CONFIDENTIAL REPORT
Project Title
: MARSS 2013 (2012 Data)
: Materials from Alternative, Recycled and
Secondary Sources (MARSS); the use of
none primary clay raw materials in the UK
brick manufacturing sector.
Client
: Brick Development Association
- Manufacturing Steering Group
- Sustainability Steering Group
Report Authorised by:
Dr Andrew S Smith
Principal Consultant
CERAM
Date of Issue
: 8th Nov 2013
CERAM Research Ltd, Queens Road, Penkhull, Stoke-on-Trent, Staffordshire, ST4 7LQ
CONTENTS
SUMMARY
1
INTRODUCTION
2
CONTEXT
3
RESULTS
4
HISTORIC DATA
SUMMARY
The 2013 MARSS Survey was undertaken during Q2 of 2013 and the results are based on
data for the calendar year 2012. The survey is reported to the Brick Development
Association’s (BDA) Manufacturing Steering Group and the Sustainability Steering Group.
The results feed into the UK Brick Industries KPI’s as published by the British Ceramic
Confederation (BCC).
The data is collected direct from Senior Management representatives from the different UK
brick manufacturers, typically technical, environmental or similar managers. The data is
taken at face value.
Returns for the survey period were received from 43 brickworks, of which 33 are currently
using MARSS, 10 are not. The remaining 11 works, thought still to be in production in 2012,
did not reply to the survey.
The 33 works using MARSS materials, account for 367,794 tonnes of MARSS and 2,549,944
tonnes of primary clays. The MARSS content therefore of these 33 works equates to 12.6%
average MARSS content, based on the total usage of raw materials (primary clays +
MARSS).
When all the reporting works (43 brickworks) are taken into account the overall MARSS
usage falls to 9.8%.
Brickworks responding to the 2013 MARSS Survey:
Hanson Building Products
Desford
Howley Park
Kings Dyke
Kirton
Measham
Wilnecote
Michelmersh Brick
Charnwood
Freshfield Lane
Michelmersh
Telford
Carlton Brick
Northcot Brick
Bovingdon Brick
Ibstock Brick
Aldridge
Atlas
Ashdown
Birtley
Cattybrook
Chailey
Chesterton
Dorket Head
Ellistown
Leicester
Lodge Lane
Nostell
Parkhead
Ravendale
South Holmewood
Stourbridge
Swanage
Throckley
West Hoathly
Wienerberger
Denton
Eldon
Ewhurst
Hartlebury
Kingsbury
Rudgewick
Sandown
Smeed Dean
Todhills
Waresley
Warnham
1
INTRODUCTION
CERAM have been requested by the Manufacturing Steering Group of BDA to
undertake a survey of BDA member companies regarding their current use of
Alternative, Recycled and Secondary materials added to the brick body during the
manufacturing process.
This survey aims to produce a “Confidential” and
“Anonymous” report, for the Industry, that will benchmark the current usage, reason
for usage, and cost of usage, for all none clay alternative materials.
Pressure over recent years from both energy pricing, environmental impact and
customer expectations, have resulted in increasing interest in the potential benefits
from the use of alternative materials, often from recycled or secondary sources, to help
achieve more efficient manufacturing, and minimise pollution and greenhouse gas
emissions.
During the last 20 years CERAM have undertaken numerous trials and materials
assessments on behalf of its Members and the Brick Industry in general, however,
there is little in the way of comprehensive information about what is being currently
used.
In order to establish a “benchmark” against which to measure usage and to report to
the wider public and Government, BDA/CERAM Member companies were requested to
return information relating to the use and cost of Materials from Alternative, Recycled
and Secondary Sources (MARSS materials).
Manufacturers were requested to supply the following information:
Works/Factory – Name of works/Factory
Kiln Type – Tunnel Kiln, Intermittent, Hoffmann etc
Primary Raw Materials:
Product Group – Extruded Wire Cut, Soft Mud, Handmade, Pressed
Clay Type – What is the normal clay type of the brick body that alternatives
are added, eg Coal Measure Shale, or Keuper Marl + Etruria Marl Blend. Etc
Yearly Tonnage Used – Tonnage of this body used in brick manufacture on
a yearly basis
Alternative Materials:
Type/Source – Type of alternative material added, pick from:
Ash Products – eg PFA, ISSA, Town Ash
Hydrocarbons – eg Coal Fines, Coal Slurry, Coke Breeze, Petcoke
Industrial Minerals – Slags, Grog
Minerals – eg mineral by-products:- Fireclays (WRAP Rules apply), Shales, Marls
Organics – eg Sawdust, Sugars/Starch
Yearly Tonnage Used – Tonnage of alternative materials used in the
specific body type (rounded to the nearest 10 tonnes)
Yearly cost – There are a number of options available to return in this box:
Cost (£xxx.xx)
Delivery Only(£xxx.xx)
The cost of purchase and delivery to your factory.
The material comes free but you pay for the transport to
your factory.
Free
No cost to you including free delivery.
Revenue (£xxx.xx)
You are paid to take this material.
Values are based on the tonnage returned in previous box
Regulatory Info – The aim of this question is to assess on what “authority”
you have to use the alternative material on your factory. Do you have a
Waste Management License for the material? Do you currently used the
alternative material under any other regulatory framework e.g. IPPC etc. If
so do who issued you with permission to use the material (Local EHO, EA etc)
and do you hold a formal Permit, if so of what type.
Benefit/Reason for Use – Please identify all the “business, environmental
or technical reasons” why you are currently using the alternative material in
brick production. In simple terms what benefit do you derive from using this
alternative material eg energy saving by faster firing, reduced firing
temperature, reduced emissions, aesthetic appearance of the product etc.
2
CONTEXT
2.1 UK Brick Production 2005-2011
To put the statements made in this report into context, it is worth reviewing the UK
brick production statistics for the period from 2005 through to 2012. This period has
seen some significant reductions in production output, reflecting the reduction in sales
(deliveries) over the same time period.
Over a longer time frame, brick deliveries have fallen by nearly 70% since the most
recent 40 year high in 1989, reflecting delivery of in the order of 4559 million bricks.
More recently in 1995 deliveries spiked at 3292 million bricks, but over the following 10
years (1996-2005) deliveries hover around 2816 (± 160) million bricks per annum.
The Department for Business, Innovation & Skills (BIS) formerly The Department for
Business, Enterprise and Regulatory Reform (BERR), collect construction materials
statistics on a monthly basis.
The Oct 2013 published statistics
(http://stats.berr.gov.uk/construction/building/#historic) are used to construct the
table:
UK
Production
Deliveries
2012
1459
1551
2011
1555
1646
2010*
1351
1484
2009
1216
1388
2008
1822
1687
2007
2313
2248
2006
2359
2254
2005
2601
2419
Stock
515
610
778
921
1090
948
887
Values are millions of bricks.
*Data from BERR Monthly Statistics of Building Materials and Components Oct 2013 (No 464)
776
The trend shows a slight decrease in production (0.1 billion) in the period, and an
associated decrease in deliveries, however delivery from stock continued resulting in a
reduction in the stocking levels of bricks. This level of stock take, whilst maintaining
deliveries and production, has continued throughout 2012, bringing a better overall
balance to the supply and demand in the sector.
3
RESULTS
3.1 The 2012 MARSS Survey shows the following values:
No of Works in Survey (data supplied)
No of Works using MARSS
No of Works not replying
43
33
10
Approximately 80% of the operations UK brick production facilities surveyed supplied
data for 2012. Approximately 60% of the UK brick production facilities actively use
MARSS as alternatives to primary clay raw materials. All of the 4 major brick
manufacturers in the UK gave complete or majority returns, therefore the data
gathered has a high degree of representation of the majority of brick production in the
UK. The 4 main manufacturers, Hanson, Ibstock, Wienerberger and Michelmersh
Group currently account for over 85% of UK production volume. Overall the data
collected is up on the level collected over the previous year, although only a limited
number of the single site operators have provided any data for the “Production Year”
2012.
3.2 Of the 33 Works that are currently (2012) using MARSS:
Total MARSS tonnage
Total Clay (Primary) tonnage
MARSS % (based on Primary + MARSS)
367 794t
2,549,944t
12.6%
As will be discussed later, the tonnage reported of MARSS usage has slightly decreased
from 2011 (0.1%). Although in previous years, where a reduction has been seen, this
has been attributed to a clarification of materials that can and can not be included in
the MARSS survey, specifically the sources of Fireclays, or as a result in a marked
reductions in production, however in 2012 the actual MARSS tonnage has remained
approximately the same as in 2011.
Based on the survey returns, the average MARSS content of bricks has decreased
slightly to 12.6.% from a 2011 value of 12.7.%. This is as a result of slight changes in
production through the period being supported by both primary clays as well as
MARSS materials.
3.3 MARSS Usage by MARSS Category:
Ash
Hydrocarbon
Industrial Minerals
Minerals
Organics
14,350t
37,234t
0t
316,210t
0t
MARSS usages remains dominated by the inclusion of mineral materials that are
recovered as by-products of other mineral extraction operations. This is widely
regarded as BPEO (Best Practicable Environmental Option) and Resource Efficiency,
maximising the usage of materials extracted in a single operation.
There have been some significant changes in the tonnage usage of all of the MARSS
categories during 2012. There is a slight decrease in the use of Hydrocarbon and
Minerals, and a total cessation of the use of Industrial Mineral products, but only a
slight increase in the use of Ash based MARSS materials. There are no reported uses
of Organic MARSS materials in 2012.
3.4 MARSS Value by MARSS Category:
There was incomplete data supplied in the value category therefore it has not been
possible to generate the value statistics for 2012.
3.5 MARSS Usage by Manufacturing Process:
Soft Mud
Ash
Hydrocarbon
Industrial Minerals
Minerals
Organics
TOTAL
Extruded
Ash
Hydrocarbon
Industrial Minerals
Minerals
Organics
TOTAL
13,584t
22,462t
0t
40,037t
0t
76,084t
766t
14,771t
0t
276,173t
0t
291,710t
There is a clear distinction between the type of MARSS being used in relation to the
manufacturing process. The soft mud process, including handmade and machine
made soft mud products, typically have a potential for higher ‘none Mineral’ MARSS
material inclusion, as the plasticity of the clays tends to be greater and moisture
content more accommodating within the process, however in terms of total tonnage
used, the extrusion process has a significantly higher MARSS usage reported. This is
attributed to the high tonnage usage of Mineral materials, dominated by the Fireclays
and other mineral extraction by-products utilised as alternatives to primary clay raw
materials.
Historically, the soft mud process has utilised Ash and Hydrocarbon materials in order
to achieve aesthetic and technical properties. This is reflected in the levels reported.
The largest MARSS category for soft mud production is Mineral, with reflects the use of
recovered sands and clays from other mineral operations as by-products.
The extruded products are dominated by the mineral materials, as previously
described. The usage of Industrial Minerals has declined since 2008 to zero in 2012.
Historically these materials were predominantly used as facing materials or body
additives. The Hydrocarbon materials are generally used in the very low organic
carbon primary raw materials, such as the Marls and Weald clays, rather than the
Carboniferous Shales.
3.6 MARSS Usage by Primary Clay Type:
Shale
Etruria Marl
Keuper Marl + Blends
Weald + Blends
Other
211,779t
64,918t
31,672t
50,062t
9,363t
The largest proportion of MARSS are used in conjunction with Carboniferous Shales
and blends, plus the Etruria Marl bodies. These tend to be blended with Mineral
materials from other mineral extraction operations of similar or complimentary
compositions.
Ash
Hydrocarbon
Ind Min
Minerals
Organics
0t
899t
0t
210,880t
0t
0t
1,889t
0t
63,029t
0t
0t
15,048t
0t
16,624t
0t
12,250t
14,620t
0t
23,192t
0t
Other
Weald
+
Blends
Keuper
Marl +
Blends
Etruria
Marl
Shales
3.7 MARSS Usage by Primary Clay Type (MARSS Types):
2,100t
4,778t
0t
2485t
0t
Table 3.7 Breakdown of MARSS usage by primary clay type.
The usage of MARSS, by primary clay type, closely reflect the situation as described
in the Manufacturing Process type. This is essentially due to certain regional
concentrations of manufacturing processed having developed on or near to specific
geological raw materials.
Ash products are used mainly in Weald Clay based production sites, with a lesser
amount used in the Other category which includes the likes of Alluvial Clays, Glacial
Clays and Brickearth. Typically these are all soft mud based processes. Levels of
usage in 2012 were very similar, and slightly up, on 2011 levels of usage.
The Hydrocarbon products have the highest usage in the Keuper and Weald based
clay bricks. These tend to be clays with little or no naturally occurring organic
content, where the use of the additive is primarily for the development of the
aesthetic (colour). Hydrocarbon usage in the Weald and Other clay sites has
increased slightly, reflecting the slight increase in production from these sites since
2011.
The largest group of Mineral MARSS are used in conjunction with Shales. As
previously described these are dominated by the use of similar type materials
recovered from other mineral extraction operations, as by products. Mineral group
usage in the Carboniferous Shale works has decreased by around 20,000t since 2011,
reflecting the decrease in production from these sites, however the use of Minerals in
the Etruria based bodies has increased by around 23,000t in the same period. In
addition the Keuper based sites have decreased Mineral usage by 10,000t and the
Weald and Other clay based sites also show a slight decrease in their usage.
Industrial Mineral usage has ceased in 2012., and there are no recorded Organic
materials usage during the reporting period.
4
HISTORIC DATA
MARSS Group
2012
2011
2010
2009
Ash
14,350
12,899
12,426
21,582
8,630
Hydrocarbons
37,234
39,241
29,443
25,306
0
1,777
650
0
Minerals
316,210
321,346
263,218
Organics
0
0
0
367,794
375,263
305,767
Ind’ Minerals
Totals
2008
2007
2006
2005
8,650
18,720
27,634
42,704
59,016
59,401
57,600
6,950
11,222
13,530
39,485
189,081
292,935
445,968
630,907
502,761
8
1,124
1,610
1,850
2,530
235,977
352,343
526,466
724,408
630,011
Table 4.1 MARSS usage grouped by MARSS type showing the tonnages used
in the 2005-2012.
Table 4.1 shows the breakdown of MARSS usage, by type, by year. Looking at the
specific data first, Ash products have increased slightly in 2012, following a dramatic
decreased in usage in 2010. This is likely to be due to changes in production output
from the “soft mud” works, however it may also reflect the availability of the Ash
products, specifically PFA and the associated cost, however Town Ash usage is up, by
approximately 700t, as highlighted in Table 4.2.
The Hydrocarbon usage had remained relatively static up to 2008, however a
significant fall is recorded in usage during 2008, and an even greater one in 2009. In
2010 there has been a small increase in the tonnage of Hydrocarbon usage, dominated
by the increase in the coal slurry usage, which in turn has off set the reductions in the
Pet/Met Coke and Anthracite usage. 2011 saw a significant increase again in the
Hydrocarbon usage, up by just short of 10,000t within the reporting period. Increased
production, specifically within the Soft Mud production sites has accounted for the
majority of this increase, though in 2012, the usage has fallen by approximately
2,000t.
The Industrial Minerals group of MARSS has reduced significantly during the 20052010 period, reflecting the closure of production of one specific range of bricks by one
manufacturer, where slag additions were a main body additive, and possibly the
availability and price of these materials. Slag, in general, are also used in the
aggregates and cement replacement sectors of construction materials and are thus
more price sensitive than some other MARSS products that have less potential
alternative uses. There was no recorded use of any Industrial Minerals materials for
2012.
The largest fluctuations in MARSS fall within the Minerals Group. The use of fireclay
from “recycled” operations reduced by nearly 70,000t in 2009. This is attributed mainly
to the reduction in manufacturing from sites in the Midlands and North during the
survey period. In 2010 the usage increased and recovered approximately 50% of this
loss. During 2011 Fireclay usage was back up to 2008 levels of approximately
158,000t a function of the increase in production at specific factories, though during
2012, this has fallen back by approximately 48,000t.
MARSS
Group
Ash
MARSS Type
2012
2011
2010
2009
2008
2007
2006
2005
Boiler Bottom Ash
0
0
0
0
0
0
370
0
Ash
ISSA
0
0
0
0
0
0
470
564
Ash
PFA
12,566
11,800
11,400
21,100
7,600
7,600
12,300
7,250
Ash
Town Ash
1,784
1,099
1,026
482
1,030
1,050
5,580
19,820
Hydrocarbon Anthracite Fines
12,966
10,626
5,235
7,205
10,591
9,889
7,640
3,324
Hydrocarbon Coal Slurry
14,862
17,176
16,300
8,830
16,756
19,796
18,820
27,640
Hydrocarbon Coke Breeze
2,107
4,972
3,029
2,791
8,502
25,731
29,341
26,636
Hydrocarbon
Industrial
Mineral
Industrial
Mineral
Industrial
Mineral
Industrial
Mineral
Industrial
Mineral
Mineral
Petcoke
7,299
6,467
4,879
6,480
6,855
3,600
3,600
0
Grog
0
1,721
0
0
160
89
0
4,188
Foundry Sands
0
0
0
0
0
0
0
20
Rockwool
0
0
0
0
0
60
60
500
Slag (All)
0
0
0
0
6,790
11,073
13,460
19,008
Glass
0
56
650
0
0
0
0
0
Boulder Clay
0
0
0
0
0
0
45,290
0
Mineral
0
0
4,144
13,700
12,319
20,060
9,500
10,747
12,406
3,791
4,043
1,307
9,486
5,060
5,012
Mineral
Colliery Spoil
Pottery Waste
(Filter cake )
Fireclay
0
109,928
158,196
114,803
88,384
156,936
266,080
289,331
396,795
Mineral
Keuper Marl
0
0
0
0
1,320
18,180
5,440
0
Mineral
Etruria Marl
34,011
17,974
52,121
0
0
0
0
0
Mineral
Lime
2,127
2,430
2,085
0
4,470
7,398
6,430
4,490
Mineral
Limestone
0
0
0
0
0
57
0
0
Mineral
Paper Sludge
0
0
0
0
0
0
1,360
0
Mineral
Red Shale
0
0
0
0
0
75,665
114,900
0
Mineral
Shale
109,938
83,284
62,117
63,425
65,822
41,279
25,050
0
Mineral
47,056
28,301
28,572
48,360
13,414
116,946
101,476
0
0
0
513
1,020
2,090
1,040
1,258
Organic
Silt Sand
Water Treatment
Residue
Sawdust
49,459
0
0
0
0
1,114
1,600
1,820
2,500
Organic
Starch/Sugar
Mineral
Mineral
TOTAL
0
0
0
8
10
10
30
30
367,794
375,263
305,767
235,977
352,343
526,466
724,398
630,011
Table 4.2 Breakdown of MARSS by specific MARSS Type 2005-2012. Values in tonnes
There has been an increase in Shale usage and a slight increase in Silt Sands from
other mineral winning operations. The use of Keuper Marls in the Midlands has
declined in direct response to the decline in the availability of this type of by-product in
the manufacturing regions, and can therefore be attributed to a supply limiting issue.
Filter press residues from the pottery industry have remained high, following the
dramatic rise in 2011 and now accounts for approximately 10,750t in 2012, slightly
down from 12,406t in 2011.
Recycled Etruria Marl, is being recovered from specific sites and is being used in a number of
brickworks. As with all mineral based arisings, this is likely to be transient in nature and the
longer term supply security is limited, as shown by the fluctuating consumption since 2010.