PROCESS ANALYSIS

PRODUCTION OF COMPRESSED STABILIZED SOIL BLOCKS (SSB)

EDGAR MALOMBE
Mzuzu University,
Department of Land Management,
Private Bag 201,
Luwinga,
Mzuzu 2. Malawi

March 2015

Page 1 of 11
Contents

1. Introduction .................................................................................................... 3
2. Tools and Equipment .................................................................................... 3
2.1. Equipment............................................................................................... 3
2.2. Tools......................................................................................................... 4
3. Raw materials ................................................................................................. 4
3.1. Soil testing .............................................................................................. 5
4. Production process........................................................................................ 7
5. Conclusion.................................................................................................... 10

Page 2 of 11
1. Introduction

This paper presents in detail the process of making compressed stabilized soil
blocks that are suitable for construction of buildings. The sizes of blocks being
considered are: 290mm long, 140mm thick and 90-100mm high. The height for
blocks can be changed during manufacture.

Compressed stabilized soil blocks are building blocks made from raw soil mixed with
an additive such as lime, bitumen or cement, and then are highly compacted in a
block press machine resulting in a very solid, dense, and low cost building block
(ApproTec). These building blocks are mainly used for construction of walls of
buildings in urban and rural areas around the world. Its most countries its production
is cheaper by appropriately 30 to 50% compared to other conventional walling
materials such as concrete blocks, while their technical performance is the same
(Adam & Agib, 2001).

The strength of the blocks can be varied depending on cement-soil ratio. The ratio of
cement to soil range from 1 to 6 and 1 to 12. Soil strengths after carrying tests and
batching will be a deciding factor for the best ratio. Weaker soils can be used by
adding river sand to it with coarse grains.

2. Tools and Equipment

2.1 Equipment

Manual and industrialised pieces of equipment are used in the production of

compressed stabilized soil blocks. This paper will discuss manual type, action
pack press machine. The machine is shown in figure 1 below.

Figure 1: SSB manual operated machine

Page 3 of 11
 Source: http://www.ndumekenya.com/ on 22 Feb 2015
The action pack press machine is operated by two people. When in use, the
machine is placed on two planks for stability. One person stands to the opposite
of another.

2.2. Tools

The following are tools required for production of compressed stabilized soil
blocks and their use has been explained:
- Shovels; are used for mixing cement, soil, river sand and water and
carrying mixed materials into the mould.
- 6mm sieve; is used for sieving soil to obtain particles within a 6mm
diameter.
- Watering can; is used for wetting materials during mixing and curing.
- Oil can is used to apply oil in the mould as a lubricant.
- Hoe; is used for digging soil.
- Wheelbarrow; is used for hauling materials to a mixing area.
- Gauge box; is used for batching materials.
- Bucket; is used for carrying water.
- Brush; is for cleaning the mould.

3. Raw materials

The first step in production of building blocks is to analyse the characteristics of

the soil in the production area. Soil is tasted for percentage content of clay, sand
silt and gravel. The right type of soil for SSB production should contain 30-40%
clay and 60-70% sandy soil (ApproTec). In general terms sub-soil, soil found
below top-soil is suitable for SSB production. Subsoil is the one which should be
tested for suitability. Below is figure 2 showing layers soil.

Figure 2: layers of soil: Source:

http://ed101.bu.edu/StudentDoc/Archives/ED101fa09/pabreu14/Layers%20of%2
0Soil.html. 24 Feb 2015.

Page 4 of 11
 3.1 Soil testing

The soil should be tested in order to determine suitability and amount of stabilizer
to be used. Several tests can be carried out to determine suitability of soils.
These are: Smell test, nibble test, touch test, sedimentation test, adhesion test,
washing test, linear shrinkage test, dry strength test, water retention test,
consistency test and cohesion test (Houben & Guillaud, 1994: p 48 - 52). Of
these methods listed above this paper will present sedimentation test.

Sedimentation test

The aim of this test is to help determine approximately the amount of clay, silt, sand
and gravel in the soil. When this is known, it helps in experimenting best batches that
produce good quality SSBs.
 The soil to be tested must fisrt be seived through a 6mm sieve.
 A clear bottle is filled with soil up to one third.
 Clean water is added until itb is over the top of the soil filling the bottle to two
thirds.
 A pinch of salt is then added to the contents. The salt helps in the fast settling
and segregation of particles.
 The bottle is then closed and thoroughly shaken until the soil and water are
mixed.
 Leave the bottle on a flat base for 30 minutes.
 Then after 30 minutes of particle settling shake the bottle again for 2 minutes.
 The let the bottle to stand for further 45 minutes. After this period the contents
will begin to clear.
 As soil settles, the big particles will settle at the bottom and small in the
middle and fine ones on top.
 That means gravel particles will be at the bottom followed by sand, silt and
clay.
 Lastly you are supposed to work out the pertanges of the clay in the soil using
the following steps:
o Total height of the soil is measured from the bottom of the bottle to the
top of soil. Record the measurement at X mm.
o Measure the height of clay and record this as Y mm.
o Use the following formular to calculate pertange for clay:

Percentage of clay in the soil = ∗ 100

If the clay contect exceeds 40%, the soil is not suityable for making stabilized soil
blocks. However clay soil can be improved by adding sand to it. Figure 3 below
shows sedimentation test.

Page 5 of 11
Figure 3: Sedimentation test. Source: Adam & Agib, 2001: P 18. 3
March, 2015.

Page 6 of 11
4. Production process

The process of production follows a step by step. If any step is left out, the result
will be production of poor quality SSBs. Below is the process layout.

Soil
preparation

Batching
and Mixing

Loading the
press

Compacting
the block

Ejecting
the block

Curing

I. Soil preparation
 The soil is dug with hoes and the big lumps are crushed.
 Then the soil is sieved in a 6mm sieve.

Sieving the soil: source: ApproTec, 15 March 2015

II. Batching and mixing

 Linear shrinkage or sedimentation test results will help to find right ratio for
cement and sand.
 Using the gauge box, batch out the soil and cement required for particular
strength.
 Cement and soil are mixed with shovels until a uniform colour is obtained.

Page 7 of 11
  Water is added to the mix gradually until it binds itself. A good cohesion is
then obtained if you squeeze the mix in your hand, no water should come
out in between the fingers.

Mixing soil: source: ApproTec, 15 March 2015

III. Loading the press

 Open the Press machine.
 Checked the piston to ensure that it is sitting on the adjusting knob.
 The inside of the mould box is oiled at the start and when blocks tend to
stick when removing.
 Fill the mould with soil and cement mix to flush.
 The mould cover is dropped to cover the mould box.

Loading the press: source: ApproTec, 15 March 2015

IV. Compacting the block

 The handle is brought to the vertical position ensuring that the rollers fit in
their curved positions.
 The lever latch is opened as the person on the other side takes over the
handle to compact the block.

Page 8 of 11
  The handle is brought down by the person compacting the block until the
lever arms touches the compaction stop gear. At this point the maximum
compaction has been achieved.

Compressing the block: source: ApproTec, 15 March 2015

V. Ejecting the block

 The handle is now passed over to the person standing on the opposite
side of the press machine to start the ejection stroke.
 The lever latch is locked in position, while the handle is moved from the
vertical position so that the cover can be opened.
 The handle is now brought all the way down as the block is being ejected
all the way up.
 The block is now removed gently by holding it along the long sides and
taken to a well sheltered area for curing.

Ejecting the block: source: ApproTec, 15 March 2015

VI. Curing
 It is a process of controlling the setting of cement in order to acquire
maximum strength.
 This is the last process which starts 24 hours after production.
 If curing is not done properly, then the final blocks will be of poor quality.
 Curing method A:
o The blocks are watered after they are 24 hours old using watering
can.

Page 9 of 11
 o Then they are immediately covered with a transparent polythene
sheet of paper. The paper is well stacked and secured in such a
way that moisture should not escape.
o Then blocks a kept in that state for a minimum of five days.
o There after the blocks are stacked in a shade.
 Curing method B:
o The blocks are covered with grass to protect them from direct
sunlight.
o The blocks are then watered twice a day. In the morning and
evening for 7 days.
o Blocks are stacked after 7 days in a shade.
 When curing process in over the blocks are left for another 7 days before
being sold or used for building. This means that it takes a minimum of 13
days to start using the blocks.

Curing blocks by covering with grass: source: ApproTec, 15 March 2015

Curing blocks by covering with polythene sheet: source: ApproTec, 15 March

2015
5. Conclusion
Process of production of soil stabilised blocks in divided into two. One uses
automatic machines while another uses manual press machines. The process that
has been described above is for manual machine. This process can be done in any
location or hard to reach areas at a low cost of both labour and materials. The most
crucial element is the availability of materials especially cement as soil is found
everywhere and in abundant.
Compressed stabilized soil blocks are used as a walling material for buildings across
the world. Different technologies in equipment have been developed and are
available on the market. While the process of making compressed stabilized soil
blocks has been tackled using press machine, the same method of material testing
and preparation can be used in other machines. It should be noted that soil will only
be mixed by manual labour in this process. Concrete mixer does not work as soil
stick to the drum.

Page 10 of 11
Manufacture of compressed stabilized soil blocks use almost unlimited resource in
its natural state and involves no pollution to the environment. There is negligible
energy consumption during production thereby benefiting the environment by saving
biomass fuel which could otherwise be used in other production methods.

Reference

“Compressed Earth Blocks- testing procedures”. ‘Technologies Series’ No.16.

A joint Center for Development of Enterprise (CDE), National Engineering
Institute for Public Works of Lyon (ENTPE) and CRATerre-EAG publication,
2000.Print.

Adam, A. E, and Agib, A.R.A. Compressed Stabilized Earth Block

Manufacture in Sudan, Paris, Graphoprint. Available at:
http://unesdoc.unesco.org/images/0012/001282/128236e.pdf. 2001. Web.

Anker, Susan. Real Essays with Readings with 2009 MLA Update: Writing
Projects for College, Work, and Everyday Life. Palgrave Macmillan, 2009.

ApproTec. Production of stabilized soil blocks using the action pack block
press: operation & maintenance procedures. U.p. Kenya. n.d. Print.

Craig, F.R., Soil Mechanics. New York: Spon Press, 2004. Print.

Houben, H. and Guillaud, H. Earth Construction - a comprehensive guide,

CRATerreEAG, Intermediate Technology Publications, London, 1994.Print.
Mrs. Nasson's Soil Website. Available at:
http://ed101.bu.edu/StudentDoc/Archives/ED101fa09/pabreu14/Layers%20of
%20Soil.html. Web. March, 2015.

Page 11 of 11