Republic of the Philippines

Tarlac State University

COLLEGE OF ENGINEERING AND TECHNOLOGY
Department of Civil Engineering
Tarlac City

FABRICATION OF MORTAR MIXER

AND
CHB FILLER PUMP

In partial fulfillment of the Requirements for the

Degree of Bachelor of Science in Civil Engineering

ENGR. LEONIDES TATU

Research Adviser

ENGR. MARIE WENDY FRANY

Research Professor

Prepared by:
SOMINTAC, ERNIE M.
URSABIA, VINCENT
CAYANAN, SYRENZ
MABALOT, ASLEY
VENUS, RENJO KIM
ANIAG, ARVIN
CE – 5B
 CHAPTER I

THE PROBLEM AND ITS BACKGROUND

Introduction

Masonry construction is one of the oldest building systems utilized by the humankind.

The basic construction methodology has not changed much for several thousand years; units are

laid one on top of another such that they form an interlocking mass in at least the two horizontal

dimensions. Trying to achieve interlocking in the third dimension with normal rectangular

prismatic units is not practical but a degree of such interlocking is sometimes used in ashlars

stonework. Most practical masonry constructions employ a mortar interlayer to allow for small

inaccuracies of size between units. The early works of masonry construction are characterized by

their massiveness and quality craftsmanship.

One of the most common building material used is Concrete Hollow Blocks. Most

construction systems in the Philippines lay out the structural “skeleton” of the building, usually

reinforced concrete columns and beams, and then layout the rest of the building in CHB, as it is

abbreviated. The popularity of hollow blocks or CHB comes from its modular use and

portability. It is easy to transport, is standard like a lego block that can create all kinds of walls –

even curves and cylinders!

Mortar is made by mixing cement, lime paste, sand and water proportionally. According

to different cementing material adopted in it, building mortar is divided into cement mortar,

cement lime mortar, lime mortar and gypsum mortar etc.; according to the main applications, it is

divided to masonry mortar and finishing mortar.

 In the Philippines, the use of CHB and cement mortar as a binding material is a common

masonry. Engineers and builders have chosen this type of masonry for its strength, durability,

fire and weather resistance. Aside from this, it is cheap, speed of installation by semi-skilled

laborers and materials are available anywhere in the Philippines.

For the Philippine CHB structures, the application of mortar is another crucial

construction activity that should be given equal importance as with appropriate reinforcements.

Mortar should be properly applied and compacted requiring proper mixing, pouring and curing to

produce homogenous fill and bond. According to The National Building Code, the National

Structural Code of the Philippines and the Full Scale Shaking Table Test for CHB Structures

emphasize adherence to design standards and proper construction implementation for CHB type

of structures in the Philippines. The walls of CHB structures play a vital function as the main

support of the structure. The code also highly recommends that all the CHB cells and joints are

filled and compacted with mortar using the correct mix of 1 part of cement to 4 parts (1:4) of

washed river sand.

At the construction site, workers are having trouble on lifting mortar mixture from the

ground level to a certain height. Masons took too much time in filling all the CHB cell and

having uncomfortable condition when working at heights that could lead to low production. In

some instances, mortar mixtures are being wasted due to improper handling of the workers.

Safety is also an issue in CHB laying process. By fabricating a Mortar Mixer and CHB Filler

Pump those given problems at the construction site could be minimize, avoid unnecessary

expenses and could give a more productive output.

 Thus, the researchers want to emphasize the proper cement mortar on every CHB laying

activities and attempt to contribute to make the CHB laying process easier, more productive and

safe for every worker without compromising the quality and strength of the structure.

Objectives of the Study

The study is made to design and fabricate a Mortar Mixer and CHB Filler Pump.

Specifically, it aims to:

1. To determine the capacity of the filler pump.

2. To design and fabricate an one (1) bagger mortar mixer with a filler pump.

3. To validate the equipment based on the on-site CHB laying process as to:

a. Average time

b. Production

c. Manpower

4. To evaluate the productivity of the equipment

Significance of the Study

The researchers’ goal is to fabricate Mortar Mixer and CHB Filler that can pump mortar

mixture to a maximum six meters high and fill CHB cells. As time goes by the work in

constructions are rapidly improving. It is the researchers’ way to provide a new or design a

machine that will help the progress in this modern era.

 This study will benefit the project manager/contractor and workers. It can be a big help

in construction site for faster and more efficient than the traditional CHB laying process at the

site that will meet the needs of a project manager/contractor and its workers.

Scope and Delimitation of the Study

The scope of the study was delimited to the designing and fabricating a Mortar Mixer and

CHB Filler that improves the process of CHB laying. Site investigation will be made to

determine how the traditional CHB laying process was done by the worker and gather necessary

data to design the machine. Mathematical computation will be used as the basis to design the

capacity and flow rate of the machine. The ratio of cement, sand and water is based on the

standard provided by the National Building Code of the Philippines. All parts of the machine will

be designed and fabricated on a machine shop own by one of the researcher. On-site testing will

be held to evaluate the productivity of the machine. The researchers will make recommendation

and conclusion based on the evaluation and tabulation of the data gathered.

Definition of Terms

 CHB - stands for Cement Hollow Block

 Mortar - is a material used in masonry construction to fill the gaps between the bricks

and

blocks used in construction.

- is a mixture of sand, a binder such as cement or lime, and water

 Manpower - the number of people working or available for work or service.

 Pump - a mechanical device using suction or pressure to raise or move liquids, compress
 gases, or force air into inflatable objects such as tires.

 Volume Flow Rate - of a fluid is defined to be the volume of fluid that is passing through

a given cross sectional area per unit time

 Horsepower - is a unit of measurement of power, or the rate at which work is done.

-a unit of power equal to 550 foot-pounds per second (745.7 watts)

 CHAPTER II

REVIEW OF RELATED STUDIES AND LITERATURE

Mortar mixer and CHB Filler

The Pump Master fills block without the need of a forklift or full-size concrete pump.

The Airplaco PG-25 provides an option for block fill contractors. It saves a lot of labor and

equipment that is needed in traditional methods of filling block, says Tom Norman, Airplaco

Product Manager. 50 ft vertical pumping 200 ft horizontal pumping max aggregate size is 3/8

inch minus Output is 6 cu yd /hr 5 inch hard-chrome material cylinder 3 inch ball check manifold

3 inch grooved outlet 5 cu ft hopper 25 hp gas engine (key start) •hydraulic drive train Pea-Rock

Discharge Wireless remote optional Auxiliary hydraulics optional Performance will vary

depending on power unit, hydraulic pressure, cycle rate, mix design and placement line. Consult

Airplaco for appropriate mix designs. Masonry Block Fill Grout Pump Model PG-25 is the ideal

machine for block fill and pea rock applications, pressure grouting, void filling and pea-gravel

pumping. Other applications include Masonry Block Fill, Masonry Wall Construction, Pea

Gravel Pumping, Insulated Concrete Foam (ICF), Sidewalk/Patio Slab Pumping, Slabjacking /

Mud jacking, Void Filling and Pressure Grouting. The Pump Master is field-tested and approved

by hundreds of contractors. Each pump is manufactured from over 60 years of manufacturing

and on-the-job experience. Other applications for the PG-25 grout pump include mudjacking,

slab jacking, concrete raising, concrete leveling and concrete

lifting.(www.youtube.com/watch?v=QW9o7h2f9DE)

Mortar mixers are built for light, medium, and heavy-duty jobs with durable construction,

an easy-to-clean design, and simple maintenance. These quality mixers are available in 6, 8, 11
and 12 cubic foot drum sizes and are built for superior mixing performance. Patented features,

like quadruple bearings and seals which feature a lifetime warranty, ensure your mixer runs

trouble-free for years. Toro’s mortar mixers also offer a design built for easy operation with a

drum latch that can be operated with a knee while the operator’s hands are busy dumping. A

patented guard lifter automatically moves the guard out of the way as the mix is discharged.

mortar mixer line up offers long lasting value for any mixing job. Knee-operated patented drum

latch makes dumping quick and easy by allowing the operator keep two hands free to discharge

heavy mixes Heavy-duty lift away guard lifter automatically opens the guard as the mix is being

discharged for easier dumping and a cleaner guard The engine cowl features a cut out to allow

engine access without leaving the cowl open Extendible axle allows high speed towing and

adjusting for in building use.(www.atsequipment.com/ats_pdfs/ATS_Toro%20Mortar%20Mixers

On the field of construction industry, concrete work holds a very important role. It could

be said that almost on all built construction, such as high rise buildings, housings, roads, bridges,

dams and irrigation channel, as well as other constructions always need concrete work, both as

the primary need or as the supporting material element. Mortar is used to hold building materials

such as brick or stone together. It is composed of a thick mixture of water, sand,

and cement. Mortar is available on demand reducing downtime and improving productivity.

Reduced mixing time, reduced labour costs, reduced mixing time, reduced labour costs.

In many branches of industry, the processes of mixing and mixing of various components

are used. In most technological processes, it is necessary to create a homogeneous system

consisting of several phases. In some cases, it is necessary to ensure the maximum full and even

in volume reacting components contact. The last one is achieved by mixing, that is, intensive

movement within the total volume of individual particles and mixture parts. Considerable
interest in technical practice is caused by the processes of mortars effective mixing. The most

widely used equipment, in which mixture uniformity is required, is achieved by mechanical

influence on the environment of special working body called the mixer. As a rule, mixers of

mechanical action are used for building mortars preparation. Power determination of the electric

drive of the compulsory action mortar-mixing equipment is rather complicated.

Mortar mixtures, which are coarse dispersion suspensions, are viscos-plastic bodies and

which properties and motion conditions are significantly different from viscous liquids. Of

immaterial significance is the volatility of mortars physical and mechanical properties,

depending on time and speed. This fact greatly complicates the situation of the mixture

movement during mixing. In this case there are significant numbers of resistances. The most

important among it can be called the resistance of internal and external friction forces, resistance

of certain masses displacement, resistance arising from inertial forces, wave formation, etc.

Many of these resistances, as noted above do not remain constant during the mixing cycle. In

addition, we have a fairly wide range of mortars according to their components composition and

characteristics. All this further complicates the problem of determining the constituents of

resistance that arise in mixing process.

(www.researchgate.net/publication/259590093_Medieval_Mortar_Mixers_Revisited_Basle_and

_Beyond_Zeitschrift_fur_Archaologie_des_Mittelalters_39_2011_189-212)

Concrete Hollow Blocks (CHB), are one of the most extensively used walling materials

in the Philippines. Some of the reasons for this is their relative low cost when compared to other

materials and speed of installation by semi-skilled labourers. CHB walls are very weak against

lateral loads (pushing or pulling forces from typhoon or earthquake). Adding steel reinforcing

bars vertically and horizontally inside the CHBs can increase their resistance to lateral loads.
CHB Laying

Good practices -Safe Structures. Good practices can prevent damages from typhoons and

earthquakes. Bad practices = Unsafe structures and higher costs in the long run due to repairs.

The following is a combination of book knowledge (NSCP and other sources) and

practical experience from my masonry mentors (Construction Foremen, each with 30+ years of

site experience; co-engineers, and architects).

CHB Laying Masonry, is the term for building structures by laying individual units (brick,

stone, concrete block) and binding them (by cement mortar and rebar).In the Philippines, the

Concrete Hollow Block is the common masonry. Advantages and Disadvantages, Why use CHB

Walls , Strong and durable, Fire-resistant and Non-combustible ,Weather Resistant, Cheap,

Availability. Materials are available anywhere in the

Philippines.(https://medium.com/@buboyvirata/chb-laying-all-you-need-to-know-within-15-

minutes-part-1-50e3642271c8)
 CHAPTER III

METHODS OF STUDY AND SOURCE OF DATA

In this chapter, the researchers present the methodology and procedures undertaken

together with the machine and the process in which it will be conducted and tested. It includes

the researchers and method of data collection. The credibility of findings and conclusions

extensively depend on the research design, data collection, data management and data analysis.

METHODOLOGY

The researchers would seek advice from experts who can help them to get started with

the study. The first part of the method is performing survey works and site evaluation on a

construction site. The second part is on the theoretical and computational aspects of capacity of

the filler pump. And the last part is designing and fabrication of the machine.

Actual Survey and Site Evaluation

The researchers will conduct an actual survey and site investigation to gather necessary

data and information specifically on how the traditional CHB laying process utilized by the

workers and to know the situation while the workers doing the activity.

Interview Techniques

Informal interviews on the technical requirement of the project will be conducted to

obtain some ideas about the study based from the experienced of the technical persons whose
expertise with great significance to the study. Their insights and suggestions will be a great help

to the researchers.

Theoretical and Computation Aspect

Using some Fluid Dynamics formulas, the researchers could design the capacity of the

Filler Pump.

Volume per CHB cell

𝑉 = 𝐿𝑒𝑛𝑔𝑡ℎ 𝑋𝐻𝑒𝑖𝑔ℎ𝑡𝑋𝑊𝑖𝑑ℎ𝑡

V=(0.05x0.02x0.075) 𝑚3

Vol= 0.00075𝑚3

Discharge per second:

𝑉
Q= assume 2 sec to fill per cell block
𝑡
 0.0075
Q= 2𝑠𝑒𝑐

𝑚3
Q= 0.000375 𝑠𝑒𝑐 required discharged

SP 750-18(pumpcrete motor)

Specification

𝑚3 𝑚3
Concrete Output ( ℎ𝑟 ) 54 ℎ𝑟

Horizontal Pumping Distance (m) 354m

Vertical Pumping Distance (m) 100m

Engine Power (hp) 100hp

Using Ratio and Proportion

Since:

Required discharge

𝑚3
= 0.000375𝑠𝑒𝑐

𝑚3
54
𝑠𝑒𝑐

𝑣𝑒𝑟𝑡𝑖𝑐𝑎𝑙 𝑑𝑖𝑠𝑡.1 𝑣𝑒𝑟𝑡𝑖𝑐𝑎𝑙 𝑑𝑖𝑠𝑡.2

=
ℎ𝑜𝑟𝑠𝑒𝑝𝑜𝑤𝑒𝑟1 ℎ𝑜𝑟𝑠𝑒𝑝𝑜𝑤𝑒𝑟2

85𝑚 6𝑚
= = 7.06 hp say 8 hp
100ℎ𝑝 𝑥ℎ𝑝
Machine Design

The design and fabrication of the machine will be base on the garthered data and

computations. Figure 1 will the propose design and specification of the machine.

The Mortar Mixer and CHB Filler Pump will be fabricate in a machine shop. The mortar

container dimensions are 0.8 m top diameter, 0.6 m bottom diameter and 1.0 m heigth to be

connected to the filler pump by a 3 inch diameter GI pipe with a 3 inch diameter gate valve to

control the flow of the mortar. The filler pump will be made up of steel iron with a 0.4 meter

diameter and 0.2 meter width. The filler pump will have a initial 1.0 meter vertical 3 inch

diameter GI pipe connected by a 6 inch flange. Vertical pipe can be extent using a straight 3 inch

diameter elbow. The 3 inches diameter elastic hose with the shotcrete will be connected to the

vertical pipe. A 10 horsepower AC Motor will provide the contineous flow in the system. Mortar

mixer and Filler Pump will be connected to the motor by a cast iron pulley and pump belt. For

maintenance purpose a 1 inch drain plug will be install at the bottom of the mortar container.

Validation of Machine

The researchers will conduct three trials on-site to compare the traditional CHB laying

process versus CHB laying, using the fabricated machine in terms of:

a. Productivity

b. Average time

c. Manpower

Every trials will be held simultaneously on one location with the same set of laborers,

amount of materials and span or length to be work.

 First trial will be held at the ground level of the site while the next two trials will be done

at the higher level of the structure.

Tabulation of Data

After all the trials will be done, the researchers will tabulate and evaluate the results of

the trials. Comparing the output, speed of work and manpower used for the activity, the

researchers will give their conclusion whether which process is more productive.