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Cutting weapons at the Weapons Destruction Workshop in Bujumbura. |
MAG is working to develop a small eco-foundry to recycle Burundian scrap metal currently exported to neighbouring countries and employ more than 30 former combatants, including many disabled ones.
At the beginning of 2009, the Burundian Minister of Defence and former combatants proposed a challenge to MAG: finding a way to recycle usefully the scrap metal resulting from weapon destruction, while using local resources and employing those who fought during the decade-long civil war.
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A container full of scrap metal resulting from the destruction of weapons. |
MAG had been supporting the Force de Defense Nationale (FDN – Burundian Army) in destroying their obsolete weapons since 2007.
The weapons were destroyed by cutting at a Weapons Destruction Workshop operated by a team of FDN personnel with the technical support of MAG. At the time, the metal pieces were overflowing from a 20-feet container [see photo, left].
After the Minister’s request, MAG Burundi started its own research into smelting technology, from very modern portable smelters to traditional metal working techniques of indigenous groups of Burundi, and finally turned to outside specialist support.
It was the École Nationale Supérieure des Arts et Métiers (ENSAM) from Lille, France, that accepted the challenge.
After an exploratory mission in November 2009, Professor Philippe Costes and his students worked for over a year to develop ovens that would use neither electricity nor charcoal (deforestation is a serious issue in Burundi, so using charcoal would not have been sustainable) and only local resources to smelt any type of metal, from weapons but also from old vehicles or kitchen tools.
In February this year, a team from ENSAM returned to Burundi to install and test two ovens they had developed in their laboratory. One could not be tested due to a delay in the production of some metal parts by a local company, but the other oven successfully passed the test, reaching even higher temperatures using peat and locally-produced vegetal waste bricks than originally thought.
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The two ovens were built by a team of six Burundian former combatants (two from the ex-Burundian Army FAB, and four from the two main ex-rebel groups FDD and FNL, including one woman), who were then trained in basic smelting and sand casting techniques. They succeeded in producing hoes and art pieces by smelting weapon magazines.
Before starting a larger scale production, the technology still requires some minor improvements and the team needs further training.
“We thank MAG and the ENSAM for teaching us a trade that will allow us to support our families, but also do something good for our country,” said Serge, the team leader. “We are eager to continue the training and produce more hoes and other items which Burundians need.”
Peace-building
It is expected that when at full production, this small eco-foundry will be able to recycle all the Burundian scrap metal currently exported to neighbouring countries and employ more than 30 former combatants, including many disabled ones.
The reintegration of former combatants after a civil war that severely disrupted the economy is a crucial task for the building of a sustainable peace in Burundi.
The exploratory and experimentation missions were both funded by the Swiss Government, and MAG is now looking for further funding to support this project.
For more on the experience of one of the ENSAM students who participated to the February experimentation mission:
http://fondeurs-du-burundi.over-blog.com/ (in French)
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Building of the first oven. |
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Production of smelting pots by a Twa woman (Twas are an indigenous ethnic group of Burundi much discriminated against). |
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Preparation of kaolin (refractory clay) and a specific kind of sand to be used in the construction of the ovens and the casts. |
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Preparation of the weapon magazines pieces to be smelted. |
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Professor Costes from ENSAM teaches to ex-combatants how to make sand casts. |
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One of the ENSAM students, Alexandre Behot, continues the training. |
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The ex-combatants can now make good casts by themselves. |
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Pieces of weapon magazines are warmed on the outside of the oven and then introduced piece by piece into the pot for smelting. |
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Under the supervision of Quentin Pinauldt and Alexandre Behot, the two ENSAM students who participated in this experimentation mission, the team checks the temperature to see if the metal is hot enough to be poured in the moulds. |
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The oven being hyperventilated during the fusion. |
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The oven during the fusion; in front, the mould into which the metal will be poured. |
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The pot is taken out of the oven... |
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...to be transferred to the lifter... |
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...and the metal, still at a liquid state, is finally poured into the casts. |
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After letting the cast cool down for 30 minutes, the team breaks it open to discover the resulting pieces. |
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From a weapon of war to art. The pieces still have to be polished; on the right, the original wooden statue. [Photos: MAG Burundi] |
20 April 2011
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• Reporting by Julie Claveau, Country Programme Manager, MAG Burundi |
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