"In the heart of Bangladesh's construction landscape, concrete blocks stand tall as the silent architects of resilience. As builders embrace innovation, the solid foundation of concrete blocks is redefining the nation's architectural narrative."
For those who are unaware, Portland cement, water, aggregates (such as sand or gravel), and frequently other additives called admixtures are combined to form concrete blocks. According to Verified Market Research, the size of the global market for concrete blocks was estimated to be USD 2,015 billion in 2022 and is expected to rise at a compound annual growth rate (CAGR) of 6% to reach USD 3,200 billion by 2030. With a 7.2% compound annual growth rate, the demand for sustainable concrete blocks is being driven by the adoption of green building methods.
The Financial Express claims that Bangladeshi producers of concrete blocks hold a sizable proportion of the brick market, which is estimated to be worth over BDT 90 billion. This corresponds to about 20 percent of the brick market. This percentage will keep rising as more people become aware of the advantages of concrete blocks and as their manufacturing capacity rises.
The manufacture of traditional red bricks is considered environmentally harmful and unsustainable for several reasons:
Resource Depletion: Clay, a non-renewable resource, is the main ingredient used to make traditional red bricks. The removal of clay for the production of bricks can result in the loss of natural habitats and soil degradation.
Energy Intensive: Traditional bricks are made by blazing clay at high temperatures in kilns, usually with the help of fossil fuels like coal or natural gas. Brick production uses 4400 MJ per tonne, according to a study from the Analysis of Environmental Performance Indicators for Concrete Block Manufacturing, but the average requirement for producing concrete blocks is 2400 MJ per tonne. This corresponds to about 1.6 MJ per kilogram of brick. This method adds to air pollution and climate change by using a lot of energy and producing greenhouse gases. According to studies, the production of burnt clay bricks produces 0.48 kg of CO2 equivalent (CO2e) per kg of brick globally, or about 1.1 gigatonnes of CO2e emissions yearly.
Air Pollution: Particulate matter, carbon monoxide, sulfur dioxide, nitrogen oxides, and other pollutants are released by brick kilns and have a negative impact on human health and air quality. Brick kilns exacerbate the pollution issue since they are either uncontrolled or run on antiquated equipment.
Deforestation: The need for firewood to run brick kilns has resulted in deforestation and biodiversity loss in some areas. This makes the state of the ecosystem even worse and adds to the loss of habitat for many different kinds of plants and animals.
Water Consumption: Water is needed in large quantities for clay extraction, brick molding, and kiln cooling in the brick making process. This can have an adverse effect on ecosystems and local water supplies, particularly in regions where water shortage is a problem. According to studies, the typical amount of water used in the brick-making process is between 300 and 500 liters per kilogram of brick. An additional MDPI study calculates that the typical brick produced requires 3.0 kg (0.0017 m³) of water directly.
Waste Generation: Brick manufacturing generates waste materials such as broken or defective bricks, as well as kiln dust and ash. Improper disposal of these waste materials can lead to environmental contamination and land degradation.
Health Risks: Workers employed in brick kilns are exposed to hazardous working conditions, including high temperatures, airborne pollutants, and physical strain. Prolonged exposure to these conditions can lead to respiratory problems, skin diseases, and other health issues.
Here is a breakdown of the process:
The concrete from the mixer is transferred to molds.
Molding:
Two main molding methods are used:
Stationary machines: Concrete mix is poured into individual steel molds, vibrated to remove air bubbles, and compressed to achieve density.
Vibration tables: Molds are placed on vibrating tables, allowing the concrete to settle and compact evenly.
Curing:
Molds are transported to curing areas where the concrete hardens through hydration.
Curing methods can vary depending on the desired strength and production speed.
Steam curing: Exposes blocks to steam and elevated temperatures for accelerated hardening.
Ambient curing: Blocks are allowed to harden naturally at room temperature and humidity.
Quality Control:
Samples are taken throughout the process and tested for strength, size, and other properties to ensure adherence to standards.
Packaging and Delivery:
Cured blocks are stacked on pallets, shrink-wrapped, and loaded onto trucks for delivery to construction sites.
Different types of blocks exist, each with specific mix designs and production variations.
Major Producers of Concrete Blocks in Bangladesh
Several notable companies lead the concrete block production in Bangladesh, including:
Concord: One of the largest players in the industry, known for its high-quality concrete blocks and diverse product range.
Mir Group: A prominent conglomerate actively promoting concrete blocks through its subsidiary, Mir Concrete Block.
BTI: Recognized for its innovative and technologically advanced production processes.
Meghna: Established manufacturer offering a variety of concrete block products.
Other key players: Companies like Unique Clay Products, Builders Block, and Dhaka Concrete Products are also contributing to the growing market share of concrete blocks.
A variation of concrete blocks is represented by hollow bricks, differing primarily in their design and weight. Concrete blocks are characterized by their solidity and substantial weight, making them suitable for applications requiring load-bearing capacity. On the other hand, hollow blocks feature voids in the center, rendering them lighter and commonly employed in constructing non-load-bearing walls for residential purposes. The empty spaces within hollow bricks contribute to effective insulation.
While traditional bricks remain a dominant building material in Bangladesh, several notable structures showcase the growing use of concrete blocks:
Large-scale projects:
Ashkona-Brahmanbaria Expressway: This major highway project utilized precast concrete blocks for rapid and cost-effective construction of retaining walls and bridge piers.
Bangabandhu Sheikh Mujibur Rahman Novo Theatre: This state-of-the-art cultural center in Dhaka incorporates concrete blocks to achieve a modern and functional aesthetic.
Hazrat Shahjalal International Airport Expansion: The expansion project utilized both precast and hollow concrete blocks for various structures, offering speed, durability, and thermal insulation.
Educational institutions:
Independent University, Bangladesh: This renowned university campus features several buildings extensively using concrete blocks, demonstrating their suitability for modern educational facilities.
United International University: The central library building showcases innovative use of concrete blocks with unique textures and colors, highlighting their aesthetic versatility.
Green Herald International School: This eco-conscious school building incorporates locally sourced and recycled materials in its concrete block construction, aligning with sustainability principles.
Other notable uses:
Bangladesh Hi-Tech Park: This modern IT hub utilized concrete blocks in some buildings due to their fire-resistant properties and efficient construction.
Residential Complexes: Several modern apartment complexes and housing projects are embracing concrete blocks for their cost-effectiveness and faster construction speeds.
Commercial Buildings: Offices and small businesses increasingly find concrete blocks an attractive option for their functional appeal and cost benefits.
Urbanization trends, particularly in Bangladesh, are boosting the demand for long-lasting and cost-effective construction materials, propelling market progress. Factors that are driving this growth are briefly discussed below:
1. Technological Advancements:
i. Automation and robotics: Increased automation in production lines will further improve efficiency, reduce costs, and enhance product quality.
ii. New materials and additives: Incorporating recycled materials, fly ash, and other sustainable additives will reduce environmental impact and create more eco-friendly blocks.
iii. Smart blocks: Blocks with integrated sensors and monitoring systems could be used for real-time data collection and improved building performance.
2. Sustainability Focus:
i. Reduced water and energy consumption: Advancements in production technologies will minimize resource usage and carbon footprint.
ii. Circular economy principles: Recycling old concrete blocks into new ones will become more prevalent, promoting resource efficiency and waste reduction.
iii. Bio-based binders: Exploring alternative binders like biopolymers could further decrease the environmental impact of concrete block production.
3. Design and Aesthetics:
i. Greater variety of shapes, sizes, and textures: More options will cater to diverse architectural styles and preferences.
ii. Coloration and surface finishes: Innovative approaches will expand the aesthetic possibilities of concrete blocks beyond traditional grey.
iii. Integration with other materials: Combining blocks with wood, glass, or metal can create unique and visually appealing building facades.
4. Innovation in Applications:
i. Prefabricated building systems: Utilizing precast concrete blocks can further accelerate construction speed and efficiency.
ii. Modular construction: Concrete blocks can be adapted for modular building concepts, facilitating flexible and sustainable construction practices.
iii. Specialized applications: Development of blocks with specific properties like acoustic insulation, fire resistance, or thermal control will open up new possibilities
The IFCM organizes the World Concrete Block Day annually to raise awareness of the material's benefits.Several countries, including India, China, and Brazil, have seen a significant rise in the use of concrete blocks in recent years. Innovative architects are utilizing concrete blocks in creative and green building ways in projects worldwide.
Overall, the future of concrete blocks appears promising, driven by economic, technological, and sustainability factors. With continued innovation and focus on addressing challenges like public perception and regulatory limitations, concrete blocks have the potential to become a dominant and versatile green building material in the years to come. With established players and new entrants continuously innovating, the future of concrete blocks in this market seems promising.
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