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Technical information

Specifications
 BLOCK DIMENSIONS; One full-sized block equals 600 mm long X 300
mm wide X 300 mm thick. (2 x 1 x 1 foot)
 WALL AREA; One square metre of wall equals 5.5 blocks, One block
equals 0-18m².
 EARTH QUANTITY; One cubic metre of earth will produce approximately
18 blocks. One full block equals 0-054m³.
 CEMENT QUANTITY; a usual earth mix of one part cement, to nine
parts earth. One 20 Kg bag equals two blocks.

Building considerations
 STRUCTURAL RATING; The FORMBLOCK system will produce load
bearing walls, with foundations of strip footing or slab floor generally
specified for double brick construction. Seek expert advice for specifics
for your application.
 FLEXIBILITY OF DESIGN Although blocks are based units of 300
millimetres (one foot), walls of any length can be produced. Along with
any door or window configurations. It is also possible (for experienced
users) to produce corners with non-square angles. (More information)
 ( click to enlarge)

 SERVICES: Electrical wall boxes with sweeps attached can be simply

cast in place when pouring earth, flush with the face of the shutter
board. Access for plumbing through walls can also be easily cast
during wall production.

( click to enlarge)

 CONTROL JOINTS are usually required to be placed in long walls made

of earth (generally every 4 metres, or under windows). The amount of
expansion and contraction of walls is related to both the earth used,
and the design of the structure and is a normal property of earth
construction. If unsure seek expert advice.
 COUNCIL BUILDING REGULATIONS in regards to the FORMBLOCK
method, which will be the same as for earth building in general, can
vary from district to district. In most cases, councils in Australia may
 require sample blocks to be tested by industry authorities such as the
C.S.I.R.O. and an engineer to certify the design of the structure.

( click to enlarge)

FORMBLOCK blocks made from the stabilized earth of 9:1have had no

problem being certified by these authorities.

A history of earth building in your area can give you an indication of the
chances of you project being approved.

Materials that can be used

EARTH required for use in FORMBLOCK’s method of earth-wall construction is
quite sandy containing a low ratio of clay. (In fact, you can actually use
100%.) Soils with high levels of clay can be corrected by mixing in sharp
sand.

 An evenly graded ‘sandy loam’ preferably with no more than about

10% clay. Also decomposed granite soils.
 It should be free of any organic matter (such as humus, or top soil.)
 Aggregate no larger than about 70 mm (large stones can cause
cracking.)
 Water should be potable (drinkable and free of salts).
 Cement ,5% to 10% general purpose cement is usual, however on site
testing is advisable.
 There are 3 main tests; shrinkage, compression and accelerated erosion
tests. The latter 2 should be carried out by a recognised authority,
however it is desirable to do shrinkage tests of you own when selecting
suitable earth. For this refer to‘ The ‘Earth Shrinkage Test Guide’. Seek
 expert advice if you remain uncertain about the suitability of the earth
you wish to use .
 A good guide to suitable material can be found in the C.S.I.R.O.'s "Earth-
wall Construction" Building Technology File 06
www.publish.csiro.au/nid/18/pid/2981.htm

CONCRETE in all its forms can be used in FORMBLOCK’s method of wall

construction with or without aggregates, and with cement content of no less
than 12%.

Earth or Concrete?
CONCRETE should be used for the following building situations;

 All sub floor walls sections below damp-course level.

 To bring walls to an even level before continuing the walls further in
earth. (an earth wall constructed on a sloping footing for example, can
settle unevenly resulting in problematic cracking.)
 For retaining walls, whether in a building wall or landscaping.
 All lintels, consult your engineer for your lintel specifications as they
can be wide and varied.
 Further general information regard cement and concrete.
www.concrete.net.au/publications/pdf/concretebasics.pdf
www.cement.org/basics/concretebasics_faqs.asp

EARTH can be used in the following building situations;

 The use of cement stabilized earth is generally acceptable for

constructing load bearing walls once the concrete sub floor wall are
complete, ( the stabilized nature of the earth used in Formblocks
method will certainly cope with incidental exposure to falling rain,
however constant exposure to dampness, from pavement splash, or
poor roof drainage may cause problems in the long term.)
 Avoid slim earth columns or pillars, FORMBLOCK recommends columns
of 900 mm x 300mm wide, but once again seek expert advice for the
 suitability of the columns application.

How much wall can be done in one day?

*Based on persons of AVERAGE fitness, and assisted with a powered cement mixer.

 ONE PERSON could comfortably accomplish a course of blocks between

6 to 12 metres (40 feet) long.
 TWO OR THREE PEOPLE could accomplish a course of blocks around
the perimeter of an average 3 bedroom home.
 THE NEXT COURSE of blocks can be produced the following day, a 2.4
metre (8 feet ) high wall would take 8 days.)

CLEANING FORMBLOCK formwork is easy with just a quick scrape, or wire

brushing.

© Copyright FORMBLOCK Australia Pty Ltd 2001 A.B.N. 85 072 393 956.

Estimating Construction Costs

The approximate material cost for using 9 parts Earth : 1

part Cement.
For this exercise here, the costs calculated are based on standard unit pricing
with cement costing $8-50 per (20kg bag) and brickies sand/loam mixed with
course/washed river sand at $60-00 per cubic metre. The cost of these
materials can vary depending on the supplier. Costs can be much less than
that used in this exercise, if the price of materials are negotiated in a bulk buy
and can be as low as $30-00 per cubic metre.

$4.25 per block (representing the cement component only and using suitable
on-site earth material, that is freely available)

$7-60 per block, (for cement and earth material purchased from a supplier)

One Square Metre of wall is equivalent to 5.5 'Formblock' blocks.

The equivalent wall comparison is a standard double brick wall which requires
100 bricks per square metre plus mortar.
A reference guide for bricklayer rates can be found on the National Federation of Bricklayers & Masonry
Employers Association
website http://www.nfbme.com.au/sitebuildercontent/sitebuilderfiles/bricklayersdompricelist2010.pdf

Material cost per Square Metre of Formblock wall

Free earth plus cement, equals approximately $23-50 per sqm (One lineal
metre of 2.4m high wall = $57-00)

Purchased earth and cement, equals approximately $ 42-00 per sqm (One
lineal metre of 2.4m high wall = $100-00)

To calculate how many blocks you will need to produce a wall, follow these
steps;

1. Find the overall area of the wall to be constructed by multiplying the length
by the height. (i.e. 2.4m high x 10m length = 24 sqm)

2. Subtract the area of any door and window openings from the overall area.
(standard single door 2.1 x 0.9 = 1.9 sqm,)
3. Multiply the remaining sqm area by 5-5 to find the number of blocks
required. (i.e. a solid 24 sqm wall = 132 blocks. The same wall with one
standard door and three windows at 1.8m x 1.8m openings = 13 sqm of wall
/ 72 blocks)

4. To calculate the amount of earth needed, divide the number blocks in the
wall by 18. (One cubic metre of earth equals approximately 18 blocks. The volume of
one full block equals .054m³). A 24 sqm wall will require approximately 8 cubic
metres of earth material

5. To estimate the number of cement bags (20kg) (at one part cement, to nine
parts earth), divide the number of blocks to be made by 2. (i.e. 24 sqm wall
would require 66 (20kg) bags)

Estimating hired labour costs

To hired a labourer, ( at daily cost of based on approximately rate of $200). A

fit and experienced labourer can generally achieve setting up formwork and
pouring between 10 - 15 blocks per day. A team of three can average around
40 blocks (7sqm of wall) per day. Cost estimate for hired help range between
$75 - $110 per sqm.

Combined with purchased earth material, costs estimates range between

$120 - $160 per sqm of wall.

Examples

A 10 metre long wall, 2-4m high (without door and window openings), 24
sqm wall = 132 blocks.

a. Free Earth, Cement and no hired labour = approx. $600 (with hired
labour = approx $3500 - $4500)

b. Purchased Earth plus Cement and no hired labour = approx $1000 (with
hired labour = approx $4000 - $5000)
The same 10 metre wall, 2-4m high (with one standard door and three 1.8m
x 1.8m windows), 13 sqm of wall = 72 blocks

a. Free Earth, Cement and no hired labour = approx. $310 (with hired
labour = approx $3200 - $4200)

b. Purchased Earth plus Cement and no hired labour = approx $550 (with
hired labour = approx $3500 - $4500)

Our estimating guide only gives an estimate of the cost of walls only. It is only suitable for use before
any detailed plans are made. For accurate construction costs you will require detailed design plans and
the services of a quantity surveyor or licensed builder.

* Figures quoted are based on average Australian retail prices as at 2010 and are subject to variation and
change.
 Frequently Asked Questions

How much does it cost to build a Formblock home?

I have never built a home before, and I am thinking of being an owner builder. What
difference would Formblock make?

We have wanted an earth home for a long time, but it is seem so labour intensive, and
to pay a builder is very costly?

What is meant by 'in-situ'?

What is 'poured earth'? and how is it different to adobe mud bricks or rammed earth?

How can I tell if I have the right kind of earth?

Are Formblock walls vulnerable to being washed away by exposure to rain, or by water
from garden hose?

In my area there are not many earth homes because we have the wrong kinds of soil
for mud brick? does this mean I can not used the Formblock system?

Why should I formulate my plans using dimensions with multiples of 300 millimetre?

Does using cement to stabilize the earth effect the finished appearance?

What about attaching timber or fixtures to the walls?

My home energy rating guide tells me that earth walls are poor insulators. What does
this mean? and What is thermal mass?

Will my local building authority approve my plans, if I have chosen to use Formblock
method?

Are Formblock walls load bearing?

I have plans to build a larger than average-sized home. Do I need to purchase a large
kit?
Where I come from, we are regularly interrupted from working by changes in the
weather. How is Formblock effected by disruption?

How does Formblock benefit the environment?

What about termites and other pests?

How long will the Formblock kit last?

I have a Question that is not answered here? Or, I seek further information

How much does it cost to build a Formblock home?

The costs can vary according to factors such as the design of the
structure, the source of materials, and the kind of labour that is utilized, site
logistics etc.

For a Formblock wall, the material costs, for cement and earth if
purchased from a suppler, would be approximately $7-60* per block or
approximately AUD$42-00* per square metre. Using your own earth can
greatly reduce this cost to just the cement component only of the blocks.
Costing you approximately $4.25* or $23.50* per square metre, that is about
2 blocks per 20kg bag of cement. Refer Estimating construction cost .

Labour is always one of the biggest cost factors. Supplying your own
labour can lead to considerable savings.

Using contract labour costs are comparable to that of double brick

construction. (more information)
* Figures quoted are based on average Australian retail prices as at 2010 and are subject to variation and
change.
 I have never built a home before, and I am thinking of being an owner
builder. What difference would Formblock make?

The Formblock system will help improve your building confidence as it is

straight forward and easy to understand. It also fits neatly with basic building
principles that apply to any method of construction.

The Formblock system allows you to easily maintain a straight and level
wall. Plus you are able to carve and shape the blocks once they have set.
Also, you may do as much, or as little as you like. Making the process of
construction both predictable and forgiving. The wall progress is unaffected
by interruption, i.e. weather.

Steve McGregor, whilst constructing a rammed earth home as an owner

builder, first conceived the Formblock system as a better and easier way to
build in earth.

We have wanted an earth home for a long time, but it is seem so labour
intensive, and to pay a builder is very costly?

When compared to the traditional methods of earth building the

Formblock system significantly reduces materials handling and hence the
labour required.

The blocks are made in -situ (i.e. on the wall, in their final resting place).
The Formblock method cuts out the many handling steps involved in making
and laying mud bricks, as in the Adobe method of earth walls.

Earth is poured into the Formblock form work, and it is not required to be
rammed or pounded, as in the rammed earth method of construction, saving
a lot of manual effort.

The Formblock form work is uniquely designed into robust yet lightweight
and easy to manage components.
 Labour saving translates into dollar savings. Refer to Estimating
Construction Costs page

What is meant by 'in-situ'?

'In-situ' is Latin meaning, 'in appropriate position'. A Formblock wall is

comprised of blocks that are made on the wall, in their final resting place.

What is 'poured earth'? And how is it different to adobe mud bricks or

rammed earth?

Poured earth is a method of earth construction in which formwork is

prepared to cast a wall in-situ. The earth material is prepared by mixing with
a cement stabilizer (Formblock recommends at least 10% cement), and water
to slump similar to that of most concrete mixes, and simply poured in the
moulds and allowed to set.

Formblock is different to rammed earth as the earth is not required to be

pounded or ramming as part of the procedure.

Formblock is different to adobe construction, in that, adobe mud bricks

are first made and allowed to dry or set, a sufficient area is required in which
to do this, and bricks need to be kept under shelter to dry before they can be
finally laid on the wall.

How can I tell if I have the right kind of earth?

The kind of soils that are suitable for Formblock are earth such as sandy
loams (containing less than 10%clay), decomposed granite soils, friable sands
and aggregates as per concretes. The Formblock system does not require the
higher clay ratio soils normally used in earth-wall construction. If the soil
available to you is high in clay, it can be adjusted by simply mixing in friable
sand. Refer Materials that can be used in the Technical Information page

Are Formblock earth walls vulnerable to being washed away by exposure to

rain, or water from garden hose?

Myth; 'Earth walls wash away when they get wet.' This is only partly true, non
stabilized earth walls will suffer if they are exposed to constant dampness. However,
well constructed earth walls can effectively resist incidental wetness from a rain
downpour or garden sprinkler.

Due to the cement stabilization of the earth blocks in Formblock method, the walls
are very resistant to water damage or water penetration. Refer C.S.I.R.O. 'Certificates
of Test' in the Technical information page.

Note: Long term exposure to puddling water is not good for walls of any type of
construction. If your walls are in a damp situation that may cause you concern, there
are available many treatments that can be applied to masonry walls to prevent any
possible water penetration.

In my area there are not many earth homes because we have the wrong
kinds of soil for mud brick? Does this mean I can not used the Formblock
system?

Not Necessarily, various soils can be suitable for use in the Formblock system.
Suitable materials such as sandy loams (containing less than 10%clay),
decomposed granite soils, friable sands and aggregates as per concretes are
usually available at your local quarry or landscaping supplier. Refer Materials that can
be used in the Technical Information page.
 Why should I formulate my plans using dimensions with multiples of
300 millimetre?

Although walls of any length can be produced, keep in mind that the
Formblock system is designed around unit lengths of 300 millimetres (one
foot). By keeping dimensions of your plans, where possible to multiple of
300millimetres, the production of each course of blocks can be easily
executed in one session. Walls with other lengths merely require each course
to be done in two sessions.

Does using cement to stabilize the earth effect the finished appearance?

Common grey, type A or GP cement at around 10% of the mix has little effect on
the colour of the original raw material. It still looks like an earth wall. The colour of the
wall can be heighten by using different cements such as 'off-white' cement or mixing
the earth with different coloured sands. Colours and finish textures can be varied
according to how the walls are finished- 'off the form', bagged or rendered, and by the
types of cement, sands and oxides that can be used.

What about attaching timber or fixtures to the walls?

Depending on the materials used, an earth wall will take anchor bolts, etc, even
ordinary carpentry nails. provided the fixing device has deep enough penetration into
the wall.

My home energy rating guide tells me that earth walls are poor insulators.
What does this mean? And What is thermal mass?

The Insulation properties and Thermal mass properties of building materials are two
separate issues in term of energy saving.
 Insulation properties; the ability to prevent the transfer of heat from one side of a
lining to the other, such as a vacuum flask, woollen clothing, insulation batts,
polystyrene foam icebox.

Thermal mass properties; the ability to absorb heat and release heat, such
as hot water bottle, hot coals in fire, a recently vacated seat, sauna rocks. Eg;
in a heated room where a door has been left open allowing all the warm air to
escape, then upon the door being closed again, the thermal mass of room will
begin to release heat back into the air and reheating the living space. In
summer, shaded and enclosed areas in the building will absorb heat from the
surrounding warm air, cooling the living space.

It is worth noting that the benefits of the properties of any material are
dependent upon how it is designed, how it is constructed and how it is
operated. refer Benefits of Thermal Masspage.

Will my local building authority approve my plans, if I have chosen to use

Formblock method ?

An indication of a local building authority's acceptance of earth building is a

presence of other earth structures

Councils in Australia may require sample blocks to be tested by industry

authorities such as the C.S.I.R.O. and an engineer to certify the design of the
structure. refer Building Considerations in the Technical information page

Are Formblock walls load bearing?

Yes, Formblock earth walls constructed with the recommended earth and
stabilized with a minimum of 10% cement are considered load bearing. Note:
your building should be constructed to engineer specifications and according
to all the relevant building codes.
 I have plans to build a larger than average-sized home. Do I need to
purchase a large kit?

The size of the kit you may need, is best determined by the size of your labour force
for acheiving a productive day. As a yardstick estimate your needs to around 10-20
blocks, per person, per day, refer to Catalogue page for a guide.

Where I come from, we are regularly interrupted from working by changes in

the weather. How is Formblock effected by disruption?

No problem. If you are in the middle of pouring a run of form work, and you must
stop work. Simply cover the job from impending rain and go. The Formblock method
allows you to do as much or as little as you wish, one block at a time if you so choose.

How does Formblock benefit the environment?

By building in raw earth, you are be building a structure with a very low "Embodied
Energy" factor. For further
information www.yourhome.gov.au/technical/fs52.html

The Earth itself, that can be used in the general earth building construction is, of
course, an abundance and a sustainable resource for housing.

The Formblock formwork is made from very durable materials and is designed for
long term repeatable use, hence, no need to be using specialized, single-purpose form
work. this means no wastage.

The 300 millimetre (one foot) thick walls provide excellent thermal mass, and will
compliment structures with good energy efficient design reducing the "Operational
Energy" component of building. That is the ongoing heating or cooling of your home.
Refer The Benefits of Thermal Mass page.
 What about termites and other pests?

Termites are attracted to timber and do not eat cement stabilized earth material. As
well, Formblock walls are of solid construction and have no cavity. Pests such as
termites and other like cockroaches and rodents have no wall cavity in which to thrive
and nest. This makes pest control much easier to manage. However, we do advise that
you consult a pest control expert, in order to incorporate the best elements of pest
control into the design of your house regarding your regional circumstances.

How long will the Formblock kit last?

The Formblock Kit components are made from the finest durable materials. The
partitions are made of cast aluminium and the shutter boards made from heavy gauge
form-ply. The Formblock kit is built to last a many a project.

I have a Question that is not answered here? Or, I seek further information.

Send an e-mail for a personal reply.

For Phone, fax, or postal details. Refer Contact page.