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By

Raghu.t DSCE,Bengalooru
Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE
Concrete masonry is already extensively used in building construction abroad, It is
likely to make

considerable headway in the future in this country due


to following reasons
    

Durability Strength Structural Stability Good sound absorption and heat insulation.
Fire resistance
Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE
 It

is a block made out of cement & aggregates.

The proportion will vary from manufacturer to manufacturer & ingredients.


 Generally

it is made of 1:6.

Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE


Concrete Block Technology is based on the principle of densification of a lean


concrete mix to make a regular shaped, uniform, high

performance masonry unit.


It is an effective means of utilizing wastes

generated by stone crushers, quarrying and


stone processing units.
Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE
Concrete blocks are of 3 types
  

Hollow & non-load bearing Hollow & load bearing Solid & load bearing.

Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE


Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE
Solid block

Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE


Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE

IS 2185-1979- Specifications for concrete masonry units ( hollow & solid concrete
block )

IS 2572-1963 code of practice for construction of hollow concrete masonry.

Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE


The most common sizes are
 400x200x200mm,(8
 400x150x200

inch)- for load bearing

& (6 inch)- for load bearing

 400x100x200.(

4 inch)( for partition walls- non

load bearing)

Other sizes can also be manufactured based on


requirements of client
Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE
Cellular block Hollow block

Corner block

Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE


 Hollow

Concrete Blocks are an excellent

replacement for
energy efficient

clay bricks since they are

Blocks are made of concrete, which absorbs


very little water. At the same time, they have

vertically aligned holes, which do not allow


moisture to seep through.
Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE
 Concrete

blocks can be used like any other

masonry unit to build foundations, walls, arches and corbels, etc.


A

typical concrete block is equivalent to 4.5

bricks, thus construction is faster than with other masonry units.

Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE


 The

mortar is also less which results in cost

saving.

They are also compatible with other materials like fired bricks, dressed stone and
compressed earth blocks for composite wall construction.

Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE


Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE
Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE
Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE
 The

strength of concrete blocks depends on its constituent materials used for its
manufacture. presences of excessive fine silt in quarry dust & use of low % of
cement leads to lower strengths. BIS prescribes a minimum strength of 2.0Mpa for
concrete blocks.

 The

 The

Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE


 Highly  Low

Durable.

Maintenance, Color and brilliance of

masonry withstands outdoor elements.


 Load

Bearing, strength can be specified as per

the requirement.
 the

hollow space in the blocks Provide good properties against sound , heat &

insulation

dampness . Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE


 Good  The

fire resistance

rough surface of blocks makes plastering

easier.
 Concrete

blocks permits adoption of thin walls

thereby achieving increased floor area & hence saving in space.


 Do

not require formwork.

Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE


 Economical

& Environment Friendly, flyash

used as one of the raw materials.

 Popular

for foundation walls.

 Blocks

are fairly inexpensive.

Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE


Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE
Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE
Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE
Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE
Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE
Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE

Bricks are obtained by moulding clay in rectangular blocks of uniform size and then
by drying and burning these blocks. As bricks are of uniform size, they can be
properly arranged, light in weight and hence bricks replace stones.

Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE


The manufacturing of brick, the following operations are involved 1. Preparation of
clay 2. Moulding 3. Drying 4. Burning

Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE


Wooden mould & Steel mould
Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE
Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE
In India bricks are generally classified as : Country bricks table moulded bricks
wire cut bricks.

Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE


 Country

bricks are made using a simple four sided mould. bricks are moulded by the soft mud
process where soil has a high moisture content facilitating easier pressing.
moulding is to be done on level ground & wet brick is left on the ground for
drying. drying the bricks are burned using firewood.
Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE

 Theses

 The

 After
 This

type of bricks are made by soil with lesser moisture ,which leads to the improved
shape & strength for the brick.  This bricks generally have ‘frog’ on one of the
bedding faces.  These bricks are dried in shade & then burned in the kiln.  This
bricks are stronger than country bricks & strength ranging from 3.5Mps to 7.0Mpa.

Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE


 These

bricks are made with very good soil & with more mechanized operations.  A
continuous slab of clay is sliced by a wire frame into a number of bricks.  After
drying, the bricks are burnt in the kiln.  A good wire cut brick retains very good
shape & strength ranges from 10Mpa to 20 Mpa.  A wirecut brick with 10Mpa strength
can be conveniently used for load bearing masonry upto 5 storeys without RC fames.
Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE
Bricks should be table moulded, well burnt in kilns, copper coloured, free from
cracks and with sharp and square edges. (ii) Bricks should be uniform shape and
should be of standard size. (iii) Bricks should give clear ringing sound when
struck each other. (iv) Bricks when broken should show a bright homogeneous and
compact structure free from voids. (v) Bricks should not absorb water more than 20
percent by weight for first class bricks and 22 percent by weight for second class
bricks, when soaked in coldwater for a period of 24 hours.
(i)
Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE
(vi) Bricks should be sufficiently hard no impression, should be left on brick
surface, when it is scratched with finger nail. (vii) Bricks should be low thermal
conductivity and they should be sound proof.
(viii) Bricks should not break when dropped flat on hard ground from a height of
about one meter. (ix) Bricks, when soaked in water for 24hours, should not show
deposits of white salts when allowed to dry in shade. (x) No brick should have
crushing strength below 55kg/cm2

Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE


 These

bricks are made of clay and are provided with one or more cavities. Hallow bricks
are light in weight and are used to increase insulation against heat and dampness.
are used for the construction of load bearing walls, partition walls or panel walls
to multistoried buildings.

 They

Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE


Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE
Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE
Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE
 The

clay fired bricks are lighter than the cement hollow blocks. They are not porous,
absorb less water and therefore do not require plastering. These blocks are equal
to six handmade bricks and hence would save cost for the buyers.

Different sizes of burnt hollow clay bricks are: Length mm Width mm Height mm 190
190 90 290 190 90 290 140 90

Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE


 The

minimum average crushing strength of the bricks should be 3-5 N/mm2 according to
the IS 3952-1988. average water absorption of the bricks by mass when shaIl be not
more than 20 percent.

 The

Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE


Here, the soil available locally are made use for production of blocks. These
blocks can be manufactured @ construction sites by a manual press;

 

Transportation cost is not incurred;


No burning process is done ( which is a must for bricks); so no wood used here,
thereby being ecofriendly.

Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE


These are dense solid blocks compacted using a machine with a mixture of soil,
sand, stabilizer (cement/lime) and

water.

OR

Stabilized mud block can be manufactured from a mixture of suitable soil-sand and
stabilizers such as Portland cement or a combination of lime and Portland cement. A
uniform mixture of soil-sand-stabilizer is compacted into a high density block at
optimum moisture content using a machine.
Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE

Soils contain particles of different sizes such as gravel,

sand, silt and clay minerals (soils containing 10-15%


clay and 60-75% sand are satisfactory )

Classify the soils into 2 broad categories: (a) Expansive soils and (b) Non-
expansive soils depending upon whether the soil contains an expansive clay mineral
or not.
Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE

Soils containing non-expansive clay minerals can be utilized for stabilized mud
blocks using Portland cement

as a binder.

Whereas expansive soils need hydrated lime to stabilize the swell-shrink properties
and hence use of lime is essential for producing stabilized mud blocks

with expansive soils.

Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE


The following steps are involved in the stabilized mud block production process: a)
Sieving the soil through 5mm sieve. b) Mixing of soil and sand (or crusher dust) in
the

requisite proportion.
In case of higher clay %, the sand fraction in the soil should be increased to
bring down the clay content.

Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE


c) Adding stabilizer (cement/lime) to soil-sand mixture
and mixing with optimum quantity of water.
The proportion of soil and stabilizer depends on the strength and performance
requirements and the type and amount of clay in the soil.

Cement stabilization is best for sandy soils in which


cement is generally added to the tune of 6 to 8% by weight of soil.

A sandy soil will need about 10-12% water for Optimum


Moisture Content.
Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE
d) Pressing the block in a machine to the
required density. e) Ejecting the block, stacking and curing.

The blocks must be stacked in a shaded area to


prevent quick loss of moisture on exposure to sun which can cause shrinkage cracks.
Curing has to be done for 28 days.

If the blocks cannot be cured for 28 days due to time constraints, then ensure that
they are cured for at least 14 days, with the remaining curing carried out by
keeping the masonry wet.
Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE
Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE
Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE
Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE
Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE

SMB production at construction site


Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE

Compacting the block


Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE

Machine with mould lid open


Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE

Block ejection
Stacking and curing
Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE
Blocks of different shapes
Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE
Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE
SMB block corbel

Rounded corner and Corbelled SMB blocks

Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE


Stabilized mud blocks can be manufactured in different sizes and shapes. Maximum
size of the block is limited by the capacity of the machine to supply required
compaction force or energy during the block production process.

Range of actual block dimensions shall be as follows. Length: 200mm to 305mm,


Width: 100mm to 200mm, Height: 75mm to 100mm.
Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE
Some typical sizes for the stabilized mud blocks are given in Table.
Sl No. Dimensions (mm) Length 1 230 Width 105 Thickness 75 or 90 or 100

2
3 4

230
200 305

190
200 143

90 or 100
75 or 90 or 100 90 or 100

Blocks of special shapes such as rounded corner, corbelled or any other shape for
the purposes of enhancing aesthetic appearance of masonry and the building can be
manufactured with special attachments to the machines.
Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE

The wet compressive strength of the stabilized mud blocks should be determined in
saturated condition. The blocks have to be soaked in water for at least 48 hours
prior to the strength test. The minimum wet compressive strength of blocks should
be 3 N/mm2 or 30 kg/cm2 for a double storeyed house construction. Using a higher
percentage of cement – more than 8% cement higher strengths in the range of 4 to 6
N/mm2 can be achieved. A block of 7 N/mm2 stength is suitable for four-storeyed
load bearing construction. Blocks of strength 2.5 – 3 N/mm2 can be used for load
bearing walls in framed buildings and for single storied houses in rural areas.
Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE


Strength and water absorption values of SMB collected from different construction
sites are given Table-3.

Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE


Composite mortars such as cement-lime-sand or cement-pozzolana-sand or cement soil-


sand mortars are best suited for stabilized mud block masonry.

The mortar selection shall be based on masonry design and the nature of application
such as plastering, pointing, etc.

Cement-soil-sand mortars of 1:2:5 or 1:1:6 give better bond strength for the
masonry when compared to 1:6 cement-sand mortar.
Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE
Stone masonry in lower part of DSCE a wall – rural housing Raghu Thyagaraj, Asst
Prof.Civil Dept,
Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE

SMB wall exposed to 10 years of natural weathering


Two storeyed load bearing seminar hall (6.2m span designed for one more storey)

Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE


Residential building with SMB walls and vault

Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE


Cost of SMB mainly depends upon: (a) cost of soil and sand or quarry dust, (b) cost
of stabilizer (cement/lime), (c) labour cost of block making and (d) depreciation
cost of machine. Range of costs for a block of size: 230 X 190 X 100 mm (2.7 times
brick volume) is as follows. 1) Cost of soil: Rs. 0.40 – 1.40 2) Cost of
sand/quarry dust: Rs. 0.50 – 1.50 3) Labour cost: Rs. 1.50 – 2.00 4) Cement (7%)
cost: Rs. 2.50 – 2.75 5) Machine depreciation: Rs. 0.50 – 0.50
--------------------Total cost Rs. 5.40 – 8.15
Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE
Cost can be drastically reduced by the use of local materials and self-help labour.
Number of blocks (of size 230 X 190 X 100 mm) required for 1 m³ of SMB masonry =
180-190 and volume of mortar in 230 mm thick wall = 20%.

Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE


Stabilized mud blocks having strength and performance equivalent to or better than
that of burnt clay bricks are being produced and used. Load bearing masonry
buildings of up to 4 storey height have been built using SMB. Properly prepared SMB
blocks do not disintegrate upon soaking in water for any length of time and the
exposed buildings can perform satisfactorily over ones life time.

Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE


Some of the major advantages of SMB are:
a) No firing or burning needed, energy efficient and environment friendly. SMB is a
recyclable and reusable

material.
b) Decentralized production as the machines are portable and the blocks can be
manufactured at the construction site. c) Block cost is independent of scale of
operation.

d) The blocks are true to shape with well defined corners and
edges. Special shapes and designer blocks can be produced with small attachments to
the machine.
Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE
e) The walls do not require plastering and offer scope for
exposed natural finish with aesthetically pleasing

appearance. f) The block strength can be adjusted by proper selection of stabilizer


content.

g) Provides good thermal comfort


h)Creates additional local employment in block production Can be made with locally
available earth which makes it cost effective.

Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE


Requires a good understanding of the type of soil available for block production
and how it can be improved/ stabilized.

Availability of soil in adequate quantity from a single

source, can be a limitation


Needs careful design and detailing of the building to ensure that the walls are not
damaged by rain.

Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE


Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE
Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE
Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE
Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE
Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE
Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE
Thank You

Raghu Thyagaraj, Asst Prof.Civil Dept, DSCE

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