Abschlussbericht

Tübinger Gründergeist versetzt Ziegelberge in Malawi
 
Es quietscht und zischt – ein Lkw hupt. Doch das stört niemanden in der Savanne bei Lilongwe im ostafrikanischen Malawi. Ganz im Gegenteil. Es herrscht Hochstimmung bei Dutz

IUDAMitglieder
von links: Einige Mitglieder des Tübinger Vereins „Ich-und-du-für-Afrika“: Ernst Gumrich, Anne Berg, Christa Gumrich, Ingrid Weichelt, Jutta Göhren, Stefan Schäfer, Oliver Ueltzhöffer, Annika Wilmes, Reinhard von Brunn, Paul Weipert.

enden malawischer Familien, bei den Verantwortlichen des „Centre for Community Organisation and Development (CCODE)“ und bei Entwicklungshelfer Peter Schramm von der Deutschen Gesellschaft für Internationale Zusammenarbeit (GIZ), der in Dettingen/Rottenburg zu Hause ist. Und in Tübingen fallen sich die wackeren Spendensammler vom Verein „Ich und Du für Afrika“ in die Arme: es ist geschafft, das Ziegelwerk steht, die Brennöfen funktionieren, die Ziegel sind hervorragend.

Zwei malawische Arbeiter verladen frisch gebrannte Ziegel
Zwei malawische Arbeiter verladen frisch gebrannte Ziegel
Die Vorgeschichte? Nicht nur uns Schwaben treibt das „Häuslebauen“ um. Unzählige arme malawische Familien sehnen sich nach einer menschenwürdigen Unterkunft: trockene, belüftbare Räume, ein dichtes Dach über dem Kopf, hygienische Böden, vielleicht sogar Wasser- und Abwasseranschluss. Seit fünf Jahren unterstützt eine Gruppe beherzter Tübingerinnen und Tübinger die Nichtregierungs-Organisation CCODE, ein in jeder Hinsicht revolutionäres kleines Ziegelwerk zu bauen. Die Brennöfen und -kammern sind einfach

Ziegel im Vergleich: links schief und krumm aus traditioneller Kleinproduktion, wobei Unebenheiten mit teurem Zement ausgeglichen werden müssen. Rechts, die maßgenauen härteren Ziegel aus dem VSBK-Ofen.
Ziegel im Vergleich: links schief und krumm aus traditioneller Kleinproduktion, wobei Unebenheiten mit teurem Zement ausgeglichen werden müssen. Rechts, die maßgenauen härteren Ziegel aus dem VSBK-Ofen.

konstruiert, jedoch höchst energieeffizient. Vertical Shaft Brick Kiln-Technologie nennt sich die Methode. Sie wurde in China entwickelt und kommt bisher vor allem in asiatischen Ländern wie Indien und Nepal zum Einsatz. Beim Aufbau in Malawi waren Ingenieure der indischen Spezialfirma TARA beteiligt, eine echte Süd-Süd-Kooperation. In Lilongwe werden die Öfen mit Tabakstrünken und anderen landwirtschaftlichen Abfällen befeuert, heimische Kohle wird nach Bedarf zugesetzt. So wird der dramatischen Abholzung der letzten Wälder entgegen gewirkt, die bisher als Brennstoff für die kleinen Hinterhof-Ziegelöfen herhalten mussten. Die Ziegel aus den VSBK-Öfen sind viel massgenauer und härter als die bisherigen. Das spart beim Mauern Zement, der für teure Devisen nach Malawi eingeführt werden muss.

Die Gesamtanlage von links. Trocknungsanlage, dahinter Terrassen für Grünlinge, Sozialräume, Büro und Lagerhalle, Sanitäreinrichtungen, Brennofen.
Die Gesamtanlage von links. Trocknungsanlage, dahinter Terrassen für Grünlinge, Sozialräume, Büro und Lagerhalle, Sanitäreinrichtungen, Brennofen.
Frauen und Männer aus dreissig Familien, die der „Malawi Homeless People´s Federation“ angehören, werden ausgebildet , die Ziegelei zu betreiben: vom Abbau des Lehms, Pressen der Rohlinge, der Beschickung der Öfen, der Regulierung der Brenntemperatur bis hin zur Auslieferung der Ziegel und Buchhaltung. So wurden dauerhaft rund 150 Arbeitsplätze geschaffen. Ein besonderer Clou, der nur bei den wenigsten Entwicklungsprojekten gelingt: das Ziegelwerk braucht keine Spenden mehr!  Ein Teil der Produktion geht zu Selbstkosten an die Mitglieder der Wohnbaugenossenschaften, der andere wird zu Marktpreisen verkauft. Die Überschüsse steckt die Partner-Organisation in neue soziale Massnahmen.
Kernstück der Anlage: Der VSBK-Ziegelofen mt vier Brennschächten
Kernstück der Anlage: Der VSBK-Ziegelofen mt vier Brennschächten
Fünf Jahre lang hat der Tübinger Verein mit Peter Schramm und seinen afrikanischen Partnern das Projekt geplant, die Gegebenheiten vor Ort hinterfragt, Lösungsvarianten für 1001 Probleme durchgespielt, dazugelernt, Ideen geboren und wieder verworfen. Und dann tatkräftig den Bau des Ziegelwerks mitfinanziert. Dafür war langer Atem auch beim Geldsammeln gefragt: mehrere Jahre Stand auf dem Tübinger Weihnachtsmarkt, Catering bei Mediziner-Kongressen, Spendendosen in Geschäften, Anklopfen bei Sponsoren. Besonders grosszügig waren die Kreissparkasse Tübingen und die Stiftung Entwicklungszusammenarbeit des Landes Baden Württemberg, Stuttgart. Insgesamt flossen rund 45.000 Euro nach Malawi.
Entwicklungshelfer Peter Schramm mit dem indischen Botschafter in Malawi bei der feierlichen Inbetriebnahme mit der Zündfackel.
Entwicklungshelfer Peter Schramm mit dem indischen Botschafter in Malawi bei der feierlichen Inbetriebnahme mit der Zündfackel.
Das erste Ziegelwerk mit VSBK-Technologie in Afrika hat in den letzten Monaten so viel Aufsehen erregt, dass inzwischen grosse internationale Entwicklungs-Organisationen vorhaben, dieses positive Beispiel an anderen Orten Malawis und des Kontinents zu wiederholen. In der aktuellen Flüchtlingsdebatte hört und liest man immer wieder so schön abstrakt, man müsse die Fluchtursachen vor Ort bekämpfen. Das war zwar nicht die vorrangige Absicht des Projekts „Ziegelofen“. Dieses zeigt aber, wie Hilfe zur Selbsthilfe, Armutsbekämpfung und die Schaffung würdiger Lebensumstände in der Praxis funktionieren können. Die Umwelt schützen, Menschen ausbilden, gesundes Wohnen ermöglichen, Arbeit und Einkommen schaffen – das ist hier gelungen.
Und die Initialzündung, Beharrlichkeit und Ermutigung der Partner sowie das Startkapital kamen von einer Gruppe weltoffener und engagierter Tübinger: Ralf Schulz, Paul Weipert, Jan Markert, Annika Wilmes, Stefan Schäfer, Reinhild und Reinhard von Brunn, Dorothee Kimmich, Wolfgang Wilmes, Ernst Gumrich, Matthias Knecht, Karin und Jörg Glatzle, Anne und Pascal , Jutta Göhren, Ingrid Weichelt, Ursula und Hermann Glatzle, Oliver Ueltzhöffer, Fatma Palecioglu, Holger Keppel.
 
Tübingen, den 4. Dezember 2015
Reinhard von Brunn, Vorsitzender „ich und Du für Afrika“

FORTSCHRITTSBERICHT 25. MAI 2015

Dear All,
 VSBK_2015-05-08_Green-Brick-Production-01 VSBK_2015-05-08_Green-Brick-Production-02 VSBK_2015-05-08_Green-Brick-stacking VSBK_2015-05-08_KILN VSBK_2015-05-08_KILN_Loading-platform VSBK_2015-05-08_SITE-OVERVIEW VSBK_2015-05-08_SITE-OVERVIEW-Evening VSBK_2015-05-15_Green-Brick_Production VSBK_2015-05-15_KILN_Dispatching VSBK_2015-05-15_KILN_Fired-Bricks VSBK_2015-05-15_KILN_Loading VSBK_2015-05-15_KILN_Measuring_temperature
Good news from the kiln site!
 
Although our big machine is not fully ready yet – some chutes, security features and consequently the electrical connection of the machines are still missing – we wanted to get bricks after the rainy season ended. Luckily we have TARA’s soft mud moulding machine hence decided to use it to commence production.
 
We started green brick making on 21st April and subsequently firing of shaft No 1 on 9th May. The green brick team is meanwhile well-rehearsed and their output in green brick production is meanwhile high (average of 12,000 bricks per day) so we decided to add one more shaft to the production and started yesterday firing on shaft No 2.
 
After the hiccups we have had in the beginning of the test phase we were quite tense how it would workout with the fire masters having to deal with all problems on their own. But as in the green brick production everything went very well and our fire masters are doing a great job.
 
Meanwhile we have produced around 150,000 green bricks and fired around 20,000.
 
Also see the pictures attached.
 
 
Cheers
Peter

FORTSCHRITTSBERICHT 01. FEBRUAR 2015

Dear All,

DSC_0015 DSC_0119

It took a while for me to send you this report as I was on leave for 4 weeks. We have not achieved to numbers of bricks we wanted, but we have enough to do our test firing in order to be ready and prepared for the real production start after the rainy season. And this start of the test firing served as occasion to inaugurate the kiln on 26th January in presence of a representative of the Ministry of Land, Housing and Urban Development, the deputy British High Commissioner, the Indian High Commissioner and the German Ambassador.

 

This inauguration also signifies the end now my reporting on the project. There will of course still be some minor works to do besides the test firing and the firemasters with their helpers getting familiar with their tasks, but that will go on unreported.

Subsequently here a last brief overview of all the works done since the last reporting:

 

  • Kiln: Machinery: All hydraulic manholes cast and the first hydraulic mounted. Will finish today with the mounting the security features on the first conveyor belt.
  • Landscaping: Establishing drains and landscaping the site around the staff facilities is done.
  • Shed for brick production/office
    Got now most of the machines we acquired from India out of the shed and into their final places thus now we can continue to work on the machinery in the workshop.
    Cast the terrazzo floor in the office part.

 

Also see the pictures attached.

 

 

Cheers

 

Peter

FORTSCHRITTSBERICHT 05. DEZEMBER 2014

Dear All, VSBK_2014-12-05_KILN_Conveyor-1 VSBK_2014-12-05_KILN_Elevation-West VSBK_2014-12-05_KILN_Unloading VSBK_2014-12-05_SITE-INSATLLATION_Water-tank VSBK_2014-12-05_SITE-OVERVIEW VSBK_2014-12-05_STAFF-FACILITIES_Overview VSBK_2014-12-05_WORKSHOP_Cable-racks

Not really hampered by rains this week we went on making bricks and have now about 25,000 brick in stock. But we are having a hiccup in the delivery of the tobacco dust due to a miscommunication. I try since 2 weeks to get the delivery back on track, unfortunately in vain and now we are completely out of tobacco dust. And to make things worse, the tobacco factories are closing production next week. Keep fingers crossed for us that we will manage to get some dust next week.

The mounting of the machines went on – the remaining construction works were still a bit on hold as we were waiting for a transfer of funds that only arrived by end of the week.

I was very busy on reporting as the year closes, but finished today with that matter. Thus starting from Monday I will be able to push works on site again.

Here the overview in brief:

  • Kiln: Machinery: Finished the excavation for the hydraulic manholes. Continued with the mounting of the second conveyor.
  • Landscaping: Started with establishing drains and landscaping the site around the staff facilities.
  • Shed for brick production/office
    Finished making and mounting the cable racks.

Also see the pictures attached.

Cheers

Peter

FORTSCHRITTSBERICHT 28. NOVEMBER 2014

Dear All, VSBK_2014-11-28_GREEN-BRICK_Production VSBK_2014-11-28_GREEN-BRICK_Storage VSBK_2014-11-28_KILN_Conveyor-I VSBK_2014-11-28_KILN_Unloading-Device-I VSBK_2014-11-28_OVERVIEW VSBK_2014-11-28_STAFF-FACILITIES_Showers

We had the first rains – hope that the real rains will still wait some 3-4 week before coming. The production of green bricks goes on – started bringing the first bricks to the storage platform. Next week the training mode ends and we will enter into “real” production; still at a rather low level of 8,000 – 10,000 bricks per day compared to 32,000 bricks per day that will be needed after the rainy season next year. Please pay attention to the shape and the size of the bricks when looking at the pictures.

The mounting of the machines went on – the few remaining construction works are a bit on hold, as we are concentrating on the machinery and at the same time waiting for a transfer of funds.

Here the overview in brief:

  • Kiln: Machinery: Finished with the works on the truss for the first of the two conveyors.
    Continued excavation for the hydraulic manholes. Did the formwork and casted the first manhole for the hydraulic unloading devices. A very delicate job, as tolerances are very narrow.
  • Installations:
    Water tank: Finished the outside of the roof and a first coat on the inside. Currently we are waiting for the curing before taking out the props.
  • Staff facilities: Showers: Started sealing the floor and the washbasin with polish, which we want to be finished before starting the painting of the walls.
  • Shed for brick production/office
    Started with the works on the cable racks.

Also see the pictures attached.

Cheers

Peter

FORTSCHRITTSBERICHT 21. NOVEMBER 2014

Dear All, VSBK_2014-11-21_BRICK-MAKING_Training VSBK_2014-11-21_KILN_Conveyor VSBK_2014-11-21_KILN_Shaft VSBK_2014-11-21_OVERVIEW VSBK_2014-11-21_SITE-INSTALLATION_Water-tank-01 VSBK_2014-11-21_SITE-INSTALLATION_Water-tank-02

This week’s focus was on starting the green brick making with TARA’s Brick Making Machine – getting the transport damages fixed, organising raw materials (e.g. 300t of soil) and training of labour. During the first days we had to fix the safety features at a period of maximum 1 hour, as they labourers were absolutely not familiar with handling machinery and we had constantly parts of the machine being blocked, but now the process is running smoothly.

We intend to produce 100,000 bricks to be able to commission the kiln.

As the training was absorbing much of our attention and we are almost done with the constructions, we did not much building works on site this week. Here the overview in brief:

 

  • Kiln: Construction: Finished the final touches at all shafts and on the handrails.
    Machinery: Continued with the mounting of the conveyors to the loading platform and started excavation works for the manholes of hydraulic unloading devices.
  • Installations:
    Water tank: We did the reinforcement of the roof (done as a ferro-cement construction) and should finish today with the first layers of the plastering.

As usual attached some pictures.

Cheers

Peter

FORTSCHRITTSBERICHT 15. NOVEMBER 2014

Dear All,VSBK_2014-11-12_DRYING-TERRACES VSBK_2014-11-12_KILN_Ramp-01 VSBK_2014-11-12_KILN_Ramp-02 VSBK_2014-11-12_KILN_Shaft VSBK_2014-11-12_MACHINES-01 VSBK_2014-11-12_MACHINES-02 VSBK_2014-11-12_OVERVIEW VSBK_2014-11-12_TOILETS

 

The week was marked by getting the container from India. It arrived Tuesday evening on the site, Wednesday we did the unloading and then started checking all machines for lost or broken parts, fixed them if needed and assembled them. It proved to be quite tricky to get spare parts for lost pieces; e.g. springs obviously found in almost every corner shop in India, we couldn’t find here and had instead to improvise to get a solution thus we were quite busy till late on Friday evening. Luckily we have Mehmud Alam here again, who manages all this works and he really pushed to get things done.

Thus I’m coming even today just now from the site where we put up the conveyors to the loading platform. We got them up, not finally adjusted of course.

 

Here the overview of all works in brief:

 

  • Shed for brick production/office
    Did the formwork reinforcement and casting of the ceiling on the mechanical workshop.
  • Staff facilities: Toilet: Flooring and casting of covers for the vaults is done.
    Showers: Curing of the floor.
  • Landscaping on site: –
  • Kiln: Second handrail is cast. Put up the conveyors. We are currently completing the finishing of shaft 3. Hope to complete the last shaft early next week. Started digging out the manholes for the hydraulic unloading devices.
  • Installations:
    ESCOM: The installation of the transformer is still missing.
    Installations on site: All manhole covers and all covers for the soak-aways are done.
    Water tank: Nothing happened. Will start with the roof over the tank on Monday.
  • Drying terraces:
    Cleared 5 terraces from grass and started to smoothen them for green brick production. We want to start production of bricks with the brick making machine we got from TARA.

 

As usual attached some pictures.

 

 

Cheers

 

Peter

FORTSCHRITTSBERICHT 31. OKTOBER 2014

Dear All,VSBK_2014-10-31_KILN-01 VSBK_2014-10-31_KILN-02 VSBK_2014-10-31_OVERVIEW VSBK_2014-10-31_TOILET

 

Friday, reporting day. During the last week I was most of the time busy with administrative tasks, thus we had not a lot that moved inside the workshop. But nevertheless works at other parts of the site kept moving. Here the overview:

 

  • Shed for brick production/office:
    Wall around internal mechanical workshop is done.
  • Staff facilities: Dining area: Planting of grass to stabilise the soil before the start of the rainy season is done.
    Dining hall/kitchen: –
    Toilet: Installations works on the urine separation are done, plastering of the internal walls was ongoing this morning, should normally be finished today.
    Showers: Curing of the floor.
  • Landscaping on site: Last slabs for the drains cast.
  • Kiln: Roofing is done. Dismantling of the formwork for the ramp ongoing. Started formworks for the handrails.
  • Installations:
    ESCOM: The installation of the transformer is still missing.
    Installations on site: Continued with the bottom slabs and covers for the manholes, 5 still missing.
    Water tank: Curing of the waterproofed floor and plaster.

 

The container with the machines from India left Beira and is on its way to Lilongwe.

 

Also see the attached pictures.

 

 

Cheers

 

Peter

FORTSCHRITTSBERICHT 24. OKTOBER 2014

Dear All,VSBK_2014-10-23_INSTALLATION VSBK_2014-10-23_KILN VSBK_2014-10-23_OVERVIEW

 

Last week no report, as I took one week off. Had refused to take leave during the summer holydays of my daughter, but now for the midterm break holydays she definitely deserved to go to the lake at least for that one week.

This week all was back to normal, thus now the oversight of the works:

 

  • Shed for brick production/office:
    Repositioned the recycling conveyor and the feeding conveyor to the extruder. Started arranging the place for the main electrical switchboard.
  • Staff facilities: Dining area: All works at the pergola are done, continued planting grass to stabilise the soil before the start of the rainy season.
    Dining hall/kitchen: –
    Toilet: Started with the installations works on the urine separation.
    Showers: Finished plastering + flooring.
  • Landscaping on site: All but 2 slabs for the drains done.
  • Kiln: All chimneys are up, we finished casting the last ring beams yesterday evening. Carpenter promised to mount the iron sheets on the last roof on Monday. Meaning that the kiln is ready for the machines coming from India – just have to do the handrail on the ramp and minor retouches to finish all works.
  • Installations:
    ESCOM: ESCOM has done all the wiring to the site, the installation of the transformer is still missing.
    Installations on site: Backfilling of the trenches is done. Bottom slabs and covers for 50% of the manholes are done.

 

The container with the machines from India finally arrived in Beira. If all goes well, it will arrive in Lilongwe by end of next week. Then we will have to wait until it gets cleared by the customs.

 

Also see the attached pictures.

 

 

Cheers

 

Peter

FORTSCHRITTSBERICHT 12. OKTOBER 2014

Dear All,2014-10-10_DRAINS 2014-10-10_KILN_Chimneys 2014-10-10_KILN_Roof 2014-10-10_Knock-off-time 2014-10-10_SITE-INSTALLATION_Electrical-service-pipes 2014-10-10_SITE-OVERVIEW 2014-10-10_STAFF-FACILITIES_Dining-area 2014-10-10_STAFF-FACILITIES_Showers 2014-10-10_STAIRS 2014-10-10_WATER-TANK_Inside 2014-10-10_WATER-TANK_View 2014-10-10_WORKSHOP_Extruder

 

We had several changes during these 3 weeks whilst you have been without reports. Lenna and Sarah, 2 of our 4 community contractors, had applied to university and actually got accepted and left within 2 days. Very nice for them – but it brought a bit of stress for the rest of the team. Thus I spend a lot of my time on the site also supervising the works on the machinery in the workshop.

 

Here the oversight of the works:

 

  • Shed for brick production/office:
    Repositioned the extruder (I haven’t seen the extruder, the pre-cutting machine and the brick cutting machine together as the last two were in Enock’s storage at the time when we bought them, thus I only realised when they were standing in the workshop that the 3 machines are at 3 different height levels) We moved the extruder (weight 9t) by 2 meters and lifted it by 25 cm. The first part of the new foundation underneath the extruder is cast. Second part will be casts as soon as the new foundation is cured.
    Repositioned the brick pre-cutting and brick cutting machine. Have now a very good concept for bringing out the bricks in front of the workshop. Finished the design of the pushcarts.
  • Staff facilities: Dining area: Finished landscaping and started planting.
    Dining hall/kitchen: –
    Toilet: –
    Showers: Inside plastering is except for some minor retouching works done.
  • Landscaping on site: Started casting the slabs for the drains.
    Stairs on the site are all done.
  • Kiln: Roof at the loading platform: After letting go our carpenter, who was really playing games with us, we have now have a new one and finished putting on the iron sheets on the lower roofs of the loading platform.
    Shafts: Cast the ring beams on the shafts. Currently the bricklayers are bringing up the chimneys.
  • Installations:
    ESCOM: ESCOM started working on the connection to the grid – sometimes they are working sometimes they are off, we have kind of slow but steady progress.
    Installations on site: Pipes for the water installations are in place, only the connection of the different buildings is still missing.
    The water tank is done up to roof level. Now we have to wait for the plaster to cure before we can continue with the roof.
    The service pipes for the electrical installation are mounted, backfilling of the trenches is going on.

Also see the attached pictures.

 

 

Cheers

 

Peter