Hey all, we have a lot of new updates to tell you about. Last time we left off we had just visited Karnivel. We had made 8 bricks using the mold we brought from home and our presumed knowledge of an acceptable clay-water-sawdust ratio for the brick mixture. Two days ago the bricks were ready for firing, and so we went to Manoj with a picture of the kilns Pete and I spotted this summer while walking through the fields near Leinguda. Because we only needed to fire 8 bricks, the process would not be so elaborate as to require a large kiln structure. Rather, Manoj helped us build a small firing set up exactly appropriate for 8 bricks. It started by placing four large sized stones forming the corners of a rectangle on the floor. On top of this formation he set a bed of small sticks, and then on top of this placed the 8 bricks, 3 on the bottom, three on the next level, and then one on top spanning the gaps between the bricks below it. (One of the bricks fell apart when we removed it from the mold, so we only fired 7.) After this, we found some larger wood pieces and surrounded the stack of bricks with them, essentially building a pyre of bricks. We tended the fire for about an hour and half, adding more sticks to the side to keep it from dying down. In future prototyping efforts, we should likely consider the brick making process as a fundamental variable in fuel consumption. In order to fire 7 bricks, we used a good deal of wood and produced a very smoky fire. (I would imagine 2-3 full fire places worth of wood was required for the firing.) That said, it is likely that as implementation scales up, brick firing will be much more efficient as kilns can be made…
Manoj told us to leave the fire until it burned down, and that he would check it in the morning to see that the bricks were okay. This is where it gets kind of complicated. Yesterday morning we headed in to Bhawanipatna, excited and apprehensive as to how the bricks would turn out. We were unsure whether the firing process was thorough enough, questioning whether or not all of the sawdust in the bricks would fire off to make them porous enough fpr a combustion chamber. We also didn’t know if the bricks would hold up. Unfortunately, this first batch of bricks did not make it. Upon checking them the next morning, it was visibly apparent that the bricks were not stable enough for a combustion chamber. When we picked them up, this was confirmed. The fired bricks were dusty, and with any additional force applied, crumbled to the touch. The main culprits are likely the clay type, as we started with a very dry clay taken from the ground’s top layer, as well as an overabundance of saw dust.
What followed was a reexamination of our approach to brick making. Before coming to India this winter, we proceeded ahead with the assumption that the ratio that worked for us in the states–12 parts water, 9 parts clay, and 5 parts water–would hold in the field as well. Placing a little bit too much faith in Aprovecho’s tutorial on making a biomass stove, coupled with the results we had obtained in the civil lab with the Improved Biomass Stove team, we failed to question enough the efficacy of variant clay types on brick strength. Without appropriate foresight, at least this is how I saw it, we planned the trip around dilligently getting a prototype finished, without first obtaining more knowledge about the nature of the clay and the traditional methods of brick making in the village.
I’m going to admit that after seeing our bricks fail, and realizing in hindsight we should’ve had a different approach from the beginning, I was truly disheartened. While this was the appropriate time to get over myself and just rethink our approach, I was initially demotivated–which is the last thing we needed at the moment. Thereafter however, we managed to turn the day around. Well, the villagers did…
While we spoke with Rashmi about why our mixture was unsuccessful, we started getting the materials together for more bricks. Rashmi essentially explained that he knew the brick mixture wouldn’t work because there was too much wood dust, and that perhaps we should consider including sand in the mixture to add more structural integrity to the bricks. He helped us consider different new ratios for brick mixture, and we ultimately put together four small batches of different ratios that are drying as I type. Essentially, the ratios are testing what mixture of the dry clay and sawdust will survive a firing, in the hope that a mixture will produce a porous enough brick that is still sturdy. Once we set this up, Rashmi asked us to walk with him so that he could show us something.
We gathered our things from the powerhouse and followed him to his home. Behind his house, he took us through a trail that led to a field where about 12 men were digging up clay from a trench about 3 feet deep and 20 feet wide. They were adding water and stomping the clay to mix and wet it further. Next to the trench was an area of hundreds of bricks drying under hay. Despite the fact that just about all of the men making the bricks were drunk, they were highly efficient, with two molds with handles. According to them the handles make it much easier to flip the molds once filled with clay. One of the village boys was working with them who I had never seen before. Rashmi explained that he is one of his students, but often has to skip school to do work like brick making to help his family make money. They are very poor. Accordingly, they make bricks in bulk and then fire them in kilns, selling then for 1 rupee per brick to people looking to make houses.
Rashmi asked the boy to help us out, and so he grabbed a bunch of clay and started mixing it on the ground in front of us. As he mixed, we added saw dust, creating a mixture that was more or less subjectively eyed based on whether or not the mixture would maintain its shape without cracking once removed from the mold. Thereafter, he started by wetting the mold, and then sprinkling a thin layer of sand in it. He also covered the outer surface of the clay-sawdust mixture with sand before putting it in the mold. This is how they get the bricks to slide out from the mold immediately without waiting for the clay to dry at all. Because of this technique, they can produce hundreds of bricks in a day with just two molds. And it took us 2 days to be able to produce 8 bricks!
As we made 10 bricks using the village technique and our molds, the men working explained that our molds were not good. For their purposes, they prefer two parallel surfaces of the mold to have excess wood extending beyond the rectangular substructure, acting as handles. They also explain that making two molds attached is terribly inefficient in light of their technique. (It looks like we have some work cut out for us Biomass team!) After about 20 minutes, we had completed 10 bricks that are now drying among the others. Rashmi expected them to be ready within 1-2 days.
What stands now is that we do indeed need to continue to rethink our prototyping approach in the village. Standing and watching the villagers make bricks professionally was briefly embarassing, but most importantly humbling and enlightening. We can’t imagine what Rashmi was thinking as he watched us spend so much time on so few bricks. I think that because he watched us make bricks over the summer, he assumed that this technique was done for a specific reason. After we fired, it became apparent to him that we just didn’t have enough experience making bricks. In short, we learned a really important lesson about a participatory rural approach to development yesterday. While we’ve been to small events that talk about the process of engaging the villagers in their own development process, it may be that we can only really understand the effectiveness of this technique once we are in the field. We needed to see for ourselves how incredibly competent the people of Purunaguma are at tasks that are foreign to our skill set as students from a developed country. While I’ve read case studies about people in villages performing tasks better than those “experts” that come to work with them, it seems I only grasped them on the surface. The idea of a participatory approach seems to make perfect sense, but it was only when I saw the capability of the village men and boys that I really understood the value of engaging people in the process of building this chullah prototype. Had we known to take a few days to just ask about the traditional brick making process, a modification of it for our own needs could have ensued early on in the trip. I’m fully aware that the type of foresight required for this type of trip planning is likely an unjust burden to place on the travel team and I still think we’ve gotten a tremendous amount done here in so little time. Essentially I just want to highlight how powerful a lesson we learned yesterday, and hope it is obvious that this can give us some crucial perspective as we approach the next semester and our implementation trip. We will be sure to update you guys ASAP about the status of the bricks, and are trying our best to bring back samples of both types of clay as well as fired bricks.
On another note, those of you on the India team might be aware that some type of first-aid and basic treatment program in the village has been a secondary goal of ours for a while. After seeing Dipti, she shot out some ideas about how she envisioned the next steps of livelihood improvement with the advent of the soon-to-be community center and mill. She brought up first aid, recalling that we used our med kit this summer to help clean and close up the village mason’s infected finger. (Apparently, everyone in the village still remembers this, and a few people have mentioned it in passing.) So, anticipating some days of wait time as our new bricks dry, we went to the Bhawanipatna market last night and put together a basic med kit for the village. This includes antibiotics, electrolyte replacements for diarrhea, ibuprofen for breaking fevers, wound treatments supplies, etc. (While it sounds elaborate the medkit only came about to about 15 USD.) Today, we came in to Purunaguma early, starting at the village daycare center and moving on, discussing to our best ability the importance of first aid. Several people voiced issues–there seems to be a lot of arthritis pain among the adults in the village, and two children were brought to us with fever. We also visited the head of the village committee, who lives in Leinguda. He helped us gather some of the tribal villagers of Leinguda so that we could explain what we had done.
Treating the people in the village was fun, and it was a good experience as we got to interact with more people. It is nonetheless clear, that some more advanced model needs to be worked out for an emergency first aid program in the village. We have been working on a manual for the supplies we bought, and hope this can be a good starting point for a sustained and collective initiative in the village for first aid and community medical needs.
Danielle and Amrita will update you guys soon on the last stages of prototyping. We still need to fire our bricks, and at the same time, work on a finalized instruction manual for building a prototype. We are hoping that Manoj and Pabitra will be able to continue work on this when we are gone, and plan to discuss this with them more thoroughly as soon as possible.
-Matt