How Concrete Blocks are Made?

The concrete blocks or cement bricks are building material used to build walls in the building. It is also known as a concrete masonry unit (CMU). The concrete blocks are one of the precast concrete products used for construction. Precast is the blocks are formed and hardened before they reach the job site. There are various concrete blocks and have one or more hollow cavities and the side may cast smooth or with design. These blocks are stacked with concrete mortar to make a wall. 

The concrete mortar was first used by Romans in 200 B.C. for binding shaped stone in the building. In the Roman emperor, Caligula in 37-41 A.D. the small blocks of concrete as construction material in modern-day Naples, Italy. The concrete technology develops by Romans is lost with the fall of the Roman empire in the fifth century. An English stonemason Joseph Aspdin develop Portland cement in 1824.

The first hollow concrete block is designed by Harmon S. Palmer in 1890 in the United States and after 10 years of research and experiment, he patented the design in 1900. The block developed by Palmer was 8 x 10 x 30 inches and heavy that the crane is used to move. 

In this time there was an average 10 blocks made by one person and it was cast by hand. With modern-day machines and advanced technology, it is 2,000 blocks per hour. 

Which Raw Materials are used?

For making the concrete bricks or blocks the raw material like a mixture of powdered Portland cement, water, sand, and gravel is used. These raw materials together make a light gray block having a fine surface texture and have high compressive strength. The weight of a typical concrete block is 38-43 lb (17.2 to 19.5 kg). There is a higher percentage of sand and a lower percentage of gravel and water for the blocks. This made very dry, stiff mixture and hold shape when removing from the block mold. 

Different types of Raw Material

The cinder block is made with granulated coal or volcanic cinders. This is a dark gray block with a medium to coarse surface texture, having good strength and good sound-deadening property with high thermal insulating than the concrete block. The typical cinder block weighs around 26-33 lb (11.8-15.0 kg). 

If there is granulated coal or volcanic cinders are used instead of sand and gravel with expanded clay, shale or slate the lightweight concrete block is made. The expanded clay, shale, and slate are made with crushing the raw materials and heating up to 2000 ^o (1093 ^o ) ^. The material is bloat or puffs up as there is rapid a generation of gases caused by the combustion of small particles f organic material inside. The light-weight concrete block weighs around 22-28 lb (10.0 to 12.7 kg) use to build a non-loading bearing wall and other partitions. Also, the blast furnace slag and natural volcanic materials like pumice and scoria are used for lightweight blocks. 

Along with basic components, there is concrete mixture is used to make blocks contains a chemical called admixture for altering curing time and it increases the compressive strength or to improve workability. There are pigments added into blocks for uniform color or make the surface of the block uniform. This also protects the surface of a block from chemicals. The glaze on the block surface is made with a thermosetting resinous binder, silica sand, and color pigments. 

Design of the Concrete Blocks

There are standardized shapes and sizes for common concrete blocks for building construction. The common block size is 8 x 8 x 16, as 8 inch high, 8 inches deep, and 16 inches wide. This measurement is including the bead of mortar and block measure is 7.63 in (19.4 cm) high, 7.63 in (19.4 cm) deep, and 15.63 in (38.8 cm) wide.

Many block manufacturers offer variation in block to look it aesthetically look better for particular applications. Like there is one concrete bricks or blocks manufacturer who designs blocks especially for water resistance through exterior walls. There is a split-faced block with rough, stone-like texture on one face of the block then the smooth face. These concrete bricks give a nice look aesthetically. 

Manufacturing Process of Concrete Bricks or Blocks

The concrete bricks manufacturing process consists of four steps: mixing, molding, curing, and cubing. There are concrete plants which only make concrete blocks while others produce a variety of precast products like blocks, flat paver, decorative pieces like lawn edging, concrete bricks, etc. With the advancement in technology some concrete brick making plants capable of making 2000 blocks per hour. 

1.Mixing

Sand and gravel are stored in silos outside and then transfer through conveyor belt when needed and the cement is stored in silos to make it safe from moisture. When the mixing has started the sand, gravel and cement are coming out from silos via weighing batcher which weighs every material. The dry materials enter into a mixer where they are blended for a few minutes. There are mainly two types of mixers that use one is planetary or pan mixer also known as a shallow pan with a lid. The mixing blades are attached to a vertical rotating shaft with a mixer. Another type is a horizontal drum mixer. This is a coffee turned on the side and has mixing blades attach to the horizontal rotating shaft inside the mixer. 

After the blending of dry materials, the small amount of water is added to the mixer. Now if the plant is located in warm places, the water is the first pass through heater or chiller to maintain the temperature. The mixing chemicals and color pigments added at this time and the concrete is mixed for six to eight minutes. 

2. Molding

After the mixing, the concrete is dump into bucket conveyor and transported to an elevated hopper and the mixing cycle begins after the next load. After that, it is conveyed to other hoppers on the block machine at a controllable speed. Then concrete is downward to flow rate and it pours into molds. In the molds, there is an outer mold box that contains other mold liners. Liners have an outer shape of the block and inner shape of block cavities. There are 5 to 15 blocks are molded at one time depend on machine capacity. 

After the mold filled with concrete, the hydraulic press compresses the concrete into the mold. The compression is complete by air or hydraulic pressure. Many of concrete bricks and concrete blocks machine uses vibration for completion of the process. 

After that, the blocked are pushed out of the mold onto a flat steel pallet. The pallet and blocks are push out of a machine to the chain conveyor. Some of the machines have a feature of rotating brush and it removes the loose material from the top of the blocks. 

3. Curing

Now the pallets of a block are conveyed to an automated stacker or loader and this places them in a curing rack. There are several hundred blocks on each rack. After the rack is full it is rolled onto a set of rails and then moved to a curing kiln. 

This is the room having the capacity to hold several racks of the blocks at a time. There are mainly two types of curing is used. First is low-pressure kiln where blocks are held for one to three hours at room temperature to harden slowly. Then the steam is introduced at 60o F (16o C per hour) to raise the temperature for hardening. The standard weight blocks are cured at 150-165o F (66-74o C) and lightweight blocks are cured at 170-185o F (77-85o C). After reaching the temperature steam is shut off and blocks soaked the hot, moist air for 12-18 hours. The curing process takes about 24 hours. 

The other type of kiln is high-pressure steam kiln it is also known as an autoclave. The temperature in this kiln is 300-375o F (149-191o C) and the pressure is 80-185 psi about 5.5 to 12.8 bar. The blocks are held for 5 to 10 hours. The pressure is vented and blocks release the moisture inside. The autoclave curing process is using more energy and also more expensive but it produces more blocks in less time. 

4. Cubing

Racks of the cured blocks are then rolled out the kiln and the pallets of a block are unstacked and place on a chain conveyor. After that, the blocks are pushed off the steel pallets and the empty pallets are fed back to the block machine for new blocks. 

If there is a split-face block, it first molded as two blocks joined. After the curing completed of double blocks, it passes through a splitter, and the heavy blade strikes between two halves. 

The concrete bricks and blocks are pass through a cuber that aligns each block and stacks them into cube three blocks by six blocks deep by three or four blocks high. Then the cubes are carried outside with a forklift and store for dispatch. 

Quality

Manufacturing of the concrete bricks and blocks are required to constant monitoring for producing the blocks for required properties. Raw material weighed electronically before goes to mixer. The water content in sand and gravel measured by ultrasonic sensors and how much water is required to measure automatically. For cold and warm conditions, the water has to pass through a chiller or heater before use. 

After coming out of the machine the height of the block should check with laser beam sensors and in the curing chamber the temperature, pressure, and cycle time should be check properly and record automatically to ensure that the blocks should cure properly for maximum strength. 

Comparison of Embossed Concrete Vs. Paver Blocks for Footpaths

The outer area of your home or your garden leaves impressions with guests, neighbors, and those who pass by your home. Pavers Blocks and embossed concrete can increase the look of this area and make it stand out. Whether you want to improve your garden or totally redesign the look of your pathway or driveway, Pavers are a wonderful option.

The pavers are easy to install and the concrete also seems simple enough, the decision as to which one to choose is not easy. Here we explained some key differences and criteria between the paver blocks and embossed concrete.

Usage of Stamped Concrete and Paver Blocks

Embossed Concrete is a relatively new product and it is not popular.

Whereas Paver blocks are a highly popular product, and that is proven in performance through wide usage over decades.

Availability

Embossed Concrete is Not widely available. On the other hand, paver blocks are widely available with a large established body of producers.

Quality Standards

Embossed Concrete had no local quality standards at all.

While on the contrary paver blocks are certified by the Bureau of Indian Standards, since 2006.

Aesthetics

Embossed Concrete is available in many designs and colors.

Whereas paver blocks are also available in many colors, finishes, and laying patterns.

Area of Application

Embossed Concrete is a limited application for low traffic areas such as swimming pool decks, pathways, private driveways, etc. It is not suitable for high wear and tears public footpaths.

On the other side, paver blocks are suitable for a large variety of applications, from low traffic pathways to public footpaths, parking lots, and heavy-duty usages such as Smart Cities, ports, and container terminals as well.

Manufacturing Process

Casting and curing at the site lead embossed concrete to poor quality control, that is why uncertainty in quality.

On the other hand, paver blocks are machine-made, robust, finished products, fully cured in a factory, leading it to superior and consistent quality products.

Site Laying

Embossed Concrete requires skilled workmanship whereas paver blocks site laying is done widely, and it requires semi-skilled labor.

Site Curing

Inappropriate curing after laying at the site leads embossed concrete to defects that cannot be rectified.

While on the contrary in paver blocks, footpaths are open for use immediately after laying without holding up for curing and any product or defects can be easily rectified immediately after laying.

Quality Testing

Difficult to check the quality of stamped concrete after it is cast at the site.

whereas paver blocks can be tested easily at any time even after laying, which most advantage of it.

Abrasion

The top color layer thickness in stamped concrete is 2mm which wears off in high-traffic applications, such as public footpaths.

While top color layer thickness in paver blocks is 6-10mm giving a much longer life for high traffic applications.

Underground Utilities

Stamped concrete cannot be accessed after laying without replacing the surface.

While paver blocks can easily access for maintenance, the same blocks are re-used afterward.

Durability

Stamped concrete is prone to cracks that cannot repair without replacing the surface.

Paver blocks give high durability and if blocks crack, it can replace individually at any time.

Rain Effect

Embossed concrete has no groundwater percolation which leads to water runoff into drains.

On the other hand, paver blocks’ percolation to base and subbase through joints can increase substantially using Permeable Paving.

Monsoon Laying

Embossed concrete cannot carry out during monsoon surface damage even if it rains within 8-10 hours of stamping.

While paver blocks can lay even during the monsoon as well as any season.

Cost of Embossed Concrete and Paver Blocks

Embossed concrete’s cost is higher for a given area whereas paver block’s cost is lower for a given area.

Conclusions

From the above differences and criteria, it is clear that paver block has better strength as compared to embossed or Stamped concrete. It can be easily specified that paver blocks can use in the park, driveway, pathway, and yards of the domestic as well as a commercial building because the strength is sufficient for the smooth utility of the user.

Fully Automatic Block Making Machine RT6B+

Today we will see RT6B+ machines and what machines are in the automation.

The RT6B+ is a fully automatic block making machine with automatic rack loading and unloading system.

RT6 model is developed as the budget solution to entrepreneurs interested in setting up the factory to manufacture concrete products in medium-size block plants.

The machine is developed to provide a system with indigenous curing solutions.

There is also the option of a rack loading and unloading system which has an automatic storage rack moving conveyor which reduces the delay and labour fatigue.

It has an automatic standard cubing system and blocks with 1.2 by 1.2 meters cubes.

There is An line palletizing of dry side and wet side handling which eliminates the involvement of labour in the plant.

The main feature is contactless product manufacturing and maintain

RT6B+ Process Flow Chart

There are two options Three bin feeder and Single Bin Feeder. After that raw material is transfer to automatic weigh batcher and dry mixes. We also provide a cement weigh batcher. Next water from the water dosing system, dry mixes, and cement sent to either Face Concrete Mixer or Base Concrete mixer. There are two options from Face Concrete Mixer and Base Concrete Mixer to choose from.

After mixing, the conveyor belt took the mixer to the RT6 machine. Here the blocks are press at different vibrant frequencies with the help of variable frequency drives. This high-frequency vibration gives the product better compaction, higher density, and maximum strength.

Now the conveyor belt takes the wet blocks to the rack loading device and stores them at the curing chamber. There is an automatic storage rack moving conveyor which stores wet blocks and sends dry blocks for packaging.

After drying, first, the rack unloading device moves the blocks to block arranging via dry block conveyor. There are two processes done here. First, the blocks picked up and sent to an automatic cuber, and empty pallets are sent back to the machine. The cuber makes the cub of the block and packed it.

Finally, the products are ready.

This is the List of Equipment of RT6B+

The general arrangement of the RT6B+ Type.

Machine installed at the site.

Here is the Production capacity of RT6B+.

Now understand the function of the main parts of the machine.

Automatic Rack Loader & Un-Loader Device

This device loads the rack after the pallet comes out from the block machine and rolled to be lift-off through the green conveyor.

In the same way after curing the racks are first moved out and placed where the unloading device is and it unloads the pallets from rack to loop line.

Both the Rack Loader and Un-Loader are automatic and PLC controlled.

Automatic Rack Moving Device for Wet and Dry Side

It places the rack in the position of loader and unloader. It is driven by chain and powered by SEW geared motors.

Dry Block Conveyor & Pallet Turning Device

The conveyor transports the pallets which are first unloaded by loader and places them in the block separate device and send them to the pallet turning device.

The pallet turning device turns the pallet and utilizes the pallet to use on both sides which gives long life to pallets and avoids bends and high pressure.

Block Separate Device and Block Arranging Device

The device arranges blocks as per even size for cuber clamping for pallet size of 900 x 700.

Automatic Cuber & Slat Conveyor

The cuber makes the cubes of the dry blocks and stacked on a slat conveyor.

It is PLC controlled and driven by a hydraulic system with an accumulator.

Hope this information will help you to choose the best one.

Things You Need to Know Before Using Concrete Block as a Building Material

In this article, we are going to discuss concrete blocks and its advantage and disadvantages, and many more.

Many centuries ago people have changed and adjusted to many structures, like caves, etc.

They begin a journey to create accommodation for themselves.

Along with the emergence of culture and civilization, people go about to settle & build their own accommodation.

There are different types of residence according to their culture, taste, environments, and available materials.

Likewise, the structure of a building is just not a house for living.

It has many parts which give the building its safety & identity, character, strength, like its foundation, stair, wall, floor, roof, etc.

The building or home has various sections like bedroom, living room, kitchen, bathroom, washroom, storeroom, etc.

Before the beginning of advanced technology, most construction is built with red bricks, stones, mortar, & wood.

Not that the only materials that contribute to creating a structure but Concrete is also used extensively for build a long-lasting building.

A few main masonry unit types are:

• Clay Bricks
• Natural Stones
• Concrete Blocks
• Fly Ash Bricks

Nowadays Concrete blocks are used widely as normal, red bricks are harmful to the environment.

Definition of Concrete Block

According to ‘David Blockley’, a Concrete Block is a ‘Building Block made totally of concrete.

which is then bonded together with Mortar to form an imposing long-lasting structure.

These types of buildings are made from ‘Hollow’ or ‘Solid’ blocks.

It can be ordinary and lightweight concrete in different standards sizes depends on requirements.

Concrete Blocks

1. Hollow Concrete Blocks

2. Solid Concrete Blocks

Hollow Concrete Blocks are very often used than solid blocks because:

Hollow Blocks are not heavy and easy to handle.

They can be grout and reinforced, yet meets difficult structural needs easily.

Solid Concrete Blocks are disappearing nowadays, because of their added mass.

It only calls for special requirements or need, such as Higher Fire Resistance, where being impassable is of paramount signification.

Let us know more.

Solid Concrete Blocks

The overall dimensions of the Solid Concrete Blocks are more than 75% of the total mass fill up with concrete that is known as Concrete Brick.

Hollow Concrete Blocks

It having solid material of around 50-70% of the total volume, calculated from the overall dimensions is designate as a Hollow Concrete Block.

Hollow Concrete Blocks have single or more large holes.

which either passes through the open cavity or just might produce to reduce the mass but the cost of its strength.

Hollow Concrete Blocks are further sorted into two divisions, viz Grade A & Grade B.

This Grade B category has been occ asionally referring to as Cinder Block, as the Cinder is the composite more often use in its material base.

The Hollow Concrete Blocks are nowadays are available in the market in different shapes & sizes.

As stated by its location or position in the wall.

These are Corner Concrete Blocks, Jamb Concrete blocks, Bullnose Concrete Blocks, Concrete Stretcher Blocks, Partition Concrete Blocks, Frogged Brick Blocks, Lintel Blocks, etc.

Pros of Concrete Blocks

Concrete blocks make a room bigger by expanding the carpet area on account of the decrease wall thickness owing to narrower Concrete Blocks than the standard brick masonry wall.

Concrete Blocks defend the interiors against noise pollution, as it soaks up the sound and it also protects against fire.

It provides superior thermal insulation.

Manufacture along with Concrete Block is faster, stronger, & structural as differentiate to the brick masonry due to the big size of blocks.

Concrete Blocks defend farmers’ land, which otherwise would have been burrow abundantly for manufacturing clay bricks.

As differentiate to conventional masonry building, Individual units can be produced to bigger custom size & shape, ensuring quick turnaround in construction cycle with fewer joints mortar consumption rate decrease, yet increase the gross robustness of the establishment.

Unlike standards bricks, Concrete Blocks’ costume size cuts down on plaster usage.

So it becomes an inexpensive viable choice.

There are a few more advantages & disadvantages of various Blocks, which are as given below.

The benefit of Solid Concrete Blocks

Relatively easier to design Solid Concrete Blocks.

These Blocks are highly resistant to utmost weather conditions, like storms, high winds, and floods, etc.

The benefit of Hollow Concrete Blocks

For reinforcement, Hollow Concrete Blocks does not need extra formwork or any special building machinery.

Fresher or semi-skilled labor can also easily do it finely.

Cons of Concrete Blocks

If the essential raw materials are not willingly convenient then this becomes a costly proposition product.

Labour should be experienced & skilled for the fast & stable production of Concrete Blocks.

Cons of Solid Concrete Blocks

It is difficult to make concealed wiring, plumbing in any structure.

Cons of Hollow Concrete Blocks

Hollow Concrete Blocks are risky during earthquakes if Without an internal reinforcement structure built.

Concrete Blocks Uses

These are perfect for extensive housing and different civil engineering projects.

Concrete Blocks applications:

Concrete Blocks for Building Walls

For fast and easy installation, partition walls advantage extremely by adopting utilization of Concrete Blocks.

Steel reinforcement gives extra strength to the construction.

Solid Concrete Blocks are right for Fireplaces & built of Chimney, yet they equally shine at Non-load Bearing & Garden Walls.

Hollow Concrete Blocks are extensively used for outdoor & indoor Load-bearing Walls, Boundary Walls, Panel Walls, Partition Walls, etc.

Used for the Formation of Material Bin

From different climatic conditions, Concrete Blocks can defend the stored materials.

No wonder, it remains engineers’ decision for the formation of Material Bins.

It helps in keeping the materials away from one another, that is why manufacturing companies choose to employ this.

They utilize these Concrete Blocks to reserve material for the long-term – like rock, aggregate, etc.

Concrete Blocks Utilized in Landscape Projects

Concrete Blocks also use in various applications.

For example, in Flower Bed, Outdoor Bar, Outdoor Seating, Decorative Screen, Patio designs & many Outdoor Furniture.

Concrete Blocks Properties

The different properties of Concrete Blocks are:

1.   Dimensions

Dimension is the size of Blocks in the matter of Length, Width & Height.

Concrete Blocks are mention by their nominal dimensions.

‘nominal’ is dimensions that consist of the thickness of mortar joints.

Actual dimensions (Length and Height only) have to be 10 mm short of the formal dimensions.

For example, a 400 mm X 200 mm X 200 mm Block has actual Length, Width, and Height measures of 390 mm, 200 mm, and 190mm respectively.

As per the Indian Standard Code 2185, The formal dimensions of Concrete Block are:

Length: 400, 500 or 600 mm

Width: 50, 75, 100, 150, 200, 250 or 300 mm

Height: 100 or 200 mm

Other than the above referred Concrete Block sizes, they tend to differ extensively based on the mutual contract between the purchaser and the supplier.

2. Density

Density is the mass per unit volume of a solidity.

There is a parameter for describing the material and form of a mass in the existence of gravity.

The density of Concrete Blocks is:

Solid Concrete Blocks -1,800 kg/m ³ (Minimum)

Hollow Concrete Blocks

Grade A – 1,500 kg/m ³ (Minimum)

Grade B – 1,100 kg/m ³ & 1,500 kg/m ³

3. Compressive Strength

Compressive strength is the capability of a material to withstand compression.

The minimum average compressive strength of Concrete Blocks is:

Solid Concrete Blocks– 4.0 and 5.0 N/mm ²

sequentially at 28 days

Hollow Concrete Blocks

Grade A – 3.5, 4.5, 5.5, 7.0, 8.5, 10.0, 12.5 and 15.0 N/mm ² sequentially at 28 days

Grade B – 3.5 and 5.0 N/mm ² sequentially at 28 days

4. Water Absorption

Water Absorption is the capability of the material to absorb and retain water and the water absorption should be less than 10% by mass.

5. Drying Shrinkage

The drying depreciation of Concrete Blocks should be less than 0.06%.

6. Moisture Movement

The moisture movement arises because material repeatedly inflates due to the outcome of swelling and shrinkage.

Concrete Blocks’ moisture movement around less than 0.09%.

Raw Materials

The basic materials needed for the manufacture of Concrete Blocks are:

Cement

The types of cement used for the construction of Concrete Blocks are Portland Slag Cement, Portland Cement, Portland Pozzolana Cement, etc. It should observe its respective standard codes.

Aggregate

The aggregate of the distinct genres utilize varying degrees of success, and they include cinder, clinker, gravel, crushed stones, etc.

The aggregates are sort lists on the virtue of their weight, texture, or composition of a unit design.

The strength, texture, and price of Concrete Block rely on the attentive grading of the aggregate.

The stratification of the combined aggregate shall conform to the needs of Indian Standard Code 383.

Water

Potable water is the basic necessity in the production process of Concrete Blocks.

Additives or Admixtures

Additives or admixtures may add either as admixtures to the concrete mix or as additives to the cement during its construction process.

Admixtures or additives used in the manufacture of Concrete Masonry Units are:

Water decrease, accelerating, air-entraining, and superplasticizers conforming to Indian Standard Code 9103.

Waterproofing representatives follow Indian Standard Code 2645.

Where no appropriate Indian Standards are available, the additives or admixtures shall be utilize based on ASTM or British Standard.

Making Process of Concrete Blocks

The manufacturing of Concrete Blocks consists of the following basic stages,

(I) Proportioning

The quantity of the material has been taking likewise the Indian Standard Code 2185 – or as per the robustness need.

(ii) Mixing

Batching of the ingredients should be done exactly and mixing shall be done in a mixture to gain a homogeneous mix.

It shall go on until there is a uniform circulation of the materials.

(iii) Compacting

The Block should be compact by Vibro compaction and accomplish to the proper size without any broken edges.

(iv) Curing

The Blocks shall cure in a curing water tank or curing yard and should keep repeatedly moist for at least 14 days.

When the Blocks are cure in an immersion tank, the water of the tank should change at least every 4 days.

  (v) Drying:

After curing, the Blocks are dried for 2/3 weeks, and then only, they become fit to use for various intent.

If you do not follow it, diminution cracks are likely to show in walls.

  Production of Concrete Blocks

The fully automatic plants are convenient for the manufacturing of high-strength Concrete Blocks.

These automatic machines produce superior quality Concrete Blocks, but they involve significant capital investment.

The manually operating machines are also obtainable and can even be installe in the project area.

This will dilute the transportation cost of the Concrete Blocks from the place of manufacturing to the place of actual use.

Conclusion

As specified previously, there is a large variation of masonry units from which an architect, owner, or engineer can choose the most suited for a particular circumstance.

As reported by Handbook on Masonry Design and Construction – SP 20 the primary discussion in choosing a particular unit are:

Dimensional Stability, Thermal Properties, Resistance to Rain Penetration, Fire Rating, Availability, Strength Requirement, Durability, Style of Architecture, and of course – Economy in Cost.

Concrete Blocks have been broadly using in buildings throughout the country.

Its properties such as Fire Resistance, Insulation, Durability, Strength & Structural Stability, and Sound Absorption make it acceptable for various types of applications.

Concrete Blocks are suitable in areas where brick or stone of sufficient quality for masonry are not available at a decent cost.

If proper variation of aggregates is available for manufacturing, they utilize masonry units for Blocks.

Which can utilize for load-bearing or even non-load-bearing walls, partitions, and panel walls.

Benefits of Using Paver Blocks

In this article, we discussed various benefits of Using Paver Blocks.

Do you have your front yard of home laid by Paver Blocks?

If not then you probably have seen those colorful paver blocks organized in the finest designs in front of homes, stations, buildings, walkways, etc.

Setting up the paver blocks is nowadays a common process.

The reasons are many, such as providing aesthetic beauty, expanding the value of the house, proffer a driveway, etc.

But have you thought about the advantage of installing paver blocks on the outside of your home?

If you want to know more about it, then keep reading.

PAVER BLOCKS

As specified, due to its benefits paver blocks are becoming more demanded.

It is one of the most popular and flexible pavements surfacing options.

It has been generally made from numerous materials such as concrete, clay, recycled plastic, etc.

Distinct types of paver blocks are available such as the regular ones and permeable ones.

Another preference of pavers is that they occur in various sizes and shapes which gained by using high-quality paver block moulds.

The permeable ones are those which have slots through which grass grows and productively minimizes surface-water runoff.

Grass paver blocks are samples of permeable block pavers.

Now you must have got an idea about pavers and their genre.

But have you wondered? why do you need paver blocks installed?

Assume, your home needs a walkway or driveway for your vehicle.

You don’t want to risk walking or driving through the grassed area, so what is the best solution?

Installing paver blocks, with this process you can lay the whole area or the specific part you want as the walkway.

There are many benefits to installing paver blocks for your home outdoors, which are explained next.

Benefits

High Durability

Paver blocks have a lifespan of minimum 20 years, so that, once installed, then replace after a long time and it is highly durable in build.

As the blocks are interlocked with each other, the chances of creating cracks are not mattered.

Owing to their long-lasting quality, paver blocks are a preferred choice for homes and commercial uses.

It is proficient in withstanding a high amount of pressure which makes it appropriate for use in airports and docks.

Eco-Friendly

If you are bothered about the safety of your ecosystem or environments, interlocked paver blocks are an alternative for protecting the environment along with getting your own driveway.

By using grass paver blocks, staves off standing water and effectively decrease water run-off by absorbing the water and promoting groundwater recharging and soil ejection.

Easy to Set Up & Repair

Paver Blocks are easy to install which is another cause for using them.

They don’t need to use heavy machinery or multiple tools.

Within 3-4 days the whole installation process is accomplished and right after completion, the place can be used for walking or driving your car through it.

Even the repairing process is easy.

Assume, if one of the blocks is broken or stained from vigorous chemicals like oil, petrol, or diesel, only the specific block can be easily changed without affecting the other blocks.

Manufacturing Cost

Commonly, the paver blocks are manufactured in mass production that is why it has the fewer prices and in fact, makes them cost economical.

Concrete paver blocks are inexpensive than clay pavers or the ones made from natural stones and also installing pavers are for a lifetime.

Having a good-quality walkway can make your house more visually attractive.

The right kind of surfacing material can complement your property, whether it’s having a patio in your back garden or other types of structure.

One of the finest materials is block paving, made from concrete and clay.

The blocks can be put down in organized patterns and shaped to individual taste.

There are many benefits to block paving.

Versatility

The versatility of block paving creates it is the highest quality material to use.

Coming in a range of styles and colors, block paving is customizing to your own specifications.

Many designs and shapes can form, and more amplify, the appeal of the material.

Durability

Owing to its durability, block paving is an enduring material.

Block paving is long-lasting enough to withstand the pressure of an airplane, that is why it’s a familiar material at airports.

You can drive your car over it many times and it won’t endure any difficulties. Also, block paving is highly extremely to most chemicals, oils, salts, and frosts.

Environmentally imperishable

Differentiating from other surfacing materials, block paving is more environmentally sustainable on account of its porous nature.

This means the paving will soak up rainwater and stop it from gathering on your patio or driveway.

The added advantage is that the surface area will have better sewerage.

Low maintenance

Additional benefits of block paving are that they do need very little maintenance. Only you have to do is apply soap and water to keep it clean. Block paving is also durable sufficient to withstand all types of weather.

Visual appeal

With the diversity of styles on offer, block paving is guaranteed to improve the appearance of your home. There’s the alternative to use a simplistic design, or go for something more complicated.

 

What is the difference between Hollow Concrete Blocks and Fly Ash Bricks?

Which is better for masonry?

The masonry is there since mankind begins and to date, it is very popular. The stones are used in masonry work for years but now the bricks are widely used material in construction. The reason behind bricks used in masonry is they are economical, durable, easy to handle, and to work with. But bricks have some disadvantages. The conventional clay bricks are made from topsoil which minimizes the land for agriculture. In the making of these bricks the carbon dioxide gas is emitted. The clay bricks are not environment friendly. These days the fly ash bricks and hollow concrete blocks gaining popularity for masonry.

This is the comparison between concrete hollow blocks and fly ash bricks to choose right for your masonry.

Hollow Concrete Blocks

The hollow concrete blocks according to Indian Standard – IS 2185 (Part-1) 2005, the hollow blocks have one or more large holes or cavities pass through the block or do not pass through the block (close cavity). The block has solid material between 50 to 75 percent of total volume from overall dimensions.

Fly Ash Bricks

The fly ash bricks are eco-friendly made from fly ash or pulverized fuel ash. These blocks are 100 percent solid and do not have any cavity.

Which Raw Material is Used?

The hollow concrete blocks have cement, aggregates, sand or gravel, and water. Also, the industrial waste like fly ash, bottom ash is added.

The fly ash bricks are made from fly ash or pulverized fuel ash, cement, sand, lime, and gypsum

Where are they Used?

The hollow concrete blocks are used in masonry for Exterior load-bearing walls, Interior load-bearing walls, curtain walls, partition wall, and panel wall, backing to stone, brick and facing, fireproofing, fire-safe walls around elevators and stairwells, piers, retaining walls, column, etc.

As the fly ash bricks provide strength and durability these bricks are used in various types of construction for load-bearing and non-load bearing walls. These bricks are also used for Raising Infrastructures, Factories, Warehous, Power plant, High rise structures, construction of pavements, water tanks, underwater works, canal lining, and irrigation work, etc.

Advantages of Concrete Hollow Blocks and Fly Ash Bricks?

Hollow Concrete Blocks

These blocks have high durability and less weight. So there is less dead load and saves reinforcement steel in RCC

The masonry practice of hollow concrete blocks is easy and faster than other conventional practices.

These blocks are environment friendly as the waste like fly ash or bottom ash is used as raw material.

The blocks have a rough texture so there is excellent bonding between cement mortar and blocks.

Semi-skill labor can also work with hollow concrete blocks.

These hollow blocks are good sound insulators and provide resistance to earthquakes.

Water consumption of concrete blocks is comparatively less than fly ash bricks

The steel reinforcing is possible with hollow concrete blocks

The weight of the block is less and less steel is required as there is less dead load

These hollow concrete blocks can be used in the construction of load-bearing structure up to 6 stories high with steel

Using the steel there is less dead load so the construction has high earthquake resistance

The special hollow concrete blocks can be used as horizontal reinforcements like lintels and horizontal reinforced concrete can build with blocks

Fly Ash Bricks

These bricks are made using the waste from fly ash which is the waste from a thermal power plants and it is hard to dispose of.

These bricks are high fire insulation

The bricks are very strong and sturdy and almost no breakage in transportation

The bricks have the uniform size so the less mortar is required for joints and plaster

Fly ash bricks provide good thermal insulation

There is no different size of fly ash brick requires for lintel, sill, and jamb

What are the disadvantages of Hollow Concrete Blocks and Fly Ash Bricks?

Hollow Concrete Blocks

The blocks are poor heat insulator as have less thermal mass

The price of the blocks is high compared to fly ash bricks for construction. The price is depending on the availability in the market

Concealed wiring is not possible in hollow concrete blocks

There is a different size of blocks required for lintel, sill, and jamb

Fly Ash Bricks

The mechanical strength of fly ash brick is less but it can improve by adding marble waste of mortar

These bricks can manufacture in limited size and modular size is produced only. The large size of brick has higher chances of breakages

The bricks have a low heat-absorbing capacity. This is can be used in a subtropical region or where the climate is warm.

Bricks are heavy in weight than the hollow blocks

The concealed wiring can be done

The steel cannot be used in the fly ash masonry

How to identify Hollow Concrete Blocks and Fly Ash Bricks?

The hollow concrete blocks are grey in color

The fly ash bricks are generally tan to dark grey

Various Properties of the Concrete Hollow Blocks and Fly Ash Bricks

Hollow Concrete Blocks

Length: 400, 500 or 600 mm

Height: 200 or 100 mm

Width: 50, 75, 100, 150, 200, 250 or 300 mm

Fly Ash Bricks

Standard Modular Size 190 x 90 x 90 mm or 190 x 90 x 40 mm

Standard Non modular size 230 x 110 x 70 or 230 x 110 x 30 mm

Dimensions Tolerance

The hollow concrete blocks have variation in length shall not more than ±5 mm and the height and width of the unit not more than ±3 mm

Fly Ash Bricks

The dimension of the block tested in accordance with IS 12894:2002 with limits of 20 bricks

For modular size

Length 3720 to 3880 mm (3800 ±80 mm)

Width 1760 to 1840 mm (1800 ±40 mm)

Height 1760 to 1840 mm (1800 ±40 mm)

 

For 90 mm high bricks

760 to 840 mm (800 ±40 mm)

For Non-Modular Size

Length 4520 to 4680 mm (4600 ±80 mm)

Width 2240 to 2160 mm (2200 ±40 mm)

Height 1440 to 1360 mm (1400 ±40 mm)

(For 70 mm high bricks)

640 to 560 mm (600 ± 40 mm)

(For 30 mm high bricks)

Dry Density

The dry density of the hollow concrete block varies from 1100 to 1500 kg/m ³ . This variation is depending on the grade of concrete and the extent of the cavity

Fly Ash Bricks

The fly ash bricks have a dry density that varies between 1700 to 2000 kg/m ³ .

Weight

Hollow Concrete Blocks

The weight is depending on the density and size of the block

Fly Ash Bricks

This depends on the density and size of the brick

Compressive Strength

The hollow concrete block has a compressive strength of hollow concrete block ranges from 3.5 to 15 N/mm ² and depend on the grade of the blocks

Fly Ash Bricks has compressive strength from 3.5 to 35 N/mm ² and depending upon the class bricks

Water Absorption

The water absorption of a hollow concrete block does not exceed 10 percent of its weight

The water absorption of fly ash brick should not exceed 15 to 20 % of its weight

Termite Resistant

Concrete hollow blocks and fly ash bricks have good termite resistance

Thermal Conductivity

The hollow concrete block has a thermal conductivity of 0.12 to 0.17 W/m K

The thermal conductivity of fly ash brick is 0.3 to 0.4 W/m K

Sound Insulation

Hollow Concrete Blocks

The sound insulation is the capacity to reduce sound transmission by building elements

It is depending upon the thickness of the wall

The blocks have good sound insulation property as it has a dense structure

Fly Ash Bricks

The fly ash bricks have moderate sound insulation property

Efficiency

Mortar Consumption

Hollow Concrete Blocks

The blocks required less mortar compared to fly ash bricks

Fly Ash Bricks

More mortar is required compared to hollow blocks

Breakage and Utilization

The hollow concrete blocks have negligible breakage and it depends on basic quality

The fly ash bricks have negligible breakage and almost utilization is possible

Cost

The hollow concrete blocks are costlier than fly ash bricks but the overall masonry cost is low. As it consumes less mortar

The fly ash bricks are cheap but the overall cost is high as it requires more mortar than hollow concrete blocks

What is an Environment Impact of Hollow concrete block and Fly Ash bricks?

Hollow Concrete Blocks

The hollow concrete blocks are environment-friendly building material and also energy-efficient as they have proper insulating properties

Fly Ash Bricks

The fly ash brick is also environmentally friendly. It is the waste of thermal power plant and not easy to dispose

There is a very low amount of carbon dioxide is emitted in manufacturing

 

You will know about the comparison between Hollow Concrete Blocks and Fly Ash Bricks. Both products are environmentally friendly and the raw material used is industrial waste. This comparison will help you to choose according to your application.