BACHELOR OF QUANTITY SURVEYING (HONS) BLD

60304CONSTRUCTION TECHNOLOGY 3

BLOCK WORK SYSTEM

CKMUHAMMAD FAREEZ

WEN JUN

INTRODUCTION

Blockwork is construction with concrete or cement blocks that are larger than a standard clay or concrete brick. To make them lighter and easier to work with they have a hollow core that also improves their insulation capacity. They are available in a variety of densities to suit different applications. Their convenience and cost effectiveness have made them a popular alternative to clay bricks although they require an additional finish for reasons of aesthetics and water resistance. They are often used to build internal partition walls and retaining walls.

MANUFACTURING PROCESS

CubingCuringMoldingMixingRaw

Material

RAW MATERIAL

GRAVEL SAND WATER PORTLAND CEMENT

Common concrete blocks

• This produces a light gray block with a fine surface texture and a high compressive strength

PORTLAND CEMENT

VOLCANIC CINDERS

WATER

Cinder block

• This produces a dark gray block with a medium-to-coarse surface texture, good strength, good sound-deadening properties, and a higher thermal insulating value than a concrete block

WATERPORTLAND

CEMENTCLAY SLATE

Lightweight concrete block

• A typical light-weight block weighs 22-28 lb (10.0-12.7 kg) and is used to build non-load-bearing walls and partitions. Expanded blast furnace slag, as well as natural volcanic materials such as pumice and scoria, are also used to make lightweight blocks.

MIXING &MOLDING

CEMENT SILO SAND & GRAVEL

MIXING PROCESS:1. The sand and gravel are stored outside in piles and are transferred into storage bins in the plant by a conveyor belt as they are needed. The Portland or common cement is stored outside in large vertical silos to protect it from moisture.2. As a production run starts, the required amounts of sand, gravel, and cement are transferred by gravity or by mechanical means to a weigh batcher which measures the proper amounts of each material

MOLDING PROCESS: 1. The concrete mixture is moving to an inclined bucket and move to an elevated hopper. 2. The concrete is conveyed to another hopper on top of block machine. The concrete is forcing downward to the mold.3. When the mold is full, the concrete is compacted with supplemented by air or hydraulic pressure cylinders on the mold head. 4. The compacted blocks are pushed down and out of the molds onto a flat steel pallet. The pallet and blocks are pushed out of the machine and onto a chain conveyor. The blocks then pass under a rotating brush to removes loose material from the top.

+

BATCHING MACHINE

(MIXING PROCESS)

MOLDING MACHINE(MOLDING PROCESS)

CURING &CUBING

CURING PROCESS :1.The pallets of blocks are conveyed to an automated stacker or loader which places them in a curing rack. Each rack holds several hundred blocks. When a rack is full, it is rolled onto a set of rails and moved into a curing kiln2. The kiln is an enclosed room with the capacity to hold several racks of blocks at a time. There are two basic types of curing kilns. The most common type is a low-pressure steam kiln. In this type, the blocks are held in the kiln for one to three hours at room temperature to allow them to harden slightly.3. Steam is then gradually introduced to raise the temperature at a controlled rate4. The whole curing cycle takes about 24 hours

CUBING PROCESS : 1. This is the process where the cured block will be remove from klin and the pallets of blocks are unstacked and placed on a chain conveyor.2. Then, place them in order into a cube form for storage or transfer to site

RESULT OF CUBING PROCESS

CUBING PROCESS

CURING PROCESS

ADVANTAGES & DISADVANTAGES

ADVANTAGES

1: Blockwork constructions are durable

• They can withstand severe weather and temperatures

2: You can construct entirely on site

• Timber constructions require lots of work to take place off site, but brick and block constructions can keep all the work in one area. In this respect, brick and block constructions are therefore much greener.

ADVANTAGES

3: Finding professionals will be easy

• Because these constructions are popular, finding skilled workers to work on them will be simple.

4: Blockwork constructions have a higher thermal mass

• Building with brick and block can save energy and money without having to reduce your indoor temperature.

5: They’re also fire resistant and block out more sound

• Brick and block should be the number one form of construction because it increases the chances of resistant against fire.

• The density of brick and block masonry also will have less noise pollution invading your house from outside.

DISADVANTAGES

1: There’s a limit to how much insulation can be installed in a brick cavity wall

• While brick and block constructions can be insulated, there is a limit to how much it can be installed between cavity walls. Ideally the cavity shouldn’t be more than 10 cm if you don’t want to risk structural issues.

2: Despite construction taking place in one location, it can be very slow

• Masonry is a form of wet construction, it needs time to fully dry out at several intervals. Therefore building with brick andblock can take longer than building with timber and other materials.

3: In cavity construction, there is a risk of settlement cracks

• Because individual walls used for cavity walls are usually tall and thin, they can often be prone to settlement cracks. Therefore precaution and good attention is required to detail if you’re mainly using brick and block for your cavity walls.

4: Block constructions can’t take place in severe weather

• If it’s raining heavily or temperatures have dropped below freezing, masonry can’t be laid or it will form a building that’s structurally unsound. This is because it is a wet form of construction and needs to dry adequately.

DISADVANTAGES

4: Block constructions can’t take place in severe weather

• If it’s raining heavily or temperatures have dropped below freezing, masonry can’t be laid or it will form a building that’s structurally unsound. This is because it is a wet form of construction and needs to dry adequately.

5: Block walling cavities could allow a route indoors for dampness

• If too much mortar drops on the cavity ties above the dpc (damp proof course) level, unintended bridges could form and allow damp to seep through to the inner skin of the wall. So it’s very important to be precise with the cleanliness of the inside of cavity walls.

CASE STUDY LOCAL

SMK BANDAR ENSTEK SECONDARY SCHOOL

INFORMATION

• Project name: SMK Bandar Enstek

• Description of project: Classroom secondary school with 11 buildings for classrooms, labs, workshops, canteen, guardhouse etc.

• Function of building: Education school with facilities for secondary science and art streams and handicapped students

• Location: Bandar Enstek, Negeri Sembilan

• Construction period: 24 months

• Owner: Ministry of Education

TYPE OF IBS

• Manufacturer: Integrated Brickworks Sdn. Bhd.

• IBS System: Loadbearing Blockwork System

• IBS Products/Components: Concrete Masonry System

CLASSROOM

• Blockwork system used to construct columns and wall panels for the classrooms. Concrete blocks used are hollow at the centre to reduce the overall weight of the block. The holes at the centre of the block will be filled with reinforced concrete and rebar to improve its durability and strength.

LABORATORY

• The beginning construction of the laboratory. The ground is filled with wet concrete for stability and is trowelled to smoothen the surface. Concrete blocks are then stacked for the wall panel.

Workshop

• Blockwork is also used to construct the workshop for the secondary school. Block are stacked at the edge to build wall panels. Block wall is left with an appealing face-brick finish and left exposed.

CASE STUDY INTERNATIONAL

OYSTER GRANDE APARTMENT

INFORMATION

• Project name: Oyster Grande Apartment

• Description of project: Residential unit, gym, multi-purpose hall, clubhouse, garden deck, shopping mall

• Function of building: Living apartment with features and facilities for convenient of residents

• Location: Gurgaon, New Delhi, India

• Construction period: 48 months

• Owner: Adani Group and M2K Group

• Type of IBS: Blockwork system

TOWER A

• 4th floor of concrete is partially completed

• Block work in progress for wall panel. The block wall will be plaster and paint to be finished

TOWER B

• 4th floor reinforcement and shuttering in progress

• Blockwork in progress for wall panel and to be plaster and paint to be finished.