HCB Manual gtz 2008.doc
- 1. Hollow Concrete Block Production & Quality Management Guidelines Prepared by Michael Geschke UCBP PM/QM Expert
- 2. Content 1. Introduction a Load bearing walls b Non load bearing walls 2. Classesof HollowConcreteBocks a Standard Dimensions b Special slab construction block c Dimensions used at UCBP 3. The HCB productionyard 4. The Productionof HollowConcrete Blocks a Aggregates b Water c Cement d Machinery & Equipment e Production process 5. Curing and Storage Guidlines 6. Operational Staff and Supervision 7. Stockpiling 8. Keeping records and Reporting
- 3. 1. Introduction Hollow Concrete Blocks ( HBC ) are blocks manufactured from concrete and processed into moulds, to achieve the required physical strength and dimensions to requirements and standards. HBC are produced, to construct: a Load bearing walls ( Class A & B ) b Non load bearing walls ( Class C ) A masonary may be constructed mainly with the following units: 1. Hollow Concrete Blocks 2. Dressed ( natural) stones 3. ( Burnt ) clay bricks While comparing with others, HCB masonery is a cost and time efficient and economical solution in construction.
- 4. 2. Classesof HollowConcreteBlocks Load bearing HCB ClassA and B Non load bearing HCB Class C a) StandardDimensionsto ESC.DC.301 10 cm x 20 cm x 40 cm 15 cm x 20 cm x 40 cm 20 cm x 20 cm x 40 cm
- 5. b) For the UCBP the HCB differ from the ESC. At the UCBP the followingHCB will be used: 10 cm x 20 cm x 41 cm 20 cm x 20 cm x 41 cm 20 cm x 22 cm x 54 cm ripped slab block
- 6. 3. The HCB Productionyard The HCB production area must be even and smooth and should ideal have a power floated surface. All facilities for production i.e. Aggregate storage places Mixing plant Material storages HCB storage places should be as close as possible to the production area. Attached is a typically layout of a HCB Prefab plant and an engeneers drwg of a HCB production ground floor.
- 9. 4. The productionof Hollow ConcreteBlocks a Aggregates, i.e. Sand, Gravel, Red Ash: should be clean, stored separatly close to the mixing plant All aggregates used for production have to be approved by an independant concrete labatory! b Water: mustbe clean and free of unpurifications c Cement: Portland Cement ( OPC ) shall be used as a binder material for the motar mix. Cement should be stored in a dry place, moisture free. d Machinery & Equipment: Must be in perfect condition and sufficient in numbers to suit the daily production needs. Regular cleaning, maintainence of all machinery & equipment is essential to keep the agreed quality standards. An adequate stock of spare parts for all machninery has to be kept, in order to safe guard production. e Production: Before production can commence, all materials have to be approved by an official concrete lab. The mixing and batching will be strictly done on the mix ratio provided by the official concrete lab. The mixing ( best results are with a compulsorymixer ) should be done thouroughly, until a uniform consistence of the mortar is achieved. The ready motar mix is poured into the vibrating mould of the block making machine. Duration of compaction depends on the type of machine and vibrator used, but is approx. 3 seconds. after compaction the unset ( green ) HCB is dropped on the Floor for curing.
- 11. 5. Curing Guidlines Curing is one of the most important activities in the production process. The purpose of curing is to replace the evaporating water through sun and / or air. Also the hydration process, a chemical reaction, needs water to set / harden the mortar. Once the HCB`s aredropped on the floor, they must be protected from sun and kept constantly moist. The day after production the HCB are removed from the production floor,placed in two layers on pallets and are again watered till saturation. The pallets are then covered with waterproof sheets, watered, cured until the seventh day, at least once a day. After that, put the blocks in five layers on the designated storage place and apply water twice a day. 6. Operational Staff andSupervision In order to achive the best possible quality a specific group of workers should be trained on: - batching - mixing - pouring into the mould - operating the block making machine - transporting the blocks - curing and stocking If the need of HCB prodution requires shift works, then the precast yard has to belayed out accordantly.
- 12. Supervision / Quality control will be carried out by the GC, the concrete lab., the Resident engeneer and the site manager of the implementing agency. 7. Stockpiling The GC has to take care that he has always a sufficient stockpile of cement, aggregates and HBC`s on site to buffer delivery problems and to safeguard production on site. 8. Keeping Records and Reporting Every daily HCB production has to be marked with the production date, in order to avoid errors in storage/curing time. The amount of daily production has to be in accordance with the building schedule. The resident engeneer will, on a daily base, record the blocks produced and the quality achieved. The official concrete lab. will on a monthly base take samples of blocks and aggregates and check those samples in their lab. Results are to be reported to the resident engeneer and to the site manager of the implementing agency. The site manager will report on a weekly/monthly turn to the main office of the implementing agency and to the client the progress and the quality of production, based on the resident engeneers reports and own supervision.
- 13. 6.0 Production site of HCB and Pre-cast Beam. DESCRIPTION Unit ITEM TOTAL Unit TOTAL PREVIOUS MONTH THIS MONTH TODATE NO QTY. price AMOUNT PLAN EXEC. PLANNED EXECUTED %com TOT.PLAN TOT.EXEC %com %COM. To date plan (BIRR) (BIRR) (BIRR) Qty Amount Qty Amount f .plan Qty Amount Qty Amount f .plan f .tot %of plan f rom tot. 1 HCB production HCB conv entional ty pe 40x20x20 pcs 823519 3.64 2997609 2997617 1373544 - - 4381 15947 - 823521 2997617 381728 1389491 46.4 46.4 100 40x20x15 pcs 464674 3.00 1394022 1394022 410100 - - - - - 464674 1394022 136700 410100 29.4 29.4 100 40x20x10 pcs 185052 2.14 396011 396011 109898 - - 750 1605.00 - 185052 396011 52104 111503 28.2 28.2 100 Slab HCB (ribbed block) pcs 290820 3.77 1096391 1096391 420400 - - 1420 5353.40 - 290820 1096391 112932 425753 38.8 38.8 100 u-block 95655 1.70 162614 162617 120356 - - - - - 95657 162617 70798 120356 74.0 74.0 100 16x32 block 82523 2.00 165046 165048 32960 - - - - - 82524 165048 16480 32960 20.0 20.0 100 Sub-total 6211693 6211706 2467258 0 22905 0.0 1942248 6211706 770742 2490163 40.1 40.1 2 **Pre-cast beam** 900x120x60mm pcs 210 38.70 8127 8127 9482 - - 25 967.50 - 210 8127 270 10450 128.6 128.6 100 1500x120x60mm > 896 63.90 57254 57254 47797 - - 51 3258.9 - 896 57254 799 51056 89.2 89.2 100 3450x120x60mm > 1260 146.70 184842 184842 188363 - - 177 25965.9 - 1260 184842 1461 214329 116.0 116.0 100 3960x120x60mm > 5572 167.50 933310 933310 696130 - - 878 147065.0 - 5572 933310 5034 843195 90.3 90.3 100 4960x120x80mm > 3438 210.60 724043 724043 506282 - - 190 40014.0 - 3438 724043 2594 546296 75.5 75.5 100 4960x140x80mm > 288 210.60 60653 60653 52860 - - 37 7792.2 - 288 60653 288 60652 100.0 100.0 100 5000x120x80mm > 1224 211.50 258876 258876 191197 - - 174 36801.0 - 1224 258876 1078 227998 88.1 88.1 100 5000x140x80mm > 144 211.50 30456 30456 30456 - - - - - 144 30456 144 30456 100.0 100.0 100 sub-total 13032 2257561 2257561 1722567 0.0 1532 261864.50 0.0 13032 2257561 11668 1984432 87.9 87.9 Grand total 8469254 4515122 4189825 0.0 284769.74 0.0 8469267 4474595 52.8 52.8 Remark: Key problems: Intermittent f ailure of production machines, inef f iciency in coordinating man power and shortage of dia. 6 re.bar.
- 15. 7.0 QUALITY CONTROL TEST CONDUCTED DURING THE MONTH No Type of material Tests expected Date of test Accepted/Not accepted Ordered Sand 2 Coarse aggregate 3 Selected material 4 Concrete work Trial mix Specimen form Foundation footing Foundation column Elevation column Beam Mat beam Grade beam Floor beams Top tie beams Slab Ground slab Suspended slabs 5 Hollow blocks HCB 40x20x20cm U - shape blocks Ribbed slab block 6 Reinforcement bar Deformed bar Deformed steel Wild Steel 7 Pre-cast beam 8 Others Metal doors March 31, 2006 Accepted with remarks