Design and Performance of Light Weight Interlocking Blocks

CHAPTER 1

INTRODUCTION

1.1. Interlocking bricks

Interlocking blocks are made up of M-sand, coarse aggregates, fly ash, sand and Portland cement
and water of desirable ratio for targeted strength, admixtures added if necessary. Normal blocks which
may in hallow or solid blocks which installed with mortar less save amount of mortar. This production
can be made in a small scale on site or in laboratory or in a large unit in industry.

The concept of technique of industry blocks provide neat, fast and economical assembling of
wall. Ring beam below windows level, ring lintel beam and overhead occurs beam should be provided
to efficiency the binding the structure.

1.2. Fly ash bricks

Pulverized fuel ash commonly known as fly ash is a useful by-product from thermal power stations using
pulverized coal as fuel and has considerable pozzolonic activity. This national resource has been gainfully utilized
for manufacture of pulverized fuel ash-lime bricks as a supplement to common burnt clay buildings bricks leading
to conservation of natural resources and improvement in environment quality

Pulverized fuel ash-lime bricks are obtained from materials consisting of pulverized fuel ash-lime bricks
are generally manufactured by intergrading blending various raw materials are then molded into bricks and
subjected to curing cycles at different temperatures and pressure. On occasion as and when required, crushed
bottom fuel ash or sand is also used in the composition of the raw material. Crushed bottom fuel ash or sand is
also used in the composition as a coarser material to control material to water absorption in the final product.
Pulverized fuel ash – lime in presence of moisture from a calcium hydrate which is binder material. Thus
pulverized fuel ash-lime brick is a chemically ended bricks

1.3. Demand of fly ash bricks

180 billion tons of common burnt clay bricks are consumed annually approximately 340 billion tons of
clay-about 5000 acres of top layer of soil dug out for bricks manufacture, soil erosion, emission from coal burning

Department of Civil Engineering,BRCE 1

 Design and Performance of Light Weight Interlocking Blocks
or fire woods which causes deforestation are the serious problem posed by brick industry. The above problem can
be reduced some extent by using fly ash bricks in dwelling units

At present 20nos units are engaged and 40lakhs nos of bricks per month are manufactured in our state.
And there will scope to start near about 100 units, which will be produced more than 2cores no of bricks per
month in future. Thus marketing of these product are well shining

1.4. History of interlocking blocks

Mortar less technology is directly associated with interlocking bricks so the two terms will be used
interchangeably. In this work we are going to deal with use of interlocking bricks, stacked dry to build a wall
while observing building construction rules of proper bonding

Bonding is the arrangement of bricks in an interlocking pattern that result in a stable well. The stretcher
bond was the only (main) such pattern used in interlocking brickwork before this research. From the beginning
most toy mechanisms were a tool for learning scientific, engineering and architectural principles the original
materials used for toy construction were tin, metal, wood and clay, through now most toys are made from plastic.
Of these various systems, Lego has the most similarity to walling. An interlocking brick construction for toys
(automatic binding bricks) was first developed in Denmark in 1949. In 1951 the “automatic binding brick” was
renamed as “Lego muster”

“Lego brick” in English “, and first produced commercially in 1958” (museum of American heritage).

The 1958 version of interlocking bricks with stubby cylinders and matching studs molded into the surface
allowed the Lego bricks to be firmly attached to one another in 1967 a simplified version called Duplo|| bricks
was launched; is the latest version available in variety of sizes, shapes and colors that form the basis for mortar
less technology using interlocking bricks/blocks.

Since 1970s the interlocking mortar less bricks/blocks for house construction, made from sand-cement,
stabilized soil and burnt/banked soil, have been pioneered in Africa , Canada, the middle east and India.

Department of Civil Engineering,BRCE 2

 Design and Performance of Light Weight Interlocking Blocks
OBJECTIVES

The main objectives of this project are as follows:-

1. The Compressive Strength of Light weight interlocking blocks (Fly ash + GGBS) is compared with Normal
Conventional interlocking blocks.
2. The Density of Light weight interlocking blocks (Fly ash + GGBS) is compared with Normal Conventional
interlocking blocks.
3. Water absorption of Light weight interlocking blocks (Fly ash + GGBS) is compared with Normal
Conventional interlocking blocks.
4. Drying shrinkage of Light weight interlocking blocks (Fly ash + GGBS) is compared with Normal
Conventional interlocking blocks.

Department of Civil Engineering,BRCE 3

 Design and Performance of Light Weight Interlocking Blocks
CHAPTER 2

LITERATURE REVIEW

2.1. Santosh bharathy. V, S. Karthik raja et.al. ,:-

This paper discuss about a technique implemented in masonry. The interlocking bricks , which stands
apart from the conventional clay brick in terms of its strength and the mechanism with which it is casted into
walls , this brick is expected to be cheaper than the conventional bricks, also processing high strength, which
helps in increasing the overall stability of the building , acacia ash derived from the acacia plants are studied and
a partial replacement of cement is made from the standard mix ratio of the fly ash bricks, these mix ratios are
made , replacing the cement with 2%, 10%, 15% of acacia ash and interlocking bricks are casted and subjected
to various tests

The experiment has provided us with the results that have been stated above. Out of the three mixes made,
the second mix where a replacement of 10% replacement of cement with acacia ash was found to be satisfactory
in terms of strength, cost, handling and workability

The compression strength was found to be higher than the conventional brick strength at a percentage of
7.2% in the 1st 3days of curing 30.6% in the 7days of curing and 36.7% in 15days of curing. The cost of
manufacturing of the bricks was calculated to be RS 5.15 per brick, which is RS 3.35 lower than the conventional
brick. This proves to reduce the overall cost of the construction as stated above the abstract

2.2. Chukwadi Onyeakpa, Lateef Onundi:-

In this research, the stated problems have been resolved by the introduction of ample compressive strength
solid interlocking blocks (with no vertical opening), it is advisable to support the wall with the ring beam,
produced by dual mould interlocking block machine as an improvement of the single mould interlocking block
machine, ring lintel beam, and ring beam below roof to improve the wall strength and can be achieved by channel
blocks have channels along the long axis, into which reinforcing steel and concrete can be placed to form lintels
or ring beam. In this project, a dual mould interlocking block machine was achieved with about 15mm protrusions
and grooves for proper locking of the sky.

The production of the interlocking blocks in this project was preceded by modelling of 250mm length,
210mm width and 125mm height interlocking toe, bottom and bottom blocks efficient production of the

Department of Civil Engineering,BRCE 4

 Design and Performance of Light Weight Interlocking Blocks
interlocking block in the laboratory using available load materials with compaction efforts (3.687 KJ/m3) was
effectively constructed for interlocking block production therefore the interlocking block attained ample
compressive strength and can resist impact of bullets and other sharp objects using available land materials such
as lateritic clay river sand, madube gravel, Portland cement and water which cannot be afforded by the hallow
sand concrete blocks.

2.3. Nasly M.A., A.A.M. Yassin et.al. ,:-

In this paper explores that the rising costs of construction materials and the need to adhere to sustainability,
alternative construction techniques and materials are being sought many methods have been used to produce earth
blocks varying according to local climate and environment as well as local traditions and customs, test have been
carried out to get the optimum mix to given the required strength as compressed stabilized soil hollow blocks.

The following conclusions can be derived from the project:

1. The strength of the compressed stabilized soil block (CSSB) is dependent on the compaction force during
manufacturing.
2. The strength of the CSSB is dependent on the type of soil as well as the amount of stabilizer and sand added
to the mix.
3. Laterite soil has the potential to be used as a compressed stabilized soil load bearing block.
4. The materials required for block production and building construction are usually locally available in most
regions. Compared with conventional masonry.
5. The dry assembly of interlocking blocks saves construction time and a large amount of mortar.
6. Additional cost reduction is achieved by building local bearing walls since there is no timber formwork
required.
7. The structural stability and durability of interlocking block constructions can be enhanced by grout holes and
channel blocks that provide means to insert steel reinforcement in vulnerable parts of buildings for increased
wind and earthquake resist.

2.4. R.K. Watile1, D.W. Gawatre2 et.al. ,:-

In this research they have conducted that concrete having possible lesser density and higher compressive
strength of interlocking blocks with using waste and also eco freely material in fly ash. These materials are raising
available into and easy to increasing fly ash increase with the age all mix proportion gives satisfactory higher
values of compressive strength at some mix ratio 1:11 gives the high value of compressive strength greater than

Department of Civil Engineering,BRCE 5

 Design and Performance of Light Weight Interlocking Blocks
10N/mm2. The density of interlocking was found 7.2 to 25% higher that of the ordinary burnt vary bricks. The
water absorption of interlocking blocks increases with the inward fly ash content

Based on the experimental investigation following conclusions are drawn:

1. Strength of interlocking bricks with increasing fly ash increase with the age
2. All mix proportions gives satisfactory higher values of compressive strength
3. Interlocking bricks with cheaply available fly ash in large proportion have sufficient strength for their use in
low cost housing, non-load bearing construction and in regions where good quality burnt clay bricks are not
available
4. Water absorption of interlocking bricks is found to be in the range of 6.42 to 12.4 percent whereas the water
absorption for ordinary burnt clay bricks should not be more than 20%. The water absorption of interlocking
with the increased fly ash content.

2.5. Bansal Deepak

The Indian masonry design standard (IS 1905-1987) does not deal with dry interlocking block masonry,
hence does not prescribe the design values for this masonry like basic compressive strength. Tensile strength and
shear strength this block masonry by hydra form interlocking has been tested in the field experiment found to
have better strength than the conventional brick masonry using cement Sand mortar (1:6), flyash the basic
compressive strength is more than the minimum values given in the Indian masonry design standard (IS 1905-
1987) these blocks have low exemplify energy compared to burnt day brick, it is resulting in promotion of green
construction technology. This paper gives the technical specifications and raw materials options and many more
with the building standards.

This blocks masonry is quite generic and does not require sophisticated machine or equipment, can be
done with local materials with optimum moisture and stabilizers on the site itself this paper deals with the testing
requirements of these blocks and had established the embodied energy parameters of these blocks. However
before making any standards on these blocks extensive testing is required as the mix proportion of raw materials

2.6. Abhinandan R. Gupta, Dr. S. k. Deshmukh et.al., :-

The study done and shown in this paper is on towards sustainability of the concept of interlocking brick
and its strength parameters are checked by laboratory testing and constructions method. When the comparison of
interlocking brick wall with the normal brick wall the strength and durability are more interlocking brick not only

Department of Civil Engineering,BRCE 6

 Design and Performance of Light Weight Interlocking Blocks
increase strength but also decrease the quality of mortar required for bonding of wall units further the application
of these type bricks used to reduce the material reduction in environmental pollution. When the bricks masonry
wall is subjected to lateral forces. It falls due to shearing or overturning as the bonding is weak in horizontal
directions.

The concept design and application of interlocking blocks design proves to effective for sustainable
approach towards construction. It has been observed that when structure is subjected to gravity load only. When
the bricks masonry wall is subjected to lateral or horizontal forces, it fails due to shearing or overturning as the
bonding is weak in horizontal directions, thus further loads to sever human hazard at the time of disasters like
earthquake. To overcome all this short comings and limitations of conventional clay brick wall, the concept of
interlocking blocks shown above proves to be very effective. With the application of this high strength
interlocking blocks there are considerable reduction in amount of binding material used for wall that is mortar.
And thus the total material consumption is also reduced thus reduction is material consumption can be increase
with application of fly ash based clay mix brick material thus the study and research done above clearly reflects
the benefits of using and adopting such bricks in construction industry and creates paradigms for sustainability.

2.7. R.K.Watile, H.C.Muley, et.al. , :-

Based on the experimental investigation reported in this paper, following conclusions are drawn:

Strength of interlocking bricks with increasing fly ash increase with the age and all mix proportions gives
satisfactory higher values of compressive strength and some without GFRP mix ratio 1:11 gives the higher
compressive strength greater than 10N/mm2. Interlocking bricks with economically available fly ash in large
proportion have sufficient strength for their use in low cost housing, non-load bearing construction and in regions
where good quality burnt clay bricks are not available.

Water absorption of interlocking bricks without GFRP is found to be in the range of 6.42 to 12.4 %
whereas the water absorption for ordinary burnt clay bricks should not be more than 20% the water absorption of
interlocking bricks increase with the increased fly ash content. The density of interlocking bricks was found to be
7.5 to 25% higher than that of the ordinary burnt clay bricks. Interlocking bricks with reinforcing agent GFRP
increases the compressive strength at maximum utilization of fly ash with the age. The water absorption and
density increase with increase in fly ash in GFRP interlocking brick. As density concern the difference between
ordinary clay brick and interlocking bricks should be minimize with reinforcing agent

Department of Civil Engineering,BRCE 7

 Design and Performance of Light Weight Interlocking Blocks
2.8. Amana ocholi, Manasseh Joel:-

The study concluded that effect of variation in temperature on compressive strength and water absorption
test and lateritic interlocking bricks stabilized with 6% and 8% cement, subjected to temperatures of 1000c, 2000c,
3000c, 4000c, 5000c, over a period of 1hour was investigated. 28 day compressive strength water absorption test
was performed on bricks before and after bricks was subjected to temperature variation. Result of test showed at
the brick stabilized with 6% and 8% cement content increased for 2.24N/mm2 and 2.72N/mm2 at room

Temperature at 350c to 4.03N/mm2 and 4.16N/mm2 respectively then subjected to a temperature of 5000C.

Water absorption values of bricks stabilized with 6% and 8% cement increased from 1.91% and 2% at
room temperature 35`c to 21.72% and 17.44% respectively when bricks were subjected to temperature of 5000c.
The temperature variation has effect of compressive strength and water absorption value of lateritic interlocking
bricks stabilized with 6% to 8% cement content.

Department of Civil Engineering,BRCE 8

 Design and Performance of Light Weight Interlocking Blocks
CHAPTER 3
METHODOLOGY

Anaylsis of code IS
2572-2005 and journals

Prepare design of
interlocking blocks

Assigning the materials

Mix design

Casting the specimens

Testing the specimens

Comparision between
specimens

Results and discussion

Conclusion

Department of Civil Engineering,BRCE 9

 Design and Performance of Light Weight Interlocking Blocks
 Referring the code book of IS 2572-2005 (construction of hollow and solid concrete block masonry)
and journals we analyzed the interlocking blocks.
 Designing the moulds for interlocking blocks.
 Using of materials M53 grade cement, fly ash, GGBS (Ground Granular Blast-Furnace Slag), fine
aggregates and coarse aggregates.
 Preparation of mix design for interlocking blocks according to IS 2572-2005 code book
 Casting the specimens and keeping it for 7, 14, 28 days curing.
 After curing for respected days conduction of the tests for density, compression, shrinkage, and water
absorption tests.
 After testing the specimens, the results are compared with Normal Conventional interlocking blocks
with that of fly ash+ GGBS interlocking blocks.
 Then discussion about the test results.
 Conclusion.

Design of Mould and Blocks

Department of Civil Engineering,BRCE 10

 Design and Performance of Light Weight Interlocking Blocks

Department of Civil Engineering,BRCE 11

 Design and Performance of Light Weight Interlocking Blocks
CHAPTER 4

FUTURE SCOPE

 Green technology- zero carbon emission

 Energy efficient
 Use of local available materials
 Reduce the need of skilled labors
 Faster to build –shortens construction time
 Helps on community based projects
 Applies to build all type of buildings
 Reduces the cost of construction
 Easily removable of wall if necessary
 Can be constructed in irregular shape of blocks/ bricks

Department of Civil Engineering,BRCE 12

 Design and Performance of Light Weight Interlocking Blocks
REFERENCES
1. Santosh bharathy. V, S. Karthik raja et.al. , “STRENGTH CHARACTERTICS COMPARISION OF FLY
ASH AND ACACIA ASH INTERLOCKING BRICKS “, volume 119 no.15 2018, 1391-1402.
2. Chukwadi Onyeakpa, Lateef Onundi, “IMPORVEMENT ON THE DESIGN AND CONSTRUCTION OF
INTERLOCKING BLOCKS AND ITS MOULDING MACHINE”, volume 11 , issues 2 vear III (mar-
apr.2014)
3. Nasly M.A., A.A.M. Yassin et.al. , “COMPRESSED STABILISED EARTH AS LOAD BEARING
INTERLOCKING BLOCK”
4. R.K. Watile1, D.W. Gawatre2 et.al. , “PERFORMANCE OF FLY ASH INTERLOCKING BRICK/
BLOCKS” volume 4 issue 6, November- December 2013
5. Bansal Deepak “SUSTAINABLE DRY INTERLOCKING BLOCK MASONRY COSTUCTION” 15th
international brick and block masonry conference Brazil-2012
6. Abhinandan R. Gupta, Dr. S. k. Deshmukh et.al. “INTERLOCKING BRICK DESIGN PARADIGM FO
SUSTAINABLE CONSTRUSTION”, volume 3 issue I, January 2015.
7. R.K.Watile, H.C.Muley, et.al., “INTERLOCKING BRICK FOR SUSTIANABLE HOUSING
DEVELOPMENT” volume 2, no 2, may 2014
8. Amana ocholi, Manasseh Joel, “ EFFECT OF VARIATION IN TEMPATURE ON SOME
PROPERTIES OF CEMENT SATBILIZED LATERITIC INTERLOCKING BRICKS”, volume 4 no1
,January 2014, IJET
9. IS 2572-2005 CONSTRUCTION OF HOLLOW AND SOLID CONCRETE BLOCK MASONRY , code
of practice ( first revision) bureau of Indian standards

Department of Civil Engineering,BRCE 13