality standard), and availability and cost of investment funds and other inputs (labor, raw materials, fuel, transport, spare parts, etc.) associated with alternative production techniques. In Uganda, considering the scale and technique of production, the brick and tile industry could be classified into artisan, small-scale and medium- scale production units. Table 3.1 summarizes the production techniques used by the various producers, and the following paragraphs briefly characterize the three modes of production. Annex 2 provides a detailed description of the organizational structure of the industry. Table 3.1: CLASSIFICATION OF BRICK AND TILE INDUSTRY Number of Scale of Bricks/day Production (averaMe) a/ Process Used Market Area Artisan b/ 1,000 Hand-made, Rural villoges clamp-fired Small 10,000 Semi-mechanized Near towns Medium o/ 40,000 Mechanized, extruded, Near Industrial- wire cut continuous ized areas of ring kiln high demand a/ Annual production per unit depends on the number of days In operatlon considering weather conditlons and other constraints. b/ Artison producers are mojor suppliers of brick In Uganda. Cl Presently Uganda Clays Is the only medium scale brick and tile producer In Uganda. Source: Mission estimates. -7- Artisan Producers 3.2 Artisan brick makers produce about 1,000 bricks/day and are located close to the clay sources, and within a short distance of the brick markets. This reduces the transport cost and concomitantly the amount of fuel used in transport. The production method used is highly labor intensive and the investment requirements are low, consisting of simple, locally available implements. Furthermore, when climatic conditions impede building construction, the brick production ceases. Although artisan production is particularly appropriate for rural and peri-urban areas, due to the severe shortage of building material in Uganda artisan brick producers are supplying the majority of fired bricks to the principal urban centers. Small-scale, Semi-mechanized Producers 3.3 Small-scale, semi-mechanized brickmakers produce about 10,000 bricks/day. The production method used is relatively sophisticated although the machinery employed, especially the brick extruders, is old. These production units are usually located close to citiis and have the potential to yield higher productivity per worker than the artisan units. Medium-scale, Mechanized Producers 3.4 In contrast to the artisan and small-scale brick production, medium-scale brickworks necessitate the capital investment of millions of dollars, mostly in foreign exchange for import of sophisticated produc- tion machinery and control systems. The complex equipment requires skilled management and trained production personnel. Employment associated with mechanized techniques of brick production is often very smell relative to the traditional methods, although these producers have the potential to manufacture substantial quantities of higher quality bricks at lower unit energy consumption. Brick and Tile Demand Components 3.5 The demand for building matarials (e.g. bricks and tiles) is more complex than simply pressure from population expansion. Knowledge of Uganda's recent history emphasizes the importance of demand for bricks and tiles caused by a large backlog in housing stock, plus reconstruction and maintenance of damaged and neglected buildings. Simultaneously, after years--- of stagnation, the construction industry has enormous building material requirements for new construction, reconstruction and maintenance in the industrial, commercial, clerical, private and public sectors. -8- Estimation 3.6 Working from a number of housing sector documents, the mission assembled disaggregated estimates of brick and tile demand which incorporate assumptions of future economic growth and recovery rates in the building industry. In order to indicate the range of uncertainty in the assessments, the results are presented in two basic scenarios: Low Case and Optimistic Case. Detailed calculations supporting the range of estimates are given in Annex 3 and summarized in Table 3.2. Table 3.2: ESTIMATED BRICK AND TILE DEMAND (millions) 1985 Demand Component 1985-87 Population Residential New 1985 Demand 1987 Product/Scenario Growth ae Backlog b/ Construction c/ Sub-Total Growth d/ Demand Bricks Low Case 123 150 27 300 50 350 Optimistic Case 123 1,078 360 1,561 260 1,821 Tiles Low Case 34 41 8 83 14 97 Optimistic Case 34 297 99 430 71 501 a/ Urban = 5.0S; Kampala - 4.0%; National n 3.2%. b/ Optimistic Case: Hlgh brick/tile housing density and backlog absorbed over one year. Low Case: Low brick/tile housing density and backlog absorbed over five years. cl Optimistic Case: New construction, reconstruction and maintenance * 30% of residentlal demand. Low Case: New construction, reconstruction and maintenance a 10% of residential demand. d/ At 8% pa.a Source: MUKD; UN/Habitat; UNOP; USAID; World Bank; Mission estimates. Brick and Tile Supply overview 3.7 Industry capacity and actual supply estimates are summarized in Table 3.3. The combined installed annual capacity of the one medium- scale, mechanized factory and six small-scale, semi-mechanized manufac- turing units is 34.5 million bricks and 1.2 million tiles per year. Due to a variety of constraints, including lack of spare parts, transport delays, electric power disruption, lack of maintenance and run-down kiln -9 - equipment, the actual combined production of these saen producers is nearer the range of 3.2 million bricks/year and 0.12 million tiles/ year. The combined annual capacity of six production units proposed to be established is 23.4 million bricks and 6.8 million tiles. 3.8 Excluding extremely small, ad hoc sun-dried brick and tile pilot programs sustained by international organizations, the informal or artisan brick production is estimated to supply 20 million low quality bricks/year. Table 3.3: ESTIMATED BRICK AND TILE SUPPLY Production at Full Capacity by Type of Fuel Capacity Coffte Rlce Production Capacity Utilization Woodfuel Husk Husk (tonnes) (tonnes) (S) (tonnes) (tonnes) (tonnes) Msdium-scele, mechanized: Uganda Clays 8,750 36,500 24 - 36,50 - Small-scale, semI-mechanized: Butendi 6,6,000 C(6,000 00- Kiblimba C 6,000 a/ C 3,000 -- 3,000 Kizubi ( 6,000 b/ C 3,000 3,000 - Mutanga Clays Ltd. 6,000 (18.6 6,000 - - Pan African C 6,000 C 6,000 - - Universal Clay Works 6 000 6.000 - Subtotal 6 _/ 3 18.6 24,000 9 000 3,000 Artisan 117,000 NWA N/A 117,00 - _ Total 132,440 72.500 d/ N/A 141.000 45,500 3,000 a/ Kibisba Is assumed on the average to use 50% fuelwood and SOS rice nIusk* b/ Kizubi Is assumed on the average to use 50S fuelwood and 50% coffee husk. S/ Total production of the small-scale, semi-sechanized producers. d/ Doe not Include capacity of artisan producers since their capacity Is flexdble and could be Increased easily. Source: Mission estimates. Artisanal Production 3.9 Artisan brickmakers produce handmade weatherproof brick and blocks suitable for the walls of one-story houses. Operations are - 10 - widespread, and artisan bricknaking can be found throughout Uganda wherever there is a demand. Production is therefore elastic, with no set "capacity" or capacity factor. 3.10 The solid bricks and blocks are shaped into various sizes using bottomless wooden molds. The length of the bricks varies from 220 to 295 mm, the width from 100 to 150 mm and the height from 65 to 130 mm. Weight thus varies from 2.5 to 7.6 kg per piece. The consistency of the brick dimensions in a lot is usually poor. 3.11 The air-dried (green) bricks are firnd in non-permanent, hznd- stacked clamps (see Annex 4) varying in design and size and containing from 30 to 180 tonnes of bricks. The fuel is firewood, mainly Eucalyptus. To save as much wood as possible, firing periods are kept short and firing temperatures low. For this reason, the quality level of bricks and blocks fired in the clamp kilns is rather poor. Generally the dry compressive strength is lower than 8 N/mm2, and especially the bricks within 300 mm from the outside surfaces of the clamp are of very low quality and partly not even weatherproof. The proportion of these very poor quality bricks is strongly dependent on the size of the clamp and varies from approximately 25X up to 45%. Due to the low quality of the clamp kiln products, the average breakage rate to the construction sites is about 17%. Small Scale, Semi-mechanized Production 3.12 The small scale, semi-mechanized production units manufacture a large variety of solid and perforated clay bricks and in some works also a U£mited number of roofing tiles. Kiln designs employed in this sub- sector include simple clamp, periodic (i.e. intermittently operated) up- and down-draft (refer to Annex 5), and Hoffman ring types. Brick size is typically 230 x 110 x 70 mm weighing somewhat under 5 kg per piece (211 standard face bricks/tonne). Fuels consumed are firewood, coffee husk and rice husk. The quality of brick and tile manufactured in these production units appears to be fully acceptable in the market for standard outer wall bricks. Medium Scale, Mechanized Production 3.13 Medium scale production of a range of brick, block and roofing tile wares takes place at Uganda Clays, located on the outskirts of Kampala. The plant is jointly owned by a private company and the National Housing and Construction Corporation, a parastatal. Clay products are fired in a continuously operating Hoffman ring kiln (see Annex 6) using coffee husks as fuel, producing high quality bricks. The products are supplied to the public, commercial and industrial sectors and, to a lesser extent, to the private residential sector for large housing units. The factory is also the major supplier of tiles in Uganda. - 11 - Future Production 3.14 In addition to the above noted small to medium scale plants, there are a number of additional plants as listed in Table 3.4 registered with the Ministry of Industry since 1981. None of these factories has yet been established. However, six of the newer proposals are in the process of securing funds and have been included in the estimates of future production capacity. Table 3.4: PROPOSED BRICK AND TILE PLANTS None Location Size Arapal Concrete Products, Ltd. Kaspala Small-scale Peckwach Bricks Arus Small-scale Nbluwoll Clays Kamull District Small-scale Nutanga Clays Masaka Small-scale Katakerya Blocks Mbarara Small-scale Nberara/GOU Plant Mbarara Medium-scale East Afrlcan Clay Products, Ltd. Kampala Msdlua-scale 10 Coffee Union Plants Mubendo Large-scale Busoga Large-scale Buqlsu Large-scale Teso Large-scale Banyankole Large-scale South Bukedi Large-scale East Mengo Large-scale Masaka Large-scale 0unkord LarWe-scale Kabole Lare-scale Supply/Demand Cap 3.15 Even cursory analysis of the supply and demand figures reveals that there is an extreme shortage of brick and tile in Uganda. At the current rate of production, the gap between supply and demastid will continue to widen, resulting in higher prices for these products to final consumers. The minimum estimated increase in supply to arrest the accelerating shortage of building construction material is 292 million bricks and 89 million tiles per year. The number of bricks and tiles needed to alleviate the existing housing backlog and support healthy public, industrial and commercial sectors is of the magnitude of 1,763 - 12 - million bricks and 493 million tiles per year. 5/ A summary analysis of the current supply/demand situation is given in Table 3.5. Table 3.5: BRICK AND TILE SUPPLY DEMAND ANALYSIS (milIlons) Estimated Supply Supply/Demand Present 1987 e 100% Present Gap 0 100% Supply/Demand Product/Scenario Demand Capacity !X Supply Capacity Gap Bricks Low Case 350 58 23 292 327 Optimistic Case 1,821 58 23 1,763 1,798 Tiles Low Case 97 8 0.1 89 97 Optimistic Case 501 8 0.1 493 501 a/ including six plants proposed for establishment. Soureo: Tables 3.2, 3.3 Energy Consumption in the Brick and Tile Industry Overview 3.16 Since various type of fuels are used to fire bricks, energy consumption has been determined in terms of cubic meters of stacked firewood equivalent for all fuels used, including coffee and rice husk. 6/ Total energy consumption in the brick and til,# industry is determined in Table 3.6 using this equivalency as 73,000 d of firewood per annum at present production rates. Approximately 911 of this energy demand is met by firewood as opposed to agricultural waste substitutes. 5/ Assums that imported roofing material (corrugated galvanized iron sheets) would be discouraged and that permanent brick buildings would have tile roofs. 6/ 1.0 m3 stacked firewood is equal to approximately 0.6 m3 on a solid basis. - 13 - Table 3*6: CURRENT ENERGY CONSUMPTION IN BRICK AND TILE INDUSTRIES Totel Totol Energy Consumption by Fuel c/ Production Energy Consumption Coffee Rice Producer Bricks & Tiles b/ per tonne of product c/ Fuelwood Husk Husk Total (tonnes) (m? FW equiv.) (m3 FI equlv.) Medium scale, mechanized a/ 8,750 0.3 -- 2,625 - 2,625 Small-scale, semI-mechanized 6,690 d/ 1.8 8,042 3,000 1,000 12,042 Artisan 117,000 e/ 0.55 --NO Total 132.440 _ 66.542 5.625 1.000 73.167 a/ Uganda Clays Is the only producer In this category with current production estimated as: (35 tonnes/day x 5 days/week x 50 weeks/year). b/ In tonnes based on estimated number of bricks and tiles produced. -ei In a3 stacked fuelwood equivalent. i/ Based on estimated total productlon of 3.2 milion bricks (4.73 kg each) and 0.12 millon tiles (2.5 kg each) by small and medium scale producers (total production of 15,440 tonnes). e/ Based on estimated total production of 20 million bricks (5.85 kg each). Source:' Mission esttiates. 3.17 The significance of total wood demand by the industry may be realized by noting that production at a level to meet maximum forecast demand would require a hundred-fold increase in brick and tile output. Scaled by this factor and converted into sol3d wood equivalent terms, the implied future wood demand is 4,380,000 m . While the estimates are proximate, this is roughly 281 of annual woody biomass production in Uganda. Ignoring residential backlog still results in a forty-fold increase over present supply to meet annual demand, requiring some 11X of national wood biomass production at present industry energy efficiency. Artisanal Producers 3.18 The firewood consumption of clamp kilns is usually known in terms of lorry loads of stacked wood. Inquirifs among brick manufactures resulted in an average consumption of 0.5 mI of firewood per tonne of weatherproof bricks or blocks. Fuel consumption varies by ±20X. On the basis of a lower heating value of 7,650 NJ/m3 of stackedt air-dried Eucalyptus wood with a bulk density of 510 kg/m , the average heat consumption is 3t800 NJ per tonne of product. This figure corresponds with the energy requirements for brick making with clamp kilns mentioned in the literature. - 14 - 8Sall Scale. Semi-mechanized Producers 3.19 The firing period in the small scale, semi-machanised kilns is much longer than that stated by artisan brick makers in order to obtain good quality brick. As a consequence, the wood consumptiot is also much higher, with a range at the six sites visited of 0.5-1.9 m per tonne of product depending on kiln type. As tJ2 former estimate is suspect, the useful average has been taken as 1.8 m Itotne. Medium Scale, Mechanized Producers 3.20 Generally, a continuous Roffman ring kiln as operated at Uganda Clays is very efficient with respect to energy consumption. Fuel input was estimated at 0.2-0.3 m3 per tonne of fired ware or 1,530-2,300 NJ/tonne. These are normal values for this type of kiln. - 15 - IV. PMPOSED MNASU8S TO INPROVY EMGY IFFICIEICY Overview 4.1 The energy consumption parameters given in the preceding chapter demonstrate that there is up to a 9:1 variation in the energy efficiency of brick and tile manufacture in Uganda. The few small and medium scale production units are functioning at 20-25 percent of mechanized and their installed capacities, and, in the case of small scale plants, are highly energy inefficient. Consequently, the traditional artisan brick producing units are furnishing the bulk (7 times the output of semi- mechanized plants) of Ugarda's burnt bricks. Unfortunately, these artisan production units are also using the btilk of the energy in the form of fuelwood, which is leading to national concern over deforestation. The country can ill afford continuing inefficiencies in brick and tile production at inadequate production rates. Yet, Uganda requires locally produced building materials to support any positive reconstruction effort. 4.2 Possible energy solutions take two formst (a) Low-cost energy efficiency enhancements through improved kiln design, maintenance and operation; and (b) Substitution of available alternative f- sls especially agricultural residues, for firewood. These enhancements are detailed in the following paragraphs. Artisan Producers Energy Efficiency Measures 4.3 Product Specification. The following recommendations for energy efficiency improvement concern brick structure and composition: (a) Introduce a cavity (frog) in the hand molded bricks and blocks as illustrated in Annex 7 in order to save about 8.5% on energy consumption, and improve firing and drying behavior and the homogeneity of of the fired ceramic body. For these reasons, brick makers in many parts of the world make solid clay bricks with frogs. (b) Investigate the use of chopped hay as a filler in the clay body for handmade bricks. Potential energy savings are 14 +21 based on a mix of 0.3 m3 of loosely dumped chopped hay and 1 m of prepared wet clay mass. The mechanical strength of the clay body in the fired state will be reduced as well, however. The optimum blend for a given clay and firing temperature should be determined by experimentation. - 16 - 4.4 Kiln Construction and Firin8. The following recommendations on kiln construction and operation should yield an energy saving of 17.5 ±2.S5 on averaget (a) Improve control on the amounts of combustion air entering the kiln and reduce heat loss in waste gases by the use of roof iron sheets for partial blocking of the fire holes. At present there is no or only very poor control of the combustion air supply in clamp kilns. The energy losses through the waste gases are the most important item in the heat balance of periodic kilns. (b) Promote the construction of clamp kilns with a square base and proper design of the kiln foot (legs and fireholes). 'Several factors will influence the design optimization: (i) The heat losses of the exterior surface of a clamp kiln per tonne of fired bricks will be lower in a kiln with a square base than in a kiln of the same capacity with a rectangular base; (ii) The heat losses by radiation from the fireholes can be reduced by minimizing the dimensions of the firehole entrance; (iii) Transverse passages in the kiln legs benefit an even heat distribution and an equal brick quality in horizontal cross sections of the kiln body; (iv) Base dimensions and height of well-sealed clamp kilns influence energy efficiency, firing technique and brick quality. Bases of clamp kilns in Uganda vary from 9 to 60 m and the kiln heights from 3 to 5 m. Annex 8 demonstrates the extraordinarily large influence of these factors on the percentage of underfired and low quality bricks; (c) Split firewood logs of greater than 200 to 250 mm diameter to obtain better control of heat input during firing; and (d) Evaluate the use of inspection holes at different heights in the sidewall. of clamp kilns for visual monitoring of kiln temperature during firing. Implementation 4.5 Artisan brick producers will rmain the prime suppliers of brick to the residential and, often, the industrial and commercial sectors for the forseeable future. In view of the scale of future wood - 17 - demand from this sub-sector and the magnitude of potential energy savings, a national dissemination/extension effort is warranted. A ouitable program would include the following components: (a) Research/Pilot Demonstration to test and adapt the proposed energy conservation measures; (b) Training to sustainably transfer the knowledge and potential benefits of the research component; and (c) Dissemination to ensure popularization of the improved techniques throughout Uganda. 4.6 The first two make up the pilot phase activities which would be overseen by a steering committee sponsored by the Ministry of Energy and made up of interested governmental representatives. Membership would include, but not be limited to, representatives of the following ministries: Industry and Technology, Housing and Urban Development, Planning, and Economic Development, Environmental Protection (Forestry Department), and Rehabilitation. Chief among the steering committee's responsibilities during this phase would be to evaluate the effectiveness of the Masaka-Rikai and Mbarara activities with a view to deciding if national extension is justified. 4.7 The program should be targeted at traditional rural-based artisan brickmakers as well as those located in medium cities, rural towns and inatitutionally-sponsored integrated development programs. While the basic rationale for the effort is based on energy conservation, program goals should be extended to encompass the promotion of improved local materials and the upgrading of standards of basic building materials. Because of their extensive prior experience in training artisans for the construction industry in Uganda, it is recommended that the day-to-day implementation of the proposed program for upgrading artisan brick production methods be placed under the supervision of the Kiteredde Construction Institute (KCI). Technical assistance, especially on administration and management aspects, should be provided to the KCI. Annex 9 presents further details on the KCI. 4.8 Research/Pilot Demonstration Phase. This phase of the proposed artisan brick production program will extend for 18 months and should initially be concerned with research, and product testing, and training aspects. A testing and demonstration center will be built at Nalluddugavu, a proven clay works owned by KCI located in one of the target districts and near transport centers. The center, which will comprise a demonstration shed with office and storage area, a series of molding pads, a dormitory, and auxiliary buildings, will initially be used to test kiln and firing techniques, and later for research endeavors on secondary activities such as roof tile production and more economical - 18 - construction techniques. The research activities will be supervised by an international ceramics expert assisted by a training specialist. 4.9 The training component of the program will begin with refresher courses and orientation training for two groups of trainers. The first group will be based at the center and will continue to assist with testing. They will later be responsible for conducting training courses of 3-4 month duration at the center. The second group will begin by training the first group of brickmakers at the center and at their respective brick manufacturing sites. From this point on, the second group's activities will take place in the field, where they will reinforce new production concepts and organize community demonstration programs. Occasionally they will return to the center with new trainees. These activities will initially be tested in the Nasaka-Rikai district, and subsequently refined for dissemination in the Mbarara district. 4.10 Dissemination Phase. Assuming satisfactory results from the pilot phase, a 3 1/2 year country-wide dissemination program will begin. Considering the availability of building materials, localized construction practices, population/backlog demands and updated market surveys, the dissemination program will commence immediately in the areas of Jinja, Kampala/Entebbe, Mpigi and Kabale (in estimated order of priority). The scheduling of the dizsemination program should be flexible to react to short-term situations (e.g. rainy seasons, protracted holidays, security restrictions, etc.) and opportunities presented by large localized brick demand for specific projects. Introduction of Brick and Block Standards 4.11 An additional benefit to the construction industry arising from the national extension program would be the promotion of standards for brick and block products. Such standardization will not only incorporate the recommended materials and brick cavities for energy efficiency, but also improve the construction materials market through tighter product dimensioning and enhanced brick durability. A provisional set of simple national standards is given in Annex 10. Potential knergy Savings 4.12 Energy savings from a successful artisanal sector extension effort are summarized in percentage terms in Table 4.1. The estimated 35% gain in energy efficiency converted to wood demand reduction is 20,475 ml/year at present production levels, equivalent to 28% of total brick and tile industry energy consumption. - 19 - Table 4.1: POTENTIAL ENERGY SAVINGS IN ARTISANAL BRICK MANUFACTURE Potential Energy Measures Savings 1) Introducing frog In the brlcks 8.5 % 2) Introducing chopped hay as a filler 14 + 2 s 3) Improving kiln construction and firing technique 17.5 ± 2.5 % TOTAL Introducing measures 1, 2 and 3 successively 35 ± 3.5 % Small Scale, Semi-mechanized Producers Energy Efficiency Measures 4.13 Improved Kiln Draft Control. The relatively high consumption of the periodic updraft and downdraft kilns is partly caused by a lack of effective draft control. Provision of technical assistance to the small scale semi-mechanized brick and tile industry with regard to firing technique can obtain up to 20X energy savings. 4.14 Replacement of Manufacturing Equipment. Several of the kilns visited by the mission were beyond their useful service lives. Replacement of the worn-out periodic kilns by a new type downdraft kiln, which can be operated continuously as well as periodically, will save 40- 602 on energy when the kiln is operated periodically and 70-80Z when operated continuously. Such new kilns offer the additional advantage of multi-fuel operation. A provisional design for a model downdraft kiln is presented in Annex 11. 4.15 Provision of Spare Parts. Lack of spare parts was a common constraint to increased capacity utilization and productivity at most of the semi-mechanized kilns surveyed. Even where kilns are in good basic condition, spare parts shortages limit the continuity of firing operations causing energy efficiency losses of 10-20X. - 20 - Implementation 4.16 The small scale brick production units promise to be highly beneficial to the country's rece4struction efforts. The semi-mechanized units require modest capital investment, can service specific markets without extensive transport costs and are of a scale that is relatively easy to manage. A program to evaluate inefficiencies in management and fuel consumption while promoting pilot scale improved brick production is therefore recommended. 4.17 The proposed assistance to the small-scale brick production sector would also. be coordinated by the steering committee (para. 4.6), in close collaboration with other local agencies such as the Uganda Deve- lopment Bank, that have some in-house capabilities to assist prospective small-scale brick makers on a number of critical tasks. Suth tasks would includes (a) expediting 'clearing house' types of operations, related specifically to identifying and arranging the procurement from abroad of spare parts and other accessories for their equipment (i.e., to reburbish or retrofitt their plants); and (b) completing project feasibility and appraisal studies in respect of ventures to retrofit individual plants (i.e., subsequent to presenting such proposals to funding agencies). 4.18 Pilot Improved Downdraft Kiln. Considering the major recurring constraints to brick production experienced by small scale brickworks (i.e. uncertain electrical service, transport and spare parts supply), the recommended production line must be adaptable to unforeseen operational interruptions. The primary component of an improved semi- mechanized production process would be an energy efficient, multi-fuel periodic/continuous firing kiln. The proposed kiln is simple and rather labor intensive in operation. The kiln will be a downdraft eight chamber type that can be fired continuously from above using any one or a combination of biomass fuels or fired periodically from below using the same fuel possibilities. When fired continuously, the kiln has the potential for producing 130 tonnes of greenware per week (2.5 million bricks and tiles/year). Due to the manageable level of production, the design, construction procedure and product;on characteristics would be documented, disseminated and promoted throughout the industry. 4.19 The pilot project is proposed to be located at the existing Kizubi Brickworks near Entebbe. The plant is owned by the Kampala Catholic Diocese and supplies product for diocese, industrial and commercial projects. The present updraft periodic kilns are poorly designed and in a run-down state. However, this brickworks is well located to the market, has management and administrative potential and production experience coupled with a functional infrastructure. 4.20 In recognition of the pending applications for new small scale brickworks, the mission has included in Annex 12 a preliminary design for a model semi-mechanized brick and tile production unit. While -,ot included in the present action plan, the model is an energy efficient alternative for future investment consideration. - 21 - Potential Energy Savings 4.21 Total energy efficiency enhancement at small scale brickworks employing improved kilns under proper management is estimated at 751. The achievable fuel savings at the six existing plants (under the assumption of normal capacity factors approaching 50%) are approximately equal to the quantity estimated for the artisanal sector. Medium Scale Producers Sub-sector Status 4.22 Uganda Clay Works, Ltd., a parastatal organization, produces the best clay masonry units and the only clay roofing tiles in Uganda at a rate of fuel consumption that is on par with more mechanized European plants. The factory is well located to major markets and has an order backlog of six months. Nevertheless, the plant is three decades old with severe needs for renovation and spare parts. Due to interrupted electrical service and lack of transport and spares, the plant is operating at 30-40X of installed capacity and is undoubtedly at a production cost disadvantage from the full payroll being carried. If Uganda Clay Works fails, the country's building material industry would be severely impacted. Energy Efficiency Measures 4.23 Lack of spare parts lowers the actual production of the unit and endangers the continuous operation of the kiln. Periodic operation of the installed Hoffman kiln would drive up fuel consumption considerably. Implementation 4.24 Provision of Spare Parts. Considering the entire brick and tile industry, Uganda Clays has the greatest potential to positively impact the industry if renovated. It has production experience and demonstrated administrative and management skills, and the plant is the only continuous firing ring kiln producing clay products with less energy than any other process in the country. The brickworks could afford the renovation of plant and associated installation expertise, yet these inputs must be paid for in foreign exchange and sales revenues are derived in local currency. At present, there is no functional mechanism for acquiring foreign exchange. If and when foreign exchange becomes available through the economic recovery program, Uganda Clay Works should be placed high on the list of critical industries. The mission estimates that approximately US$500,000 would be needed to assure adequate spare parts supply. - 22 - 4.25 Increase in Production Capacity. The longer term goal should be to increase Uganda Clay's production capacity through the addition of another production line to produce preferentially for the public sector. The secondary benefit of this second production line would be to transfer to the original older line the less demanding task of producing roof tiles exclusively. 4.26 Technical Assistance. As proposed for the small scale production units, a technical assistance component would be provided within the body of the overall brick and tile program. This technical expert would be attached to the artisan brick program but would be available to Uganda Clay Works and to funding agencies approached for new financing. Initially, technical assistance will be needed to define and substantiate the amount of spare parts required. In later phases, expertise will be required to study the feasibility of adding a new production line. Potential Energy_Savings 4.27 The level of energy consumption of a continuously operated Hoffman kiln offers no or only slight possibilities for energy savings. Preventing possible future periodic operation is very important however, as potential energy losses could amount to some 30X. Alternative Fuels 4.28 The other major option for the reduction of firewood demand in the brick and tile industry is to substitute alternative biomass fuels such as papyrus, coffee husk and rice husk. Pursuit of this strategy will be carried out in conjunction with efforts to improve the energy efficiency of the brick and tile industry, as follows: (a) In the artisan sub-sector, experiments regarding the use of papyrus in clamp kilns will be carried out as part of the research program centered at KCI. In addition, the use of blede-set clamp kilns fired with rice or coffee husk should be evaluated. This technique in operation in Indonesia is illustrated in Annex 13. (b) In the small scale sub-sector, fuel substitution will be promoted through the dissemination of the improved multi-fuel downdraft kiln. The kiln is described in para 4.17 and Annex 11, and is compatible with papyrus, coffee husk and rice husk fuels. (c) In the medium scale sub-sector, Uganda Clays is already firing their Hoffman ring kiln with coffee husk and thus no further actions are proposed. - 23 - V. PROJECT COSTS AND SCUEDULING Summary 5.1 Implementation of the action plans described in Chapter IV is estimated to cost a total of approximately US$2,900,000 as shown in Table 5.1. These '%osts cover: (a) Esa ablishment and operation of a research and training/ dissemination program for the artisanal sub-sector; (b) Establishment of a revolving fund for provision of spare parts to the small scale producer sub-sector; (c) Pilot installation of an improved downdraft kiln at Kizubi Brickworks, and follow-on extension to four other small scale producers; (d) Feasibility evaluation of the addition of a new production line at Uganda Clay Works, Ltd.; and (e) Provision of technical assistance to all three sub-sectors in kiln design and construction, firing techniques, fuel substi- tution, and enterprise management (amounts included in artisanal budget). About 701 of the total cost will be in foreign exchange and the balance in local currency. Table 5.1: SUNWARY OF COST OF RECCMENDED COSMPOENTS (USS) Phase I Phtsm II Total ProJeet Type of Producer Forelign Local Total Foreign Local Total Foreign Local Total Artisan 342,420 158,805 501,225 789,753 208,991 998,744 1,132,173 367,797 1,499,970 Seall-scale, SemI-mechaniz ed: Spare parts 100,000 - 100,000 - - 100,000 - 100,000 Replacement kilns i50,000 100, 250,000 600.000 4CX.000 1t000,000 750.000 500.000 1.250.000 Subtotal 250,000 100,000 350,000 600.000 400,000 1,000.000 850.000 500.000 1,350,000 Mediur-scale, Machanized: (Uganda Clays, Ltd.) Technical assistance S .D 50t oao -- - -- 50,000 - 50.0CO TOTAL 642.420 258,805 901,225 1.389,753 608.991 1,998.744 2,032.74 867.797 2.899,970 Source: Mission estimates. - 25 - 5.2 In addition to these expenditures, the mission envisions in the longer term an investment of US$4 million for equipment, installation and technical services at Uganda Clays. The feasibility of the investment in the proposed new production line will be established in component (d) above. 5.3 Implementation of the action plan will require five years and will proceed in two phases. The first phase consists of pilot activities aimed at demonstrating proof of concepts and designs and is estimated to require 1 1/2 years. Following a program review, a 3 1/2 year long national dissemination phase is anticipated. A more detailed cost and schedule breakdown is discussed in the following paragraphs. Artisan Producers 5.4 Total costs of the research/pilot demonstration, training and dissemination phases of the artisan program are estimated as US$1.5 million. Activities preceding the nationwide dissemination effort consume approximately one-third of this total, with the balance of US$1.0 million expended in the ensuing national dissemination phase. Included in these amounts are provisions for technical expertise to be shared with the other, larger scale sub-sector producers. Line item costings are furnished in Annex 14. Small Scale, Semi-mechanized Producers 5.5 Project components directed at the small scale sub-sector account for US$1.35 million of the project budget. A spare parts revolving fund will be capitalized in the first phase with US$100,000 in foreign exchange. Additionally, the installation of an improved down- draft kiln is scheduled for Phase I at a cost of US$250,000. Detailed costs of equipment, materials, labor and supervision are given in Annex 15. If the Rizubi installation proves successful, it will be replicated at four other sites at comparable unit cost in Phase II. 5.6 Investment requirements for the "greenfield" construction of the model small scale brick and tile production unit described in Annex 12 are on the order of US$1.25 million. Financing for these new ventures is to be arranged by the entrepreneurs and is not included in the project costing. Medium Scale, Mechanized Producers 5.7 A feasibility study of the proposed production line addition at Uganda Clays is estimated to cost US$50,000 and to require four man- months of consultant time. The study will lay the groundwork for a US$4 million investment which, along with US$0.5 million in short-term renovations, is likely to be financed tbrough COU foreign exchange _sS i_ :^ ....k. F2 T.18A Unimim Rrnnnmir Recoverv Credit. - 26 - VI. PROJECT BMEEIT8, JUSTIVICATION AND RISKS Project Benefits 6.1 Benefits of s project to improve the energy efficiency of Uganda's brick and tile industry take both direct and indirect forms. Efforts to improve energy efficiency through rehabilitation and training will have numerous spin-off benefits to the construction industry, such as reduced equipment down time and higher capacity utilization, increased operator ski'l levels, and improved overall management. These benefits should all favorably impact on productive efficiency, enhancing the in- dustry's important role in supporting economic recovery. However, the indirect benefits are difficult to quantify, and the mission has there- fore focused on the more direct measures of project value. Direct Fuelwood Savings 6.2 The main quantifiable benefit of the proposed project is an expected major reduction in fuelwood demand by the brick and tile industry, both through gains in end-use efficiency and substitution of agricultural residues. The total fuelwood savilgs at present production levels is estimated as just under 40,000 m /year, fairly small in absolute terms relative to demand in the household sub-sector. However, given the great brick and tile supply/demand gap and the expansion potential of the industry, the 60X economies achievable in the artisan and small scale sub-sectors are very significant. The breakdown of these savings is given in Table 6.1. Table 6.1: FUELWOOD SAVINGS DUE TO PROPOSED ENERGY EFFICIENCY MEASUES FOR ARTISAN AND SMALL-SCALE PRODUCERS AT VARIOUiS LEVELS OF PRODUCTION Artisan Production Small-Scale Production Assumed Increase Present One Replaced Unit Current 10% 20% Current CapacIty Kiln Total brick and til, production Tonne 117,000 128,700 140,400 6,690 24,000 6,500 Fuelwood consumption a/ m3 stacked 58,000 64,350 70,200 8,042gf 43,200 11,700 Fuelwood savings due to efficiency (t) b/ m3 stacked 20,475 22,523 24,570 6,032 32,400 8.775 Fuelwood savings due to substitution (2) c/ m3 stacked 9,506 10,457 11,408 503 2,700 731 Fuelvood savings due to less product breakage (3) d/ m3 stacked 2,852 3,137 3,422 75 405 110 Total fueloood savings (4 a 1+2+3) m3 stacked 32,833 36,117 39,400 6,610 35,505 9.616 Value of fuelvood savings (5) e/ USS 243,949 268,349 292,742 49,112 263,802 71,447 Cost of coffee husk substituted for fuelwood (6) fu USS 37,986 41,786 45,586 2,010 10,789 2,921 Total savings (5-6) USS 205,963 226,563 247,156 47,102 253,013 68,526 a/ Fuelvood consumption Is estimated at 0.5m.i stacked for artisan producers and 1.8 Or5 stacked for small-scale producers. b/ Average fueluood savings due to efficiency measures Is estimated at 35S for artisan producers and 750 for small-scale producers. cJ Fuelvood savings due to substitution by coffee husk is estimated at 25% for both artisan and small-scale producers. df Fuelwood savings due to reduction In breakage is estimated at 10% for artisan and 5% for small-scale producers. of The cost of fuelvood per m3 stacked is estimated by adding the average cost of fuelwood (m3 stacked) at roadside, the royalty to be paid to the government, 52.57, and the transportation cost of USt 10/ka for 20 km round trip, or a total of 57.43 (446 USI)/m3 stacked. f/ To estimate the cost of fuelwood saved due to substitution by coffee husk, it Is assumed that the heating value of 1m3 of stacked, air-dried Eucalyptus wood with a bulk density of 510kg9/3 and a heating value of 7,650 MJIm3 to be equal to the heating value of 1.2 m3 of black coffee husks. Coffee husk Is assumd to cost USS3.33 (200 USti)/m3. g/ This Is the fuelwood part of the energy consumption only. Total energy consumption Including coffee husk and rice husk Is estimated at 12,042 m3 stacked fuelwood equivalent. SOURE: Tables 3.3, 4.1; Mission estimates, - 28 - 6.3 Improved Fuelwood Consumption Efficiency. Reduced fuelwood consumption due to improved combustion and heat distribution in kilns accounts for the largest share of savings. These reductions are estimated at 351 in the artisan sub-sector, and some 751 for the small scale producers. 6.4 Fuelvood Substitution. The mission estimates that an additional 251 reduction in wood demand is possible through the substi- tution of coffee and rice husk for fuelwood. This substitution is well underway at the medium and small scale producers, but virtually unknown in the artisan sector even though quite common in other countries where clamp kilns are used. Improved Product Quality 6.5 Better kiln construction, draft control and firing techniques can all be expected to improve the quality of the brick and tile "ware". Reduction of kiln "hot spots" will lower the quantity of under- and over- fired bricks produced per firing cycle while simultaneously reducing the breakage rate experienced during delivery of product to construction sites. The fuelwood savings due to these improvements has been conser- vatively taken as 101 for the artisan and 51 for small scale producers. Project Justification Financial Analysis 6.6 Financial Cost of Fuelwood. The key variable in the financial analysis is the unit value of the fuelwood savings. Obviously, a single value for fuelwood will not represent t.#e market price paid by every brickmaker. The figure chosen, 446 USh/m (US$ 7.43/m ), is based on an average roadside price for stacked fuelwood plus the government levied stumpage fee and transport charges for a 20 km round-trip haul. The price build-up is shown in Table 6.2. Conservatively, no real price inflation over time has been included. While this is in accord with recent historical experience in Uganda, the pattern is unlikely to continue in the face of predicted growing actual and perceived scarcity of the more accessible fuelwood resources. - 29 - Table 6,2? FINANCIAL COST OF FUELWOOD Component USSIMh Stacked Imputad Residual Stumpage 1.9O Entrepreneurial Factor (25%) 0.47 Felling end Extraction a/ 0.49 Roadside Price: 2.86 Stumpage Royalty (paid to Government) 2.57 Transport b/ 2.00 Total at Plant Gate: S7.43 a/ Estimate of one man-day per m3 stacked. b/ 20 Km round-trip at US10"/Km. Source: Mission estimates. 6.7 Artisan Sub-sector. It is not possible to calculate the returns to individual producers from the project, since the cost of the training and technical assistance provided is not borne by the brickmakers. However, the return to the artisan sub-sector component of the project has been calculated in Annex 16 and the results summarised in Table 6.3. Financial rates of return are satisfactory in all production growth scenarios, with even the pessimistic "no growth" scenario returning 12 percent. More realistic growth scenarios give returns ranging from 20 to 27 percent. Table 6.3: PROJECT FINANCIAL RATE OF RETURN Sub-Sector/Scenareo FIRR (%) Artisan No growth in current production 12 10% annual Increase In years 6-20 20 20% annual increase in years 6-20 27 Small Scale, Semi-mechanized Replacement of 1 kiln 25 Replacement of 5 kilns over 5 years 24 Replacement of 5 kilns over 3 years 24 Replacement of 5 kilns over 2 years 25 Source: Annex 16. - 30 - 6.8 Small Scale, Semi-mechanized Sub-sector. Returns for replacement of existing inefficient kilnas operating at five sites are excellent at 25 percent. As shown in Annex 16 and Table 6.3, this conclusion is robust and holds over various s-enarios of diffusion of the recommended multi-fuel downdraft kiln. Economic Analysis 6.9 The economic analysis attempts to measure project worth from the national planning perspective and substitutes economic scarcity or "shadow" prices for market prices. The economic analysis herein incorporates two principal shadow pricing assumptions. First, local currency amounts are converted to US Dollar sums using a shadow exchange rate of 1.00 US Dollar equal to 85 Ugandan Shillings derived from IMF estimates of purchasing power parity. Secondly, the value of fuelwood has been adjusted per the following rationale. 6.10 Economic Value of Fuelwood. The economic value of fuelwood should be the opportunity cost to the national economy of a unit of fuelwood consumption. This figure can be approximated by estimating the marginal cost of fuelwood production, and then adding economic felling and extraction costs, a wood producer's "normal" profit, and transport costs to point of consumption. 6.11 The marginal cost of production is the most difficult component to estimate, as it depends both on location and mode of wood produc- tion. A range of estimates from Bank sources for wood production costs is given in Table 6.4. Consistent with the Uganda Forestry Rehabili- tation Appraisal Report, the mission has selected the residual cost of fuelwood production in multi-purpose plantations for use in the economic analysis. The figure is a mid-range value, and there are arguments to use a lower value, such as an estimate of wood production costs in managed natural forest. However, a good case could then be made to incorporate a "locational rent" in the cost of production, so as to reflect the wood resource's locational convenience relative to the brick producers. Table 6.4: ESTIMATES OF MARGINAL ECONOMIC COST OF FUELWOOD PROCUTION Estimate USS/miw Stacked Uganda Tobacco Dryer Fuelwood Plantation 4.20 Uganda Multi-Purpose Plantation 2.57 Tanzania Managed Natural Forest 1,14 Source: Energy Efficiency in the Tobacco Curing Industry, UNDP/World Bank, 1985; Uganda Forestry Rehabilitation Appraisal Report, World Bank, 1987; Tanzania Woodfuel/Forestry Project, UNDP/World Bank, 1988. - 31 - 6.12 The summation of the other cost components making up fuelwood value is ,hown in Table 6.5, and results in a estimate of US$5.46 per stacked m . This figure is about US$2.00/m lower than the demonstrated willingness to pay of brickmakers for fuelwood derived from unmanaged "bush" sources, indicating the conservatism of the estimate. Table 6.5: ECONOMIC VALUE OF FUELWOOD Component US$/m. stacked Marginal Productlon Cost 2.57 Entrepreneurial Factor (250) 0.64 Felling and Extraction a/ 0.25 Transport 2.00 S5.46 a/ Unskilled labor shadow valued at one-half daily wage. Source: Tables 6.2, 6.4; Mission estimates. 6.13 Artisan Sub-sector. Due to the lower value of fuelwood assumed, returns in the economic analysis shown in Annex 17 and Table 6.6 are lower than those calculated in the financial analysis. Nevertheless, they are favorable for all but the most pessimistic brick production scenario, indicating ample justification for a national research and training/extension program targeted at artisan producers. Table 6.6: PROJECT ECONOMIC RATE OF RETURN Sub-Sector/Scenario EIRR S) Artisan No growth in current production 7 10% annual Increase In years 6-20 15 20% annual Increase In years 6-20 22 Small Scale, Semi-mechanized Replacement of 1 kiln 21 Replacement of 5 kilns over 5 years 19 Replacement of 5 kilns over 3 years 19 Replacement of 5 kilns over 2 years 20 Source: Annex 17. - 32 - 6.14 Small Scale, Semi-mechanized Subsector. Results of the economic analysis of the small scale producer component are also shown in Annex 18 and Table 6.6. With returns averaging 20 percent across all kiln dissemination scenarios, the kiln replacement program is similarly well justified. Project Risks 6.15 The major project risks rest primarily in the artisan sub- sector. As with any national training and extension effort, implementa- tion is subject to delay or failure to reach target populations. Renewed deterioration of the security situation could compound these difficul- ties. The ristt is minized through careful choice of implementing agents and use of a two-phased pilot/wide-scale dissemination approach to project scheduling and oversight. 6.6 The second major risk is failure to obtain anticipated energy savings. Especially in the artisan sub-sector, this could be the result of producers failing to follow technical advice and new techniques. However, purchased fuelwood makes up a substantial portion of brick and tile production costs, so there thus appear to be adequate incentives for adoption. In addition, the training/extension design incorporates in- field, community-level demonstrations in order to illustrate the new techniques under plausible operating conditions. - 33 - Annex 1 Page 1 of 3 List of Institutions and Individials Contacted Ministry of Energy Mr. S. Bachou Deputy Minister Mr. H. 8. Opika Opoka Permanent Secretary Mr. Ndiwa-Ndikora Under Secretary Mr. Kapampara Senior Assistant Secretary Mr. Ziad Alahdad Senior Energy Advisor Mr. K. Tugume Energy Officer Ministr, of Plannig and Economic Development Mr. D. Okullo Ongar Principal Eccnomist, Industrial Sector Mr. J. Atria Economist, Social Service sector Officer Mr. K. Kayondho Economist, Social Service Sector Officer Ministry of Housing and Urban Development Mr. E. M. Byaruhanga Chief Housing Officer Mr. J. Rucecerwa Principal Assistant Secretary Mr. Z. I. Qasi Principal Housing Economist Mr. C. Walakira Engineer, Building Research and Material Development Ministry of Industry and Technology Mrs. J. Mumbule Senior Industrial Officer Mr. F. Rwahwive Officer Ministry of Cooperatives and Marketing Mr. A. M. Kaliisa Chief Economist Mr. W. S. Ssenfuma Project Officer Mr. T. Carr Computer Specialist Ministrr of Environment Protection and Forestry Mr. E. D. Olet Ag. Deputy Chief Forest Officer Mr. L. Ntiru Forest Officer - 34 - Annex 1 Page 2 of 3 Reconstruction Development Corporation Mr. H. S. Mwaks Officer Mr. V. ByabamaiAma Liaison Officer UNDP Resident Mission Mr. von Mallinckrodt Resident Representative Mr. M. Al-Jaff Deputy Resident Representative Mr. B. Moro Program Officer Mr. A. Disch Assistant Resident Representative Mr. N. Kulkarni Assistant Resident Representative Mr. P. K. Das Program Assistant ILO Project Staff Mr. A. Bazargan Chief Technical Advisor, National Manpower Survey Mr. T. Crudele Chief Technical Advisor, Intensive Employment Program Mr. E. Black Volunteer Forester Mr. S. Ofori Civil Engineer IMF Resident Mission Mr. Z. Ibrahim-Zadeh Resident Representative IBRD Resident Mission Mr. C. Slade Resident Representative The Experiment in International Living (EIL) Mr. S. Hanson East Africa Representative Uganda Development Bank Mr. P. R. Behl Head, Project Operations Kiteredde Construction Institute (Bannakaroli Brothers) *Brother L. Mutebi Superior General *Also met other "Brothers" in charge of the Institute. - 35 - Annex 1 Page 3 of 3 Makerere University Professor B. G. Kirya Vice-Chancellor Professor E. Lugujjo Dean, Faculty of Technology Mr. C. H. Mukunya Asst. Prof., Department of Civil Engineering Private Sector Enterprises Mr. 0. Botti Consultant to and Previous MD, Uganda Clay Mr. L. 1. Kasule Production Manager, Universal Clay Works Mr. M. Olowo-Opoya Chairman, Century Works, Ltd. Institute of Teachers Education Hr. G. Sizoomu Instructor of Ceramics 36 Annex 2 Pa-oge 1f 3 STRUCTURE OF THE BRICK AND TILE INDUSTRY Artisan Brick subsector 1. The bulk of bricks used in Uganda is produced by traditional artisan brickmakers, an estimated 20 million bricks/year. Sites of artisan commercial brick production are along all major roads (up to 3 miles off road) and concentrated within 15-20 miles radius of major Urban Centers. Production sites are close to clay deposits, mainly swamps, with production interrupted only by long rains. In general, artisan brickmaking can be found throughout Uganda, wherever there is a demand. The subsector is independant and not bound to electrical power or external inputs. These producers supply the residential, agricultural and commercial sectors in rural, small as well as large towns. To some extent, people also produce bricks in their "backyards" for their personal use. Bricks are hand-made and are fired in various sizes of fuelwood-fired clamp kilns. The bricks are of low quality, weather proof and load bearing for single story structures. The subsector is highly labor intensive. Energy consumption of these producers is estimated at 0.5 mJ fuelwood stacked per ton of fired products (about 114 solid weatherproof bricks). Small-scale, Semi-mchanized Subsector 2. Butendi Brick Works - A small-scale, semi-mechanized brick plant with an installed capacity of about 6,000 tons/year and operating at about 25Z of capacity, is located north of Masaka. The plant is owned and operated by the Catholic Diocese and supplies its products to the diocese and industrial and commercial enterprises. The high quality products is fired in periodic up-draft kilns, without proper draf control, using wood as fuel. Fuel consumption is estimated at 1.8 m stacked wood per ton of fired product (211 standard facing bricks). The plant suffers from usual production, management and financial constraints; i.e., lack of spare parts and adequate transport, management problems, as well as insufficient funds for reconstruction of kilns and maintenance of plant. 3. Kizubi Brick Works - Also a small-scale, semi-mechanized plant with an installed capacity of about 6,000 tons/year, operating at about 25Z of capacity, is located on the road from Kampala to Entebbe. The plant is owned and operated by the Kampala Catholic Diocese and supplies the diocese, commercial and industrial projects with bricks and tiles. The products are of high quality and are fired in periodic up-draft kilnas without effective draft control. The plant uses a combination of fuelwood and coffeM husks as fuel. Fuel consumption is estimated at equivalent of 1.9 m stacked wood per ton of fired products (211 standard facing bricks). The plant suffers from lack of spare parts, interruptions in electrical power, inadequate drying shed and poorly designed, run-down periodic kilns. - 37 - 2 Page 2 of 3 4. Kibimba Brick - a small-scale, semi-mechanized plant also with a capacity of about 6,000 tons/year is located on the road between Junja and Tororo. The plant is part of the Kibimba rice scheme, operated by the Chinese, and producing primarily for itself and the Tororo rice scheme consumption and selling the surplus in the surrounding markets. The products are of high quality and are fired in a down-draft kiln without effective draft control, using rice husks and fuelwood as fuel. Fuel consumption is estimated at l.8 m3 stacked wood equivalent per ton of fired product (211 standard facing bricks). 5. Matanga Clays Ltd. - A semi-mechanized production plant in the Masaka area, uses a normal clamp kiln fired with wood. The fuel consumption is estimated at 1.3 m stacked wood per ton of fired product. The plant produces solid bricks and blocks which are formed by semi-dry clay dust pressing, using hand-operated leverpress. The clay dust is prepared by successive open-air drying, hand-operated crushing and sieving of the raw material. 6. Pan African Enterprises Ltd. - This is also a small-scale, semi-mechanized brick plant located across from Uganda Clays on the Kampala to Entebbe road. The plant is privately owned. However, due to plant's deteriorated conditions and lack of inputs, it lies dormant and requires complete reconstruction. This plant also has a designed capacity of 6,000 tons/year. 7. Universal Clay Works, Ltd. - A small-scale plant with an installed capacity of about 6,000 tons/year is operating at about 30Z of capacity. The plant is located 15 miles north of Kampala. The company is privately owned and produces a range of high-quality bricks and blocks. The products are fired in a Hoffmann ring kiln. The kiln should be fired continuously but due to lack of drying capacity, it is fired periodically. Although the kiln is designed to be fired by used motor oil as well as coffee husks, it is using coffee husks oily because of high price of used oil. Fuel consumption is about 1.5 m stacked wood equivalent per ton of fired product, whereas the potential fuel consumption in a continuously operated kiln is much lower. The kiln is poorly built. The clay joints in the arch of the kiln are too wide which endangers the durability of the kiln's structure. The production constraints also include transport delays, electrical power disruption, lack of spare parts and a need for kiln repairs. Mediumr-scale Brick Subsector 8. Uganda Clay Works, Ltd. - A medium-size plant with a production capacity of about 36,500 tons output/year, is located in the outskirts of Kampala and owned by a private company and the National Housing and Construction Corp. (Parastal). Producing a range of high- quality bricks and tiles, the factory is operating at about 25X of production capacity. Clay products are fired in a Hoffmann Ring Kiln, using coffee husks as fuel. Fuel consumption is estimated at equivalent of 0.2-0.3 m3 stacked wood per ton of fired products (about 211 standard Annex 2 Page 3 of 3 - 38 - facing bricks). Bricks are supplied to the public, commercial and industrial sectors and, to a less extent, to the private residential sector for large housing units. The factory is the major supplier of tiles in Uganda. The plant is presently in dire need of spare parts and suffers from frequent electrical disruptions. 9, In addition to the above-mentioned mechanized/semi-mechanized brick and tile producing plants, there are a number of other plants registered with the Ministry of Industry. Although some of the registrations date back to 1981, to mission's knowledge none of these other factories has been established. Cement Bonded Bricks and Tiles 10. In comparison to clay buidling products in Uganda, there are also some small production units making cement bcnded bricks and tiles. The raw materials mix commonly used, on the volume basis, are: Laterite (Karam) 75Z Sand 20 Cement 5 Bonded Water added as necessary The bricks are shaped with a hydraulipally or mechanically operated presses at a pressure of 600 Bar (60 N/mm ). The hardening of the bricks takes place in sheds and there is no heat treatment involved. The size of the currently produced bricks is 290x140xlO0 mm, weighing 8.0 kg and having a dry compressive strength of 8.5 N/mm2. The preparation and shaping of the raw materials mix takes 5 persons/press. The press has a capacity of 40 bricks/hour which, in conjunction with shortage of cements and other technical problems, restricts the significance of this production method. There are also firms making concrete tiles with wooden hand-made moulds. The production capacity, however, is dependent on the number of moulds avaiable, which in case of one manufacturer visited by the mission (in Tororo) was about 200 tiles/day. 11. Sisal cement tiles are also being produced on a very small scale in Uganda. The raw materials for these tiles are cement, sand and sisal, with the cement sand ratio of 1 to 3 by volume. The cement and sisal consumption amount to 450 kg and 11 kg per 1,000 tiles, respectively. The tiles are shaped in plastic moulds, and one such unit visited by the mission in Jinja had a capacity of 120 tiles/day. In general, the production of this type of tiles depends on imported materials sisal, cement (at present), machines and extruded forms, in addition to limited production possibilties. - 39 - Annex 3 Page 1 of 15 ESTIMATION OF BRICK AND TILE DEMAND A. Estimation of Demand for Bricks a/ 1. Estimated Brick Needs for Various Residential Prototypes 1.1 Building "Type A" - 3m2 - 1 Room Building "Type B" - 60m2 - 2 Rooms Building "Type C" - 9 - 3 Rooms Building "Type D" - 120m2 - 4 Rooms Building "Type E" - 150m2 - 5 Rooms Building "Type F" - 180m2 - +5 Rooms (Rooms include bedrooms, living rooms, dining and other habital space.) Assume: Plate height of 2.5 meters or 24 courses, increase to 30 courses to include gable ends. Typical brick/block 300mm x 150mm x 100mm 1.2 Buildin "Tye A": Sm X 6m X 22 lm. - 74 stretchers x 1.25 (interior walls) = 92.5 bricks x 30 courses = 2,775 bricks Buildins "Type B"t 6m X 10m = 32 lm. = 106 stretchers x 1.5 (G-terior walis)= 159 x 30 = 4,770 bricks Building "Te C": 9m x 10m - 38 lm. 126 stretchers x 1.75 (interior walls) - 220 x 30 * 6,600 bricks Building "Tye D": 10m x 12m 44 1m. 146 stretchers x 2.0 (interior walls) = 292 x 30 8 8,760 bricks Building "Type E"s 10m x lSm = 50 lm. * 166 stretchers x 2.25 (interior walls) * 373 x 30 - 11,190 bricks Buildin "Type F": 12m x 15m = 54 lm. - 180 stretchers x 2.5 (interior walls) - 450 x 30 * 13,500 bricks 2. Housing Demand and Composition Opposed to Population Projections. 2.1 Current backlog as of 1982 140k units (See section 3.0 backlog) - Urban growth 3.8X plus demolition, renovation and maintenance - Unit demand by 2000 estimate 300k units = 20k units/year a/ Mission estimates. - 40 - Annex 3 Page 2 of 15 2.2 Existing housing stock (Urban) * 120k units 2.3 Percentage of housing stock in permanent construction type (assume +30 year material life - bricks, iron sheets, concrete, tile...)t Jinja 61.6 Tororo 25.5 Mbale 20.0 Soroti 25.7 Lira 24.7 Gulu 45.0 Lugazi 34.6 Kabale 30.5 Kasese 45.4 Kabarole 4.3 2.4 Number of rooms (includes bedrooms, dining, living room and other habital space): Number of Rooms* I 1 2 3 4 5 +5 Percent Permanenti 10 201 402 80% 1002 1001 Jinja 4.1 3.4 6.9 8.6 4.6 6.4 Tororo 2.1 3.6 6.6 15.8 8.2 15.9 Nbale 4.2 2.6 4.5 11.4 11.5 8.1 Soroti 4.0 2.6 5.6 11.2 7.4 11.0 Lira 3.4 3.3 6.6 15.4 6.8 6.8 Gulu 3.4 4.9 5.8 13.4 3.8 6.9 Lugazi 4.8 3.5 7.4 8.6 1.5 3.1 Kabale 1.1 2.8 7.4 19.6 9.5 23.0 Kasese 3.0 5.7 7.7 8.0 3.7 8.5 Kabarole .05 4.5 8.6 18.5 11.2 16.9 * Number of rooms assumes all 5 and +5 room houses of a quality and status to be all or 1002 brick whereas this percentage decreases to assuem that only 102 of the polled 1 room houses would be built of permanent materials. 2.5 Average household size: Jinja 5.4 Tororo 5.8 Mbale 5.4 Soroti 5.2 Lira 6.5 Gulu 6.5 4 Lugazi 4.3 Kabale 5.7 Kasese 5.4 Kabarole 5.9 Average 5.6 Annex 3 - 41 - Page 3 of 15 2.6 Population growtht assuming 52 urban, 42 Kampala, 3.22 national: 1980 1985 1990 1995 2000 Kampala 458.5K 557.5K 678.6K 825.3K 1.OM Entebbe 21.2 27.0 34.3 43.8 56.2 Masaka 29.1 37.1 47.1 60.2 77.2 Mbarara 23.3 29.7 37.7 48.2 61.8 Jinja 45.1 57.5 73.0 93.3 119.6 Tororo 16.7 21.3 27.0 34.5 44.3 Mbale 28.0 j5.7 45.4 57.9 74.2 Soroti 15.0 19.1 24.3 31.0 39.8 Lira 9.1 11.6 14.7 18.8 24.1 Oulu 15.0 19.1 24.3 31.0 39.8 Lugazi 10.4 13.3 16.8 21.5 27.6 Kabale 31.5 27.4 34.8 44.5 57.0 Kasese 9.9 12.6 16.0 20.5 26.2 Kabarole 26.8 34.2 43.4 55.5 71.1 Minor Towns 370.4K 472.6K 600.0K 766.7K 982.3K Total Urban l.1M 1.4M 1.78M 2.27M 2.9M Rural 11.5M 13.3M 15.5M 17.9M 20.7M Total 12.6M 14.7M 17.3M 20.2K 23.6M 2.7 Number of new households since 1980 (average 5.6 people/ household): Household Size 1985 1990 1995 2000 Kampala 5.6 17.7K 21.6K 26.2K 32.0K Entebbe 5.6 1.03 1.3 1.7 2.2 Masaka 5.6 1.43 1.78 2.34 3.04 Mbarara 5.6 1.14 1.43 1.87 2.43 Jinja 5.4 2.3 2.87 3.76 4.87 Tororo 5.8 .8 1.0 1.29 1.69 Mbale 5.4 1.4 1.8 2.3 3.0 Soroti 5.2 .8 1.0 1.3 1.7 Lira 6.5 .38 .48 .63 .81 Gulu 6.5 .63 .8 1.03 1.35 Lugazi 4.3 .67 .81 1.09 1.42 Kabale 5.7 1.03 1.3 1.7 2.19 Kasese 5.4 .5 .63 .83 1.05 Kabarole 5.9 1.25 1.56 2.05 2.64 Minor Towns 5.6 18.25K 22.75K 29.77K 38.5K Rural 5.6 321.4K 392.8K 428.6K 500.K - 42 - Annex 3 Page 4 of 15 2.8 Number of new houses of brick: Percent Brick Houses 1985 1990 1995 2000 Kampala 61.6 10.9K 13.3K 16.1K 19.7K Entebbe 61.6 .6 .8 1.0 1.3 Masaka 61.6 .88 1.1 1.44 1.87 Mbarara 61.6 .7 .88 1.15 1.5 Jinja 61.6 1.42 1.77 2.3 3.0 Tororo 25.5 .2 .26 .33 .43 Nbale 20.0 .28 .36 .46 .6 Soroti 25.7 .21 .26 .33 .44 Lira 24.7 .094 .118 .156 .20 Gulu 4.5 .028 .036 .046 .061 Lugazi 34.6 .23 .28 .38 .49 Kabale 30.5 .31 .39 .52 .67 Kasese 45.4 .23 .29 .38 .48 Kabarole 4.3 .054 .067 .088 .113 Minor Towns 25.0 4.56K 5.69K 7.44K 9.63K Rural 5.0 13.4 K 16.1 K 17.8 K 19.5 K 2.9.1 Number of "Type A" houses (30 m2 - 1 room - brick): Percent of Brick #'Type A's" 1985 1990 1995 2000 Kampala 4.1 .72K .88K 1.07K 1.31K Entebbe 4.1 .04 .05 .07 .09 Masaka 4.1 .04 .05 .06 .08 Mbarara 4.1 .03 .04 .05 .06 Jinja 4.1 .09 .12 .15 .20 Tororo 2.1 .04 .005 .007 .009 Mbale 4.2 .012 .015 .019 .025 Soroti 4.0 .008 .010 .13 .017 Lira 3.4 .003 .004 .005 .006 Gulu 3.4 .001 .001 .002 .002 Lugazi 4.8 .011 .013 .018 .023 Kabale 1.1 .003 .004 .005 .007 Kasese 3.0 .007 .009 .011 .014 Kabarole .05 - - - - Minor Towns (average) 3.3 .15K .187K .245K .317K Rural - 13.4 K 16.1 K 17.8 K 19.5 K Annex 3 - 43 - Page 5 of 15 2.9.2 Number of "Type B" houses (60 m2 - 2 rooms - brick): Percent Brick "Type B's" 1985 1990 1995 2000 Kampala 3.9 .70K .84K 1.02K 1.25K Entebbe 3.9 .04 .05 .06 .08 Masaka 3.9 .03 .04 .06 .07 Nbarara 3.9 .03 .04 .05 .06 Jinja 3.9 .09 .11 .15 .19 Tororo 3.6 .007 .009 .012 .015 Mbale 2.6 .007 .009 .012 .015 Soroti 2*6 .005 .006 .008 .011 Lira 3.3 .003 .004 .005 .006 Gulu 4.9 .001 .001 .002 .002 Lugazi 3.5 .008 .010 .013 .017 Kabale 2.8 .009 .010 .014 .019 Kasese 5.7 .013 .016 .022 .027 Kabarole 4.5 .002 .003 .004 .005 Minor Towns (average) 3.8 .173K .216K .283K .366 2.9.3 Number of "Type C" houses (90 m2 - 3 rooms - brick): Percent Brick ";Type C" 1985 1990 1995 2000 Kampala 6.9 1.22K 1.50K 1.8K 2.2K Entebbe 6.9 .07 .09 .12 .15 Masaka 6.9 .06 .07 .10 .13 Mbarara 6.9 .05 .07 .08 .10 Jinja 6.9 .16 .19 .26 .33 Tororo 6.6 .013 .017 .022 .028 Mbale 4.5 .013 .016 .020 .027 Soroti 5.6 .012 .015 .018 .025 Lira 6.6 .006 .008 .010 .013 Gulu 5.8 .002 .002 .003 .004 Lugazi 7.4 .017 .020 .028 .036 Kabale 7.4 .023 .029 .038 .050 Kasese 7.7 .017 .022 .030 .037 Kabarole 8.6 .005 .006 .007 .010 Minor Towns (average) 6.7 .30K .38K .49K .64K -44 Annex 3 Page 6 of 15 2.9.4 Number of "Type D" houses (120 m2 - 4 rooms - brick): Percent Brick Type D 1985 1990 1995 2000 Kampala 8.6 1.52K 1.85K 2.25K 2.75K Entebbe 8.6 .08 .11 .15 .19 Masaka 8.6 .07 .09 .12 .16 Mbarara 8.6 .06 .07 .10 .13 Jinja 8.6 .19 .25 .32 .42 Tororo 15.8 .03 .04 .05 .07 Nbale 11.4 .03 .04 .05 .07 Soroti 11.2 .02 .03 .04 .05 Lira 15.4 .014 .018 .024 .031 Gulu 13.4 .004 .005 .006 .008 Lugazi 8.6 .020 .024 .033 .042 Kabale 19.6 .061 .076 .102 .131 Kasese 8.0 .018 .023 .030 .038 Kabarole 18.5 .010 .012 .016 .021 Minor Towns (average) 11.8 .54K .67K .88K 1.14K 2.9.5 Number of "Type E" houses (150 m2 - 5 rooms - brick): Percent Brick "Type E" 1985 1990 1995 2000 Kampala 4.6 .81K .99K 1.2K 1.47K Entebbe 4.6 .04 .06 .08 .10 Masaka 4.6 .04 .05 .07 .09 Mbarara 4.6 .03 .04 .05 .06 Jinja 4.6 .10 .13 .17 .22 Tororo 8.2 .016 .021 .027 .055 Mbale 11.5 .032 .041 .053 .070 Soroti 7.4 .015 .019 .024 .033 Lira 6.8 .006 .008 .011 .014 Gulu 3.8 .001 .001 .002 .002 Lugasi 1.5 .003 .004 .006 .007 Kabale 9.5 .030 .037 .050 .064 Kasese 3.7 .008 .011 .014 .018 Kabarole 11.2 .006 .007 .009 .013 Minor Towns (average) 6.2 .28K .35K .46K .60K - 45 - Annex 3 Page 7 of 15 2.9.6 Number of "Type F" houses (180 m2 - 5 plus rooms - brick): Percent Brick "Type F" 1985 1990 1995 2000 ampala 6.4 1.1K 1.4K 1.7K 2.0K Entebbe 6.4 .06 .08 .1 .14 Masaka 6.4 .06 .07 .09 .12 Kbarara 6.4 .04 .06 .07 .09 Jinja 6.4 .14 .18 .24 .31 Tororo 15.9 .03 .04 .05 .07 Kbale 8.1 .023 .029 .037 .049 Soroti 11.0 .023 .029 .037 .049 Lira 6.8 .006 .008 .011 .014 Gulu 6.9 .002 .003 .003 .004 Lugasi 3.1 .007 .009 .012 .015 Kabale 23.0 .071 .089 .119 .154 Kasese 8.5 .019 .025 .032 .041 Kabarole 16.9 .009 .011 .015 .019 Minor Towns Average 9.4 .43K .53K .70K .90K 2.10 Demand for bricks for various cities by type of housing through year 2000: Housing Type A B C D E F Subtotal Kampala 1985 2.00M 2.22M 8.05M 13.31M 9.06M 14.85M 49.49M 1990 2.44 2.67 9.90 16.21 11.08 18.90 61.20 1995 2.97 3.24 11.88 19.71 13.43 22.95 74.18 2000 3.63 3.97 14.52 24.09 16.45 27.00 89.66 Entebbe 1985 .11 .13 .46 .70 .45 .81 2.66 1990 .14 .16 .59 .96 .67 .95 3.60 1995 .19 .19 .79 1.31 .89 1.21 4.72 2000 .25 .25 .99 1.66 1.12 1.62 6.16 Masaka 1985 .11 .09 .40 .61 .45 .81 2.47 1990 .14 .13 .46 .79 .56 .95 3.03 1995 .17 .19 .66 1.05 .78 1.21 4.06 2000 .22 .22 .86 1.40 1.01 1.62 5.33 Nbarara 1985 .08 .09 .33 .52 .33 .54 1.89 1990 .11 .13 .46 .61 .45 .81 2.05 1995 .14 .16 .53 .87 .56 .94 3.20 2000 .16 .19 .66 1.14 .67 1.21 4.03 Annex 3 - 46 - Page 8 of 15 Housing Type A B C D E F Subtotal Jinja 1985 .25M .29M 1.05M 1.66M 1.12M 1.89M 6.26M 1990 .33 .35 1.25 2.14 1.45 2.43 8.00 1995 .42 .48 1.72 2.80 1.90 3.24 10.56 2000 .55 .60 2.18 3.68 2.46 4.18 13.65 Tororo 1985 .01 .02 .08 .26 .18 .40 .95 1990 .01 .03 .11 .35 .23 .54 1.27 1995 .02 .04 .14 .44 .30 .67 1.61 2000 .02 .05 .18 .61 .39 .94 2.19 Mbale 1985 .03 .02 .08 .20 .36 .31 1.06 1990 .05 .03 .11 .35 .46 .39 1.39 1995 .06 .04 .13 .44 .59 .50 1.76 2000 .07 .05 .18 .61 .78 .66 2.35 Soroti 1985 .02 .01 .08 .17 .17 .31 .76 1990 .03 .02 .10 .26 .21 .39 1.01 1995 .04 .02 .12 .35 .27 .50 1.30 2000 .05 .03 .16 .4A .37 .66 1.71 Lira 1985 .01 .01 .04 .12 .07 .08 .33 1990 .01 .01 .05 .16 .09 .11 .43 1995 .01 .02 .07 .21 .12 .15 .58 2000 .02 .02 .09 .27 .16 .19 .75 Gulu 1985 .01 .01 .01 .03 .01 .03 .10 1990 .01 .01 .01 .04 .01 .04 .12 1995 .01 .01 .02 .05 .02 .04 .15 2000 .01 .01 .03 .07 .02 .05 .19 Lugazi 1985 .03 .02 .11 .17 .03 .09 .45 1990 .04 .03 .13 .21 .04 .12 .57 1995 .01 .04 .18 .29 .07 .16 .79 2000 .06 .05 .24 .37 .08 .20 1.00 Kabale 1985 .01 .03 .15 .53 .33 .96 2.01 1990 .01 .03 .19 .66 .41 1.20 2.50 1995 .01 .04 .25 .89 .56 1.61 3.36 2000 .02 .06 .33 1.15 .72 2.08 4.36 Annex 3 - 47 - Page 9 of 15 Housing Type A B C D E F Subtotal Kasese h 1985 .02M .04M .11W .16M .09M .26M .68M 1990 .02 .05 .14 .20 .12 .34 .87 1995 .03 .07 .20 .26 .16 .43 1.15 2000 .04 .09 .24 .33 .20 .55 1.45 Kabarole 1985 .01 .01 .03 .04 .07 .12 .33 1990 .01 .01 .04 .11 .08 .15 .40 1995 .01 .01 .05 .14 .10 .20 .51 2000 .01 .01 .06 .18 .14 .26 .66 Winor Towns 1985 .42 .55 1.98 4.73 3.13 5.80 16.61 1990 .52 .687 2.51 5.87 3.92 7.15 20.66 1995 .68 .900 3.23 7.71 5.15 9.45 27.12 2000 .88 1.16 4.22 9.99 6.71 12.15 35.11 Rural 1985 37.19 - - - - - 37.19 1990 44.68 - - - - - 44.68 1995 49.40 - - - - - 49.40 2000 54.11 - - - - - 54.11 2.11 Summary of brick demand estimate based on population growth: 1985 1990 1995 2000 14 Major Towns 69.44 86.44 107.93 1133.49 Minor Towns 16.61 20.66 27.12 | 35.11 Rural 37.19 44.68 49.40 | 54.11 Total 123.24M 151.78M 184.45M j 222.71M 3. Number of bricks demand due to backlog in national housing stock: 3.1 Backlog Estimate, 1983-85: Urban Rural Total 1983 72K 88K lfOK 1984 83 101 184 a/ 1985 95 117 212 al al Assuming 15% annual increase. Annex 3 - 48 - Page 10 of 15 3.2.1 Scenario A 212K Units x Assumed 251 Brick Construction = 53R Brick Units 53K Units x 7,932 Bricks (Average Brick House) = 420 Million Bricks Number of Bricks, 1985 420 Million 3.2.2 Scenario B 95K Urban Units x 7,932 Bricks (Average Brick House) = 753.5 Million 117K Rural Units x 2775 Bricks ("Type A"' House) = 324.6 Million lumber of Bricks, 1985 1,078.1 Million 4.0 Estimate Scenarios (Order of Magnitude): Optimistic Case 1985: Residential Demand - Population Generated (see Section 2.11) 123.24M Residential Demand - Backlog (see Section 3.2.2 Scenario B) 1,078.1 M Subtotal 1,201.34M Assumption: Industrial, commercial, clerical and public new construction, reconstruction and maintenance 10 - 30 percent residential demand. Assumption: Optimistic Economic Climate 1.3 x 1,201.34 - 1,561.7M Bricks 1985 Demand for Brick, Optimistic Case, 1987 Estimated demand for 1985 1,561M Annual increase since 1985 1986t 81 p.a. 125 1987t 81 p.a. 135 Total Optimistic Case 1,821M Low Case 1985: Residential Demand - Population Generated (see Sec. 2.11) 123.24M Residential Demand - Backlog - Assume 201 annual absorption of backlog over 5 year period. Use average of Backlog scenarios A and B. 1,078.1 + 420 x 201 149.81 2 Subtotal 273.05M Annex 3 - 49 - Page li of 15 Assumption: poor economic climate for non-residential new construction, reconstruction and maintenance 1 x 1.1 X 273.05 * 300.35 Bricks 1985 Demand for Brick, Low Case, 1987 Estimated demand for 1985 300M Annual increase since 1985 1986: St p.a. 24 1987: 81 p.a. 26 Total Low Case 350X B. Estimation of Demand for Tiles 5.0 Estimated Tile Needs For Various Residential Prototypes (See Section 1.0, Estimation of Demand for Bricks for the size of the building type and the number of room in each). 5.1 Assume: Simple pitched roof with continuous .5m overhang and 1/2 slope with long axis excluding ridge cap. d3uilding "Type A": 5m x 6m - 46.9m2 x 16 Tiles/m2 - 750 Tiles Building "Type B": 6m x 1lm = 86.m2 x 16 Tiles/m2 - 1,376 Tiles Building "Type C": 9m x 1lm = 123m2 x 16 Tiles/m2 * 1,968 Tiles Building "Type D": 1lm x 12m = 160m2 x 16 Tiles/m2 = 2,558 Tiles Building "Type E": 1lm x 15m = 197m2 x 16 Tiles/r2 - 3,148 Tiles Building "Type F": 12m x 15m 212m2 x 16 Tiles/m2 * 3,400 Tiles 6.0 Housing Demand & Composition are Based on Population Demand (See Section 2.0 - 2.9.6: Housing Demand & Composition) 6.1 Demand for tiles through year 2000 for various cities (in millions): Annex 3 - 50- Page 12 of 15 Housing Type A B C D E ! Subtotal KAMALA 1985 .54m .96m 2.40m 3.89m 2.55m 3.74m 14.08m 1990 .66 1.16 2.95 4.73 3.12 4.76 17.38 1995 .80 1.40 3.54 5.75 3.78 5.78 21.05 2000 .98 1.72 4.33 7.03 4.63 6.80 25.49 ENTEBBE 1985 .03 .05 .14 .20 .12 .20 .74 ;990 .04 .07 .18 .28 .19 .27 1.03 1995 .05 .08 .24 .38 .25 .34 1.34 2000 .07 .11 .29 .49 .31 .47 1.74 MASAKA 1985 .03 .04 .12 .18 .12 .20 .69 1990 .04 .05 .14 .23 .16 .24 .86 1995 .04 .08 .19 .31 .22 .31 1.15 2000 .06 .10 .25 .41 .28 .41 1.51 MBARARA 1985 .02 .04 .10 .15 .09 .14 .54 1990 .03 .05 .14 .18 .12 .20 .72 1995 .04 .07 .16 .26 .16 .24 .93 2000 .04 .08 .20 .33 .19 .31 1.15 JINJA 1985 .07 .12 .31 .48 .31 .48 1.77 1990 .09 .15 .37 .64 .41 .61 2.27 1995 .11 .21 .51 .82 .53 .82 3.00 2000 1.15 .26 .65 1.07 .69 1.05 3.87 TORORO 1985 ---- ---- .02 .08 .05 .10 .25 1990 ---- .01 .03 .10 .06 .14 .34 1995 .02 .04 .13 .08 .17 .44 2000 .02 .05 .18 .11 .24 .60 MBALE 1985 -- -- .02 .08 .10 .08 .28 1990 .01 .01 .03 .10 .13 .10 .38 1995 .01 .02 .04 .13 .17 .12 .49 2000 .02 .02 .05 .18 .22 .17 .66 SOROTI 1985 ---- ---- .02 .05 .05 .08 .20 1990 .01 ---- .03 .08 .06 .10 .28 1995 .01 ---- .03 .10 .07 .12 .33 2000 .01 .01 .05 .13 .10 .17 .47 -1 Annex 3 51 Page 13 of 15 Housing Type A B C D E P Subtotal LIRA 1985 ---- ---- .01 .03 .02 .02 .08 1990 ---- ---- .01 .05 .02 .03 .11 1995 ---- ---- .02 .06 .03 .04 .15 2000 ---- ---- .02 .08 .04 .05 .19 CULU 1985 ---- ---- ---- .01 -- .01 o2 1990 ---- ---- ---- .01 ---- .01 .02 1995 ---- ---- ---- .01 ---- .01 .02 2000 ---- ---- .01 .02 ---- .01 .04 LUGAZI 1985 .01 .01 .03 .05 .01 .02 .13 1990 .01 .01 .04 .06 .01 .03 .16 1995 .01 .02 .05 .08 .02 .04 .22 2000 .02 .02 .07 .11 .02 .05 .29 KABALE 1985 ---- .01 .04 .15 .09 .24 .53 1990 --- .01 .06 .19 .12 .30 .68 1995 -- .02 .07 .26 .16 .40 .91 2000 --- .03 .10 .33 .20 .52 1.18 KASESE 1985 .02 .03 .04 .02 .06 .17 1990 .01 .02 .04 .06 .03 .08 .24 1995 .01 .03 .06 .08 .04 .11 .33 2000 .01 .04 .07 .10 .06 .14 .42 KABAROLE 1985 ---- ---- .01 .02 .02 .03 .08 1990 ---- ---- .01 .03 .02 .04 .10 1995 ---- ---- .02 .04 .03 .05 .14 2000 ---- -- .02 .05 .04 .06 .17 MINOR TOWNS 1985 .11 .23 .59 1.38 .88 1.46 4.65 1990 .14 .30 .75 1.71 1.10 1.80 5.80 1995 .18 .39 .96 2.25 1.45 2.38 7.61 2000 .24 .50 1.26 2.92 1.89 3.06 9.87 RURAL 1985 10.05 ---- ---- ---- ---- 10.05 1990 12.07 ---- ---- ---- ---- 12.07 1995 13.35 ---- ---- --- ---- 13.35 2000 14.62 ---- --- ---- ---- 14.62 Annex 3 - 52 - Page 14 of 15 6.2 Summary of Tile Demand Based on Population Growth 1985 1990 1995 2000 14 Major Towns 19.56 24.57 30.5 37.78 Minor Towns 4.65 5.80 7.61 9.87 Rural 10.05 12.07 13.35 14.62 TOTAL 34.26 42.44 51.46 62.27 7.0 Demand for Tile. Due to Backlog in National Housing Stoc (See Sec. 3.1, Backlog Estimate). 7.1 Scenario A 212 Units x Assumed 25X Brick Construction - 53K Brick Units 53K Units x 2200 Tiles (average tiled roof) 116.60M Tiles 1985 Demand for Tiles, 1985 116.60M Tiles Scenario B 95K Urban Units x 2200 Tiles (average tiled roof) u 209.00M Tiles 117K Rural tUnits x 750 Tiles (Type 'A' House) a 87.75M Tiles Demand for Tiles, 1985 296.75M Tiles 8.0 Estimate Scenarios (Order of Magnitude): 8.1 Optimistic Case - 1985 Residential Demand - Population Generated (see Sec 6.2) 34.26M Residential Demand - Backlog (see Sec. 7.1, Scenario B) 296.75M SUBTOTAL 331.01M Assume: Industrial, Commercial, Clerical & Public New Construction, Reconstruction and Maintenance 10-30% Residential Deand Assume: Optimistic Economic Climate: 301 x 331.01 99.30M Optimistic Case - 1985 430.31M Tiles Demand for Tiles, Optimistic Case, 1987 Estimated demand for 1985 430.M Annual increase since 1985 1986: 8% p.a. 34 1987: 8% p.a. 37 Total Optimistic Case 501M 53 - Annex 3 Page 15 of 15 8.2 Low Case - 1985 -Residential Demand-Population Generated (Ref. Sect. 6.2) 34.26. -Residential Demand-Backlog - Assume 201 Annual Absorption of Backlog Over 5 Year Period Use Average of Backlog Scheme A$B 116.6 + 296.75 x 201 - 41.33m 2 Assume poor economic Climate For Non-Residential New Construction, Reconstruction & Maintenance 10 x 75.59M 7.56 Low Case - 1985 83.15M Tile Demand for Tiles, Low Case, 1987 Estimated demand for 1985 83M Annual increase since 1985 1986: 81 p.a. 7 1987: 8Z p.a. 7 Total Low Case 97M Partial List of Referenced Materials and Documents: MHWD Report Survey - 10 Major Urban Centers 1984 MKU Entebbe Housing St - UNIDO Mission 1980 UN/HABITAT Pre-Investment Appraisal Mission for Uganda National Housing Development Programmes 1982 UNDP Building Construction Material Appraisal Mission for Masaka and Mbarara 1981 USAID Housing Policy Review in Uganda - Padco Mission 1984 IBRD Urban Study CRAMN - 54 - Annex 4 r '. .. -. .--.<.. . . - 71 making in Uganda TheWorldBank S !~~~ ~~ .-- - * ~ e r s - W =-- wrv * -f t ,+,~~~ ~~ -,-'' C,; i X ' - *'vA ' '& 1~-r- - r ^ * ., .. . ^ tr .... p Brick making in Uganda The World Bank - 55 - A SAMPLE OF PERIODIC KILNS Annex 5 Clamp Kiln 3-Wall Updraft Kiln Cross Section A A Rice-Rusks Fired Clamp With Blade Setting of Bricks Vertical Cross Section of a Periodic Downdraft Kiln - 56 - HORIZONTAL AND VERTICAL CROSS SECTIONS OF A Annex 6 HOFYHIN- RINGtKILN us Horizontal Cross Section of a Hoffmann Ring Kiln %'g;~~~~~~~4 Vertical Cross Section "A-All Of A Hoffmann Ring Rlln *5*..~~ ~ ~ ~ . - _- - 57 - BRICK AND BLOCK WITH FROG Annex 7 (Average Reduction in Weight: 8.5%) bricks blocks scale: 1:2 scale: 1:2 Ito 28 38--1 0 | a tll. 2ai L 3a E7 i 38 E rlf.H -6mm 30 28 IL . 4 1t7. 28 I I ref.He9O mm 290 . j4, l 1 40 -.81.51.5Wv 3 I 90~~~~~~~~~~~~~~~~~~~~~~~~~~~~~4 L FROG:8.56%V/V) V ROG: 8.57%(V/V) RELATIONSHIP OF OUTPUT OF CLAMP KILN TO KILN SIZEl-/ Annex 8 (Jrick Dimtasion: 290 X 0 x 90 mm; Weight 5.85 kg) Page 1 of 2 :op :empersrure t700 'C Number of Layers 6 +16 a 22 Number of Bricks 5300 Mass of Bricks 31.0 ton Well Fired / 542 Under Fired 3/ 462 ^op tmpe.rarur- o700 IC Number of Layers 6 +25 - 31 3 / \ Number of Bricks 16860 Mass of Bricks 98.6 ton Well Fired / 692 Under Fired 31 31X l1 ool_mo ul-es y ?op rvmpt.raruru Y11OO IC Number of Layers 6 + 25 -31 Number of Bricks 30840 / 4 ;.3 m / \ Mass of Bricks 180.4 ton Well Fired/ 762 \ Under FiredC3/ 242 \-ap.cQ jog I \1:\0 /7~~~~60 g6 t n t . ( g X . 1/ Occupied area in horizontal cross sections of clamp body: 852 of clamp shall (0.3m): 902. 2/ Firing breakage included. 3/ Damaged, Plastered bricks included. FOOT MDDULE OiPAC 0`KILN AnnexO (Firehole Area: 0.40 tn') PAn oe 2 Number of Bricks ' . - -*- - - *-.- - - per Layer''l Lt ' ~~~~~~~~~6 layers .t~~~~~~~~~~~~~~*IO 84 mu'75 . .~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~O Bric Dimen dos 90x10 0m 49 15001Imm Brick Dimensions: 290 x 140 x 90u Number of Bricks per Module: 264 Extra Bricks for Filling Gaps: 24 Bricks per Side Extra Bricks for Blocking Firehole: 30 Bricks per Hole - 60 - Annex 9 Page 1 of 3 Kiteredde Construction Institute Background 1. The Kiteredde Construction Institute (KCI) was established in 1980 by The Experiment in International Living (ZIL), a private voluntary organization, and the Bannakaroli Brothers, an African Catholic order with headquarters in Kiteredde in the Rakai District of Uganda. The Center was specifically designed to train young men and adults in construction skills using locally available materials. 2. Initial funding support was provided by the U.S. Agency for International Development (USAID) (1979-1981). Additional support was provided by the Canadian International Development Agency (CIDA), the Australian High Commission, Catholic Relief Services, and EIL. Land, work space and start-up facilities were provided by the Bannakaroli Brothers. 3. Training specialists from EIL worked side-by-side with the technical and construction personnel of the Bannakaroli order in all phases of planning and implementation of the project, i.e. from the design of the curriculum to the actual construction of classrooms, dormitories and work spaces. From the beginning, the emphasis of the program was on practical skills development, learning by doing, the preparation of trainees for jobs in the construction industry and in public works departments, and the placement of each student in wage- earning employment immediately upon graduation. 4. The Bannakaroli Brothers have utilized the excellent clays and other materials available in southern Uganda for the construction of their own buildings, as well as carrying out construction assignments for others. This knowledge of brick, tile, block and clay moulding; of efficient kilns and appropriate firing techniques; of masonry and carpentry; of tropical building design; of the use of local materials to make mortar, paints, plasters and other necessary elements of construction, in the absence of manufactured and imported materials, form the basic components of the training program at the KCI. Extension Activities 5. In January, 1985 EIL, in cooperation with the KCI, began the implementation of a three-year Extension Training Project, to provide training seminars and workshops in the development of the use of local materials for various groups and institutions in Uganda. During the six month pre-implementation period (June-December, 1984), KCI conducted several local materials development workshops for primary school teachers, Boy Scout leaders and Girl Guide leaders. The 250 participants from schools and groups in Rakai District received instruction in: (a) identifying clays and soils for brick-making; - 61 - Annex 9 Page 2 of 3 (c) brick moulding; (d) drying, stacking, curing of bricks; (e) kiln construction and kiln fuels; (f) kiln firing, operation and management; (g) solar drying, air-drying of bricks; and (h) basic practical instruction in the construction of foundations and walls for houses, classroom buildings and other structures. 6. The initial phase of construction of a Local Materials Demonstration Site and Resource Centre has been undertaken on the grounds of the KCI. This demonstration site is currently being utilized to train Ugandans in the use of local materials, and in basic building techniques. 7. The KCI is also providing technical assistance to the Busoga Multi-Sectoral Rural Development Program in eastern Uganda, which carries out development activities in 41 villageo, parishes and project locales. KCI, as part of its extension program, has assisted many Busoga villages in the construction of seepage wells and protected springs, and has provided training in the repair and maintenance of clean water sources and supplies. 8. The current KCI/EIL Extension Training Project at the KCI responds to numerous requests from educational and development-related institutions, contractors and builders, farmers and local citizens, for KCI to "extend" its knowledge to a wider constituency in the fields of: production of local building materials, clays, bricks, blocks, tiles, local cements, local paints, roofing materials, and in basic construction techniques using local materials. 9. In response to these requests, KCI, in cooperation with EIL, is expanding their extension, technical assistance and training services to cover up to 13 districts in Uganda. Graduates of KCI known as "Old Boys", have been hired by KCI to form a team of extension field work specialists to assist KCI in providing training and technical services to rural areas, to local institutions, to schools and to farmers. Extension Training Project Objectives and Goals 10. The objectives of the Extension Training Projects at the KCI are as follows: (a) continue to strengthen KCI's extension training capacity by constructing demonstration and resource centers that will aid in the dissemination of information on building techniques, and the uses and applications of local building materials; (b) conduct an ongoing needs assessment through community surveys to assess the problems in rural areas and to identify places where KCI can contribute skills training activities; (c) organize a cadre of KCI "Old Boys", prepared to serve as skilled training team, to design and carry out technical - 62 - Annex 9 Page 3 of 3 assistance, training and outreach activities by applying practically oriented skills, for the benefit of schools, institutions, groups and individuals; (d) more effective use of local materials for low-cost housing, and for the construction and repair of schools, public and commercial buildings, private homes, food storage and farm buildings, and other agricultural and livestock facilities; (e) upgrade and standardize materials for clay moulding, bricks, blocks and tiles; appropriate kiln construction and management; the use of supplementary kiln fuels; management of lumber supply; and the proper preparation, drying and seasoning of lumber; and (f) finally, improvement and protection of water sources and supplies; the construction and maintenance of wells, water catchment and water storage facilities. PROPOSED DIMENSIONS Po STANDARD BRItCKS AND BLOCKS-l Annex'10 - 63 - Number of Units per , Unit Weight of Bricks end Blocks In kg Strecher Wall; joints: 10 m Hantmae Extruded 10Densit 3 Density - 1850 kg/m3 DiAmenslons of Units No Cavity Perforation Horizon in V , Vertical: V tal: N Solid 85% Solid 10 20% 30% 60% - - - w#lJ 0 52 2.83 2.59 3.28 2.95 2.62 _ _ Na'.~ & sqt& j&rj ibe.I. (433/m3) 250 J11e t70 Vwe : 34 4.45 4.07 4 4.63 4.12 _ 2.06 standard Wo&l 283/m3) -~ --0 - --- - 33 5.85 5.35 _ _ _ 4.73 2.70 50o. bLo2k:22/0 t90g 140 tso 22 _ _ _ _ _ 7.36 4.21 _. * LS 290 .5c . bbocls tl68 2goo 140W 140 J - Tha Satarn u are-deslg ted aasonae n craa cions ! na recoinnanaTl of the Intermational Organization for Standards (ISO). 64- Ann"z 11 Page 1 of 3 //~ft '/, '// -,/ I , , /= ,, X // // ~~~~~~~/ ////di 1 //*///// 7,// 11-- M Ili,. PC, lUlil-=^nml-^ L- t ..I 4 ~~~~~~I EHUE, 5MEhUE.I~ w - ,.,1 1 ,,.... ............ ,!=L*\0 E~~~~~~~1o E- £ ,, Engineertng Bricks for KILN Body: 230 x 113 x 74 ;m Jotnts: 4 - Arch Brichs. 78 Bricks per Row: 230 x.113 x 74/65; Jotnts: 3.5 4 m Load of KILN Chamber: 9960 Standard facing Bricks, 230 z 110 x 70 mmsPERP: 202 Number of herck Blades per Chamber: 12: Number of Bricks per Blade: 830 Dimensions of Dried Green Bricks: 232.3 x 111.1 x 70.7 =me Weight Fired: 2.62kg Load Per Uamber: 26.1 ton TOP VIn OF A IlDT-1u- . Damn" MN FOR coN r- -- - -~ - _ _ _ -Z s, t-1~~~ . . ;' I q t l ¢ ~~~~~~5- ! mo V;--- ---4;-M I~~~~~~~~~~ ! Ss+z stt '*-,* > . a u s ;~~~~~~ * v . S- xi '1 *l *, l @,+ty' . ;;' ~Cf 4 <, I t ....................... _ . L : : : * : *~___ X_2_______ S 'f* * b7Io - _m JONWoow<+AO .vio -66- Annex 11 Page 3 of 3 m . P . | r 731°F ( W~~~~~~~~~~~~~~~I $I aI PENCE ~~~~~~~~~~~A?E14AC ... .... NS!ON s I ^. o.X .. .._.a . S_... *- * *- _ -1 jI ,P:aonut I g~~~~~~. *-* . - .j __...ii ttwia*^5 ii;. ._ ~.. __-, . El~~ 1.~' 6 ,i l, ,~~~~ I.IkS W _ rt* 3PIR SU PPLY b10 \ I ; ,( + ' -- '- 1 i~uPL S S . 1 - ----.1 1 1 ' 1~~~~~~~~~~~~~~~Ol-iN S41 N i I h- ffi l | ; .. _ . | , O~~~~~~~~~~~~~~RYaING "ILtD ~~I*-*- R I I. .lo:"ogts a I ------1 r 1 l 1I tS~~~ ,L~ 41_ I I*OO ,._ _ . ......t^AUF UAC?t __- - _ _ _ 0° 1p 2p [ O to See^te Annex 12 Page 1 of 24 - 67 - MODEL SMALL-SCALE, SEMI MECHANIZED BRICK AND TILE PRODUCTION UNIT TABLE OF CONTENTS SUMMARY ................................................ 68 IT. INTRODUCTION. ........** .....** ..*..****.*..*** .*****e*** 69 II. INROP8DUCTIANT¢¢¢¢v*******eooooo**************Oeooo** 69 II, MPRPOSED .O...0............... 69 Products.......................................... 69 Output............................................ 69 Plant Loation 69 Raw Materials....e.........................e...e.. 70 Process Design .......70 III. LAY-OUT OF THE PROPOSED PLANT....................... 72 Plant Area .............. 72 Structures and Buil4ings l. d i n gs................... 72 Stock Area for Fired Productsoducts............... 73 IV. KILN CONSTRUCTIONS..................... 73 V. MAIN MANUFACTURING EQUIPMENE.N.................... 0* 75 Mining and Storage of Raw Materia1s9erials#*...... 75 Feeding, Claybody Preparation and Shapinging#..... 75 Transport and Handling of Ware*.****.********** 75 Drying ~~~~~~~~~~~~75 Firining.. ................ ....................... . 76 Ancillery Equipment.u.i p m en.6... 76 VI. PRODUCTION PERSCUNEL ................. 76 VI. FUEL CONSUMPTION AND POTENTIAL FUEL SAVINGSN..... S... 77 VIII. INVESTMENT REQUIREMENT..***S.*.*******..... ........... 77 FIGURES 1 to 12 Annex 12 - 68 - Page 2 of 24 , 4 SUMMARY 1. One of the technical options available for improving the efficiency of entry use and the productivity in the small-scale, semi- mechanized brick and tile production units in Uganda is the substitution of existing worn out manufacturing equipment, particularly kiln., with more efficient means of production. 2. The design of the proposed small-scale, semi-mechanized brick and tile production unit presented in this Annex, provides the technical information necessary to prepare the final feasibility studies. The estimate of the cost is to help attract and negotiate with interested investors. It also provides the basis for procurement operation and construction planning. Considering the main production problems of this category of producers, much attention is paid to the selection and design of the kiln. Special features of the proposed eight - or ten - chamber downdraft kiln are its suitability for relatively small production capacities - an annual capacity for production of 2.1 million standard bricks (230mm x 110mm x 70mm), and 0.3 million roofing tiles (20 tiles/m2); its flexibility to use different types of fuels; and its potential for efficient use of energy. -69- Annex 12 Page 3 of 24 I. INTRODUCTION 1.1 The design of the following small-scale, semi-mechanized brick and tile production unit is a basis for the final feasibility studies, negotiation with interested investors, procurement operations and construction planning. II. PROPOSED PLANT Products 2.1 The plant will produce solid and perforated extruded standard quality clay bricks and blocks with several sizes, as well as clay roofing tiles. The design of the plant is based on the production of a standard brick with 201 perforations by volume, a length of 230mm, a width of 110mm, a thickness of 70mm and a weight of about 2.6 kg per piece. As such, one square meter of a stretcher wall will need 52 standard size bricks. For roofing tiles the provisional size selected has been 310mm x 240mm (gross), or 250mm x 200mm (net), requiring 20 tiles per square meter roof, with the weight of about 2.0 kg per piece. Thus, a packed row of tiles with a length of one meter will contain 34 tiles. output 2.2 Based on information provided by brick makers in the existing small-scale, semi-mechanized, clay brick industry of Uganda, the output of the designed plant has been selected at 130 tons of fired ware per week. Depending on the actual range of products made, the output of the brick and tile production unit will vary from 120 to 130 tons of fired ware per week, of which about 12 tons per week will be roofing tiles. These figures correspond with a yearly output of 2.1 million standard bricks (230trw L 110mm x 70mm) and 3C0,000 roofing tiles (20 tiles/m=). However, thu designed lay-out of the factory allows for a possible doubling of the output in the future. Plant Location 2.3 It is assumed that the plant will be located near ample and suitable raw material deposits with adequate source of process water. It is further assumed that the site area is flat, well above water table and well drained. The area must have stable subsoil with acceptable load bearing properties as well as necessary infra-structure, i.e. electricity, man-power and roads for the transportation of the ware to brick and tile market. Annex 12 -70- Page 4 of 24 Raw Materials 2.4 A process design must be based primarily on the technological behavior of a specified raw materials mixture. Therefore, it is assumed that the test results of the raw material prove the suitability for the manufacture of perforated bricks and tiles. The following data can be used for technical calculations: Bulk Densities: Clay deposit, undisturbed 1950 kg/m3 Clay lumps, loosely dumped 1100 kg/m3 Clay in a 3 meter high stockpile 1600 kg/m3 Firing Shrinkage: 1X Total Shrinkage: 7Z Weights of a Standard Size Brick (230mm x 110mm x 70mm): Just shaped, wet 3.5 kg Air dried 2.9 kg Fired 2.6 kg Process Design 2.5 Mining and Storage of Raw Material, Claybody Preparation and Shaping. It is assumed that mining and storage of raw material, claybody preparation and shaping are mechanized; mining and storage of raw materials are preferably done in the dry season and the raw materials are stored in a spacious shed at the plant site. 2.6 Preparation and shaping are scheduled for one shift, 8 hours per day (including one hour lunch break), for 5 working days per week, and 49 weeks per year. The clay clots for the weekly roofing tile production are extruded each Monday morning and transported to the tile manufacturing unit where they are stored and used for the tile making during the week. The rest of the week, the extruder is used for brick making. 2.7 Handling of Raw Materials and In-Plant Transportation. The handling of raw materials and in-plant transportation of wet, dried and fired ware is done by hand, using simple means of transportation like trolleys with solid tires and wheelbarrows. Therefore, good condition for the plant's internal roads is a prerequisite for an efficient brick and tile production. 2.8 Drying of Bricks and Tiles. The bricks and tiles are dri.ed in drying sheds. Por the initial drying and stiffening of the bricks, they are placed in racks. This period covers 3 working days. The bricks and -71- Annex 12 Page 5 of 24 blocks are then stacked in open settings. It is assumed that the total drying process will take a period of 15 working days. 2.9 For the initial drying of the roofing tiles, the tiles are placed on wooden supports and subsequently are set in racks for a period of 3 working days. Then the tiles are set by juxtaposition in rows on the floor of the shed. As far as weather conditions permit, the final drying of the tiles can be improved by exposing them to direct sun radiation in the open areas in between the drying sheds for bricks. It is assumed that the total drying process of the tiles will also take a period of 15 working days. 2.10 For the transport and handling in relation to the natural drying of bricks and tiles, the working hours are in accordance with those for the shaping of the ware. 2.11 Firing of the Ware. The air dried bricks and tiles are fired in a downdraft chamber kiln, having eight chambers, each with a capacity of 10,000 standard size bricks. A special feature of the recommended kiln is the possibility to fire the kiln with all types of fuel; i.e., split wood logs, coffee husks, rice husks, papyrus, peat, coal, oil and gas. Another important feature is that the kiln can be operated continuously as well as periodically, depending on the actual supply of dried green ware. As such, from full capacity down to half of the capacity, the kiln can be operated continuously by diminishing the number of bricks and tiles fired per chamber. Below 50% of capacity, the kiln chambers can be operated periodically. 2.12 The energy consumption of the kiln with continuous operation will be slightly higher than the energy consumption of a normal Hoffmann ring kiln, the latter also being very efficient in terms of energy use, but not having some of the special features mentioned above. A Hoffmann ring kiln is, for instance, less suitable for the use of fuel wood. The main reasons for the selection of the proposed type of downdraft kiln are the rather low production level and the desirable flexibility of small- scale, semi-mechanized produccion units as envisaged in this Annex, as well as its low fuel consumption per ton of ware. Figure 2 illustrates the firing schedule for a continuous operation of the eight-chamber kiln. The planned production is five-chamber loads per week. 2.13 The waste gases are exhausted by a centrifugal fan. In case of interruptions of power supply, an electric generator with a capacity sufficient for the fan and the illumination of the top floor of the kiln can be used. For bridging short periods of power interruption, the fan can also be bypassed. 2.14 The size of the kiln is based on the assumption that the ware presents a normal firing behavior. If, for instance, very thick raw materials are to be used however, it is recommended to erect a ten- chamber kiln, instead of an eight-chamber kiln. The two extra chambers can be used for final drying of the ware utilizing the hot air extracted Annex 12 -72- Page 6 of 24 from the cooling zone. The design of the kiln offers the possibility to install hot air ducts for this purpose. The steel ducts can be buried alongside the main chimney channel. In addition, a ten-chamber kiln has to be considered also if the ware is sensible on cooling. In this case, the two extra chambers can be used to lengthen the cooling zone. The firing of the kiln is a continuous operation, i.e. three shifts per day, 7 days each week. 2.15 Filling and Emptying of the Kiln Chambers. Hand operated trolleys are used to transport the dried green ware to the kiln. The setting of the ware in the kiln and the emptying of the kiln chambers is done by hand. 2.16 In consequence of the restricted setting and de-hacking front in kilns, the filling of one chamber per day and the emptying of one chamber per day, during 5 working days per week, have to be a continuous operation during about 10 hours per day. It is recommended to work with two teams, for transport and handling, in two shifts, supplemented during resting periods of the teams by workers who also have other duties. The setting patterns of bricks, blocks and roofing tiles in the kiln are specified in Figures 4,5,6 and 7. 2.17 Fuel Supply. Fuel transport to the kiln occurs from a central fuel stock at the plant site. Here, tbe fuel is prepared for feeding the firing zone of the kiln (thick and long wood logs have to be sawn and split to logs measuring about 330&m x lOOmm x 100mm; rice husks and coffee husks have to be packed in jute sacks; papyrus stalks have to be cut to 1 meter length. The prepared fuel is transported to the top of the kiln, with hand operated trolleys, using a simple winch to facilitate the haulage of the trolleys up to the kiln top. The fuel is stored alongside of the kiln top floor where it is ready for use by the stokers. III. LAY-OUT OF THE PLANT Plant Areas 3.1 The lay-out of the brick and tile factory is illustrated in Figure 1. The plant area has a length of 165m and a width of 65m. In case of a possible future doubling of the production, the width has to be extended to 90m. The plant roads are indicated with center-lines. The whole area is well drained and bordered by a fence. Structures and Buildings 3.2 The following structures and buildings can be distinguished: (a) an office building, 126 m2; 2 (b) a roofed shelter for fuel storage and fuel preparation, 350.2; (c) a roofed shelter for a 3 meter high stock pile of raw materials, sufficient for a production period of 7 to 8 weeks; 73 Annex 12 Page 7 of 24 (d) a partially gnclosed structure for claybody preparation and shapingg 31Sm ; (e) a totally enclosed structure for maintenance1, spare parts, power supply, water supply and lavatories, 112m ; (f) a drying shed, with thatched roof for roofing tiles, 60m x 12m, constructed as illustrated in the Figures 10 and 12; (g) a partially enclosed structure for the manufacture of roofing tiles, 100.2; (h) ten drying sheds with thatched roofs for bricks and blocks (20m x 7.5m), constructed as illustrated in the Figures 10 and 11; and (i) a roofed shelter for an eight-chamber down-draft kiln, 23.5m x 16.5m as illustrated in the Figures 3 and 8. Stock Area for Fired Products 3.3 The area for storing fired products is about 500m2. By stacking bricks to a height of about 1.5 m, the area can store about 400,000 bricks (230mm x 110mm x 70mm), corresponding to 8 weeks of production. IV. KILN CONSTRUCTION 4.1 The main components of the structure of the proposed eight- chamber down-draft kiln are illustrated in the Figures 3, 4, S, 8 and 9. The kiln body can be erected from solid homemade engineering bricks and homemade mortar. Refractory concrete however, has to be used for the walling of the various holes in the kiln body. The kiln must be built on a stable subsoil, well above the water table. 4.2 The thickness of the joints in the brickwork should not exceed 5mm. Therefore, the bricks must be dimensionally consistent and have well coordinated dimensions. As such, these bricks are slightly different from those used for brickwork in houses. The proposed dimensions are 230mm x 113mm x 74mm, giving 4mm joints. The bricks can be handmade or extruded. It is recommended to use professional advice in finding the best possible raw materials mix for the manufacture of bricks and mortar. Resistance to deformation under load at high temperatures and spalling resistance are important properties in this respect. 4.3 The bricks could be fired in existing kilns or clamps and sorted out into three quality classes (prime, select and common), for distinct applications in the kiln structure. The building materials needed for the construction of an eight-chamber downdraft kiln are estimated as follows: Annex 12 74 Page 8 of 24 Quality... Part of kiln body Type and Size (mm) class.... Amount - Chamber walls and arch bricks: 230 x 113 x 74 prime.....78,000 wedges: 230 x 113 x 74/65 prime.....20,000 - Connecting channels bricks: 230 x 113 x 74 prime..... 3,000 wedges: 230 x 113 x 112/74 prime..... 4,500 - Chimney channel bricks: 230 x 113 x 74 prime..... 4,000 wedges: 230 x 113 x 112/74 prime..... 3,000 - Chamber gates bricks: 230 x 113 x 74 select.... 4,500 wedges: 230 x 113 x 74/55 select.... 5,500 - Support structures bricks: 230 x 113 x 74 select....60,000 - Outer walls and ascent bricks: 230 x 113 x 74 select .... 40000 - Foundations bricks: 230 x 113 x 74 common....80,000 - Casings arch holes refractory concrete prime..... 15 m3 -Brickwork joints clay mortar - .....7 7Om3 - Filler in structure mix of sand and clay - ..... 300m3 4.4 The estimated total number of bricks required (230mm x 113mm x 74mm), are 270,000 and the total number of special shapes are 33,000. 4.5 Other components required for the kiln construction are: - 104 refractory grate bars (650mm 8 230mm x 110mm); - 44 firehole covers (150mm 0); - 24 gas outlet covers (250mm 4); - 8 gas inlet covers (400mm 0); - 2 sets of bipartite manifolds (see Figure 9): - 1 draft control damper (960 x 500mm); - 1 man hole cover (960 x 500mm); - 1 set of steel ducting with bypass and 2 dampers; - 1 steel exhaust pipe (470mm 0, length - 10m); - a centrifugal fan, capacity 7000m /h, total pressure 1000 Pa, maximum temperature 200 *C, electric motor = 3 kW; - a generator (5 tot 10 1W), to guarantee power supply to the fan In case of power interruptions; and - 10 oil lamps for emergency illumination. 75 Annex 12 Page 94of 24 4.6 The feeding of the fireholes with fuel is done by hand, using a simple hook for lifting the firehole covers. Visual process control is supported by movable instruments indicating the temperature (range 0-500 eC, probe length 2500mm) and the draught (range 0-250 Pa) in the pre- heating zone and by an instrument indicating the temperature of the exhaust gases (range 0-500 eC, probe length 250mm). V. MAIN MANUFACTUDIUG DQUIPMKET 5.1 The Main equipment required for manufacturing at various stages of production are as follows: 5.2 Mining and Storage of Raw Materials: (a) one excavator; (b) one all purpose truck; and kc) spades. 5.3 Feeding, Clay Body Preparation and Shapini (a) one box feeder, with a clay compartment, a smaller filler compartment and a rotating scraper; Cb) one double roll crusher; (c) one set of smooth rolls; (d) one double shaft mixer; ge) one deairing extruder, 350mm 0 complete (capacity at least 25 perforated bricks of 3.5 kg each per mirsute); (f) five dies for 5 product types; (g) one harp cutter and take-off conveyer; (h) one roofing tile sliding frame screw press (capacity at least 3 tiles of 2.7 kg each per minute); (i) four conveyors; (C) steel structures for machinery; (k) electric motors and control systems; (1) equipment for water supply; (m) 4000 wooden supports for roofing tiles; and (n) concrete foundations for machinery. 5.4 Transport and Handling of Ware and Fuel: (a) 25 trolleys with solid tires, each capable of transporting 150 standardized size bricks 230mm x 110mm x 70mm in wet, dried or fired condition; (b) 10 wheelbarrows; and (c) one winch. 5.5 Drying See paragraph 3.2, items f and h. Annex 12 Pagel1of 24 -76- 5.6 Firing See section IV 5.7 Ancillary Equipment (a) equipment for maintenance and repairs; (b) an ample set of spare parts; (c) a power supply unit; (d) equipment for fuel preparation (sawing and splitting equipment, bags); (e) office inventory; and (f) sanitary installations. VIa. PRDUCTION PSLOSE 6.1 The number and duties of the personnel required for the production function are as follows: Number of Task Persons Function - Managing the production 1 manager - Excavation 2 drivers 2 laborers - Preparation and shaping bricks 2 laborers - Loading trolleys with bricks 1 laborers - Transport of bricks to dryer 3 laborers - Handling of bricks in dryer 3 laborers - Shaping of tiles 3 laborers - Transport of tiles to dryer 2 laborers - Handling of tiles in dryer 1 laborers - Transport of bricks and tilis to the kiln 6 laborers - Kiln loading 6 laborers - Kiln service 2 laborers - Kiln firing 4 strokers - Fuel preparation and supply 3 laborers - Unloading kiln 6 laborers - Brick and tile storage 4 laborers - Maintenance and repairs 2 mechanics - Area and road maintenance 1 laborers - Administration 1 administration Total number for production persennel 55 persons Annex 12 X X - 77 4 Page 11 of 24 VII. FUEL CONSUNPTION AND POTENTIAL FUEL SAVINGS 7.1 It is estimated that the heat consumption of an eight-chamber downdraft kiln as specified in this proposal will amount to 3,000 MJ per ton of well fired ware when operated continuously at full capacity and to 6,500 NJ per ton of ware when the kiln is operated periodically. TLU heat cpnsumptions correspond with fuelwood consumptions of 0.4 m3 dnd 0.85 m per ton of fired ware, respectively. In comparison to proposed kiln, the present small-scale, semi-mechanized brick and tile production industry in Uganda is using periodically operated updraft or downdraft kilns without effective draft control, fired with fuelwood, coffee husks or rice husks. The equivalent fuelwood consumption of these kilns, based on four inspected units, are estimated at 1.8 m' fuelwood (+ 20%) per ton of fired ware. Therefore, the potential fuelwood savings, by substitu- tion of existing worn out periodic kilns with an eight-chamber downdraft kiln as specified in this proposal, will amount to ')-601 when the kiln is operated periodically, and to 70-80X when the kiln is operated continuously at full capacity. VIII. INVESThENT RDQUIR3EENTS 8.1 The mission estimates of the investment cost of the recommended brick and tile units, i.e. the cost of investment for a new, small-scale, semi-mechanized brick and tile production unit with the output of 130 tons of fired ware per week, as US$ 1.25 million, which in broad catagories, are indicated in the following table. -78- Annex 12 - 78 - Page 12 of 24 ESTINATED COST OF THE RECOMNENDSD BRICK AND TILE PLANT (US$) Description Foreign Local Total Foreign Exchange Components Machinery for excavation and storage of raw materials including excavator and truck 70,000 - 70,000 Machinery for preparation, extrusion and cutting 470,000 - 470,000 Imported component cost of a multi-fuel, downdraft eight-chamber kiln 40,000 - 40,000 Spare parts 100,000 - 100,000 Ancilliary equipment 25,000 - 25,000 Transportation to Kampala including insurance 150,000 - 150,000 Supervision of installation and commissioning 100,000 - 100,000 Contingencies 45,000 - 45,000 Subtotal ls0o0o00 - 1,ooo,ooo Local Cost Components Land and site preparation - 20,000 20,000 tiln construction - 15,000 15,000 Shed for kiln and drying of the bricks and tiles - 22,000 22,000 Clay preparation building - 15,000 15,000 Office building - 10,000 10,000 Electricity and telephone connection - 9,000 9,000 Water supply and pumps - 2,500 2,500 Machinery and electrical installation - 35,000 35,000 Office furniture - 2,000 2,000 Other local materials including bricks - 25,000 25,000 Pre-operation expenditure - 50,000 50,000 Contingencies - 44,500 44,500 Subtotal - 250,000 250,000 Total 1,000,000 250,000 1,250,000 Ains,irrA Mission estimates. - { *tXtt @ 5^kAnnex 12 _ 1 - , , Page 13 of 24 , _ _ ~~~~~~ ~~~- p : OfftCI SJILOI'41 ... _ .. 1 ' L ~~~~~~~~~S'C:t ^c .E. It L I I~ r S $ Y | .. . _ .1 | | ....................... P452Ut'S l ~ *1 .: I --~~~~~~~~~- OA AERSPL * 'K~IS 6 0 S? ...... ..._.r. ! AaPIE'5A sCI ij -i- -- - 3 V. . TORy 1 Jb4 . I IIL"t_ - -1 Si7 zs N | i --- - -ZM ----.--- ii R I.. .. 0 ~~I | .~ . i l I, R PR"ING SHtO N .. | i1! 3 ~~~~~~~~~~~~~~~~~~.. . ANPA'.a I . . . = 1 , Figure 2 PRODUCTION SCHEME OF AN EIRT-CHMNER D(WNDRAP1' KILN WIT 50,000 BRICK EUALENTS PRODUCTIONII CWA.4S2 WEEIK A WE.E * 'a bfiE K C Wf MO __ Ws TN F2 5A SI M. T1 v1 r, It SA 40 | F| 1-~~~~~~ 0Xi X \;s j ~filling chamer, bricking up door '.9~~~~~~~~~~~~~~~~~~C _. _~ ~ ~ ~ ~ ~~~~~~~~~~~~~~. P' /.preheating ware by combustion gases :P~~~~~~~~~~~~~~~~~~~' w ~firing, tuel supply Z> g- cooling. (cooling holes in top of chamber closed) 0 o \C163 cooling, (cooling holes open) S" end colloing, opening door, reoving door * - - emptoing, cleanin, sealintg chamber, reloriog as8 from ash p±t next chamber Fimure 3 TOP VIEW OF A MLTI-FU DO nRAPT mL FR coNTnuOs sm P O?U-OPAION WMT EIGNT -- -- --- L~~~)~ eV * 4. . ' i * t ; +s fl + + 6-tt +~e _ r . ' * ;, ; t ~' ; ..... cr.A...i. - _ .._ _,,_, !..................... Lt * . I. + + * 4-4..- . *8-F -1 s ww L_ __ .1 vein I;K::f w , , 4, 0 *n ,' \. -118 e502 _~~6. .9 4 . .4 1 'S * ' - '' I o'-'|w4^wa Annex 12 I49 -Pagpe 16 of 24 1 D i r> I I o II I* -, I -I- _ , ij, / J i iH z ; /w~~~~~/ / / 4t , KI I I/ ",14Z' / / , - /,s,^w,0w1 7 i~~~~~~~~~~~~~~~~~~~~~/ //i t1 '1 g'S 8 Ug sa 1ll-l!,- I ___________.JZa~~ 1700 Engineering Bricks for KILN Body: 230 x 113 x 74 um; Joints: 4 mm Arch Brichs, 78 Bricks per Row: 230 x -113 x 74/65; Joints: 3'5 -4 Load of KILN Chamber: 9960 Standard facing Bricks. 230 x 110 x 70 mm$PM: 201 Number of I ck Blades per Chamber: 12: Number of Bricks per Blade:- 830 Dimensions of Dried Green Bricks: 232,3 x 111.1 x 70.7 amm Weight Fired: 2.62kg Load Per Chamber: 26.1 ton HORIZOTAL CROSS-SECTTlM BB OF A CHAM OF A - MLTI-UL DODRAFT CONTINUOUS OR PEODIC OPERATION - /,47~~~// /Y.~~~V ~~7V >~~;7;2-V .c .._ ._ , -//y . |~~~~~~ ; -1 - 1 _. AA w f ., ^| :.+gI 4801 1~~~~~~~~~~ _ / ( joo) rv - _ s ,~ft rA ft mm.~~~~~~~~~~~~~~~A ..~~~~ ~ .. .. - .I - Q E _____ -~ r lL i: :I-riivrrr7z ,/,w Annex 12 - 84 Page 18 of 24 Ftaure 6 SETTING OF BLOCKS, 290 x 140 x 140 mm, IN A KILN CHAMBER / \ / ' ' i I I I I . /~~~~~~~~~~A00ov /# Mt".I| ~~~~~, . . . ALTERNATIVE LOAD OF KILN CHAMBER- 3240 BLOCKS 290 x 140 x 140 am, PER?: 30o NMER OF BLADES PER CRAMBE: 10, GAP BETWEEN BLADES: 70 am NUMBER OF BLOCKS PER BLADE: 324 DIMESIONS OF DRIED GREEN BLOCKS: 292,9 x 141.4 x 14.1 sm.,WEIGHT FIRED: 7.36 kg LOAD PV.R C.RA?R! 2. . . TM - -5 Annex 12 Page 19 of 24 Fisure 7 COMINED SETTING OF BRICKS AND ROOFING TILES IN A KILN CHAMBER 1e~~~~~~~~~~f EPAPS 19X j L+~~l - . I I . I T I i!i I I CI * 6a ? 4j-|> it ;I | | _ i j I !; '* JAI ALTERNATIVE 'LOAD OF KILN CHAMBER: 12 Blades, Each Consisting of: 710 Bricks, 230 x 110 x 70 m Plus: 102 Roofing Tiles, 310 x 240 _m (20 tiles per _ Roof) (Setting Density: 34 Tiles per meter) LOAD PER CHAMBER: 12 x 710 - 8520 Bricks = 8520 x 2.62 kt- 22,3 ton 12 x 102 - 1224 Tiles = 1224 x 2.00kt" 2.4 ton TOTAL LOAD 24,7 ton T*Tl "tMUMCM 5 CRAMBERS PER WEEK a 42600 BRICKS t230 x 110 x 70 mm) Plus: 6120 Roofing Tiles (20 tiles/m2) ANNUAL KILN CAPACITY (49 wEES, LOSSES LEFT OUT oF ACCOUNT) 2,1 Million Bricks (230 x 110 x 70 mm) Plus 0.3 Million Roofing Tiles(20 tiles/m Figure 8 165099 150000- _ B 0 n l 1 wI - I I lr k W @n n 1 1 S ¢ >Wm / S< / { l i i~~~~~1 °l e.A^ ' * r^ = >-"s--tt- L~~~~~~~~~~~~ 87 - Annex 12 Figure 9 Page 21 of 24 BIPARTITE TRANSPCBTABLE MANIFOLD POF EXTRACTING WASTE GASES FROM THE KMN !Ar..TAL: St 37/1mm 2)AO -120 ~~~ °r8__L Oii7 l n _ n t, ,. , ' t~~~~~~~~~~~~~i4i- - - 0 1000 gaoo I * I * * I . 4V4AV imm - 88 - Figure in Annex 12 PRE-DRYING OF FRESH BRICKS AND FRESH ROOFING. TILES Page 22 of 24 IN RACKS DURING TRE FIRST THREE WORKING DAYS 24tS~~~~~~~~4 i-. 130AIV< =~~~~~~~~~rT r II ~I ii 298 U& e de *~~~~~~~~~~o 11 3 - Jr N I%=.MR - ,t-wSflovia.qJ I ._ R1A 1 PR I . _ _ i~~~~~~~~~~~ I III ii I £1C: SI I S A IIEt ,I Lg _t 'I ' NUMBER OF RACKS FERPR wE-flIYT fli RQl 120 NUMBER OF RACKCS FOR PiE-DRYING OF TILES : 40 - 89 -, Figure 11 SHEDS FOR DRYING OF BRICKS Annex 12 DRYING SCHEDULE FOR BRICKS Page 23 of 24 ± . H - - ___ I IEiZI~oz0 13 1- 1 I ______ I - I ~~~~~~~~~~~~1 tj 6/88 Thailand Accelerated Dissemination of Improved Stoves and Charcoal Kilns 9/87 079/8? Rural Energy Issues and Options 9/85 044/85 Northeast Region Village Forestry and Woodfuel Pre-Investment Study 2/88 083/88 Togo Wood Recovery in the Nangbeto Lake 4/86 055/86 Uganda Fuelwood/Forestry Feasibility Study 3/86 053/86 Energy Efficiency Improvement in the Brick and Tile Industry 2/89 097/89 A MAP SECTION tt 32' 33e 0o |ovw Ao S _U D A N4 |UGANDA Ka*6cwq - Molor Roods 4-.-Roilroads 30 Rivers 4, ARU ' I OT 30 OD District Capital$ District Boundories Internationol Boundaries MORO' ni ) Pak~~~~~~~~C a 23 60 75 100 ILOIUS bt AOROTO ' -1 APAC~~~~~~~~~~~~~~~~~~MKPNO1k -2- < < A J APAC *Ad ySOROTt. < V . , 2. #A I DI~~~~~~~~~~~~~~~~~~~~~CMCbi 'AI vI s~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~' < or ,. wIvd, B 7. _ < >~~~~~~~~~4 VW1 RO AfV I7 BAL > ETHOI "- ot The PWoC.Cd bM 0 r~~~~~~~B JWND\ s- ( J*u T I MUB 'ND *--- UKON OIOnhufee Ct. V*W "oSnr d Io.W t.-b dA!w00 C' 000wb0 Of Gi -h bx-ft~~~~~~~~~~ 33' .0. KASE A /MA AK '-'C. ~~ETHIOPIA RUKUNG~~~~~I) RRRAKAI' RAR ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~~~~~~~~~~~~~Aa 9