SOLID CONCRETE BLOCK MASONRY SCHEME

Introduction Concrete can be converted into precast masonry units of suitable size to be used for walling. Use of such blocks is more appropriate in a region where bricks are costly, poor in strength and are not available. Depending upon the structural requirements of masonry units, concrete mix can be designed using available ingredients. The blocks can be cast to desired shape and size to facilitate construction of wall of requisite thickness and appearance. A thickness as low as 15 cm is feasible for a load bearing wall and 10 cm for a non-load bearing wall, adopting solid concrete blocks. A series of lean concrete mixes were developed at the Central Building Research Institute, using gap-graded concrete with 50 mm coarse aggregate and fine aggregate. Pilot-scale trials and field applications have proved that the newly produced masonry unit has significant techno-economic potential. This Building Research Note describes, in brief, the manual production process of solid concrete masonry blocks, their physical properties, design and construction details, material and labour constants, involved in production and assembly of the blocks. The Block It has been observed that a block weighing about 16 to 18 kg. can be handled by a mazdoor or a mason. The Institute had been promoting the use of precast stone masonry block, weighing about 18 kg. of a nominal size of 15x20x30 cm. The masonry unit described in this Research Note also is of the same size and weight. The dimensions allow the designer to use the same block for wall thicknesses of 15 cm. 20 cm. or even 30 cm. only by changing its face and orientation. This does not impose any structural problems within the masonry units, as the strength of block is fairly consistent in all directions. Although the nominal size of the block is 30x20x15 cm. the actual size is 29x20x14 cm. These dimensions are assumed for commonly occurring 20 cm. wall thickness. Thus, each block with 10 mm. thick horizontal and vertical joints, occupy effective measurements of 30x20x15 cm. PRODUCTION OF BLOCKS Casting Platform The blocks are produced on a smooth, level and hard surface of 30 mm. thick 1:3:6 cement concrete platform simultaneously finished smooth with 1:3 mortar. A base of brick soling of 12 cm thick lean concrete 1:8:16 may be used as a sub grade. The platform shall be cast in bays of

2m to av void random m surface-cra acks. A casting platform of about 80 0 m (10 mx8 8 m preferab bly) is required for productio on of 500 blo ocks per day y. Mould A battery y of single moulds m fabric cated with mild steel plate is used u to cast t the blocks. Steel moulds yield clean, sh harp edged blocks b with pre p finished faces. f It is advisa able to use 8 to 20 mo oulds arrang ged in a row with no gap in between b to fo orm a batter ry. Each mould is provided wi ith two hand dles made of f ms rod to facilita ate lifting of the t mould. Concrete e Mix Properly selected, clean c ingred dients of concrete shou uld be used d in appropr riate proport tions. Mixing of o concrete should be done d preferably in a mixer. m Basica ally two typ pes of mixes s are proposed d to carter fo or situations (i) where co oarse sand is available and a (ii) wher re coarse sa and is not availa able. Althoug gh it is advis sable to do precise p mix design d with the t available e ingredients s at a place, the e following two t mixes co ould be follow wed in gene eral with loca al modificatio ons. ate Compos sition A Aggrega 28% fine e sand (FM 1.35) (BD* 12 295) 28% 10m mm aggregat te (FM 3.40 0) (BD 1422) ) 44% 50m mm aggregat te (Crushed d or broken) (BD 1367) Agg gregate Ce ement 18 12 9 *BD Bu ulk density (k kg/m3) ate Compos sition B Aggrega 56% cou urse sand (F FM 3.1) (BD* 165 50) 44% 50m mm aggrega ate (Crushed d or broken) (BD 1367) C Cement composition per r m3 of concr rete 2.40 3.60 4.65 Water W C Cement 1.60 1.14 0.90 Cemen nt consumpt tion per m3 of o concrete O 2.20 3.28 4.33

Ag ggregate C Cement 18 12 9

Water Cement 1.20 0.85 0.65

Release Agents Before starting and also after completion of the work, the platform and the moulds are cleaned properly. Lubricating oil is applied inside the moulds and on the area of platform under the moulds, to act as release agent. This helps in an easy, clean release of blocks and avoids the breakage of platform. The blocks may also be cast over alkathene sheet for easy release from the casting floor. Concreting The moulds are filled up thoroughly by using a trowel, at compacted with a surface vibrator. Pressure is exerted on the handles of the vibrator to impart the vibrations more effectively. Moulds of the compacted blocks are lifted up in the same sequence of concreting and are arranged further in the row for reuse. Filling of the moulds is done in two stages. Vibration should be stopped as soon as there is occurrence of slurry under the mould sides. The top is finished with the slurry formed at the surface and that available under the sides. A plate vibrator with a frequency of 3,000 VPM is often used. It is however, advisable to use a high frequency vibrator of 5,000-6,000 frequency, if available. In remote areas without any power supply, the concrete blocks may be cast by using a vibrator run by a 1KW portable generator. For mass production of these blocks, it is recommended to use the concrete block making machine developed by CBRI, for which a Building Research Note is available. Curing and Stacking The blocks are cured on the casting yard for first 24 to 48 hrs, depending on the weather conditions. Handling before this period may damage the blocks. Half kg. of calcium chloride per bag of cement may be used in extreme cold weather to achieve this handling strength. The blocks lifted from the casting yard are stacked on a nearby level ground over a layer of sand to ensure a full surface contact. Each day's production is accommodated in not more than two tiers of blocks. The blocks cured for three weeks by frequent sprinkling of water. This is followed by two to three weeks of air drying. It must be ensured that the block is fully dry before use in masonry, to avoid shrinkage cracks. Thermal Performance Thermal performance of solid masonry block for various wall thicknesses is tabulated below U value (Kcal/hr/C/m) 3.750 2.668 2.288 1.931 1.790 Thermal Performance Index (TPI) 186 132 96 71 95

Wall thickness (cm) 10 20 30 40 25 cm thick cavity wall with 5 cm cavity between two walls of 10 cm

For non-industrial buildings specified U-value is less than 2Kal/hr/C/mand thermal performance index is less than 100. Thus the figures in bracket satisfy the thermal

requirements. Theoretically a wall thickness of 30 cm and above as well as a 10-5-10 cavity wall with solid concrete blocks offer satisfactory thermal insulation. However in practice only the south-west wall has a severe exposure to the sun, if no sun shading device is provided. Only such severely exposed wall be of 30cm, all other external walls be of 30 cm, and all other external walls may be 20cm thick. Physical Properties of block The physical properties of block are mainly governed by the nature of ingredients and their proportioning. Trials were done on two aggregate compositions ('A' and 'B' as indicated under heading 'Concrete Mix') and physical properties were found out for different aggregate cement ratios and their optimum water cement ratios. The compressive strength, water absorption, drying shrinkage and moisture movement were determined as per respective Indian Standard and the result is tabulated below:
Aggregate Composition A A A Aggregate cement ratio 18 12 9 Water Cement ratio 1.60 1.14 0.90 Cement consumption bags/m 2.20 3.28 4.33 Av. density (kg/m) 2240 2346 2360 Av. compressive strength (kg/m) 72 108 148 Water Absorption (%) 4.9 4.7 4.3 Drying shrinkage (%) 0.026 0.027 0.036 Moisture movement (%) 0.022 0.027 0.036 Initial rate of absorption gms/200cm 11 (All figures are based on laboratory trials) B 18 1.20 2.40 2453 100 4.5 0.016 0.016 13 B 12 0.85 3.60 2480 145 4.5 B 9 0.65 4.65 2480 176 4.3 0.040 0.040 -

Dimensional Tolerance Deviation in the block length should not be more than () 5mm, and that in the height and width of the block should not be more than (3mm) these tolerance limits can be achieved without any difficulty with the help of steel moulds fabricated to an accuracy of 3.0mm in length and 1.5mm in height and width. Structural Design Masonry Strength The wall made of solid concrete masonry blocks is designed like other masonry wall. The values of basic permissible stresses given in IS: 1905-1980. "Structural Safety of Building Masonry Wall" hold good for solid concrete masonry blocks also. (Although the actual values achieved are about 30% higher). Provision of vertical reinforcement at corners and opening to impart desired protection to the structure in seismic regions can easily be made by using special blocks with recess. Masonry Construction Mortar Composition Commonly used 1:6 cement sand mortar is compatible to solid concrete blocks. However, it is preferable to use 1:2:9 composite mortars if good quality lime is available. The composite

mortar has a quality of autogenous healing of shrinking cracks. In case the mortar should be such that the minimum flow after suction should be 60% to 70% of that before suction. Masonry Bonds Typical 'T' and 'L' junctions occurring generally in various combinations of wall thickness are illustrated in figure 6(a) to 6(h). Alternate courses are clearly indicated in the sketches. The figures illustrate two typical wall to pilaster junctions. These also indicate how bonding for 20cm thick wall with special grooved blocks is provided, which facilitates introduction of vertical reinforcement at opening and corners, wherever desired. Field Applications 1) At Dehradun, 330 residential quarters (LIG & EWS) have been constructed by MDDA at Dallanwala site. 2) A 2000 meter long boundary wall of CBRI colony and 40 meter long boundary wall of director's residence. 3) For the construction of 8 NV schools and 1000 residential quarters in Rajasthan, where 80 lacks blocks were used in place of 4 caror bricks. Basic Data for Material and Labour Requirement PRODUCTION OF BLOCKS Item For 30x20x25 (29x20x14 nominal) For 30x15x20 (29x15x14 nominal) For 30x10x15 (29x10x14 nominal) 0.08 13

(a) Mould (one) MS plate 4mm thick(m)

0.15

0.12 16

Fabrication charges 20 including cost of handle (Lump sum Rs.) (b) Casting of blocks (Aggr : cement=18) (i) Material (100 blocks) * Cement * Coarse sand * Fine sand * Coarse aggr. 50mm (m3) * Coarse aggr. 10mm (m3) (iii) Labour (100 Blocks) * Mason(man days) * Unskilled(man days) (iii) casting platform mould oil etc. lump sum in Rs. (100 blocks) Mix A Mix.B

Mix A

Mix.B

Mix A

Mix.B

1.787 ---0.345 0.527 0.314

1.950 0.590 --0.570 ----

1.340 ----0.260 0.392 0.236

1.460 0.444 ---0.427 -----

0.893 ---0.172 0.261 0.157

0.975 0.295 ---0.285

0.33 1.66 1.60

---------

0.28 1.43 1.30

---------

0.25 1.25 1.00

-----------

Observed Production

By gang of 1 mason and 8 unskilled workers

900

1000

1100

(This includes casting, curing & handling on site) Masonry work Material for 1m3 (30x20x15 size) Number of blocks Mortar 1:6(m3) Labour ( For 1m3) in substructure Mason(mandays) Unskilled(mandays) Labour (for 1m3)in superstructure, upto 2nd floor level Mason(mandays) Unskilled (mandays) 20 cm wall (5 cm2) 0.75 1.60

115 0.1 0.65 1.30 15 cm wall (6.66 m2) 0.80 1.60 10 cm wall (10m2) 1.00 2.00

Basic Data for Material and Labour Requirements In cost of production of blocks, the labour included casting, lifting, curing and stacking of blocks with in a lead of 10 meters. Cost of scaffolding, T&P, water, contractor's profit and overheads are to be added extra. The labour for transportation of blocks from stacking yard to construction site has been included for a lead 0.40, 0.30, and 0.20 mandays of unskilled worker for 100 blocks may be added for 20 cm, 15 cm, and cm thick blocks respectively. In general the requirement of fractional blocks is follows, although it will vary with the type and size of building. 1/2 blocks 8 to 10% 2/3 blocks 3% 1/3 blocks 2% 3/4 blocks 2% Performance against Rain Water Penetration Laboratory tests were conducted on wall panels, by using simulated rainfall to find out their resistance to water penetration. Occurrence of second damp patch was considered as the failure criteria. Thus the 'Ultimate Equivalent Rainfall' was found out, from which "Safe Rainfall" was computed by applying a factor of safety equal to two. Specimens with three commonly adopted specifications were tested side by side for comparison. The test result indicated that the water penetration takes place through joints, mainly the vertical joints. It is therefore advisable to take extra care in placing mortar along the vertical joints surfaces. In general the solid concrete block masonry should be provided with 12 mm thick plaster on external face to avoid dampness, however in the hot and dry regions with low rainfall, naked walls can be provided with 12mm thick plaster on external face to avoid dampness, however in the hot and dry regions with low rainfall, naked walls can be provided. Performance of the 20cm, externally plastered solid concrete block masonry was found to be better than 23 cm brick wall with identical specifications. NOTE: blended sand of fineness modulus of 1.8 was used for making cement mortar.

Advantages The solid Concrete Block Masonry has following advantages 1) 2) 3) 4) It is a labour intensive appropriate technique and hence does not call for for heavy capital investment. It is suitable for site oriented production. Thus transportation cost can be eliminated. Quality control is easy. The wall thickness is reduced to 20 cm for load bearing wall and 10cm for partition walls. Thereby reducing the cubic contents of the material, obviously resulting in to saving in substructure as well as superstructure. It also offers larger floor area for the same plinth area as compared to conventional random rubble masonry or even non modular brick walling. Internal plaster can be eliminated with proper care during production and laying. When plastered, the thickness of the plaster required is also lesser as compared to that in the case of brick wall. Can be produced in remote areas without power supply by using a portable 1 KW generator.

5)

6)

Do's and Don'ts 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) Plan the building to a 10 cm module to avoid cutting of the blocks. Check the accuracy of new moulds before starting the production. Check accuracy of the angles of the mould every day, before starting the work. Keep strict watch on quality and the proportions of ingredients used in concrete. Modify the mix to suit the local sand and coarse aggregate. Confirm result of the trial mixes before commencement of the production of blocks. It is a must. Do not forget to use release agent or alkathene sheet on the platform before casting. Clean the moulds, alkathene sheet and, the production floor as soon as the day's production is closed. Do not disturb the freshly cast blocks before 24 hrs, in any case. Do temporary stacking near the casting yard on a level ground provided with sand cushioning. Each day's production is accommodated in not more than 2 tiers. Cure the blocks by sprinkling water for three weeks and then air dry for two to three weeks depending upon weather conditions. Do not use a partially dry block in masonry. Do not soak the block before using in the masonry. It should be only surface wet. So, a light water spray, about half an hour an hour before use, is enough. Do not use harsh mortar in masonry. Fill up the vertical joints with extra care. Provide control joints at appropriate locations for wall more than 10 meter long.

Figure 1 Materials and Moulds

Figure 4
Figure 2, 3 & 4 different stages of casting

Figure 2

Figure 5 : Construction site at dallanwala, Dehradun

Figure 6 a 30cm pilaster with 20 cm wall

Figure 3

Figure 6b 40cm pilaster with 20 cm wall

Fig. 6c corner T- Junction of 20 x20 cm wall Fig.6d corner & T- Junction of 15x 15cm wall

Fig.6e corner & T- Junction of 20x 10cm wall

Fig.6g corner & T- Junction of 15x 10cm wall

Fig.6f corner & T- Junction of 10x 10cm wall

Fig.6h corner & T- Junction of 30x 30cm wall

CONCRETE BLOCK MAKING MACHINE

Introduction Concrete blocks can be made either by manual method or with a block making machine. In the manual method single block moulds kept in a row are often employed and concrete is compacted in the moulds with a plate vibrator. On the other hand, the block making machine invariably has a replaceable gang mould system to produce two to eight blocks (or even more) in one operation of casting. The vibrating system in the machine is an integral part of the mould. The machine made blocks are superior in strength and finish due to better control possible during compaction of concrete. The production of blocks becomes much faster with the machine as compared to the manual method.\ Indigenous block making machines are available for making concrete blocks of solid and hollow type. When stone blocks or large aggregate concrete blocks are cast on some of these machines, these blocks are found to be deficient in terms of strength and other qualities. It was observed during trials that these machines were suitable for handling only those concrete mixes in which maximum size of the aggregate was limited to about 15mm. Concrete with bigger aggregates showed segregation and lack of compaction. The stone and solid concrete blocks developed by CBRI are made with concrete having much bigger aggregates, 40mm and above and therefore, the available block making machines could not been actively utilized for casting these blocks In absence of a suitable machine, both the stone blocks and the large aggregate Blocks are cast in the field by manual method using single mould and plate vibrator. The method has been found slow for mass production. An altogether new type of block making machine was therefore, developed by CBRI to promote and popularize its low cost concrete blocks. The machine works on the principle of pressure-vibration technique and is capable of effectively handling concrete mixes with a wide range of consistency. The machine has been successfully used for casting stone blocks, large aggregate concrete blocks and the traditional concrete blocks. CBRIs Block Making Machine Design Parameters Compaction of concrete in mould depends on frequency. Amplitude and duration of vibration,. These in turn depend on the conditions of vibrating system comprising the mould and the concrete to it. For concrete having coarse fraction of aggregate, a lower frequency of vibration and high amplitude are required whereas for concrete containing fine fractions, the high frequency with low amplitude is necessary. Since concrete normally contains particles of varying sites, the most satisfactory compaction is obtained by using vibrators with different speed of vibration as in case of poly frequency vibrators. This however, makes the vibrating system costly. The vibrators used in practice therefore work only at single frequency suitable for average particle size of the concrete to be compacted. By using increased frequency of vibration, it is possible to obtain high values of exciting forces with a much lighter vibrating system, but with increased vibration frequencies, the resistance of wear of the vibrator is markedly reduced. The most widely used form of vibrators therefore have vibration frequencies

varying from 2800 to 6000 VPM and amplitude of vibrations correspondingly varying from 1.0 to 0.1 mm. Besides frequency and amplitude, the acceleration of vibration is also an important factor. For external vibration of concrete (as in case of block making machines in general), the criterion for effective compaction at constant workability and constant time of vibrations acceleration with the provision that at frequencies up to 6000 VPM, the acceleration is greater than 1.5 g and at frequencies greater than 0.04 mm. The available block making machines work at higher side of frequency range, 6000 VPM and lower amplitudes and are therefore more suitable for concrete with smaller aggregates. Since the new block making machine was required to primarily cast the stone blocks and the large aggregate concrete block wherein lean mixes of concrete with larger size aggregates are involved, a lower frequency of 3000 VPM and a corresponding higher amplitude of 1.5 mm with an acceleration of about 7 g were considered desirable in the light of the recommendations of IS: 4656 1968 Specifications for Form Vibrators for Concrete. A top pressure of 30 to 100 gm/cm2 has been reported to improve the flow ability of concrete during vibration and is particularly helpful in handling stiff mixes. A top pressure of about 50 to 80 gm/cm2 was found effective in case of stone blocks and large aggregate blocks respectively. Features The CBRIs block making machine (Fig.1) comprises a four wheel trolley with front pair of wheels having steering arrangement and a portal frame which its top carries a horizontal power shift connected to an electric motor through V belt and pulleys mould block with a number of mould cavities placed centrally inside the portal frame. Two vertical power screws, onset each end of the mould block are used to raise or lower down the mould block. The lower end of the power screw after passing through the edge of mould block is supported in a bearing which in turn is supported with the trolley. The top end of power screw is connected with the aforesaid horizontal power shaft through gears. The arrangement helps in lifting or lowering down the mould block by motor power. The mould block has a number of cavities or moulds for castling more than one block at a time. On form vibrator is rigidly fixed with each opposite face of longer side of the mould block. A bridge arranged just above the mould block carries as many number pressure platens as there are mould cavities in the mould block. The pressure platens keep the concrete pressed in the mould during vibration and later help during ejection of the new casts blocks from the moulds. The bridge also carries a system which provides required amount of to pressure through the pressure platens on the concrete in moulds at the time of the compaction of concrete. The vertical upward movement of the bridge is achieved through the mould block when the later is lifted up with the help of two power screws. The connection between the power screws and the mould block is through two lifting pads each fitted on the edge of opposite shorter faces of the mould block. The lifting pads have built-in vibration isolating devices that help in confining the vibrations (during compaction of concrete) only to the mould block. Salient features of the machine are given in the following: A portable egg laying type machine. Six blocks of size 30x20x15 cm case in one operation. Output of 120 to 150 blocks of above size in one hour. Better compaction ensured through pressure vibration. Two vibrators each of 0.5 KW capacity and frequency 3000 VPM used for consolidation of concrete. Suitable for casting stone block, large aggregate concrete blocks traditional concrete block and hollow blocks.



Operator's access right upto the moulds help in easy placement of stone spalls in casting stone blocks and screeding of concrete in the moulds while casting large aggregate blocks. Power required: 3KW

Working and trials The machine is placed on the casting platform which should be a levelled and well finished concrete floor. Waste newspapers or polythene sheets are laid on the platform for easy removal of the block next day. The mould block is first made to rest on the platform by operating the powers screws. Concrete prepared in a concrete mixer is received in special trolleys and brought to the block making machine and dumped in the moulds. Screeding of concrete is done manually to bring the concrete to the same level in all moulds. The operator then allows the bridge to drop freely. This results in sudden impact which passes through the pressure platens on the concrete filled in the moulds. Vibration of concrete is later carried out by switching vibrators simultaneously. The vibration is maintained till the full height of the compacted block is achieved. The height of the compacted block is achieved. The mould block is the lifted uo leaving cast concrete blocks on the platform. During upward moving when mould block completely clears the cast blocks, the former comes in contact with the bottom face of bridge. From this stage onwards. the bridgeis also lifted up along with the mould block resulting in simultaneous breaking of the contact between all pressure platens and the top face of the cast blocks. When both the mould block and the bridge are raised to acertain height, their upward movement is automatically stopped with a limit switch. The machine is then moved forward on its wheels to a new position of casting while leaving the newly cast blocks behind on the floor.

Figure 1 CBRI Concrete Block Making Machine

Figure 2 Mechanized Productions of Concrete Blocks

The prototype block making machine was extensively tried first in the institute ( Figure 2) and later at the construction site of building centre, Sangeer., Jaipur. Both the stone blocks and the large aggregate concrete block were successfully cast during trails. The concrete with stone aggregate as large as 75mm could be handled effectively. Since the screeding of concrete in the moulds take little more time in case of large aggregate blocks than stone blocks, the machine recorded as an average cycle time of 3 minutes for a large aggregate blocks and 2.5 min. for stone blocks, with 6 blocks cast in one cycle in both cases. The traditional concrete blocks with smaller aggregate (15mm and down), however, recorded a shorter cycle of 2 min. for the same number and size of blocks. Strength and Quality of machine made blocks Large aggregate concrete blocks cast with the newly developed block making machine were tested for strength and other properties. The following table highlights the test results. The age of the blocks was about three months at the time of testing.

S.No. Mix. No. 1

Mix. Details Cement Sand(F.M. 3.2) River shingles 40mm.

Test results 1 Av. Comp. strength- 128kg/cm2 9 range of comp. strength- 116 to 138 kg/cm2 9 No. of blocks tested-21 Water absorption-4.1% 1.1 Density(Av.)-2458kg/m3 Range of density 2440-2470kg/m3 1 Av. Comp. strength-127kg/m3 10 No. of blocks tested-6 8 water absorption-4.36% 1.25 density (Av.)-2420kg/m3 Range of density 2410-2430kg/m3

W/c Mix. No. 2 Cement Sand (F.M.3.2) 50mm crushed aggregate W/c

Economy in production It has been observed in the field that the contractors normally employ a gang of about 20 persons to produce 1000 large aggregate concrete blocks of size 30x20x15 cm in one shift of 8 hours with manual ,method of casting. The gang includes labour for mixing concrete in moulds vibrating the concrete with two plate vibrators. Demoulding the blocks and preparing moulds for next filling. Based on the july 1990 rate at construction site at Jipir, labour cost of production estimated in the manual method at Rs. 0.50 per block. An estimate was also prepared for labour charged for making blocks with newly developed machine. The operating charges for the machine are Rs. 160.00 per day per shift of eight hours. Considering a production rate of 1000 large aggregate concrete blocks of size 30x20x15 cm in one shift and using concrete mixer of 200 liters capacity with Rs. 80.00 per day labour charges the total cost of labour was estimated at Rs. 0.24 per block which is 50 percent of the labour cost of manually made blocks. Since in the field the labour charges are about 20 % of the total cost of a block, the mechanized production of blocks brings in substantial savings in the labour charges in addition to improving strength and other properties of the block. Commercialization At 1990s pricing, the CBRIs Block Making machine is likely to cost around Rs. 50000.00. The know how of the machine was available for commercialization from National Research Development Corporation (NDRC), 20-22, Zamroodpur Community Centre, kailash colony extension, New Delhi-110084