NEW BUILDING MATERIALS AND TECHNOLOGIES

CONSTRUCTION
BLOCKS

CONSTRUCTION BLOCKS
Divisha JINDAL
Jindal
DIVISHA

M.B.E.M. I

2009-10
BEM
/ 471

S.P.A., New
Delhi DELHI
SPA, NEW

CONTENTS:
INTRODUCTION

BUILDING ENVELOPE
BUILDING MATERIALS
CRITERIA FOR SELECTION

TRADITIONAL WALLING SYSTEMS

BURNT CLAY BRICKS

CONVENTIONAL WALLING SYSTEMS

BRICK 9 X 4.5 X 3

NEW WALLING SYSTEMS CONSTRUCTION BLOCKS

COMPARATIVE 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 BLOCKS
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M.B.E.M. I

2009-10

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CONTENTS:
NEW WALLING MATERIALS & TECHNOLOGIES

INTRODUCTION

INTERLOCKING HOLLOW CORE BLOCKS - ANANGPUR BUILDING CENTRE

VARIOUS INVENTIONS BY BMTPC:
BMTPC

Rubble Filler Concrete Block

Precast Concrete Stone Masonry Blocks
Hollow and solid lightweight concrete blocks/ Cinder blocks
Fal G sand blocks
Fly Ash Bricks
etc
etc.

VARIOUS INVENTIONS BY CBRI:

Compressed stabilized earth blocks

Stabilized Adobe blocks
LATO blocks
Clay
y red mud burnt bricks/ tiles

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)
GLASSCRETE BLOCKS
VEROT OAKS BUILDING BLOCKS(VOBB) BY NEWELLS DESIGN, USA
GREEN BRICKS MADE FROM CRUSHED TILES AND OLD MORTAR
BAMBOO/TIMBER MAT BASED WALLS (EKRA WALLING)

CONSTRUCTION BLOCKS
Divisha Jindal

M.B.E.M. I

2009-10

S.P.A., New Delhi

INTRODUCTION

CONSTRUCTION BLOCKS
Divisha Jindal

M.B.E.M. I

2009-10

S.P.A., New Delhi

INTRODUCTION:
The construction sector alone counts for nearly 50% towards the
countrys economics as well as energy consumption..

Buildings
Transportation
Industries

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.

CONSTRUCTION BLOCKS
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M.B.E.M. I

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NEED:

The developing nations are today

following the advanced nations policy
of achieving economic growth through
macro-industrial
production.
Large-scale
production
and
consumption
necessitates
large
distances for transportation of raw
material and end product, high
marketing costs and other add-ons.

Developing
Nations GDP

50% for
Building &
Construction

60% for
Material
Consumption

50% for
Industries &

Transportation

Advanced nations today have 30%

actual production costs and 70% addon value to a product. Developing
nations still have 70% production costs
and 30% add- on value, but are rapidly
following the unsustainable patterns of
the
h developed
d
l
d nations.
i
Therefore, in order to have sustainable
development, it is imperative to
identify the areas where macro
industry and micro enterprise are
required.

40% for Labor

Source: www.anangpur.org

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2009-10

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BUILDING ENVELOPE

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COMPONENTS OF BUILDING ENVELOPE:

BUILDING
ENVELOPE

VERTICAL

WALL

HORIZONTAL

FENESTRATIONS

ROOF

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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
through a wall
Source: ECBC, 2006

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MISUSE OF BUILDING MATERIALS:

Misuse of building materials is probably the largest single factor that contributes to environmental
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
requirements.
i
t The
Th ideal
id l block
bl k would
ld therefore
th f
require
i a resilient
ili t non-erodible
dibl surface
f
with
ith a lean
l
backup body material. Another important criterion should be the feasibility of manufacture at the
site, with minimal capital.

Source: www.anangpur.org

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Source: www.anangpur.org
NEED OF NEW BUILDING MATERIALS:
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
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
g
Despite
p
a number of innovative cost-effective building
g materials,, components
p
and
technologies.
construction techniques developed through research the housing and building agencies have not
adopted them in their construction practices.

CONSTRUCTION BLOCKS
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M.B.E.M. I

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CRITERIA FOR SELECTION:

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

Walling
Elements

Economy

Non-erodible

Low Thermal
Conductivity

Leastt amountt off

L
consumption of
processed
material

Color &
Texture

They
They account for the maximum capital resource in the structure.
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.
Maximum thermal exchange in a building takes place through walls.
Appropriate technologies are those that respond to the local environment, resource and
economic needs.

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TRADITIONAL
WALLING SYSTEMS

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BRICK:
INTERNATIONAL HISTORY OF BRICK
Bricks 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 Valley
Civilization, where it was used exclusively. In particular, it is evident from the ruins
of Buhen, Mohenjo-daro and Harappa
The first sun
sun-dried
dried bricks were made in Mesopotamia (modern Iraq),
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 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
y
y; these bricks were made by
y a fired p
process.
the Western Zhou dynasty;
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

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BRICK:

Roman Constantine
Basilica in Trier,
Germany, built in the 4th
century with fired bricks
World s highest brick
World's
tower
St. Martin's
Church, Landshut,
Germany, 1500
Worlds largest brick structure
Jetavanaramaya Stupa,
Anuradhapura Sri Lanka

Worlds biggest brick castle

Malbork Castle

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TRADITIONAL INDIAN BRICKS:

M h l Brick,
Mughal
B i k Lakhori
L kh i Brick
B i k , Nanakshahi
N
k h hi Brick
B i k etc.
t
These were small thin bricks, tested by time, highly weather
resistant, frost resistant, durable and sturdy bricks, very well
suited for all thin brick applications.
applications
These bricks were patted by hand. Therefore, these were
uneven, irregular, multihued, and imparted an aesthetic aspect to
the building structure.
structure
The size of these bricks varies but is approx. 6x3.5x1.25 and
individual weight is around 650gms.
These 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.
y, clay
y was burnt adequately.
q
y
To ensure non-erodability,

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Divisha Jindal

M.B.E.M. I

2009-10

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CONVENTIONAL
WALLING SYSTEMS

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2009-10

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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.

Source: www.anangpur.org

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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

CONSTRUCTION BLOCKS
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2009-10

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NEW
WALLING SYSTEMS

CONSTRUCTION BLOCKS
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2009-10

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INTRODUCTION
Construction Blocks as alternative walling elements
AN ENVIRONMENT CONSCIOUS PRODUCT AND SUSTAINABLE BUILDING
TECHNOLOGY
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
energy.
energy
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,
output for example,
example construction debris,
debris etc.
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
rubberstamping 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
people.
p
number of p

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INTRODUCTION
Concrete block technology offers a speedier,
speedier cost effective,
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 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 available.
available

UNIQUE FEATURES:
Cost effective compared to other traditional walling systems
Maximum utilization of wastes and local resources
Structural performance can be engineered
Decentralized local production
Offers business opportunities for micro enterprise

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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 concrete
Solid
t blocks
bl k

H ll
Hollow
concrete
t blocks
bl k

C ll l concrete
Cellular
t blocks
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
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

Source: BMTPC, CBRI

constructional reasons.

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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
Various
t
type
off interlocking
i t l ki
bl k
blocks
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
resources. The blocks can be made directly at the building site, or on a larger scale in a
production yard.

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2009-10

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INTERLOCKING HOLLOW
CORE BLOCKS

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1. INTERLOCKING HOLLOW CORE BLOCKS BY ANANGPUR BUILDING

CENTRE
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.
2.
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
concrete
block unit, that can be
manufactured at site

Integrated
permanent
finish;
various
size
options

Schematic
through block

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section

CONSTRUCTION PROCEDURE:
Step 1:

Step 2:

A mould of mild steel of the required

shape and size is manufactured

The desired impermeable diaphragm is

laid at the bottom of the mould,, which
could be waste material such as
stone, broken tiles or PVC chips. A
laterally
inverted
pattern,
sketched on a piece of paper and PVC
with chips glued on,
on forming the
exterior nonerodable
diaphragm resulting in the Integration
of Art in the block.

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CONSTRUCTION PROCEDURE:
Step 3:

Step 4:

Rich cement slurry is poured over the

first impermeable diaphragm.

A lean
backup material (fly ash,
burnt rice husk, mud) is then laid over
and
compacted
compacted.

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CONSTRUCTION PROCEDURE:
Step 5:

Step 6:

A pipe is then inserted in the mould.

mould

The balance mould is filled up leaving

enough space to finish the second
impermeable diaphragm if so desired.
desired

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CONSTRUCTION PROCEDURE:
Step 7:

Step 8:

Marble powder is spread over the finish

which acts as a dewatering agent.
If desired, a thin board may be used to
divide the external diaphragm into two
halves, so as to make it look like two
different blocks

Marble powder is washed using a soft

paintbrush and water.

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CONSTRUCTION PROCEDURE:
Step 9:

The pipe is removed first by rotating it

gently. The block is demoulded after few
minutes of casting and cured for 48
hours before usage.

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BENEFITS:
Simple procedure -universally accessible. The equipment is easily affordable.
Integral permanent finish lower maintenance costslabor intensive but conserves building
material.
Does
D
away with
i h expensive
i scaffolding
ff ldi for
f post- construction
i finishing.
fi i hi
Horizontal bore allows for easy handling by the mason.
Filling the hollow core with waste polythene can increase thermal insulation. waste utilization
A technology
t h l
th t cuts
that
t across economic
i barriers.
b i
P
Permanent
t finish
fi i h is
i the
th aspiration
i ti off the
th rich
i h and
d
the poor

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

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BENEFITS:
Diagonal interlocking to resist lateral thrusts and better load distribution in
unpredictable soils.
Year after year we have to contend with natural disasters such as earthquakes and cyclones. Todays
walls 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 such
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 soil
areas. The principle of diagonal bonding can be seen in Maharashtra in India, Pompeii and Naples in
Italy, Dresden in Germany, in Palestine, Guatemala etc.

Pompeii, Italy

Naples, Italy

Maharashtra, India

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BENEFITS:
Using
g the p
plasticity
y of concrete,, the simple
p molding
g p
process delivers an Interlocking
g Block with
tremendous resilience against horizontal thrusts and the resultant tension.
The diagonal bond has been developed to resist lateral thrusts during an earthquake. These thrusts
g
y to the foundation with each p
perpendicular
p
wall acting
g as a buttress for the
are transferred diagonally
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.

Diagonal bonding
resists
lateral
thrust

Swelling & shrinking in black

cotton soil

Different bonding options

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

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CASE STUDIES:
Diagonal
g
interlocking
g blocks have been used for earthquake
q
resistant housing
g in Gujarat,
j
, India
20 ft. high freestanding walls recently withstood an earthquake measuring up to 5.8 on the R. scale.

Medical
Centre,
Dudhai, Gujarat

New

Primary School, New Dudhai, Gujarat

Architects
A
hi

Residence,
Anangpur,
Faridabad

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CASE STUDIES:

Pushkarna
Residence,
Chandigarh

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CASE STUDIES:

Bharatyamgram

Bhoomiheen Camp

Jaunapur Slum Rehabilitation

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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
S.No.

Description

Quantity

Energy KwH/
unit

Energy
consumed (KwH)

Brick Wall

Brick

500 No.s.

0.88/ brick

440

Cement

60 Kg (1.2 bags)

2.25/Kg

135

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

Interlocking
g Concrete Block Wall

Cement

168 Kg (3.36 bags)

2.25/Kg.

378

Fine Aggregate

525 Kg. (0.23

cu.m.)

0.06/Kg.

31.5

Cement Plaster 6mm 1:4

6.25 Sq.m.

10.325/ Sq.m.

64.53

Cement (Pointing)

21.8 Kg. (0.43 bag)

2.25/ Kg.

49.2

Total

523.23

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VARIOUS INVENTIONS
BY BMTPC

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1. SOLID/ HOLLOW CONCRETE BLOCKS

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1. SOLID/ HOLLOW CONCRETE BLOCKS

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2009-10

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1. SOLID/ HOLLOW CONCRETE BLOCKS

CONSTRUCTION BLOCKS
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2009-10

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1. SOLID/ HOLLOW CONCRETE BLOCKS

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2009-10

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1. SOLID/ HOLLOW CONCRETE BLOCKS

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1. SOLID/ HOLLOW CONCRETE BLOCKS

Tentative Project Costs
HAND HELD TYPE BLOCK MACHINE

STATIONERY BLOCK MACHINE

STANDING TYPE BLOCK MACHINE

CONCRETE BLOCK MACHINE

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2. CELLULAR LIGHT WEIGHT CONCRETE BLOCKS

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2. CELLULAR LIGHT WEIGHT CONCRETE BLOCKS

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2. CELLULAR LIGHT WEIGHT CONCRETE BLOCKS

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2. CELLULAR LIGHT WEIGHT CONCRETE BLOCKS

Tentative Project Cost

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