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STRUCTURAL ELEMENTS
Brick is a natural, quality and maintenance-friendly product which is durable during all phases of its life cycle
most efficient in Europe – significantly reducing the carbon impact of each brick manufactured on the site compared with its current factory. The new factory features state-of-the-art automated processes that will minimise the plant’s environmental impact. Meanwhile, as part of its mission to achieve net zero business practices, Forterra has teamed up with textiles disposal company Avena to develop a workwear recycling programme across its UK sites. Like Forterra, brickmaker Ibstock is determined to cut carbon emissions and is aiming to create the world’s first net zero brick factory for ‘Scope 1 and 2’ emissions. It is hoped that a combination of reduced process emissions and greater thermal efficiency will cut the carbon intensity of bricks produced at the site by 50%. The remaining emissions will be offset using high quality emission reduction projects. Ibstock has been on a journey to reduce the carbon emissions from its production facilities for more than a decade, with investment projects in new production capacity at its Throckley, Chesterton, Eclipse and Lodge Lane plants all reducing the carbon intensity of the process. Its new Atlas factory in Walsall is the next step in this ongoing programme and the company is proud that its “net zero journey is one it shares with the UK Government’s net zero ambition.”
The company has seen what can only be described as a transformational shift in attitudes from its key stakeholders regarding global climate emissions. It believes passionately that the construction products sector has a responsibility to play its part in helping the world meet its emission reduction targets by reducing the carbon intensity of the manufacturing process.
Meanwhile, York Handmade Brick Company, who provided the bricks for Magdalene College Library in Cambridge – the winner of last year’s RIBA Stirling Prize – has just invested £1.5m in brand- new machinery which is transforming how the company makes bricks and helping its sustainability and net zero objectives. At the same time, the company has been awarded a grant to improve its energy efficiency and reduce carbon emissions, having successfully applied for the “game-changing” Industrial Energy Transformation Fund (IETF) for £38,800 to pursue its sustainability agenda. This project aims to improve the energy
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efficiency of the site by capturing the high- grade (high temperature) waste heat from the kilns; by utilising it in the dryers, it will potentially replace the need for gas-firing in the dryers and lead to significant energy, carbon and cost reductions. The kilns operate at high temperatures (up to about 1,100°C) and the exhaust gases from the kilns carry substantial amounts of heat which is currently being wasted. The solution involves installing a heat exchanger in the exhaust stack of each kiln to capture this heat into high pressure hot water or thermal oil. This hot water/ oil will then be stored in a thermal battery. The thermal battery can then provide heat to the brick dryers using a radiator system on demand and allow the operations of the kilns and dryers independent of each other.
BDA’s policies for brick manufacturers
All but the most hardened climate change sceptics believe that the planet faces an existential threat because of global warming. It is the duty of the brick manufacturing industry to respond positively to this challenge and that is why the BDA is committed to implementing five overarching policies aimed to reduce waste and increase sustainability. These are as follows:
• develop better understanding of wastes generated in clay brick and paver industry; • minimise wastes produced, and single-use plastic packaging consumed;
• develop partnerships to cultivate a high level of awareness of waste minimisation and management throughout the industry, and a desire to reuse and recycle materials where practicable;
• establish the contribution that the clay brick and paver industry can make to the circular economy; • protect the environment by ensuring we are good stewards of the materials we use. These aims are fully espoused by all
BDA members. Ultimately, responsible brickmakers are passionate about consumers being able to make informed choices about the credentials and provenance of their products. They are relentless in looking for more sustainable ways of working so they can look after the planet for future generations, and they are proud to do so.
Keith Aldis is chief executive of the Brick Development Association (BDA)
ADF MAY 2023
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