Technical

The Hydraform building system replaces the conventional brick and mortar by using Hydraform blocks. The other components of the conventional building system remain largely unchanged. Hydraform system is a largely dry stacked-Interlocking masonry system that enables speedier construction of high quality, aesthetic and affordable building. The Blocks have an extremely appealing face-brick finish and provide a pre-pointed straight masonry. The walls may be left exposed, plastered or finished with cement paint. These blocks are made using Hydraform Block making machine with an option to make at the site of construction itself. The interlocking construction is suitable for both Load bearing structures as well as framed structures – single or multistory.

In conventional construction, brick could be good but is mortar used is normally weak thus making the over all masonry weak. This is taken care by Hydraform blocks which virtually use NO MORTAR making masonry uniform and strong.

The user also has option to use mortar slurry within the blocks. These are solid blocks for all kind of wall applications. Blocks can be made with fly ash based combinations or soil based combinations to meet relvent technical requirements.

Dry interlocked masonry provides flexibility in application and technically superior for making earthquake resistant structures. For Earthquake resistant construction, blocks with Vertical & Horizontal cavities for reinforcements are also available.

These blocks have been successfully used in making earthqualke resistant houses / community centres in Gujarat in line with GSDMA guildelines and HUDCO.

EARTHQUAKE RESISTANT CONSTRUCTION

Hydraform interlocking block masonry can be effectively used in Earthquake resistant constructions incorporating necessary structural design and reinforcements – horizontal / vertical. HUDCO in consultations Dr. Arya, Seismic advisor to Gujarat State Disaster Management Authority arrived at suitable designs to use these blocks in Earthquake resistant houses and buildings in Gujarat. HUDCO & other NGOs implemented these projects Hydraform machine made compressed earth interlocking block masonry. Vertical & Horizontal reinforcements can be effectively done for Earthquake construction. We continue to improve Earthquake construction techniques using Hydraform Building Systems with its continuous research process to improve the construction standards to meet Earthquake construction requirements.

BLOCK MAKING

This involves following steps:


Loading the soil	Mixing, soil, cement and water

Loading the Hydraform machine	Carrying the block

Stacking and curing the blocks	Laying the blocks

INTERLOCKING BLOCK SPECIFICATION:

	HF 220 / 200 Conduit	HF150 / 115
Use	External walls / Fencing / Load bearing constructions	Interior / Partition Walls / Framed Constructions
Width	220 mm (9")	150 / 115mm (6/4.5")
Height	115 mm	115 mm
Length	120 mm to 240 mm	120 mm to 240 mm
Weight	9-11 Kg approx (Full block)	4.5-5.5 – 7 kg approx

By size, one HF220 is equivalent to three to three & half size of conventional fired bricks. Other sizes are also available.

Raw Material for making blocks:

The blocks can be made in Hydraform machine using Fly ash – Lime – Gypsum – Cement- Sand, Fal-G or other fly Ash based tested combination OR Soil-Cement (compressed Stabilized Earth Blocks) OR Stone Dust - Cement. We can provide mix design assistance in this respect. Other option with Hydraform machine is to make Blocks using as well.

Raw material Mix:

Different mix designs are possible depending upon the quality of raw material and strength required, please consult our technical team in this respect.

Fly ash Cement Block

Fly ash = upto 60%
Coarse sand = upto 70%
Stabilizer = 5% - 15% (including lime, cement, gypsum)

Stabilized Earth Block

Soil = upto 70%
Coarse sand = upto 30%
Cement = 5 - 10%

Note: It is important to check the soil composition for contents like: Clay, Silt, fine and coarse sand. Normaly sandy - loam soils are better suited however other soils can be worked upon to get the right mix and strength. Black cotton soils are not suitable.

Block Strength:

The block strength is determined by Soil / Fly Ash type, quantity of Cement used and other materials used and the extent of curing after manufacture of block.

We have obtained results as indicated below:

Soil - Cement Blocks		Fal-G - C. Sand
Cement Content	Strength	Cement Content	Strength
5%	4 to 5 MPa	5%	7 to 8 MPa
10%	7 to 8 MPa	10%	10 to 15 MPa

1 MPa is equal to 10 Kg / Sq. cm

It is important to note that the results may vary and a proper training and technical assistance is must before you start the production and random sampling is must.

Thermal Quality:

Depending on ratio of soil or fly ash in mix, it can be up to 2- 3 times better than conventional brick or concrete masonry.

Water Absorption:

Good quality blocks can be made from Hydraform machine to give:

For Fly Ash- Cement: Up to 15%.
For Stabilized Earth Block: Up to 12%.

Density

Density can vary with raw material used and its mix ratio. To suit respective application and technical parameters, blocks of different density can be made.

Fly Ash based Blocks can be made in range: 1500 to 1700 kg / cu.m

Stabilized Earth Blocks can be made in the range: +- 1950 kg / cu.m

Block Finish

Block finish is very good and compares even better than face brick finish. It provides option to keep the wall with or without plaster. In case of without plaster, the wall could be given a groove pointing / varnish / sili-coat or tereline coat.

Conduiting

Conduiting can be done using Conduit blocks.

Application

The blocks can be used in conjunction with or alternative to conventional masonry. Interlocking block masonry can be used with dry or with cement- sand slurry between the interlock to suit the structural design requirement.