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Bricks, pavers from construction debris

Around 2,300 tonnes of construction waste is generated in Mumbai,


everyday. Authorities in the country's financial capital have very little clue
about how to deal with such staggering amounts of solid waste. In September
2005, the Municipal Corporation of Greater Mumbai (MCGM) did issue the
Demolition and De-Silting Waste (Management and Disposal) guidelines. But
there has been little enforcement at the field level. Consequently, the debris
ends up in dumping grounds, where it mixes with other waste rendering them
unfit for treatment. But now, a decentralized solution for debris management,
promoted by the Youth for Unity and Voluntary Action (YUVA), offers hope.

The initiative has the support of City and Industrial Development Corporation
(CIDCO), the land owning and planning authority of Navi Mumbai. The
collaboration has resulted in the formation of CIDCO - YUVA Building Centre
(CYBC) that has recycled over 1,500 tonnes of waste in the last four years.
That's a small amount, but the project holds promise if given the right push.

Crushing and powdering The debris has been recycled into construction
material such as bricks and interlocking pavers. An electric-powered machine
basically used in pharmaceutical and chemical industries has been modified
for the purpose. Cement and water are other inputs. The debris is sourced
from construction sites and is broken down into particles, 30-40 millimeters
(mm) in diameter. The particles are then powdered down by a pulverizing
machine. Special screens enable the machine to ground the particles to
desired levels of fineness. Coarse aggregates around 10 mm in diameter, for
example, require screens with large gaps. The dust controller sections of the
machine filter out unwanted light materials like wood particles and sundry
other organic items.

Cement and water is then added to the pulverized material to mould it to a


brick-like shape. Moulded bricks are then cured (hardened by repeated
wetting and drying) for 14 days and then sun-dried. Shashank Ninave,
principal of L S Raheja College of Architecture, Mumbai, approves of this
method. "Over a period, all waste material loses its ability to bind. But adding
cement reinforces the debris's binding qualities and it can be reused to make
other products, he says. CIDCO and Strucwel Laboratories, Mumbai, test the
products for their compliance with Indian standards on moisture absorption,
compressive strength and abrasion.

Teething problems Setting up the plant costs around Rs 2.5 lakh. It can
recycle around a tonne of debris in a day. YUVA gets its debris free and
people who supply the waste are given discounts on the products. "One
recycled brick costs Rs 1.35 and pavers cost Rs 16 per sq ft,' explains Bejoy
Davis, manager CYBC. He rues that the recent increase in cement prices has
made things difficult for YUVA.

"Increasing demands of regular earthen bricks are being fulfilled at the cost of
agricultural land. Many farmers in Mumbai's outskirts have become brick-
makers and large tracts of fertile land have become barren. Loss of energy
during transport is an added liability. In such a situation, debris recycling is
both economical and ecological,' says Davis. Two community centres in
Rapar, Gujarat, one such centre in Mumbai, and a few other buildings in the
country's financial capital have already used the recycled debris. But the
project is facing teething troubles. Most builders claim they have not heard of
this initiative. "Has the Central Building Research Institute certified it,'asks
Shankar Desai, chairperson of Builders Association of India, Mumbai. Other
builders too say they can't use the recycled debris till an authorized
government agency certifies it.

Davis also points to other problems. "We need to set up at least one unit that
can recycle 50 tonnes of debris in a day. But getting funds has been a
problem. The recycling unit should be supported by MCGM's infrastructure.
That doesn't always happen. The debris delivery is not very efficient,' he
says. The CYBC manager says that some municipal authorities did visit his
organization’s demonstration project and S S Shautriya of the municipality's
solid waste management department seemed impressed by this technology.
The municipality also suggested that YUVA rope in private players. But the
authorities haven't offered anything more than this.

Debris to Development
by kedar — last modified 2007-11-30 11:27

The CYBC developed debris recycling techniques to decrease the environmental degradation caused by
construction practices in India. Our processes engender a number of environmental benefits: Recycling
debris diverts waste from the landfill; it also provides an alternative to conventional building materials,
whose production causes environmental degradation. What’s more, our debris recycling methods are
low cost, allowing us to sell our concrete masonry at prices substantially below market rates.

If you are building in the Greater Mumbai area, we can supply your project with high quality recycled
masonry manufactured at our Debris Recycling Plant in Kharghar, Navi Mumbai. We will shortly be
expanding our ventures to provide debris recycling services directly at Mumbai’s construction sites,
using portable debris recycling machinery. This service can save your project on both waste disposal
and new materials costs. Contact the CYBC for more information on incorporating our products and
services into your construction projects.

There are a host of reasons for organizations to utilize debris recycling as part of their waste
management and construction practices. Read on to learn more about the environmental problems
debris recycling addresses, and about the CYBC’s products and services.

Debris Recycling: Reducing Waste & Providing Alternatives

The pace of new development in Mumbai, and indeed across all of India, is staggering. The Municipal
Corporation of Greater Mumbai (MCGM) estimates that each day in Mumbai, construction generates
more than 2000 tonnes of waste - this figure is growing rapidly. The MCGM reports that within a decade,
Mumbai’s landfills will reach their capacity.

In a city starved for space, finding socially and ecologically responsible waste dumping grounds is next
to impossible. If we do not adopt recycling practices, future dumping will likely occur in Mumbai’s
mangroves, the city’s last remaining uninhabited low-lands, and other ecologically sensitive areas.
Dumping in mangroves destroys their beauty and biodiversity. Moreover, such dumping decreases the
city’s storm water drainage capacity, leading to flooding, and eliminates the protection mangroves
provide against storm surges and tsunamis.

In addition to the generation of waste, the demand for many common construction materials negatively
impacts our environment. The production of kiln fired clay bricks is especially harmful. Construction in
Mumbai uses 18 lakhs of clay bricks every day. These bricks are made of baked topsoil, mined from the
prime agricultural lands surrounding the city. The removal of topsoil leads to severe soil erosion, and
devastates these lands’ agricultural potential. Furthermore, brick kilns are typically fed with very dirty
fuels, such as coal or old tires. Brick kilns contribute greatly to air pollution where they operate and
produce relatively large emissions of the greenhouse gases that cause global warming. Producing virgin
aggregate concrete also incurs environmental effects – it requires the mining of sand and aggregates
that degrades the landscape.
For India to shift towards sustainable, healthy development, we must find construction solutions that do
not degrade our ecosystems. Debris recycling is one such solution: it makes use of waste that would
otherwise be dumped in landfills, and lessens the demand for environmentally unsound building
materials.

The CYBC’s Products: Proven Quality

The CYBC produces high performance concrete bricks, blocks, street pavers and construction-grade
sand using 100% recycled debris aggregate. Our products have been used in projects throughout Navi
Mumbai and Western India – check out our photo gallery to see a few examples of construction using
the CYBC’s masonry.

The CYBC prides ourselves on the quality of our recycled debris products. Independent laboratory
testing by CIDCO has shown the CYBC’s concrete bricks to be significantly stronger than clay brick. Our
pavers too exceed industry strength standards, and feature high-traction, non-slip surfaces; they can be
customized to infiltrate storm-water, adding to their environmental benefits. Recycled debris sand is well
suited to use as sub-base for street pavers, as pipe bedding, or for other fill applications.

Our Services & Community Outreach

The CYBC currently provides Greater Mumbai with high quality, affordable recycled debris masonry,
manufactured at our Debris Recycling Plant in Kharghar, Navi Mumbai. We will shortly be expanding to
provide debris recycling services directly to construction sites. Our service will save construction
projects on both waste disposal and new building materials’ costs, while lowering these projects’
environmental footprint.

Members of industry, civil society, government and the general public are welcome to tour our debris
recycling plant. We hope to spread knowledge of debris recycling processes, and see this practice
adopted widely. The CYBC is willing enter knowledge sharing partnerships with agencies interested in
using or propagating debris recycling.

Contact the CYBC to enquire after our services, arrange a visit to our Demonstration Plant, and to learn
more about the Debris to Development process.
Contact Us: The YUVA Centre Sector 7, Plot No. 23, Kharghar, Navi Mumbai 410 210
Tel: +91 (22) 2774 0999 / 90 , Fax : +91 (22) 2774 0970

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