Construction Blocks - PPT

NEW BUILDING MATERIALS AND TECHNOLOGIES

CONSTRUCTION BLOCKSBLOCKS

CONSTRUCTION BLOCKSDivisha Jindal M.B.E.M. – ‘I’ 2009-10 S.P.A., New DelhiDIVISHA JINDAL BEM / 471 SPA, NEW DELHI

CONTENTS:

INTRODUCTION

BUILDING ENVELOPEBUILDING MATERIALS

CRITERIA FOR SELECTION

TRADITIONAL WALLING SYSTEMSBURNT CLAY BRICKS

CONVENTIONAL WALLING SYSTEMS

BRICK 9” X 4.5” X 3”

NEW WALLING SYSTEMS – CONSTRUCTION BLOCKS

COMPARATIVE ANALYSISCOMPARATIVE ANALYSIS

ADVANTAGES & DISADVANTAGES

INITIAL COSTS & EMBODIED ENERGY

IS CODES - SPECIFICATIONS

IS: 2180 – 1988

IS: 2185 – PART I 1979; PART II 1983; PART III - 1984

CONSTRUCTION BLOCKSDivisha Jindal M.B.E.M. – ‘I’ 2009-10 S.P.A., New Delhi

CONTENTS:

NEW WALLING MATERIALS & TECHNOLOGIESNEW WALLING MATERIALS & TECHNOLOGIES

• INTRODUCTION

• INTERLOCKING HOLLOW CORE BLOCKS - ANANGPUR BUILDING CENTREVARIOUS INVENTIONS BY BMTPC• VARIOUS INVENTIONS BY BMTPC:

Rubble Filler Concrete BlockPrecast Concrete Stone Masonry BlocksHollow and solid lightweight concrete blocks/ Cinder blocksFal – G sand blocksFly Ash Bricks etcFly Ash Bricks etc.

• VARIOUS INVENTIONS BY CBRI:Compressed stabilized earth blocksStabilized Adobe blocksLATO blocksClay red mud burnt bricks/ tilesy

• ECO BLOCK BY DAVE JENKINS CONSTRUCTION, USA• MONOLITHIC WALL SYSTEM (POROTHERM/KLIMABLOC)• HAENER BLOCK – MORTARLESS INTERLOCKING SYSTEM• AIRCRETE BLOCKS BY H + H CELCON• AUTOCLAVED AERATED CONCRETE BLOCKS (AAC)• AUTOCLAVED AERATED CONCRETE BLOCKS (AAC)• GLASSCRETE BLOCKS• VEROT OAKS BUILDING BLOCKS(VOBB) BY NEWELL’S DESIGN, USA• GREEN BRICKS MADE FROM CRUSHED TILES AND OLD MORTAR• BAMBOO/TIMBER MAT BASED WALLS (EKRA WALLING)


INTRODUCTION


INTRODUCTION:

The construction sector alone counts for nearly 50% towards theThe construction sector alone counts for nearly 50% towards thecountry’s economics as well as energy consumption..

BuildingsTransportationIndustries

Buildings and building related activity:

• Largest consumer of resources whether it is material, capital or energy

• Causes the largest amount of environmental degradation

• Largest progenitors of waste output i.e. construction debris etc.


NEED: The developing nations are todayfollowing the advanced nations’ policyof achieving economic growth through

Developing Nations’ GDP

of achieving economic growth throughmacro-industrial production.Large-scale production andconsumption necessitates largedistances for transportation of raw

50% for 50% for

material and end product, highmarketing costs and other add-ons.

Advanced nations today have 30%actual production costs and 70% add-Building &

ConstructionIndustries &

Transportationactual production costs and 70% add-on value to a product. Developingnations still have 70% production costsand 30% add- on value, but are rapidlyfollowing the unsustainable patterns ofh d l d i

60% for Material

Consumption40% for Labor

the developed nations.

Therefore, in order to have sustainabledevelopment, it is imperative toidentify the areas where macroidentify the areas where macroindustry and micro enterprise arerequired.

Source: www.anangpur.org


BUILDING ENVELOPE


COMPONENTS OF BUILDING ENVELOPE:

BUILDING ENVELOPE

VERTICAL HORIZONTAL

WALL FENESTRATIONS ROOF


FUNCTIONS OF BUILDING ENVELOPE:

BASIC FUNCTION : To control physical environmental factors such as heat, light and sound in

order to ensure comfort conditions inside, with minimum energy consumption.

SECONDARY FUNCTION: Climatic factors such as protection from harmful effects of Sun;

provide natural ventilation and daylight; add to the aesthetic value; protection from fire, dust and

pollution; structural and security purposes.

Schematic showing three modes of heat transfer

Source: ECBC, 2006

modes of heat transfer through a wall


Misuse of building materials is probably the largest single factor that contributes to environmental

MISUSE OF BUILDING MATERIALS:

degradation. In the last century, the largest amount of development in the construction industry

has been that of surfacing materials. Universal application of brick and RCC was clearly not the

answer and it is to protect RCC that several surfacing materials have been developed, which also

provide color and texture.

Unfortunately, apart from high technology surfacing materials that have emerged over the

years, the basic performance criterion required of a walling material remains unexamined. The

entire development has revolved around stronger walls to give more resilient surfaces whereas

logically the decisions should have been based around resilient surfaces with lean back up materials

for the body of the wall.

The strength requirement of a walling material rated at 150 Kgs/sq cm in itself is a fallacy. The soil

bearing capacity is usually 2 to 3 Kg/sq cm and the load on a wall is less than 1 Kg/sq cm per floor.

The high compressive strength of a walling block is the direct consequence of its surface

i t Th id l bl k ld th f i ili t dibl f ith lrequirements. The ideal block would therefore require a resilient non-erodible surface with a lean

backup body material. Another important criterion should be the feasibility of manufacture at the

site, with minimal capital. Source: www.anangpur.org



The scarcity, frequent non-availability, constantly rising costs of building materials and the

declining quality of housing and building construction are causing concern to Central & State

NEED OF NEW BUILDING MATERIALS:

declining quality of housing and building construction are causing concern to Central & State

Governments. It is now widely recognized that the cost of housing can be reduced and speed and

quality of construction stepped up through the use of emerging innovative building materials and

technologies. Despite a number of innovative cost-effective building materials, components andg p g , p

construction techniques developed through research the housing and building agencies have not

adopted them in their construction practices.


CRITERIA FOR SELECTION:

Walling materials constitute approximately 30% of construction and the largest mass of a

Walling Elements

building.

L t t f Non-erodible Low Thermal

ConductivityColor & Texture

Least amount of consumption of

processed material

Economy

•They account for the maximum capital resource in the structureThey account for the maximum capital resource in the structure.

•They have the largest surface area and account for maximum recurring maintenance costs.

•Failure of the walls is the single largest factor responsible for the collapse of structures

in case of calamities such as earthquakes.in case of calamities such as earthquakes.

•Maximum thermal exchange in a building takes place through walls.Appropriate technologies are those that respond to the local environment, resource and

economic needs.


TRADITIONALTRADITIONAL WALLING SYSTEMSWALLING SYSTEMS


BRICK:

INTERNATIONAL HISTORY OF BRICKINTERNATIONAL HISTORY OF BRICKBricks dated 10000 years old were found in the Middle East.

Israelites made bricks for their Egyptian rulers with earth and straw

Examples of the civilizations who used mud brick are the ancient Egyptians and the Indus ValleyExamples of the civilizations who used mud brick are the ancient Egyptians and the Indus Valley

Civilization, where it was used exclusively. In particular, it is evident from the ruins

of Buhen, Mohenjo-daro and Harappa

The first sun-dried bricks were made in Mesopotamia (modern Iraq) in the ancient city of Ur inThe first sun dried bricks were made in Mesopotamia (modern Iraq), in the ancient city of Ur in

about 4000 BC

The Romans made use of fired bricks, and the Roman legions, which operated mobile kilns,

introduced bricks to many parts of the empireintroduced bricks to many parts of the empire

Early traces of bricks were found in a ruin site in Xi'an, China in 2009 dated back about 3800

years ago. Before this discovery, it is widely believed that bricks appeared about 3000 years ago in

the Western Zhou dynasty; these bricks were made by a fired process.y y; y p

In the 12th century, bricks from Northern Italy were re-introduced to Northern Germany

The buildings of the Industrial Revolution in Britain were largely constructed of brick and timber


BRICK:

Roman Constantine

World's highest brick

Basilica in Trier,Germany, built in the 4th century with fired bricks

World s highest brick tower St. Martin's Church, Landshut,Germany, 1500

World’s largest brick structure Jetavanaramaya Stupa, Anuradhapura Sri Lanka

World’s biggest brick castleMalbork Castle


TRADITIONAL INDIAN BRICKS:

M h l B i k L kh i B i k N k h hi B i k tMughal Brick, Lakhori Brick , Nanakshahi Brick etc.These were small thin bricks, tested by time, highly weather

resistant, frost resistant, durable and sturdy bricks, very well

suited for all thin brick applicationssuited for all thin brick applications.

These bricks were patted by hand. Therefore, these were

uneven, irregular, multihued, and imparted an aesthetic aspect to

the building structurethe building structure.

The size of these bricks varies but is approx. 6”x3.5”x1.25” and

individual weight is around 650gms.

These bricks of yesteryear were of excellent quality in terms ofThese bricks of yesteryear were of excellent quality in terms of

strength and surface requirements. This was because the clay of

the region formed the raw material for the brick.

To ensure non-erodability, clay was burnt adequately.y, y q y


CONVENTIONALCONVENTIONAL WALLING SYSTEMSWALLING SYSTEMS


BURNT CLAY BRICKS:Bricks are one of the oldest types of building blocks. They are an ideal building material because

they are relatively cheap to make, very durable and require little maintenance. Bricks may be

made from clay, shale, soft slate, calcium silicate, concrete or shaped from quarried stone. Clay is

the most common material; with modern clay bricks formed by soft mud method are the most

common, as it is the most economical and readily available. It starts with raw clay, preferably in a

mix with 25-30% sand to reduce shrinkage. The clay is first ground and mixed with water to the

desired consistency; then it is pressed and fired ( burnt) at 900-1000° C to achieve strength.

“ There is a basic error in standardizing the size of the conventional brick at 3” x 4.5” x 9” for the

entire country. The physical aspect of clay and its content varies from region to region. Large scale

production of conventional bricks needs High Draft Kilns, which further leads to consumption of

coke that aggravates the fragile ecological balance. In attempting to standardize this building

element, we are actually trying to standardize the quality of clay that the earth yields.“



BURNT CLAY BRICKS:Physical Appearance: Brownish red color but reddishness depends upon the iron oxide content

of the soil.

Dimensions: 230mm x 115mm x 75mm ( 9” x 4.5” x 3”)

Application & installation: Bricks are laid with a thin-set mortar. The material is easy to

finish, too. Exterior walls can be painted, plastered, or finished with claddings. Interior surfaces

can be plastered, sheet rocked, tiled, painted, or simply left exposed.

Maintenance: An unfinished exterior wall needs maintenance because of efflorescence deposits.

Quality & Durability: Burnt clay bricks are quite durable in natural weathering conditions.

They are heat resistant up to 10000C.The acid resistance of bricks is determined by boiling a

sample in a mixture of HNO3 and HCL, where the loss in weight should not be more than 2

percent. It has 2 hrs. fire rating. It is non-toxic.

Energy Efficiency: In case of rat-trap bond or cavity walls, acts as energy efficient.

Embodied energy:- 4.50 MJ/Kg

Drawbacks: Unfinished exterior walls are exposed to physical damages such as efflorescence.

Initial cost: Rs. 2.60/- as per DSR, 2007

Life Span: 60 years


NEWNEWWALLING SYSTEMSWALLING SYSTEMS


INTRODUCTION

Construction Blocks – as alternative walling elementsConstruction Blocks as alternative walling elements

AN ENVIRONMENT CONSCIOUS PRODUCT AND SUSTAINABLE BUILDING TECHNOLOGYIssues & Basis:Issues & Basis:

Shelter is a basic human need affecting the largest number of people worldwide.

The Building Industry is the largest consumer of resources whether it is materials, capital or

energyenergy.

It causes the largest amount of environmental degradation as a result of quarrying, mining

process, depletion of natural resources.

It is also one of the largest progenitors of waste output for example construction debris etcIt is also one of the largest progenitors of waste output, for example, construction debris, etc.

Building materials produced in industrial processes are responsible for pollution and global

warming.

Monopolized Industrial processes increase cost of building products resulting in a rubber-Monopolized Industrial processes increase cost of building products resulting in a rubber

stamping effect of products and negating a response to locally available materials and needs.

The building industry is second only to agriculture in providing employment for the maximum

number of people.


p p

INTRODUCTION

Concrete block technology offers a speedier cost effective environmentally soundConcrete block technology offers a speedier, cost effective, environmentally sound

alternative to conventional walling materials. It is based on the principle of densification of a lean

concrete mix to make a regular shaped, uniform, high performance masonry unit. Concrete Block

Technology can be easily adapted to suit special needs of users by modifying design parametersTechnology can be easily adapted to suit special needs of users by modifying design parameters

such as mix proportion, water/cement ratio and type of production system. It is an effective means

of utilizing wastes generated by stone crushers, quarrying and stone processing units. The

technology has high potential in areas where raw materials are easily availabletechnology has high potential in areas where raw materials are easily available.

UNIQUE FEATURES:

Cost effective compared to other traditional walling systemsCost effective compared to other traditional walling systems

Maximum utilization of wastes and local resources

Structural performance can be engineered

Decentralized local productionDecentralized local production

Offers business opportunities for micro enterprise


BASIC TYPOLOGY:

The variety of construction blocks is extensive, from dense through to lightweight, offering a range of

load bearing strength and sound & thermal insulation properties.

Construction blocks are defined as solid , hollow or cellular as shown.

S lid t bl k H ll t bl k C ll l t bl k

Construction blocks are manufactured to various workface dimensions in an extensive range of

thickness, offering a wide choice of load bearing capacity and levels of insulation. The standard

Solid concrete blocks Hollow concrete blocks Cellular concrete blocks

workface size, which coordinates to three courses of metric brickwork allowing for 10mm mortar

joints, is 440*215 mm. There are other sizes which are to be considered for aesthetic and

constructional reasons. Source: BMTPC, CBRI


BASIC TYPOLOGY:

A variety of interlocking blocks have been developed during the past years, differing in material

composition, shape and size, depending on the required strengths and uses.

V i t f i t l ki bl k

Interlocking blocks are produced in special moulds, in which compaction can be done by hand or

mechanically, depending on the type of block, material used, required quality and available

Various type of interlocking blocks

resources. The blocks can be made directly at the building site, or on a larger scale in a

production yard.


INTERLOCKING HOLLOWINTERLOCKING HOLLOW CORE BLOCKS


1. INTERLOCKING HOLLOW CORE BLOCKS BY ANANGPUR BUILDINGCENTRE

The hollow core interlocking blocks have these intrinsic characteristics:

1. Impermeable non-erodable diaphragm with colour and texture.

2 Lean back up material for the body of the block with rationalized crushing strength Appropriate2. Lean back up material for the body of the block with rationalized crushing strength. Appropriate

locally available material such as fly ash, burnt rice husk, stabilized mud or exfoliated vermiculite

may be used for the body of the block.

Interlocking concreteblock unit, that can bemanufactured at site

Integrated permanentfinish; various sizeoptions

Schematic sectionthrough block


CONSTRUCTION PROCEDURE:

Step 1: A mould of mild steel of the required Step 1: A mould of mild steel of the required shape and size is manufactured

Step 2: The desired impermeable diaphragm islaid at the bottom of the mould, which,could be waste material such asstone, broken tiles or PVC chips. Alaterally inverted pattern,sketched on a piece of paper and PVCwith chips glued on forming thewith chips glued on, forming theexterior non- erodablediaphragm resulting in the Integrationof Art in the block.



Step 3: Rich cement slurry is poured over theStep 3: Rich cement slurry is poured over thefirst impermeable diaphragm.

Step 4: A lean backup material (fly ash,burnt rice husk, mud) is then laid overand compactedand compacted.



Step 5: A pipe is then inserted in the mouldStep 5: A pipe is then inserted in the mould.

Step 6: The balance mould is filled up leavingenough space to finish the secondimpermeable diaphragm if so desiredimpermeable diaphragm if so desired.



Step 7: Marble powder is spread over the finishStep 7: Marble powder is spread over the finishwhich acts as a dewatering agent.If desired, a thin board may be used todivide the external diaphragm into twohalves, so as to make it look like twodifferent blocks

Step 8: Marble powder is washed using a softpaintbrush and water.



Step 9: The pipe is removed first by rotating itStep 9: The pipe is removed first by rotating itgently. The block is demoulded after fewminutes of casting and cured for 48hours before usage.


BENEFITS:

Simple procedure -universally accessible. The equipment is easily affordable.

Integral permanent finish – lower maintenance costs—labor intensive but conserves building

material.

D i h i ff ldi f i fi i hiDoes away with expensive scaffolding for post- construction finishing.

Horizontal bore allows for easy handling by the mason.

Filling the hollow core with waste polythene can increase thermal insulation.— waste utilization

A t h l th t t i b i P t fi i h i th i ti f th i h dA technology that cuts across economic barriers. Permanent finish is the aspiration of the rich and

the poor


BENEFITS:

Using interlocking blocks as a base several adaptations are possible Holes on both sides are alsoUsing interlocking blocks as a base, several adaptations are possible. Holes on both sides are alsopossible in order to accommodate additional services if required.


BENEFITS:

Diagonal interlocking to resist lateral thrusts and better load distribution inunpredictable soils.Year after year we have to contend with natural disasters such as earthquakes and cyclones. Today’swalls unfortunately are the most susceptible, owing to their inability to withstand horizontal thrust.Reinforced cement concrete bands do solve the problem to a certain extent but the life span of suchsolutions is often environmentally questionable. Feasible solutions to withstand these thrusts,solutions is often environmentally questionable. Feasible solutions to withstand these thrusts,however involve prohibitive costs.Traditional solutions also existed for containing the swelling or contraction of soil in black cotton soilareas. The principle of diagonal bonding can be seen in Maharashtra in India, Pompeii and Naples inItaly, Dresden in Germany, in Palestine, Guatemala etc.

Pompeii, Italy Naples, Italy Maharashtra, India


BENEFITS:

Using the plasticity of concrete, the simple molding process delivers an Interlocking Block withg p y , p g p g

tremendous resilience against horizontal thrusts and the resultant tension.

The diagonal bond has been developed to resist lateral thrusts during an earthquake. These thrusts

are transferred diagonally to the foundation with each perpendicular wall acting as a buttress for theg y p p g

other. This bond also allows better load distribution while building on unpredictable soils such as

black cotton soil, which have a tendency to swell and shrink.

Swelling & shrinking in blackcotton soil

Diagonal bondingresists lateralthrust

Different bonding options

In case of differential settlement of soil the corbelled arch action prevents cracks and in case ofswelling,This bond works in reverse and helps in a more even distribution of the loads, thus avoiding collapse.


CASE STUDIES:

Diagonal interlocking blocks have been used for earthquake resistant housing in Gujarat, Indiag g q g j ,

20 ft. high freestanding walls recently withstood an earthquake measuring up to 5.8 on the R. scale.

Medical Centre, NewDudhai, Gujarat

Primary School, New Dudhai, GujaratDudhai, Gujarat

A hi ’Architect’sResidence,Anangpur,Faridabad


CASE STUDIES:

PushkarnaResidence,ChandigarhChandigarh


CASE STUDIES:

Bharatyamgram Bhoomiheen Camp

Jaunapur Slum Rehabilitation


S No Description Quantity Energy KwH/ Energy

ENERGY CONSUMPTION COMPARISON CHART:Energy is listed for per cu.m. of 230mm. Brick wall and 1 cu.m. of 200 mm. interlocking block wall

S.No. Description Quantity Energy KwH/ unit

Energy consumed (KwH)

A Brick Wall

1 Brick 500 No.s. 0.88/ brick 440

2 Cement 60 Kg (1.2 bags) 2.25/Kg 135

3 Cement Plaster

12mm 1:4 4.7 Sq.m. 20.65/Sq.m. 97.24

19mm 1:4 4.7 Sq.m. 32.69 Sq.m. 153.64

Total 825.88

B Interlocking Concrete Block Wallg

1 Cement 168 Kg (3.36 bags) 2.25/Kg. 378

2 Fine Aggregate 525 Kg. (0.23 cu.m.)

0.06/Kg. 31.5

3 Cement Plaster 6mm 1:4 6.25 Sq.m. 10.325/ Sq.m. 64.53

4 Cement (Pointing) 21.8 Kg. (0.43 bag) 2.25/ Kg. 49.2

Total 523.23


VARIOUS INVENTIONSVARIOUS INVENTIONS BY BMTPC


1. SOLID/ HOLLOW CONCRETE BLOCKS










1. SOLID/ HOLLOW CONCRETE BLOCKSTentative Project Costs

HAND HELD TYPE BLOCK MACHINE STATIONERY BLOCK MACHINE

STANDING TYPE BLOCK MACHINE CONCRETE BLOCK MACHINE


2. CELLULAR LIGHT WEIGHT CONCRETE BLOCKS






2. CELLULAR LIGHT WEIGHT CONCRETE BLOCKSTentative Project Cost


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Construction Blocks - PPT