Acknowledgements

We have taken efforts in this project. However, it

would be not having been possible without the kind
support and help of many individual and organizations.
We would like to extend many sincere thanks to all of
them.
We are highly indebted to Mr. Deepthi Fernando,
building contractor of Sri Pahana and Ran Asipatha Tile
Kiln

and

Samastha

Manufacturers

Lanka

Association

Clay

Roofing

President

Mr.

Tiles
Baptist

Fernando for their guidance and constant supervision.

As well as our sincere gratitude goes to staff Of
Marawila Tile Factory for providing us necessary
information regarding the project.
We would like to express our gratitude towards our
parents

for

their

kind

co-operation

and

encouragement which help us in completion of this

project.
Our thanks and appreciations also go to all the people
who have willingly helped us out with their abilities.

CONTANT
Page No

1. Description
.
2. Objectives and

Goals.
4
3. Resources
analysis
..
5
4. Manufacturing
Process....
5. Work Plan & Time

Line.
6. Implementation

Consideration.
7. Risk

analysis
.... 10
8. Sustainability
. 11
9. Finalizing the
Proposal.
12
2

10. Approval
..... 13
11. Team
members
14

DISCRIPTION
When we talk about green in terms of design and
manufacturing, what do we mean? This is a big
question and lots of debate surrounds the details, but
there are a few main points. First, a green design or
product saves energy either in its use Orin its
Manufacturing. Second, it reduces waste by being
recyclable or using recycled materials. Third, it
reduces the impact on the earth by reducing the
carbon emissions or other pollutants. And fourth, it
utilizes local resources. Minimizing the need to

transport materials saves energy and reduces

pollution.
That said, choosing green roofing products for a
building project can seem challenging. Manufacturers
claims about the green qualities of their products can
be misleading or sometimes even confusing. Having
quantifiable measures to determine how green a
product really is can go a long way in helping us to
pick the right product for our project. Clay and
concrete roofing tiles are made with inherently green
materials, and an examination of their lifecycle and
carbon footprint will substantiate this quality.
Measuring the lifecycle and carbon footprint of a
roofing product will help you choose environmentally
friendly products, and help improve the sustainability
of our product.
Flat clay roof tiles are the dominant roof covering
material used in Sri Lanka for hundreds of years. Still
the majority of people has tended to use clay roof
tiles, since it equals the need and levels of social,
economic, architectural and environmental conditions
in the country.

Objectives and Goals

To make clay Roof Industry More sustainable.

4

 Decrease the pollution due to the smoke.

Use renewable energy resources for burning
process.
Minimize the transport cost.
We develop solutions for concrete roof tile
equipment, extrusion machines, clay or ceramic
tile packaging equipment, machinery and
services always focusing on the customers
budget and return on investment.
Increase job opportunities, raise the income levels
of the tile industrialists and thereby improve
living conditions of employees.
We hope to get necessary steps to reducing CO2
emission.

Resources Analysis

Raw Materials
The clay tile is composed of fired clay. Raw material sources are
typically located relatively close to tile plants, so an 80 km (50 mi)
transport distance is assumed in the model. For the underlayment,
Type II No. 30 roofing felt is used, which consists of asphalt and
organic felt in the quantities given in the Table below. The organic
felt is assumed to consist of 50 % recycled cardboard and 50 %
wood chips.

Table 1: Type-30
Roofing Felt
Constituents
Constituent

Kg/m2
(lb./square)*

Mass Fraction

Asphalt

0.57 (12)

45 %

Organic Felt

0.51 (10)

10 %

Limestone

0.13 (2.6)

5%

Sand

0.06 (1.3)

40 %

Total

1.27 (25.9)

100 %

Manufacturing Process
After extraction from quarries, the clay raw material is
laid out in order to obtain a homogeneous mixture.
Several stages are involved in preparing the clay. It is
stockpiled, then crushed to attain the required grain
size and then stockpiled again for several days or even
6

months.
Before processing, the moisture content is controlled
and it may be necessary to add water to obtain the
right consistency for forming. Materials such as
sawdust or residue of paper industry can be added to
increase the porosity of the final product.
For bricks, the clay is extruded or molded to obtain the
shape required and then cut to size. In roof tile
making, the clay can undergo a two-stage process, the
second of which may occur after extrusion, depending
on the roof tile being manufactured. For example, for
interlocking tiles, the extruded clay is pressed
between two molds.
The formed clay is dried in order to reduce its moisture
content and then loaded into kilns for firing. When this
is completed and the products have cooled, they are
packed ready for dispatch. Throughout all stages of
production, the process is subject to rigorous quality
control.

Work
&
Line

plan
Time

Using

locally

sourced

raw

materials reduces cost, energy, and transportation

associated with shipping raw materials to distant
manufacturing facilities. As a result, this helps to
reduce the embodied energy of a product.

We think to establish our work plant in one of this

cities. There are Wennappuwa, Katana and
Katugampol. There are 312 tile factories out of which
256 are small ones.

Date

March (weeks)
1st
2nd
3rd

4th

April (weeks)
1st
2nd

3rd

4th

Activity
Select a
product
Identify the
facilities
Feasibility
study
Hand over
Project
proposal
Designing
Project
Improve
facilities
Implementati
on
Finalizing
project

Implementation Consideration
There are 3 ways of managing energy consumption:
o

Choice of energy

Reduction of energy consumption

Use of renewable energy

Modern manufacturing has new advantages as well.

Computer modeling and engineering design tools help
minimize the use of raw materials by designing
stronger and more efficient systems. In the case of
concrete roofing, the tiles are engineered to allow
greater airflow between the tiles and roof deck.
Clay roof tile has a long service life. Many clay roofs
have been in existence for more than one hundred
years. Clay tile generally does not need to be
replaced; however, the underlayment may need
replacement after 10 years to 15 years. When the
underlayment is replaced, the roof tiles are typically
reused. The tiles themselves are replaced after 70
years.
Natural gas, LPG and fuel oil are used for most drying
and firing operations, but solids fuels and electricity
are also sometimes used, as is gas from landfills.
The Factory we decided will be run from the Natural
gas.

Risk analysis
10

The clay building product industry has taken positive

steps to deal with the inherent environmental aspects
of the process.
Factories are usually located in rural areas (close to
raw material supplies). They generally employ local
labor, often for generations, and in so doing help
stabilize local communities.
The industry has gone to great lengths to improve its
presence in these communities. For example, storage
areas are tarred and regularly cleaned in a bid to
reduce airborne dust, while fast growing hedges are
often planted.
To improve the working environment, measures are
taken to reduce dust emission from machinery.
Waste. Clay tile scrap or rejects that occur before the firing process
are recycled back into the manufacturing process. After firing, any
scrap or rejects are recycled by crushing for use on tennis courts,
baseball fields, and other applications.
At end of life, clay tiles are recovered and re-used. Usually, clay tile
removed for underlayment replacement is saved on a pallet for reuse on the same building. If the tile is not to be replaced on the
building, the roofer will use it on another building that specifies the
same tile type and color.

11

Sustainability
The substitution of non-renewable energy by
renewable energy is in constant progress. In many
ceramic production processes, biogenic additives,
such as sawdust can be added to the raw clay. The
utilization of such additives offers two advantages.
The first one is an additional energy source and the
second one is to lighten the products and increase
their insulating performance.
This additional energy works by reducing the
consumption of fossil fuels and therefore the emission
of CO2.
These additives are primarily selected on technical,
environmental and health grounds. They must have a
beneficial effect on the product's technical properties;
they must not produce harmful emissions or if they do
must be amenable to control. And they must not pose
a health risk to factory and construction workers.
o

use of raw materials that are low in sculpture,

nitrogen, chloride and fluoride

incorporation of inert additives in the clay body

incorporation of fine limestone in the clay body

to retain fluoride (and some sculpture)

Recirculation of low temperature carbonization

gases into firing zones of kilns (to combust CO
and VOC's).
12

o
o

thermal after burners

exhaust gas treatment by purification (gravel or
lime filter)

The extraction of clay usually occurs very close to the

plant so emissions (CO2 and Nox ) from transportation
are minimized.

Finalizing the proposal

The manufacture of clay building products is
constantly improving. The clay brick and tile industry
is continually monitoring its energy usage which forms
a significant part of total production costs. Much work
has already been done to decrease energy
consumption and consequently CO2 emissions in line
with government guidelines. Firing gives our products
their exceptional performance, long life and durability
and is an indispensable part of the production process.
We have solutions for both standard and customized
design tile profiles which we have successfully
delivered to a large number of Customers Island wide.
Besides standard profiles, we are often asked to
design special tile profiles to meet specific market and
customer demands.
The choice of profiles is dependent on climate, culture
and local market trends.

13

Below you can see examples of our most popular roof

tile profiles...
In order to help consumers, designers, and builders
make the best selections for the home or building,
third party groups are establishing rating systems to
make it possible to tell at a glance which product will
best fit the needs of the project.

APPROVAL

We will handover this Project before end of April 2014.

..
........................
(Group Leader)
(Date)

14

I approve this Project Proposal.

.
.
(Instructor/ Lecturer)
(Date)

Team Members

EN14547720
EN14547898
Abeywansa

M.V.K.C. Perera
H.A.D.A.P.

EN14547966

M.K.M.M. Prasadi

EN14548024

D.H. Nishmani

EN14548192
Weerasekara
EN14548260

W.M.R.K.
G.L.S. Dabare
15

EN14548338
Ilangasinghe
EN14548406

T.C.B.
M.P.N. Aravinda

16

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