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Concrete block technology |
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In present
construction scenario, concrete blocks are well-accepted 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. The mortar used is
also less which results in cost saving. Concrete blocks have been
extensively used in combination with conventional roofing systems like RCC,
RBC, GI sheets, ACC sheets etc. They are also compatible with other
materials like fired bricks, dressed stone and compressed earth blocks for
composite wall construction.
Acceptability of concrete blocks is very high in urban areas for all types of buildings. It is a popular walling material for major qualities like low maintenance and investment for institutional and industrial buildings. The durability of a cement-based product is making concrete blocks a preferred choice in rural areas as well.
The Product
Specifications and the characterizations of concrete blocks depend upon
design mix and the machine used to manufacture
the block. The most common size of solid concrete blocks is 300x200x150mm.
The SAKAR machine from Susanji Udyog Pvt Ltd. is a versatile equipment which
produces solid, hollow, paving, tree guard and toilet interlocking concrete
blocks of various sizes with the same equipment. It is possible to produce
all these blocks with the single machine by just changing the mould. The
basic raw material is cement, fine aggregate and coarse aggregate. The
mechanised compaction and vibration, gives the block high quality, inspite
of the lean mix, which uses very little cement. Weight of an average
concrete block is about 18-20 kgs. Concrete blocks can be surface engineered
by using pieces of stone or ceramic waste on their face.
The production process
This machine with high quality tabletop vibrator provides optimum vibration
in the mix so that the ratio of cement used can be reduced substantially
without compromising on the strength of the blocks. The design mix
corresponding to required compressive strength is prepared using the mixer
and then it is filled in the moulds, which are placed on the vibrator. The
machine also compacts and consolidates the mix so that the blocks are
uniform in size and attain desired physical properties. The blocks are cured
for a minimum period of 14 days, before they are ready to use. On an average
600-800 blocks can be in 8 hours with 1 supervisor, 1 skilled and 6-8
unskilled workers.
Advantages
| ● | Cost effective compared to other traditional walling systems |
| ● | High quality – high strength, uniform size and shape |
| ● | Energy efficient - Does not require any non-renewable resources for production |
| ● | Environmental friendly - Utilises wastes and local resources |
| ● | Structural performance can be engineered as per application |
| ● | Decentralised production – allows both factory and on-site production |
| ● | Machine production provides smooth finish which offers savings on further cement plaster etc |
| ● | Semi mechanised process produces high quality material and provide adequate working opportunities |
Areas
of Application
Concrete blocks have various
types like; solid, hollow, paving, treeguard blocks, and each of them are
available in various shapes and sizes. This vast range of products offers a
large market for application.
| ● | In load bearing structures - low rise residential and office buildings, bungalows, shelter units for rural housing, highway constructions, institutional buildings, godowns and warehouses etc |
| ● | In frame structures – High rise residential apartments, office buildings, market complexs, hospitals and hotels etc |
| ● | As ground laying units – interlocking paving blocks for roadside walkways, garden pathways, curb stones, exhibition grounds, fuel pumping stations, movement corridors, high traffic movement areas like : bus and train stations etc. |
| ● | Specific usage areas: tree guard blocks for road side and garden tree plantations |
Development Status
Commercialized
Technical Data
| Annual production | for solid or hollow blocks 180,000 (with 600 blocks/day) for paving blocks 300,000 (with 1000 blocks/day) |
| Land requirement | 180 m2 of covered working space and cement godown Total 2000m2 for casting, demoulding, curing,stacking and movement space |
| Electricity requirement | 5 KVA |
| No.of jobs created | 8 (1 supervisor, 1 skilled, 6 unskilled) |
Economic Data
| Infrastructure cost for office and workshop includes: Working shed, office space, cement godown, facilities-electricity and water) | Rs 100,000 |
| Equipment (With 25 No of moulds for solid, hollow and paving blocks and concrete mixer and accessories) | Rs 122,000 |
| Hydraform with pan mixer (with hydraulic machine) | Rs 475,000 |
| Transportation and insurance (in India) | Rs 12,000 |
| Installation and know how transfer | Rs 15,000 |
| Total (package with hydraulic machine) | Rs 2,49,000/- (US$ 4,820) |
| These cost do not include cost of land, as it varies considerably from place to place) | |
Business
Concrete block technology
is a highly profitable business for small scale building material producers
or civil contractors and builders. A total investment of Rs. 2,49,000/- for
a semi-mechanised production system assures a turnover of Rs 16,50,000/- per
annum. Looking at the fast growing market for concrete blocks, it has a
recovery potential of more than 50% percent of investment, within first year
of operations. The equipment is marketed by TARA (Technology and action for
Rural Advancement), a leading sustainable technology marketing organisation.
Transfer forms
Product, process on
turnkey basis
For further
information, please contact:
Mr. Subroto Roy
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