CHAPTER ONE

INTRODUCTION

1.1 Background of Study

Mould are said to be as old as man, the early day’s blacksmiths were able to

construct, forge and design materials of different shapes and sizes using moulds.

Now moulds are widely used in industries and manufacturing establishment to

produce materials with different shapes, pattern, embossment etc. (Adam, et al, 2001).

The design and fabrication of manually operated 6 inches(152.4mm) block

moulds is an important field of research in the manufacturing industry. This type of

machine can be used in small business and home-based production of building blocks.

The increased use of concrete technology for construction has made manual block

making a desirable manufacturing method. With the help of the manually operated 6

inches(152.4mm) block moulds, building blocks can be produced in an economical

and fast manner. Therefore, the development of a more efficient and cost-effective

machine is required to keep up with the demand in the industry. There is a need to

develop a robust machine that has the ability to produce various shapes and sizes of

concrete blocks without compromising on quality. The aim of this research project is

to design and fabricate a manually operated 6 inches(152.4mm) ×block moulds that

is reliable, user-friendly and cost-effective.

A mould is said to be a pattern constructed for the production of a materials of a

material of a desired shape of the same prototype. In other words, mould is a designed

equipment that has the shape of the materials to be produced. After production, the

substance usually in molten form, power into mould, takes the shape of the mould on

solidification. Moulds have diverse applications. (Adam, et al, 2001)

1
 The rapid growth of urban areas of Nigeria due to its developing economy and

industrialization is drawing the attention of builders. One of the ways of recognizing

urbanization has been heavy concentration of population in large cities demanding for

efficient housing layout. The rapid progress and research over years, has led builders

to prefer framed structures over conventional load bearing structures. Frame structure

walls are simply to serve as a screen for privacy of various rooms. They support their

self-weights only. Hence in such structures for masonry component low density, low

strength material can be used to reduce dead load. The higher density conventional

concrete blocks give heavy self-weight of masonry, thereby increasing the cost of

frame structure (Adam et al, 2001).

Manually block mould are used by a variety of industries, including concrete and

construction, and have many different functions, such as creating decorative paving

stones, industrial blocks, and architectural blocks for use in various projects. The

design and fabrication of a 6-inch(152.4mm) manually operated block moulds is an

important step in the production process for many businesses.

This report provides an overview of the design and fabrication process for a 6-

inch manually operated block mould, including the selection of materials, design

considerations, and other key steps involved. Additionally, this report includes a

literature review of relevant research and publications on the topic, as well as a

discussion of the results and conclusion.

1.2 Aims of the Study

The specific aim of this project is to design and fabricate manually operated Six

Inches(152.4mm) Block Moulds.

2
1.3 Objectives of the Study

The specific objectives of this project are to:

(a) identify suitable materials for the mould

(b) select material for the fabrication

(c) carried out fabrication process

(d) assemble fabricated machine parts

(e) carried out performance test on the mould

1.4 Statement of Problem

There is wide application of moulds in different disciplines or professions in the

society such as its application construction industries etc. The fabrication of a 6”

(152.4mm) block mould requires a particular sequence of operations such as casting,

cutting, machining, designing, patterned filling etc. This sequence of operations is

characterized with skills and techniques. Thus, as a student fabricating of block

mould, there is need to be acquainted with necessary skills, knowledge, techniques

and peocedures that underlined the fabrication process involved in the production of a

block mould.

1.5 Significance of the Study

This project tend to solve inadequate block mould to withstand huge demands.

1.6 Scope of the Study

The specific aim of this project is to design and fabricate manually operated Six

Inches (152.4mm) Block Moulds. We develop detailed design plans for the manually

block mould that involve schematics, selecting materials, and determining the mould

dimension and specification. Hence this project report contains the introduction,

3
literature review, materials and method, result and discussions, conclusion and

recommendation

1.7 Limitation of the Study

This project work is limited to six (6) inches (152.4mm) moulds using mild

steel materials for the fabrication.

a) Cost: The cost of materials and tools required to create a 6-inch block mould can

be prohibitively expensive, especially if multiple molds need to be made for

experimentation.

b) Time: Depending on the complexity of the mold, it can take a significant amount

of time to design and fabricate a 6-inch(152.4mm) block mold.

c) Skill: The skill level needed to design and fabricate a 6 inch(152.4mm) block

mold is usually beyond that of an average user. It takes a great deal of knowledge

and experience to design and construct this type of mold correctly and safely.

d) Accuracy: Even with the most precise tools and techniques, the accuracy of a 6

inch (152.4mm) block mold can vary significantly from one piece to another. This

variance can lead to inconsistencies in the quality of the product produced using

the mold.

4
 CHAPTER TWO

LITERATURE REVIEW

2.1 Framework of the Mould Fabrication

The design and fabrication of a manually operated block mould involves many

technical and engineering considerations. Several studies and publications have

provided an understanding of the design and fabrication process for manually

operated block moulds. One research study conducted by Kumar et al. (2018) on the

design and fabrication of manually operated block moulds focused on the

development of a curved mould. This study found that a curved mould can be

designed with the use of CAD software and then fabricated using steel plates and

welding techniques.

Other studies have focused on the selection of materials for the design and

fabrication of manually operated block moulds. A study conducted by Al-Mulla and

Jaber (2016) examined the effects of using different types of cement and binders to

create the required strength and durability of the block mould. This study found that

the use of a blend of cement, sand, and lightweight aggregates resulted in a better

quality of block mould and improved strength.

Fabrication is the construction of items from different parts using at least one

of a range of processes and materials such as metal, laminates, wood and other solid

surface materials. The fabrication process tends to make items from manufactured

materials like steel, that can then be assembled to create larger metal structures. In

addition, fabrication involves making components for items such as engines,

machines, tools, and household appliances (Akhire, 2013).

Therefore, this fabrication uses semi-finished or raw materials to make

something from start to finish, as opposed to simply assembling it. This work is

5
typically completed by a fabrication shop (or fab shop) that will bid on the contract

for the job based on engineering drawings and specifications. The fabrication process

can involve a range of different steps, depending on what is being produced and from

what materials. However, the first stage in any fabrication is design.

Although it is possible to use hand-drawn diagrams for simpler work, more

complex or detailed designs can be created and tested with computer aided design

(CAD) programs. More complex fabrications will also often involve prototyping,

which helps with visualizing and testing product iterations (Arya, 2009).

2.2. Manual block moulding machine characteristics

A block machine also known as manual block moulding machine is used to

produce hollow blocks, interlocking blocks, paving blocks, curbstones, porous blocks,

solid blocks, insulation blocks and sidewalk blocks, other includes: grass planting

blocks, stretcher blocks, corner blocks, pillar blocks, partition blocks, lintel blocks,

frogged brick blocks, bull nose blocks, concrete stretcher blocks, concrete corner

blocks, solid construction blocks and many others designs. The price of manual block

moulding machine can vary considerably depending on the model and the

manufacturer.

Although simpler and cheaper machines are developed, but they require high

level skilled operator and diligence to produce good quality block/brick. In addition,

due to the tedious or awkward procedures of running these simple machines, they are

used mostly by intending house owners themselves to make the blocks or bricks.

Locally fabricated is the most common manually operated lever-action CEB press. It

costs between N120, 000 and N180, 000 defending on the quality of the fabrication.

Even though it is very cheap, it possesses the following disadvantages: low capacity

(usually not more than 1,000 bricks per day), no quality control mechanism and it

6
involves high level of physical labour. Therefore, first and foremost, there is need to

develop a machine that will be relatively in-expensive, easy to be maintained, easy to

operate and, most importantly, has a good quality control mechanism (such as

compaction pressure control).

Secondly, although the basic principle of block/brick making whether concrete

or earthen is the same, no commercially available machines, to best the knowledge of

the author, that produces both concrete block as well as compress earth bricks. Thus,

this research seeks to address the aforementioned challenges. (Chuku, 2014).

2.3 Type of manual block moulding machine

There are various types of manual block moulding machine namely:

a) Automatic concrete block making machine

b) Semi-Automatic Concrete Block Making Machine

c) Concrete Paver Block Making Machine

d) Concrete Solid Block Making Machine

e) Concrete Hollow Block Making Machine

(a) Automatic concrete block making machine: is the mechanical

equipment for manufacturing and producing bricks. Generally, stone powder, fly ash,

slag, crushed stone, sand, water, etc. are used to add cement as raw materials to

produce bricks through hydraulic power, vibration power, and pneumatic power. Full

Automatic Brick Making Machine Concrete Block Molding Machine for sale are

small in size, easy to install, disassemble and transport and the produced bricks are

free-burning and high-density. Definitely, a no-brainer if you’re planning on doing a

brick making project! On the one hand, the small brick making machine mixes

industrial or household wastes such as fly ash, river sand, sea sand, mountain sand,

7
mineral powder, stone powder, cinder, etc. with cement materials such as proportion

cement and lime, and by using different molds for producing various shapes of bricks.

(b) Semi-Automatic Concrete Block Making Machine: semi-automatic block

making machine can produce hollow block, solid block, paver brick, porous block,

curbstone, and interlocking brick. It can adapt to the diverse needs of different

customers. semi-automatic block making machine has the characteristics of simple

structure, easy require to operate and maintain, durability, etc. It is usually small in

size, feeding raw material manpower. Also, workers transfer finished blocks from the

machine.

(c) Concrete Paver Block Making Machine: A concrete paver block machine is

being used in the construction industry to manufacture high-quality paver blocks.

Concrete blocks are used in almost every construction project due to their strength

and durability. These machines offer various benefits over the conventional block

making methods. The concrete paver block making machine can manufacture

hundreds of blocks every day without any chance of error or mistake. This increases

the production capacity of manufacturers and helps them complete every order on

time. Latest models produce high-quality paver blocks and designer tiles. In the

production of this, highly flowing colour pigments along with grey are poured into the

rubber moulds & solidified in Vibro forming vibrating tables. These machines are

manufactured by making use of optimum grade components with the help of modular

machines in compliance with set industry norms. Concrete paver Block Machine

produces paver blocks, solid blocks, hollow blocks. All blocks size can be designed

by your requirement. There are manual and semi-automatic type.

8
(d) Concrete Hollow Block Making Machine: Hollow machine that produces

hollow blocks using pressure and vibration. The latest models can produce hollow

concrete blocks without pallets but molds are limited in capacity and shape as well.

Concrete Hollow Block Making Machine has moulds in the shape of hollow blocks,

and when the mortar is poured inside these molds, the machine uses vibration and

hydraulic force to press the mortar into the molds. Any type of concrete block can be

produced with consistent quality by fixing different types of concrete mould and ram

into the machine. Our new spares are readily available to replace the interchangeable

wearing parts.

2.4 Advantages of Manual Block Moulding Machine

Manual block moulding machine has many major advantages and benefits

such as high production capacity, blocks with good precision and accuracy, best

production quality production on time, aggregate measurement, cement measurement.

(i) High Production Capacity

A single machine can product more than 10,000 hollow blocks in a single day.

The machine can also make more than 600 m2 per day. If you want to produce

curbstone the same multifunctional machine can produce more than 3,000 curbs in a

day. That is equivalent to 3 kilometers of curbstone in a single day.

(ii) Blocks With Good Precision and Accuracy

It is important to have the same quality for all the blocks. Both hollow blocks

and solid blocks are used in the Construction Project. Concrete blocks come in

different shape and size. Pavers also come in different sizes and patterns. The

machine can produce with precision and accuracy.

9
(iii) Best Production Quality

It can have a good production quality with the multifunctional machine. One

of the major advantages of concrete hollow blocks is their high durability and

stability. Concrete hollow blocks are compacted by high pressure and vibration. By

this way, the blocks are very strong and able to withstand a high level of loading.

They also have high fire resistance and no salinity which reduces their maintenance

cost. Compared to other surfacing materials, a good quality block paving is more

environmentally sustainable because of its porous nature. This means the paving will

absorb rainwater and stop it from gathering on your patio or driveway. (Akelere et al,

2013)

2.5 Types of manual block moulding machine based on blocks production

Based on blocks production, we can divide manual block moulding machine into two

types: single pattern block type and double pattern block type.

a) Single Pattern Block Type of Machine

Hollow blocks, solid blocks, lintel block are some examples of single pattern blocks.

To produce these blocks, you need only one type of mixed aggregate and commonly

do not need color. If you produce only single pattern blocks, then you need a machine

with a single mortar hopper (UN Habitat 2007).

b) Double Pattern Block Type

Pavement blocks or pavers and interlock blocks are some examples of double pattern

blocks. When you produce double pattern blocks, you need a machine with a double

mortar hopper. These blocks are made of different kinds of mixed aggregate. In many

10
cases you use at least two kinds of mixed aggregate and color as well ( Ajao et

al,2012).

2.6 Concrete Blocks Mould

Concrete blocks are a basic commodity of the building industry. If you are

looking for a great business with a solid foundation this may be the one for you.

Concrete products are used everywhere for building. There is a constant strong

demand. They are always in style unlike here today gone tomorrow products. They

are used to build large buildings. There is a market for cement blocks around the

world and particularly in North America. If you are looking for a good business,

which you can start from home at low cost, making concrete blocks and other

concrete products is a great opportunity. Starting with a part time business, using

handmade molds, you can get going with as little as a few hundred dollars for supplies

and materials. You can operate out of your garage then as business grows and you

need more room you can expand to rented premises. The secret is to keep your costs

as low as possible to start with. Too many businesses fail in the first year because they

spend too much money unnecessarily on tents and equipment.

11
 Figure 2.1 An Image of 6 Inches block

Figure 2.2 An Image of Block Mould

2.7. Types of Concrete Mould

According to the literature the Hollow concrete and Solid concrete mould are:

i. Hollow concrete mould

The concrete hollow block mold is used to make foam concrete blocks with holes, the

working process is very sample, just pouring fluid foam concrete into the concrete hollow

block mold, and when the foam concrete is solid, removing moulds.

ii. Solid concrete mould

The concrete solid block mold is used to make foam concrete blocks without

holes, the working process is very sample, just pouring fluid foam concrete into

the concrete solid block mold, and when the foam concrete is solid, removing

moulds.

12
 Figure 2.3: 6 inches Solid and Hollow Mould

Figure 2.4: 6 inches Solid and Hollow Mould

iii. According to its size

(a) 225mm

(b) 150mm

(c) 200mm

(d) 450mm

Advantage or benefits of concrete mould

(a) Uniform shape and size

(b) High compressive strength

(c) Fire resistant

13
 CHAPTER THREE

MATERIALS AND METHOD

3.1 Design Analysis

The design of a 6-inch(152.4mm) block mould is important for any

construction project. Depending on the application, molds can be designed to meet

various specifications, such as an accepted form size, strength requirements, and

desired finish. The design of a 6-inch block mould must consider both the effect of

compressive and tensile forces that the block will experience when in use.

Specifically, these forces are affected by the shape of the mould, and the materials

that it is made out of.

The internal shape of the mould is an important factor in how the block will

perform under stress. Generally, the block should have a rectangular shape that is

slightly wider than its height. This shape creates optimal strength while also providing

the necessary space for air circulation during the curing process. The exterior of the

mould should also be designed for maximum strength and rigidity, as well as for easy

removal of the finished block. Ribbing, grooves, or both may be used to increase the

rigidity of the mould while also ensuring that the finished block can be easily released

from the mould.

14
 Overall, the design of a 6 inch (152.4mm) block mould is critical for any

construction project. By selecting the appropriate material and shape, the finished

block will be able to withstand the compressive and tensile stresses that it will

experience when in use.

18” 457.2mm

9’’ (228.6mm)

6’’152.4mm

mmmmmm

Figure 3.1: Isometric Drawing of 6 inches block Mould

3.2 Materials Selection

15
 The materials needed are:

i. Mild Steel Plate of 3mm thick and 2mm thick: The 2mm thick plate is plate that

is bend into an appropriate size and length of 150mm x 150mm, which is serve as a

function of hollow block mould shape. While the 3mm thick plate is the inner part of

the block mould that is welded together with 2mm thick plate to form a complete hole

Plate 3.1. Mild Steel Plate

ii. Gasket: Used to seal the edges of the mould

iii. Flat Bar of 2mm thick: Flat bar is a welded feed of the frame work of the block

mould hich prevent the inner part from separating during the block mould

process as stated in figure 3.3.

Plate 3.2: Flat Bar

16
 iv. Hammer: Used to form the steel sheet into a square shape

v. Bench Vice: Used to hold the steel sheet in place while forming it

vi. Protective Gloves: Used to prevent injury while handling the mould

vii. Paint: Used to coat and protect the surface of the mould

viii. Try Square: The Try square was used to take the dimension of the plate for accurate

measurement of the block mould to avoid any misalignment during the fabrication and

the measurement length for the expected shape using square as shown in plate 3.3

below

Plate 3.3 Try Square

IX. Welding Machine

This is a device used to join materials together and it is an electrical equipment that as hat

and thong. Its produce heat that melts metal parts so that the part can be joined, when is

cool it becomes a fixed and resistant joint as shown in fig 3.5

17
 Plate 3.4: Welding Machine.

3.3 List of Equipment Required

The list of equipment used to carry out the test are:

i. Acetylene Gas

ii. Welding machine

iii. Electrode

iv. Generator

v. Fuel

vi. Welding Tong & Hatt

3.4 Construction Procedure:

(i) The first step is buying and assembling of the materials for the fabrication process

ready.

(ii) The second step of the fabrication process involved cutting the steel sheet to the

correct size and shape, using a ruler and hammer.

(iii) The third step involved grinding or filing the steel sheet plate using grinding disc

(iv) The steel sheet was then placed in a bench vice and hammered into a square

shape.

(v) The steel sheet was wield with the wielding machine using wielding thong and

electrode.

18
(vi) The steel sheet was then painted to protect the surface of the mould.

(vii) Once the painting process was complete, the mould was ready for use.

Plate 3.5 – 3.8 shows the sequence of operation procedure process of the block

moulds and Bill of Engineering Material and Evaluation aa stated in Table 3.5.

Plate 3.5: Fabrication process of mould.

Plate 3.6: Fabrication process of mould

19
 Plate 3.7: Thong and Electrode

Plate 3.8: Curved sheet plate

Table 3.5: Bill of Engineering Material and Evaluation

S/n Material Quantity Size Total Cost

(N)

1 Plain Sheet Plate 3mm 600mm x 600mm 14000

2 Flat Bar 2mm 1400mm 4000

3 Plain Sheet Plate 2mm 1500mm x 8000

230mm

4 Diesel 15liters 976/lit 14640

5 Transportation 5000 500/trip 5200

6 Anti rust (Paint) Light 2liters 4500

20
 7 Workmanship 10000

TOTAL 60,340

CHAPTER FOUR

RESULT AND DISCUSSION

4.1 Results

The mould can attain its 90% percent efficiency in lined with steel plates

standardization and also to prevent damage during tamping and to reduce wear in the

mould in large scale production steel mould. This project therefore was aimed to

complete a conceptual design of an innovative undemanding stationary manually

21
operated concrete block machine. This Project was found to be more cost effective

due accurate dimension using appropriate measuring instrument compared to local or

unprofessional method of fabrication.

(i) Durability

Manual block making machine has durability properties of withstanding

excessive heat when moulding. The mould are most professional block laying

machines in construction areas especially for those heavily involved with the produce

concrete blocks, solid block and etc. they produce blocks in a straight line in the

ground without using pallets. Manual block making machines are the highest quality

on the market. The design is thoughtfully done, carefully considering the functionally

as well as high performance output.

(ii) Ductility

Ductility property of the mould helps in the structural misalignment since it

describes the ability of a structural element to sustain inelastic deformation prior to

collapse without significant loss in resistance.

The ductility of this manual block mound it has the ability at tolerate, excess loadings

and generates a predictable form of a ductile failure.

4.2 Discussion

Automated moulding machines usually have more capacity compared to manual block

moulding machine. The most ideal Blocks can be made by using a simple block-making

machine operated by an engine or by hand.

Performance Test: Performance test was achieved by evaluating the block mould performed

in terms of quality due to good qualities used which passed performance test. The block

22
mould gives the block smooth surface, perfect shape, accurate sizes and no trace of crack on

the block.

4.3 Calculations:

(b) Conversion of inches to Metric Units Dimension

1” inch = 25.4mm

6” inches = 6 x 25.4 =152.4mm

9” inches = 9 x 25.4 = 228.6mm

18” inches = 18 x 25.4 = 457.20mm

(b) Dimensions

Length = 18” inches (457.2mm)

Breadth = 6” inches (152.4mm)

Height = 9” inches (228.6mm)

To calculate the volume of the dimension:

Length x Breadth x Height = 18 x 6 x 9 = 972” inches

Converted to mm = 972 x 25.4 mm = 24, 688.8mm3

To calculate the volume of the two holes:

V1= Length x Breadth x Height = 6 x 6 x 9 = 324” inches

Converted to mm = 324 x 25.4 mm = 8, 229.6mm3

V2= Length x Breadth x Height = 6 x 6 x 9 = 324” inches

Converted to mm = 324 x 25.4 mm = 8, 229.6mm3

Combine Volume (V1 + V2) = 16, 459.2mm3

23
Total Volume Of Hollow Block Mould = ( 24,688.8 – 16,459.2) mm3

= 8, 229.6mm3

4.4 Advantages Of Manual Block Moulds Over Automated Block Moulds

i. Cost Effective: They are generally more affordable than automated

counterpart making them accessible for smaller business or project with

budget constraint.

ii. Simplicity: Manually operated block moulds tends to be simpler, requiring

less training for operators and reducing the livelihood of technical issues.

iii. Flexibility: Operators have more control over the process, allowing for

adjustments and customization based on specific project requirements.

iv. Lower Maintenance: Manual block moulds have lower maintenance

requirement compared to complex automated systems.

v. Suitable for Small Scale: Ideal for smaller production volumes where the

cost of automated machinery may not be justified.

vi. Adaptability: They can be used in various locations, especially where

access to power or advanced infrastructure is limited.

4.5 Advantages of Automated Block Moulds

i. Higher Production Efficiency

ii. Consistency

iii. Precision

iv. Labour Savings

v. Increased Output

vi. Minimized physical strain

24
 vii. Automated block moulds can operate continously

4.6 Performance Evaluation Test

To achieve our objective five (5), the mould fabricated was used to produce

samples blocks using mortar (mixture of sand and cement) and the results output was

found be sustainable and good at about 95%.

CHAPTER FIVE

CONCLUSION AND RECOMMENDATION

5.1 Conclusion

The fabrication of block mould of 6 inches x 6 inches(152.4mm) by size,

was achieved. The materials used by the machines for making hollow blocks are

Mild steel plates of thickness 2mm, 3mm. This project was mainly on the production

25
manual blocks mould which offer a significant difference in terms of accurate

dimensioning compared to other conventional way of fabricating the mould.

Therefore, the research also came out that there is need to develop a machine that

will be relatively in expensive, easy to be maintained, easy to operate and, most

importantly, has good quality control mechanism (such as compaction pressure

control) mild steel plate 3 mm is the major materials use in this and is advisable to

use nothing less than 3mm thickness of the plate for the purpose of durability

The new design block of making machine makes a tremendous impact to

technological innovation features and simplifying the operation in order to reduce

cost, labour loss and maximize the production rate. The mild steel was very reliable,

highly rigid and easier to operate. The mobility nature of this project provide added

advantage to maximum efficiency and affordability by builders or contractors.

5.2 Recommendation

(i) I recommend 5mm mild steel plate to be used for rigidity purpose for future

study.

(ii) Brittle material must not be used for the fabrication of manual block mold

due to its breaking nature of the material.

26
(iii) Anti-rust paint must be used to prevent corrosion and wear.

(iv) Stainless or cast electrode should not be used to join mild steel material

because strength weld joint

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Research Marcel Dekker, Inc., USA. Ireri, F. (2010, July 19). Monday View,

Daily Nation, p.27

APPENDIXES

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