Concrete

Blocks

Submitted By
Avinash Kaur
09607
Raw Materials Required

 Cement
 Sand
 Gravels
 Water
 Production Processes
1. Raw Materials Mixing
2. Brick/Block Molding
3. Vibrating & Compacting
4. Curing/Drying
5. Brick/Block Packing
 MANUFACTURING
 Concrete Masonry Blocks are made by blending different materials together at a
predetermined ratio through the following procedures.
 1. Raw materials preparation There are two major types of materials in the
composition of concrete blocks. Namely, aggregates and cements: The function of
aggregates is to form the main structure of a masonry block. Different materials can
be used for aggregates. Sands and crashed stones are typical examples of natural
aggregates. Cinder, slag and fly ash are typical examples of industrial waste
aggregates. The function of cement is to combine the aggregates together. The
procedure to prepare raw materials is not a continuous process. It is done in batches.
 a) Aggregate material preparation: Aggregates come in different types and sizes.
Usually, different materials are delivered by big trucks into the raw materials yard.
Different materials must not be blended in the yard. The size and purity of different
materials should be consistent. They are transferred to large bins by a loader to be
stored for production. To get good physical and chemical performance from the block,
in each batch, the ratio of different aggregates must be determined. Each aggregate is
weighed according to the design by a weight belt underneath the bins and then
dumped in a large mixer waiting to be blended.
 b) Cement preparation Different types of Cement are delivered in bulk by cement
trucks to the plant, and then blown into cement silos. Different cement types or even
the same type of cement from different manufacturers must not be blown into the
same silo. When in production, cement is weighed according to the design by a
weighing system and then dumped in the same mixer as the aggregate.
 MANUFACTURING
 2. Concrete preparation After the preparation of all
the raw materials, one batch of different materials is
put into the large mixer. The mixing procedure starts,
all the materials are blended together by big blades in
the mixer and water is added to the mixture. The
function of water is to hydrate (harden) cement. In this
procedure the materials must be completely blended
to guarantee the consistency of the mixture; which is
now called concrete. In the block business, concrete is
not prepared wet (ready top flow) or too dry. Water
content is controlled precisely between a certain
ranges
 MANUFACTURING
 3. Concrete transferring and block forming This is the most
important procedure in the process of block manufacturing. The
concrete is transferred to a block forming machine by belt, and
dumped into the block forming mold on pallets. Then the
concrete is compressed and vibrated into certain forms; stripped
from the mold but still on pallets and delivered to be loaded on
racks. Now the product is called green block. The green block is
not hard yet as cement needs time to become hard. The block
forming machine is ready for another cycle. Different quantities
of blocks can be made on different block machines. Bigger
machine can make more blocks each time. Different molds can
be placed in the block machine to make different shape blocks.
As this process is very important too for the strength and form of
the block, much attention must be paid the procedure. Materials
must be fed evenly, and completely. The vibration time and force
must be controlled properly to guarantee the height and
strength of the block.
 MANUFACTURING
 .

 4. Stacking and Curing After green block is stacked on the rack, they are
transferred to the kilns. There they are kept on the rack for about 24 hours to
become hard (curing) enough for handling. In the kiln, high temperatures (still
durable for human beings) and humidity needs to be kept for the fast curing of
the block.
 5. Depalletizing and Cubing After they stay in the kiln for about one day, the
green blocks become hard enough (finished products) for handling. They are
transferred out to be removed from racks and then removed from pallets.
After that, the blocks are transferred for stacking into cubes on wood or plastic
pallets, packaging and removal by forklift to the yard.
 6. Yard Storage Concrete blocks are stored in the yard for further curing
because cement needs about 28 for complete hydration (hardening). Different
products are stored in their designated areas for good yard management. They
are stored according to types, strengths, colors and so on. Good storage
management is also very important for good customer service.
Brick/Block Machines
End Product : Bricks
End Product : Blocks
End Product : Pavers
USES
 Used for Lintels, corners, jambs, sash, control
joints, headers, bonding and other special
conditions.
 Square-edged units for outside corners except
where bullnose units are indicated.
 Paving walkways and parkings.