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INDEX FOR THE HYDRAFORM MANUAL

INDEX PAGE NO.:

1. Introduction ....................................................................................................... 4
2. DiscIaimer .......................................................................................................... 5
3. Hydraform Safety Instructions and Warranty Information ............................ 6
3.1 Safety nstructions ......................................................................................... 6
3.2 Set Up of Machine on Site ............................................................................ 8
3.3 Hydraform Warranty ...................................................................................... 9
4. The Layout and Parts of the Hydraform Machine ......................................... 11
4.1 Hydraform Blockmaking Machines .............................................................. 11
4.2 Parts List & Drawing: Corner and Side View of M7 Chamber ..................... 12
5. Operating and Maintenance of the Hydraform Machine .............................. 13
5.1 Machine Operation ...................................................................................... 13
5.2 How to Change Hydraulic System Pressure ............................................... 13
5.3 How to Produce One Hydraform Block ....................................................... 14
5.4 Maintenance of Machine ............................................................................. 15
5.5 Diesel Engine Maintenance (Antor - Lombardini) ........................................ 16
5.6 Diesel Motor (Diesel powered machines only) ............................................ 17
5.7 Hydraulic Maintenance ................................................................................ 17
5.8 Changing of Wearplates on all Machines .................................................... 18
6. SoiI SeIection................................................................................................... 20
6.1 ntroduction ................................................................................................. 20
6.2 Finding correct Soil ..................................................................................... 20
6.3 Plasticity ndex ............................................................................................ 20
6.4 Field Soil Tests ............................................................................................ 21
7. Mix Design & SeIection ................................................................................... 24
7.1 Block Yield .................................................................................................. 24
7.2 Block Mixes & Strength Measurements ...................................................... 25
7.3 Quick Ratio Guide for Pan Mixing ............................................................... 26
8. BIock Production ............................................................................................ 27
8.1 Manufacturing a Simple Soil Sieve .............................................................. 27
8.2 Sieving ........................................................................................................ 28
8.3 Mixing by Hand (Not Recommended) ......................................................... 29
8.4 Hydraform Pan Mixer (Recommended) ....................................................... 30
8.5 Mixing by Pan Mixer .................................................................................... 31
8.6 Checking the Moisture in the Mix ................................................................ 32
8.7 Checking the Water Content in the mix, block length .................................. 32
8.8 Hydraform Block Length Variation. .............................................................. 33
8.9 Block Measuring Tool Example ................................................................... 35
8.10 Maintaining Block Quality ......................................................................... 35
8.11 Stacking and Curing ................................................................................. 36

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8.12 On-Site Water Requirements ................................................................... 37
8.13 Costing ..................................................................................................... 37
9. QuaIity Checks on BIocks .............................................................................. 38
9.1 Problems Causes & Remedies ................................................................... 38
9.2 Excessive Feathering of Block Edges. ........................................................ 40
9.3 Low Block Production. ................................................................................. 40
9.4 Non-Square Blocks. .................................................................................... 40
9.5 Rounded Edges & Reduced nterlocks. ...................................................... 41
10. Site Management .......................................................................................... 42
10.1 Caring for Your Workers .......................................................................... 42
10.2 Block Production. ..................................................................................... 42
10.3 Foreman's Duties. .................................................................................... 42
10.4 Log Books ................................................................................................ 43
10.5 Method for Producing 1500 Hydraform Blocks per day ......................... 43
10.6 Method for Producing 2200 Hydraform Blocks per Day ........................ 46
10.7 Block Yard Layouts .................................................................................. 48
11. The Hydraform BIock Tester ....................................................................... 51
12. Hydraform BIocks for SpeciaI AppIications ............................................... 52
12.1 The Conduit Block .................................................................................... 52
12.2 The Coping Block. .................................................................................... 52
12.3 The 180 mm Dry-Stacked Block .............................................................. 52
12.4 The 140 mm Semi-Dry-Stacked Block ..................................................... 53
12.5 Hydraform Splitter-Brick Blocks. .............................................................. 53
13. Understanding Hydraform Construction .................................................... 54
13.1 Cross Section of a Wall ............................................................................ 54
13.2 The Hydraform Block ............................................................................... 54
13.3 General points on construction ................................................................ 56
13.4 Corners .................................................................................................... 59
13.5 T Junctions .............................................................................................. 59
13.6 Cross-Junctions ....................................................................................... 59
13.7 Joints and Angles ..................................................................................... 60
13.8 Preparing the blocks and masonry........................................................... 60
14. Summary of BuiIding Tasks ........................................................................ 62
15. TooIs for Production and Construction ...................................................... 63
15.1 Tools: ....................................................................................................... 64
16. Construction Process .................................................................................. 65
16.1 Setting Out the Foundation Walls & Slabs ............................................... 65
16.2 Foundations ............................................................................................. 67
16.3 Floor / Surface Bed .................................................................................. 71
16.4 Leveling the First Course of Blocks (Superstructure) ............................... 75
16.5 Laying a Wall. .......................................................................................... 76
16.6 Above Lintel Level (Ring Beam) .............................................................. 78
16.7 Hydraform Ring Beam ............................................................................. 82
16.8 n-Filling Steel Frames. ............................................................................ 83

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16.9 Supporting Columns for Buildings. ........................................................... 83
16.10 Supporting Columns for Boundary Walls. ................................................ 84
16.11 Bonding Columns to Walls. ...................................................................... 84
16.12 nternal Walls. .......................................................................................... 84
16.13 Boundary Walls ........................................................................................ 85
16.14 Building Circular Walls with Hydraform .................................................... 87
16.15 Block & Wall Statistics ............................................................................. 87
17. EIementary Roofing...................................................................................... 88
17.1 Corrugated ron Sheeting. ........................................................................ 88
17.2 Roof Trusses............................................................................................ 89
18. BuiIding Finishes.......................................................................................... 91
18.1 Plastering Gable Walls, Ring Beams & Sub Structure. ............................ 91
18.2 Plastering. ................................................................................................ 91
18.3 Damp. ...................................................................................................... 92
18.4 Pointing. ................................................................................................... 92
18.5 Other Services and Finishes. ................................................................... 92
18.6 Agrment specifications for finishes ......................................................... 93
19. TroubIe Shooting Construction .................................................................. 94
20. Concrete ........................................................................................................ 98
20.1 Components & Strength. .......................................................................... 98
20.2 Concrete Mix Ratios. ................................................................................ 98
20.3 Portland Cement. ..................................................................................... 98
20.4 Cement Storage. ...................................................................................... 98
20.5 Concrete Sand (Fine Aggregate). ............................................................ 98
20.6 Stone (Coarse Aggregate). ...................................................................... 99
20.7 Water. ...................................................................................................... 99
20.8 Hand-Mixed Batches. ............................................................................... 99
20.9 Machine-Mixed Batches. .......................................................................... 99
21. Hydraform DieseI Servicing (Antor - Lombardini) .................................. 101
21.1 Replacing Engine Oil ............................................................................. 101
21.2 To Replace Fuel Filter ............................................................................ 103
21.3 Replacing Oil Filter Element .................................................................. 104
21.4 Servicing the Air Filter Oil Bath .............................................................. 105
21.5 Starting and Stopping the Engine .......................................................... 106
22. Annexure A: Agrment Certificate ............................................................ 108
23. Annexure B: BIock Making Logbook ExampIe ........................................ 112
24. Annexure C: Maintenance Logbook ExampIe .......................................... 113
25. Annexure D: Terms and Conditions ......................................................... 114


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1. Introduction

Welcome to Hydraform, a company founded in Johannesburg, South Africa in 1988.
Hydraform is the leading manufacturer of interlocking blockmaking machines
(nterlocking stabilised soil blocks/ compressed soil blocks) (SSB/CSB). Hydraform
also manufactures conventional brick and block machines (Vibraform machines),
accessories such as pan mixers and crushers. The latest addition to the Hydraform
range is a roof tile machine.

The Hydraform system is different to conventional bricks in that it replaces regularly
used bricks and mortar with Hydraform blocks that interlock and are dry-stacked.

Local communities can benefit from building with the Hydraform machine range as
unskilled men and women can become active participants in the building process.
The practical experience gained and the training provided by Hydraform gives people
an opportunity to empower themselves by learning new skills.

The Company has sold machines in more than 50 countries on six continents.
Hydraform products are used and trusted by many NGO's, Governments, Private
nvestors, Developers, nternational Agencies, Mining Houses and Entrepreneurs
worldwide.

Hydraform offers training worldwide. Full training in block production and building
methods is provided on site with all the technical assistance whenever and wherever
it is needed.

Training and support can also be provided at the training school at the office in South
Africa.

Vibraform machines have been included into the Hydraform company profile as a
product offering and can make a range of concrete products, from paving bricks,
hollow concrete blocks to retaining wall blocks. These products are more
conventional and well known in the construction industry

Hydraform also sells a roof tile solution which includes a roof tile machine that
produces concrete roof tiles and all the requirements to cure the roof tiles.


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2. DiscIaimer

Machine, Training and BuiIding ManuaI
Hydraform's manual has been prepared for the clients use to advise on the best
possible use of the machine, blockmaking and building system incorporating years of
experience in the field.

"Other Factors" to be considered
Soils, cements, mix preparations, material codes, building materials, building codes,
local regulations, external conditions and more are all important to produce a quality
block and achieve acceptable building standards.

DiscIaimer
Hydraform cannot be held responsible for the clients not achieving acceptable quality
levels in block production and building as the "Other Factors are out of our control.

Received Manufactures
Like any other machinery or finished building product (block or finished building) the
necessary maintenance, care and preventative servicing needs to be carried out by
the client.

Water Penetration
As the case would be with any other building system, brick, block, cement or
concrete, water penetration is the biggest nemesis of the finished product. Water
penetration causes erosion and deterioration of the final constructed product or
project. Proper water proofing and water penetration principals and procedures
needs to be followed in any construction or manufacturing of a product. Hydraform
cannot be held responsible for not achieving acceptable quality levels in block
production and construction if the proper rules, as indicated in this manual, building
codes and building regulations with regards to sealing from water and moisture, and
the penetration thereof are not adhered to.


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3. Hydraform Safety Instructions and Warranty Information

3.1 Safety Instructions

Injuries can be costIy
Read these few points thoroughIy

When towing or moving the Hydraform machine.

x Do not speed.
x Make sure mobiIe machines are hitched to the towing vehicIe correctIy.
x Secure aII machines on the pick-up or traiIer.

When operating - producing bIocks

x Do not hit top ram and bottom ram together during an empty chamber
cycIe.
x Do not operate the compression chamber without soiI in the machine.
x Never produce bIocks shorter than 100 mm.

CIeaning the Hydraform machine.

x Do not cIean the machinery if the dieseI motor is idIing or the eIectricaI
power is on.

DANGER

x Beware of TOP RAM opening and cIosing during bIockmaking. It can
cause damage to your hands, fingers and body.
x OnIy a trained operator must operate the machine.















Top arm
Top ram
Bottom ram

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Hydraform and Vibraform machines are equipped with safety signs which are there
for your own protection and these signs must not be removed, replaced or tampered
with.

t is important to give attention to your own safety and the safety of others around
you. Please don't disregard these signs. They are applied to the machine for your
own safety.




No hands: this sign shows you that no hands must be in the
area especially when the machine is in operation.





These signs indicate the moving parts on the specified machine and must not be
tampered with during operation. These parts could cause serious damage, injury or
death.



























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3.2 Set Up of Machine on Site

The Hydraform machine must be in a IeveI position resting on the four corner
stands or Iegs.

IMPORTANT! A 50 hour run in service must be done on your new dieseI
engine. PIease see section 5.5

Check list before block production or starting the machine

x Check hydraulic oil level gauge on tank (aII machines)

x Check air filter for cleanness (dieseI machines onIy)

x Check engine oil (dieseI machines onIy)

x Check electric connections (eIectric machines onIy)

x Check mixer for free movement (M7ExM or mixer machines onIy)


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3.3 Hydraform Warranty













WARRANTY REGISTRATION CERTIFICATE

The manufacturers guarantee that the machine is free from defects of design,
workmanship, and material for a period of 6 months from the date of delivery.
The guarantee is confined to defects, which render the machine unusable or
materially impair its function due to faulty materials, workmanship or design. Defects
of this nature should be notified at once in writing to the nearest Hydraform office,
and substantiated. Replaced parts become the property of the manufacturers. The
manufacturers will meet all reasonable costs of the replacements in all cases of
expressly admitted claims. Repairs require the prior permission of the manufacturers.
The guarantee does not apply to natural wear and tear, nor to defects resulting from
negligence or misuse. The guarantee becomes null and void in the event of failure to
observe the operating instructions or if the machine is repaired by the purchaser or
third parties without authorization by the manufacturers.


MACHINE TYPE______________________DELIVERY DATE______________


SERIAL NUMBER_________________________


ACCEPTED CLIENT_______________________


DATE_________________
HYDRAFORM
ESTABLISHED 1988

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Compression
chamber
(wear plates
inside 4
Soil hopper
Diesel engine
Top Ram
Bottom
Cylinder &
Ram
(hidden)
Top
arm
Tow hitch
Hydraulic oil
tank
Legs/stands
(x4)
Pressure
gauge
Control
4. The Layout and Parts of the Hydraform Machine

4.1 Hydraform BIockmaking Machines






































Hydraulic oil tank
Top arm
Legs/Stands
(4)
Bottom cylinder
Control levers
Pressure
gauge
Soil hopper
Tow Hitch
Diesel Engine
Pan Mixer:
Standard = 100
Super = 150
Compression chamber (wear
plates inside 4 Pieces = 1 set)

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4.2 Parts List & Drawing: Corner and Side View of M7 Chamber


NO.

DESCRIPTION
1. SOL HOPPER
2. SOL HOPPER SUPPORT
3. VALVE BANK
4. TOP ARM CYLNDER LEVER (TOP RAM)
5. BOTTOM CYLNDER LEVER (BOTTOM RAM)
6. CHAMBER
7. WEAR PLATES (4 PER SET)
8. TOP HEAD
9. TOP ARM
10. REAR PN AND BEARNGS
11. MAN CYLNDER
12. FRAME (FXED OR MOBLE)
13. CLEVS PN
14. BOTTOM RAM HEAD
15. TOP ARM CYLNDER
16. TOP RAM EXTENSON
17. CLEVS



























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5. Operating and Maintenance of the Hydraform Machine

5.1 Machine Operation

t is important that only one person, (the trained operator) is in charge and
responsible for the machine and the block production.

Two Iever operation
There are two levers to operate the machine, each lever must be moved separately.
By letting go of any of the two, the spring-loaded lever goes back into the neutral
position.

Lever: Nr.4. This is the left hand lever when standing in front of machine, this
controls the top ram (top arm), when pushed forward, top ram (top arm) opens, when
pulled back, top ram (top arm) closes.

Lever: Nr.5. This is the right hand lever when standing in front of machine, this
controls the bottom ram, when pushed down bottom ram moves down, when pushed
up bottom ram moves up.

VaIve Bank Components:
1. Adjustment bolt for pressure setting.
2. Lock nut.
3. Double bank valve body.
4. Top ram lever.
5. Bottom ram lever.












5.2 How to Change HydrauIic System Pressure

Your machine will be delivered with the system pressure pre-set to 90 100 BAR
(9-10 MPa), it is not necessary to reset the pressure.

Super machine models system pressure is pre-set to 150 160 BAR (15-16 MPa).

4
5
3
2
1

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f you are working with high sand content soils, then you may need to increase the
system pressure to 120 130 BAR (12-13 MPa) and to 170 180 BAR (17-18 MPa)
for the Super machine models.

If you are working with high cIay content soiIs do not adjust the system
pressure but rather adjust the mix design!

f adjustment is required it should be done as follow:
1. Loosen locknut (Nr. 2).
2. Loosen adjustment bolt (Nr. 1) for lower pressure.
3. Tighten adjustment bolt (Nr. 1) for higher pressure.

To take the reading on the pressure gauge open the top ram and hold the bottom
ram in the down or up position.

NB!! Make sure the top ram is in the open position, when changing the
pressure.

5.3 How to Produce One Hydraform BIock

STEP BY STEP INSTRUCTIONS
1. Bottom ram in down position.
2. Top ram open.
3. Fill mix into hopper.
4. Push hopper across chamber and return to original position.
5. Close top ram.
6. Move bottom ram upwards to compact the soil-cement mixture.
7. Open top ram.
8. Move bottom ram upwards until the produced block is completely ejected out of
the chamber.
9. Remove the block and take it away to be cured.
10. Move the bottom ram downward until the end.
11. Stop.
Repeat Step 1 To 11 for Further BIocks

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5.4 Maintenance of Machine

Maintenance to be Done Every Day
x Machine must be cleaned overall.
x f production is stopped, make sure bottom ram is down and the top ram is
closed.
x After stopping the engine, release the pressure in the hydraulic hoses by moving
the hydraulic levers in the respective directions.
x The air filter oil to be changed every day during normal operation.
x (See section 5.5 and 5.7)
WeekIy Maintenance
x Once a week, check machine for wear and tear, leaks and loose bolts. Clean
machine thoroughly, check engine, and hydraulic system.
x Air filter to be washed in kerosene weekly or more often in dusty conditions.
WearpIates Maintenance
x Wearplates may need changing anywhere between 40 000 80 000 blocks. The
wearplates need to be changed when the block height reaches 118 mm
(See section 5.8 and section 9.1)


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5.5 DieseI Engine Maintenance (Antor - Lombardini)

For dieseI engine maintenance refer to engine manuaI, which is suppIied with
aII new machines.

IMPORTANT! For New Engines - A 50 hour run in service must be done to ensure
contaminants are removed from the oil after the initial 50 hour run in period.

For the 50 hour run in service see the blocks marked in the maintenance schedule
below.

Maintenance ScheduIe for Antor DieseI Engines

Operation Part TIME (HOURS)
10 50 125 250 500 1000 2500 5000
CIeaning Air filter (with oil bath)
Head and head cylinder fins (*)
Fuel tank
njector
ControIIing Oil level
Crankcase oil level

Fuel pipes connections
Valve-rocker clearances
njector opening pressure
Changing Air Filter oil (**)

(***)

Crankcase oil (***)
Oil filter cartridge
Fuel filter cartridge
OverhauI
and repair
Partial (****)
General

For new engines onIy
NormaI maintenance scheduIe requirements
(*) The cIeaning operation for the engines that are working in hand conditions wiII be done
everyday
(**) The air fiIter oiI must be changed every 2-3 hours for the engines that are working in
dusty conditions especiaIIy construction machine
(***) See instructions for recommended oiI
(****) ControI of cyIinders, piston-rings, vaIve guides and springs



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5.6 DieseI Motor (DieseI powered machines onIy)

Hydraform backs our customers with technical advice on all kinds of service
questions, spare parts and engine repairs.

Contact Hydraform:

Johannesburg/ South Africa

220 Rondebult Road
Libradene
Boksburg
1459

P.O. Box 17570
Sunward Park
1470

Tel: +27-11 913 1449
Fax: +27 -11 913 2840
Email: sales@hydraform.com
nternet: www.hydraform.com
Spares: aftersales@hydraform.com

5.7 HydrauIic Maintenance

Service instructions
Main points to check are as follows:

1. Visually checking correct oil level of hydraulic tank (hydraulic oil must always be
visible in sight glass). Top up hydraulic oil with oil grade 68 if required.

2. Visually checking all hydraulic hose connection points for leaks tighten if
necessary.

3. Every 1000 hours (6 months of operation) the return line filter must be replaced.
To do this remove the three bolts on the aluminum housing and remove the filter.
Replace it with a new filter, refit the spring and tighten the housing.

The above checks shouId be done on a reguIar basis to ensure safe operation
of the machine.





HydrauIic Maintenance ScheduIe

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DAILY: Check hydraulic oil level in tank. Check for external leaks and worn
hoses.

EVERY 6 MONTHS: Change return - line filter element.

Recommendation: To be done by a Hydraulic company or specialist.

5.8 Changing of WearpIates on aII Machines

WearpIates
There are four wearplates in the machine, which give the shape of the block. These
are of special material to achieve wear resistance. However, depending on the
working conditions and the soil abrasion, wearplates must be changed when
necessary.

When the block height reaches 118 mm, the wearplates must be changed. The
blocks will show signs of cracking and no longer fit together properly. (See section
9.1)

Important note:
1. Wearplates must always be replaced as a set.
2. Every time wearplates are changed, new bolts, washers and spring washers
must be used.
3. All bolts are high tensile.
4. After wearplates have been fitted, check bottom ram and top ram for free
movement, (top ram is designed to have free play).

Taking out wearpIates
1. Open the top ram and move bottom ram down to its lowest position.
2. Switch off Diesel engine or Electric motor.
3. Front and back wearplates are bolted into the compression chamber with six
bolts. Remove them.
4. Side wearplates are bolted into the compression chamber with four bolts.
Remove them.
5. Take out front and rear wearplates (if you have difficulty in taking them out, use a
block of wood and a hammer to loosen the plates).
6. Take out left and right side wearplates bolts.
7. Take out side wearplates.

Fitting the new wearpIates
1. Always use new bolts and spring washers.
2. The wearplate compression chamber form must be cleaned and lightly oiled.

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3. Fit side plates first, ensuring that the top of the plate is level with the top of the
compression chamber, tighten bolts.
4. Fit front and rear plates ensuring that they are level with the chamber.
5. Tighten bolts.
6. Start machine and move top ram up and down slowly to ensure free movement
into the block chamber.
7. Move bottom ram up and down to ensure free movement, tighten all bolts again.
8. Proceed with blockmaking.


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6. SoiI SeIection

6.1 Introduction

A Hydraform block is produced from a soil and cement mixture. The soil type is
classified as a sandy loam. The soil should contain more sand than clay and silt
(fines). f the clay content is too high, sand will need to be blended in with the soil.

The clay keeps the block together so it is easy to carry the block during blockmaking.
The sandy portion is what binds with the cement to give the block its ultimate
strength.

Too little clay will make block handling difficult, too much clay will make the block
shrink and crack during curing.

Hydraform blocks are made from sub-soiI 1 meter below ground level, never top
soil, which contains organic material.

StabiIised SoiI BIocks:
Hydraform machines produce "stabilised soil blocks. The required "stabiliser is
Cement; this is mixed with subsoil and about 5 - 10% water to produce a mix which
feels slightly moist. The mix is moulded under high pressure to produce interlocking
blocks.

6.2 Finding correct SoiI
Soil can vary markedly around a blockmaking site. Try to find soil which:

1. is weII graded; the more coarse material you have, the less blending is required;

2. has a cIay content of between 15% and 35%; when very high-clay soils are
used, the outer surfaces of the blocks "relax when the pressure is removed,
causing surface cracking; this is due to:
a. a combination of the "plasticity (or compressibility) of the clay which
expands when the pressure is released, but should not be confused with
cracking, and
b. the water content of the mix;

3. is free of roots, Ieaves and grass; organic matter inhibits the hydration of
cement.

6.3 PIasticity Index
The plasticity index (P) is a measure of the plasticity of a soil. The plasticity index is
the size of the range of water contents where the soil exhibits plastic properties. The
P is the difference between the liquid limit and the plastic limit (P = LL-PL). Soils
with a high P tend to be clay, those with a lower P tend to be silt, and those with a
P of 0 (non-plastic) tend to have little or no silt or clay.


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P and their meanings:
x 0 - Nonplastic
x (1-5)- Slightly plastic
x (5-10) - Low plasticity
x (10-20)- Medium plasticity
x (20-40)- High plasticity
x >40 Very high plasticity
This test is generally carried out in an accredited laboratory. Hydraform has a
laboratory facility to be able to evaluate and test soil for the purpose of block or brick
production using Hydraform or Vibraform machines.

Soil range "A, with a plasticity index of 15, will not produce blocks as strong as soil
range "B. Soils with a plasticity index >15 require treatment with lime (to stabilise the
clay) or the addition of sand.









6.4 FieId SoiI Tests

The visuaI test

x Dig a hole 1m deep.
x Look at the different soil layers.
x Does the soil look sandy or does it
have lumps?
a. f it is has lumps and cracks in the
soil then there is clay.

b. f it is very sandy then dig deeper
to find a more clayey soil.

x DO NOT USE TOPSOIL!







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The wash test













x Take some soil in the hand, pour water on it and rub and squeeze it.

x Does it feel gritty or soapy?
a. f it is gritty there is a lot of coarse sand.
b. f it is soapy then there is clay.

x Wash the hand with water. f soil washes off easily then it is mostly sand or silt.
x The ideal result is if it is difficult to wash off and leaves colour on your hand, then
there is a lot of clay.

The jar test






x Fill a straight sided, flat bottomed jar /

with soil.

x Fill to
2
/
3
with water








x Shake well (1 minute).



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x Leave to stand for 24 hours.

x Measure the thickness of the layers of clay and
sand.

Note: IdeaIIy there must be 15-35% siIt and cIay, if
the cIay & siIt content is higher than 35%, sand
shouId be bIended with soiI





Shrinkage test




x Fill a shrinkage trough 60cm long x
4cm deep x 4 cm wide with wet soil.


x Scrape it level and leave to dry in
the sun for 5 days.



x After 5 days in the sun measure the
shrinkage.
x f shrinkage is no more than 10mm
then the soil is sandy. t might be
difficult to handle the block, during
blockmaking.
x f shrinkage is more than 60mm then
the soil has too much clay. Sand
must be added or find another soil.
x An ideal soil should shrink around 20
mm 40 mm.
Clay and silt upper layer
Sand and gravel lower layer

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X1
X12
X8
7. Mix Design & SeIection

7.1 BIock YieId
TheoreticaI BIock YieIds per Bag of Cement & per m
3
SoiI.

The general yield for 1:12 superstructure blocks is 40 45 blocks per 50 kg bag of
cement and approximately 100 blocks per m
3
of freshly-sieved soi.

























Never exceed more than 45 bIocks from one bag of cement, the bIock strength
wiII be too Iow.

1 MPa (Mega PascaI) = 10kg/cm = 1000 kPa = 145 psi

Note:
x BIock strength and quaIity is affected by cement content and curing
duration (7 days minimum). GuideIines are based on fresh 42,5N OPC
(cement) at 28 days and are approximations onIy. "Other factors" can
infIuence bIock strength.
x ConsuIt a quaIified IocaI engineer about IegisIations and standards for
bIocks before buiIding.
BIock Strength Cement (Parts)
SoiI
(Parts)
BIocks per 50kg
bag of cement
Mix 1
8% cement
( 7MPa after 28
days). SingIe
Story BuiIding

40 - 45
Mix 2
11% cement
( 10MPa after 28
days). DoubIe
Story BuiIding

30 - 35
X1

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7.2 BIock Mixes & Strength Measurements

BIock Strength Measurement.
This is done by compressing a block with a Hydraform block tester or a standard
compressive-testing machine until it breaks, and is defined as the block's
"compressive strength. Compressive strength should not be confused with
machine mouIding pressure (the pressure at which a block is moulded).
Compressive strength is measured in units of pressure, commonly:

MPa (mega, or 1 million Pascals) 1 MPa = 10 bars = 1N/mm
2
= 145.04 psi = 10.2 kg/cm
2

N/mm
2
(Newtons / square millimetre)

1 N/mm
2
= 1 MPa = 10 bars = 145.04 psi = 10.2 kg/cm
2

bar (1 bar is approximate sea-level
air pressure)
1 Bar = 1,000 millibars = 14.50 psi = 0.1 MPa = 1.02
kg/cm
2

psi (pounds per square inch) 1 psi = 0.07 bar = 0.007 MPa = 0.007 N/mm
2
= 0.07
kg/cm
2

kg/cm
2
(kilograms per square
centimetre)
1 kg/cm
2
= 0.1 MPa = 0.1 N/mm
2
= 1 bar = 14.50 psi


BIock CoIour.
This is derived from the soil you are using. We are often asked if block colour can be
modified by using cement dyes; this is possible, but it is expensive because most of
the dye is contained within the block. Our experience is that the natural colours of
soils are by far the most attractive.

BIock Strength Requirements.
The recommended minimal strength for all blocks is 7 MPa.

NB: Measuring Mixes.
The more cement in a mix, the stronger the blocks will be. Wheelbarrows are used to
measure soil, and cement is usually packed in 50 kg bags or pockets:
x a standard builder's wheelbarrow levelled at the rim contains 65 Iitres, and
x a 50 kg pocket of cement contains 33 litres, so
x 1 level wheelbarrow holds 2 pockets of cement, so, for example,
x 1 pocket of cement mixed with 4 level wheelbarrows of soil is a mix ratio of 1:8.















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WheeIbarrow Capacity.
The wheelbarrows commonly used vary from country to country. Check the capacity
of your wheelbarrows by filling them with soil, using a graduated container. Once the
wheelbarrow volume has been determined, the mix ratios must be adjusted if
necessary. Whilst a standard builder's wheelbarrow leveled at the rim contains 65
liters, the same wheeIbarrow, heaped to maximum capacity, wiII hoId 92 Iiters.
















Moisture Content.
This determines block length: the drier the mix, the longer the block and, conversely,
the wetter the mix, the shorter the block.

7.3 Quick Ratio Guide for Pan Mixing

Mix guide for a 1:8 mix ratio:

x 100 Pan Mixer: 8 x 10 buckets soil with 1 x 10 bucket cement
x 150 Pan Mixer: 2 x 65 wheelbarrow soil with 1 x 10 bucket cement
x 300 Pan Mixer: 4 x 65 wheelbarrow soil with 1 x 1 bag of cement or 3 x
10 buckets cement.

Mix guide for a 1:12 mix ratio:

x 100 Pan Mixer: 8 x 10 buckets soil with x 10 bucket cement
x 150 Pan Mixer: 12 x 10 buckets soil with 1 x 10 bucket cement
x 300 Pan Mixer: 4 x 65 wheelbarrow soil with 2 x 10 buckets cement.

/boundary wall)

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8. BIock Production

8.1 Manufacturing a SimpIe SoiI Sieve



MateriaI requirements:
1. 8 to 10 mm expanded metal or welded mesh size 1,000 x 2,000 mm
2. 6 m size 50 x 50 x 5 mm angle iron (sold in 6.0 m lengths)
3. 6.6 m size 50 x 5 mm flat bar (sold in 6.0 m lengths)
4. 8.0 m size 25 x 5 mm flat bar (sold in 6.0 m lengths)
5. Nuts & bolts for securing mesh to frame
6. 5 m size 100 x 50 mm softwood (for supports)

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8.2 Sieving























CyIindricaI SoiIs Sieve

This soil sieve is a little more
complicated to construct than the
previous one shown but is much more
productive.

The sieve mesh should be 8 to 10 mm
expanded metal or weld mesh size.

The cylinder is either made slightly
conical or can be mounted at a slight
angle to move the waste towards the
open end.

Strong steel frame 2 m long
X 1m wide
Stand
8-10mm steel mesh

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8.3 Mixing by Hand (Not Recommended)

Note: The soiI-cement mix must be used within one hour of mixing never Ieave a
mix unused for more than one hour.











































Batch the soil and cement
Mix three times
until the cement
& soil are mixed
thoroughly.
Add water with watering can.

x Do not pour the water onto a single spot creating a
pool of water.

x Water must be sprinkled onto the mix slowly while
mixing.




Mix three times
until the water is
spread evenly
throughout the
mix.

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8.4 Hydraform Pan Mixer (Recommended)

Note: Do not aIIow bIades to touch drum







































Drum
Bearing housing
and motor support
Hydraulic motor
White Hydraulics -
USA
'U' bolts
Outer blade
nner blade
Centre blade

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8.5 Mixing by Pan Mixer

Note: The soiI-cement mix must be used within one hour of mixing. Never
Ieave a mix unused for more than one hour. Never fiII more than 100 in
a standard machine and 150 in a Super machine.




x Switch mixer on before
loading material.
x Empty the wheelbarrow into
the mixer from the ramp.
x Add the cement second.
x Dry mix for 1 minute.
x Add water slowly and mix for
1 minute.


Note: water must be SPRINKLED in sIowIy.





x Empty mixer by pulling lever
after soil-cement is well
mixed.








Note: If the mixer struggIes to mix, the soiI may contain too much cIay, add
sand or reduce the mixing voIume.


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8.6 Checking the Moisture in the Mix

The Drop Test
















1. Squeeze the soil - cement mix into a ball.

2. Drop ball from waist height.

3. - f ball shatters into many small pieces it is too dry.
- f ball breaks into 5-6 lumps then the water content is correct.
- f ball does not break or only breaks into a few lumps it is too wet.

NOTE: A dry mix wiII produce a poor quaIity bIock. The mix shouId be cIose to
the Optimum Water Content of the soiI. The water content wiII vary bIock
Iength. When the soiI - cement mix is too dry the bIock Iength wiII be
Ionger than when the water content is correct.

8.7 Checking the Water Content in the mix, bIock Iength















Too Dry
Good
Too Wet




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8.8 Hydraform BIock Length Variation.

Note: If you are getting more than 100 bIocks from one cubic meter of mix,
then there are 3 possibiIities for this.

FirstIy: the operator is not filling the chamber fully with the required 10 liters of
mix per block. The hopper will automatically level the chamber when
the hopper is pulled back after filling.
SecondIy: the water content in the soil-cement mixture is not consistent.
ThirdIy: the operator might not be returning the bottom ram to the very bottom
during block manufacture. The ram must go all the way to the bottom
before returning the hopper.

Also ensure the quantities of soil being mixed is in fact the same every time. The
person mixing the soil may heap the soil on some mixes and then under fill the
wheelbarrow on other mixes.




Operator must maintain block length by maintaining consistent water content in the mix




Too wet, block is short and has cracks Too dry, block is long and difficult to handle

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1) Under fiIIing the mouId / chamber:

Note: one full length block is 10 liters before compaction. Normally one cubic
meter of mix should produce 100 blocks. When measuring out the mix it is
important to ensure the wheelbarrow or buckets being used are leveled every
time, ensuring the same quantity of soil and cement is being used. Length may
be intentionally varied when producing half blocks or special length blocks. 5
liters of soil put into the chamber will give a half block of approx 110-120mm
length. Never produce a bIock with a Iength of Iess than 100mm or 4 Iiters
of soiI; this may cause damage to the top gate arm during compaction of
the soiI cement mix.

2) Water content in the mix:

First we need to establish the ideal block length for a given soil type. This is done
by preparing a mix of soil, cement and a little water (The first mix should be
slightly dry).
x Mix thoroughly and produce a block.
x Measure the 1
st
block.
x Add water to the mix and mix thoroughly again, produce the 2
nd
block and
note the length. The block length will reduce as the water content is
increased.
x Repeat the process adding more water to each mix and make new blocks
noting the length.
x Finally fine cracks will begin to show on the bottom of the block, this indicates
there is too much water and the mix is too wet. Note the length of the block for
this mix.
x The best average length would be a little longer than the block length when
fine cracks start to show. Assuming this length is 230mm instruct the machine
operator to manufacture blocks in the range of 225mm 235mm. Give the
operator a steel rod of length 235mm with a marking at 225mm. The average
block length should always be between the upper marking and lower marking.
x f the soil is a little dry, the block will be longer than the average length. The
operator then simply adds a little water to the mix and continues producing
blocks.
x The steel rod gives a visual and easy check for the operator to check and
maintain the water content of all blocks being produced.

Consistency in mixing and water content in the mix is the key to good
block quality.


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8.9 BIock Measuring TooI ExampIe






























8.10 Maintaining BIock QuaIity

BIock QuaIity.
The more consistent your blocks, the easier and faster they are to build into an
attractive wall. The machine operator must Iook at every bIock and discard any
block which is sub-standard.

Measuring BIocks.
n order to achieve even "bonds (the vertical joints between blocks in a wall), block
length must be controlled. The Machine Operator must measure at Ieast every
fifth bIock, and the first bIocks of every new mix untiI the Iength is correct (220
mm) using a block measuring tool (see sketch). They soon become skilled at
balancing block length to moisture content. The Foreman must continually monitor
both block length and quality. This wiII greatIy assist the bIock Iayers to buiId
attractive waIIs quickIy.

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8.11 Stacking and Curing

Stacking


x Stack the blocks 5 high and 7
wide (depending on the width of
the plastic).

x Cover the blocks, as they are
stacked.

x Never leave the blocks in the sun
or wind uncovered.

x Even when producing blocks in
the shade, plastic must be used.


Curing

Note: Curing gives the bIock its durabiIity and strength


x Uncover the blocks and water
the blocks twice a day once in
the morning & once in the
evening, and cover again
immediately. This is curing.

x The blocks are cured for 7-14
days. The longer the curing
period the stronger the block.










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Hydration.
Wherever cement is used, it is vitally important that it be properly cured. Cement
needs water to "hydrate, or gain strength, and it requires 28 days curing to achieve
full strength. Ordinary Portland Cement (OPC) achieves only about 60% strength in
the first 7 days, and about 85% in 14 days. Curing is particularly important with
Hydraform blocks because the cement requirement is low.















8.12 On-Site Water Requirements

Water Required for BIockmaking.
The amount of water required varies with the moisture content of the soil, but is
usually not more than 1litre per block.

Water Required for Curing.
A typical block-yard, at full production, would consume approximately 500 litres of
water per day for curing.

TotaI Water Requirement.
Assuming that your blockmaking team is consistently producing 1,500 blocks per
day, with 500 curing and approximately 1 per block, this will amount to
approximately 2000 /day for the totaI water requirement for a singIe chamber
bIock-yard Iayout.

8.13 Costing

BIock Costing Spreadsheet.
Hydraform has compiled a spreadsheet which will allow Hydraform owners to input
their own parameters and cost their blocks with a high degree of accuracy. This
spreadsheet covers a commercial block yard operation selling standard 220 mm
Hydraform blocks. f you are not familiar with complex spreadsheets, we will e-mail a
questionnaire for you to complete and send your detailed comparative costing back
to you promptly. The spreadsheet is available from our Hydraform sales
representatives.

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9. QuaIity Checks on BIocks

9.1 ProbIems Causes & Remedies

PROBLEM CAUSE REMEDY

1. Rough surface on
blocks









2. Cracks in blocks
Horizontal cracks
seen as block ejected
from chamber











Cracks developing
during 7 day curing
period














-Mix too dry

-Rough wearplates


-Soil build up in joints or on
wearplates

-Course aggregate



-Too much water in mix



-High clay content









-Blocks losing too much
water too fast during curing





-High clay content




- wearplates worn out



-Add more water to mix

-nspect wearplates and
change if necessary

-Clean excess soil from
joints and plates





-Use less water in mix
Add cement to mix
already made to dry out

-Add coarse sand to the
mix


-Add more cement
(see section 7)




-Cover blocks properly
with plastic and water
twice daily as per
Hydraform
recommendations


-Add coarse sand to mix

-Add more cement
(see section 7)

(see point 7 beIow)







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3. Blocks being damaged
and broken during
stacking and storage



4. Blocks shorter than
chosen length






5. Blocks longer than
chosen length



6. Block length changing
continuously









7. Block height is
different



-Careless handling of blocks

-Blocks too dry



-Too much water in mix

- High clay content





-Mix too dry

(see section 8.6, 8.7 & 8.8)


-Water content changing
continuously

(see section 8.6, 8.7 & 8.8)

-Soil properties changing
continuously.

-Filling of chamber


- Wearplates are worn.




-New wear plates produce a
block height
of 115 mm




-Closer supervision of
stacking
-Check production
process and/or add more
cement to mix

-Use less water in mix

- Add coarse sand to mix

-Add more cement
(see section 7)


-Add more water to mix




-Keep water in mix
constant. Check water
content by checking
length of block with ruler

-Use same soil source for
all production

-Ensure that chamber is
filled level

-Replace wearplates
when block height is
118 mm. (see section
5.8)







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9.2 Excessive Feathering of BIock Edges.

There is always some "feathering caused by the necessary
gap between the ram head and the wear plates along the
edges of blocks. This is more pronounced when using fine
soiIs. Some of this will come off with proper brushing of the
blocks when they emerge from the compression chamber,
but any surplus is easily removed with a builder's trowel when
the blocks are dry after curring.

9.3 Low BIock Production.

f you organise your site in such a way that the machine makes blocks continuously,
production will be excellent. A well-motivated team can make nearly 1,800 blocks in
an eight-hour day. Refer to the method for producing 1,500 blocks per day.

9.4 Non-Square BIocks.

f either the pre-compression (top) or main (bottom) ram heads are tilted off square in
any direction, the blocks will not be square. This can cause the following problems:

1. Either of the ram heads tiIting aIong the Iong axis (see arrow A) wiII
resuIt in the bIock courses forming a wide circIe if they are butted
up against each other correctly (see exaggerated sketch below).













Ensure that the bottom ram head extension is seated square on the
piston, and that the front and rear grub screws are tight; inspect the top
rim of the compression chamber; if there is a build-up of soil on the rim,
this can prevent the frame of the ram from settling properly on the
compression chamber rim, displacing the pre-compression ram head.

2. Either of the ram heads tiIting aIong the short axis (see arrow B) wiII
resuIt in gaps in the 'bonds' (see exaggerated sketch below).



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nspect the bottom ram head for displacement and correct if necessary;
check that the rails of the soil hopper are clean, and that the hopper is
levelling the soil in the compression chamber without leaving hollows.

















9.5 Rounded Edges & Reduced InterIocks.

These faults indicate that the wear plates need to be replaced. Measure the blocks
and, if the hight has increased from 115 to 118 mm, it is essentiaI that the wear
pIates are changed (See section 5.8).