Topic

Sustainable Building Materials Technology

Interlocking Blocks

Name: Chaula Trivedi

M.Arch ( Sustainable Architecture )
Sem I
2016-17

Bharati Vidyapeeth Deemed University

College of Architecture, Pune-43

INTERLOCKING BLOCK CONSTRUCTION TECHNOLOGY

1 INTRODUCTION
The dry stacked interlocking block masonry replaces the conventional brick and mortar
construction masonry by interlocking blocks masonry construction. The other components of
the conventional building system remain largely unchanged. The system is a dry stacked
Interlocking masonry but can be done with mortar/slurry/grout also that enables aesthetic and
affordable building, speedier construction of high quality in stretcher bond, and as well as in
the normal English/Flemish bond with mortar. The blocks have an extremely appealing
facebrick/wash finish and provide a pre-pointed straight masonry. The walls may be left
exposed, plastered/rendered or finished with cement wash. The system has originated during
the time of Egyptian pyramids construction and may be even before that period, and has
extensively been in use over different continents. A number of constructions have been made
using interlocking building system in India over last decades. The interlocking block
masonry system is not uniform in India, and as per information available with the author,
there are three types of interlocking blocks available (as per information available with
author) in India:
1. Hydraform Interlocking Blocks ( stabilized earth blocks(SEB) and fly ash blocks
2. 2. IIT Delhi, India, fly ash interlocking blocks
3. 3. IIT Madras, India, cement concrete interlocking blocks Out of all these interlocking
blocks, the author has the practical
Out of all these interlocking blocks, the author has the practical working experience only
with Hydra form interlocking blocks, and the same is explained in this paper. However
the same is generic and can be extended with other types of interlocking blocks also.
Stabilized earth blocks (SEB) are produced with local sandy loam type of soil with
cement or lime or gypsum as stabilizer and are pressed in a hydraulic press in a mould,
cured for 7 days and used as masonry blocks. The typical composition of SEB block
chosen is given in table no 2 and fly ash block is given in table no 3.The amount of
stabilization depends on the soil characteristics and strength desired, but generally varies
from 2-10% by weight.

INTERLOCKING BLOCK
TECHNOLOGY

Interlocking Profile The locking of a male

face of one block with the female face of
another or the locking of the bed of one
block with the ridge of the one below , is
called Interlock.
Bed and Ridge The recessed under
surface of the block is referred to as
the bed. The raised top surface of the
block is called the Ridge.

Corners Corner requirements are: Shaved blocks is prepared. It must be remembered to

shave off the ridge and male face of the corner block, as shown in Figure 4, and further
ensuring that the shaved ridge points upward and the shaved male face points outwards. One
must start the first course with a block. 2.6 Compatibility for Reinforcement for
Earthquake Resistant Construction The interlocking blocks can be easily reinforced (because
of the grooves) against the conventional masonry. All the relevant bands i.e. roof bands,
gable band, lintel band, cill band and plinth band etc. can be easily incorporated in the
masonry ( as per the requirements of the seismic design). Both vertical and horizontal
Reinforcement can be provided by means of the grooves. The sizes of the grooves can be
increased also. 2.7 Interlocking Masonry Features The interlocking blocks if made with fly
ash combination has following unique advantages over other comparable products: Density
of masonry can be reduced in the range of 13 17kN/cum against the conventional fired
brick system (19.20 kN/cum) in terms of unit weight. High finish blocks are made; result in
exposed finish aesthetic walls, saving on plaster/rendering & finishes. Blocks can be made
with lower water absorption properties making them useful for even relatively wet
applications.

INTERLOCKING BLOCK
TECHNOLOGY

 Dry-stacked masonry results in speedier construction.

Blocks can be made with reinforcement / conduit features facilitating earthquake resistant
construction.
Blocks made are eco friendly as no burning is involved
IThe Interlocking Building System
t comprises of three primary aspects:
(1) Interlocking Block
(2) (2) Block making Machine
(3) (3) Advantages of interlocked stacking of blocks
Interlocking Masonry System The interlocking dry stacked masonry comprises of SEB
(stabilized earth blocks) / fly-ash interlocking blocks that can be laid dry - stacked or using
minimal mortar slurry/grout in a stretcher bond. Dry stacking is mortar- less method of
masonry construction. Except first two block layers/courses above DPC( damp proof course
of 40mm thick plain cement concrete of M20 mix at plinth level) and top two courses
leading to roof band(if required ), blocks are not laid on mortar but can be laid with cement
slurry, they rely on the interlocking mechanism to provide resistance to applied loads. Dry
stacking results in reduction of building costs due to saving in construction time, reduced
requirement for skilled labour and costly material especially cement and reusability of the
blocks. The usage of unskilled labour makes dry stacking particularly attractive when
compared with masonry with use of mortar. With an extremely appealing face-brick finish
that provides for pre-pointed straight masonry, these blocks gives flexibility of achieving the
final finish. The masonry uses minimal or no mortar, construction is fast, blocks are
produced on the site saving transportation cost, requirement of skilled labour is reduced,
blocks are water cured and do not require burning of fuel, wall face surfaces are even,
plastering/rendering is not required but can be done as an option, the thickness of the
masonry can be controlled giving more carpet area by using less cubic contents of the blocks,
are advantages of using this masonry.

Bonding -Steel Bars & Conduits

INTERLOCKING BLOCK
TECHNOLOGY

Construction Procedure
A dry stacked interlocking masonry is laid on conventional strip footing. Foundation walls
are built with blocks of higher strength laid in mortar bed or even conventional type
foundation. Hudco (Housing & Urban Development Corporation, a government of India
undertaking) has done a large number of construction using Hydra form Interlocking and
other type of SEB (Soil stabilized Blocks), throughout India (Gujarat Earthquake
Rehabilitation Works, Vivekananda Kendra, Kanyakumari, Development works around
Qutub Minar Delhi and many more places and found these blocks suitable for masonry.
However in all these places, cement slurry/grout was used to join these blocks, as per IS
1905, as Indian Design Standards do not recognizes the Interlocking block based masonry,
concept yet. Different conventional finishes can be applied to suit the aesthetic needs of the
owner.
Load Bearing Masonry Since blocks are 220 mm width and can be made of block strength
> 75 MPa, same can be safely used for load bearing construction. Depending on structural
requirements of the building, appropriate RCC bands can be used. Extensive tests have been
conducted from time to time for conformity of dry stacked masonry in G+2 storey building.
Fly Ash based interlocking blocks can be made of higher compressive strength to suit the
load bearing construction requirements beyond ground floor to suit structural requirements.
In terms of IS 1905, masonry can be done with thin mortar slurry of 1:3 to satisfy this
requirement.
Framed Structure Masonry Framed construction mainly require brick / block work to be
used as an infill only, therefore dry stacked interlocking block work can be used in out walls
of 220/230 mm thickness. For block work of lesser width it is recommended to use cement
mortar slurry/grout. Blocks have standard height of 115 mm, makes it easier to design the
beam height for required number of courses.
Reinforced Masonry Interlocking blocks with horizontal and vertical cavity provide and
ideal solution for using reinforcements to suit the structural design requirements, of
reinforced masonry.

INTERLOCKING BLOCK
TECHNOLOGY

INTERLOCKING BLOCK
TECHNOLOGY

Interlocking blocks
2 Types of Bricks
(based on Raw Materials)
Soil-Cement
Concrete

4 Types of Bricks (by size)

Regular -15 cm x 30 cm x 10 cm
Half -15 cm x 15 cm x 10 cm
U-shape -15 cm x 30 cm x 10 cm
U-half-15 cm x 15 cm x 10 cm

Construction with Interlocking

Bricks
Load bearing construction system
No need for mortar between 2 layers of
bricks
Reduces reinforcements as it eliminates
concrete lintels, beams and columns
Cement based and Reinforced wall resists
fire, wind and earthquakes
Modular -No material wastage
Simple construction with little training
unskilled labor can be used to build the
buildings
Cost-effective construction system
Can be use as composite structure

INTERLOCKING BLOCK
TECHNOLOGY

Production of Soil-Cement Interlocking Bricks

Selection of raw materials
Preparation of Mixes
Filling mould box with mixes
Compression
Removal of brick and placing it on a pallet
Air curing / storage
Water curing
Testing

INTERLOCKING
BLOCKTECHNOLOGY

Why Interlocking bricks?

Can be produced at or near the site reduced
transportation cost
Green technology Zero carbon emission
Energy Efficient
Uses local available materials
Reduces the need for skilled labor
Maximize the use of unskilled labor
Faster to build shortens construction time
Creates local employment
Permits self-help construction or community
based projects
Can be used to build all types of buildings

Is it Expensive?
Construction cost can be reduced as much as 50% in comparison with conventional
system depending upon the local price.
Initial cost for the equipments and trainings might seem big amount, but once it is in place,
it will show that it is much cost effective than traditional technologies.
Thailand -20% to 40%
Bhutan -40% to 50%
Nepal-13% to 30%
INTERLOCKING BLOCK
TECHNOLOGY

Community Projects
KhaoKhoResettlement Project, PhetchabunProvince, Thailand

Location:-PhetchabunProvince, Thailand
Total no. of houses: -150 units
Floor area: -32 sq.m. x 2 storey = 64 sq.m.
Area of the Plot: -400 sq.m.
Construction cost: -approximately US$ 20 / sq.m. (500 Baht/sq.m.)
Total construction cost: -approximately US$ 1,300 (excluding labor cost)

INTERLOCKING BLOCK
TECHNOLOGY

A concrete layer locks in the rebar beam,

which is now covered and not visible,
and the vertical rebar pictured.

Tie in corners, windows, doors

and inner walls.

In low-seismic areas, dry-stacking the blocks without

mortar is possible, but on this build in El Salvador,
the rows of blocks sandwich a slurry made of the
same dirt, sand and cement mixture of which the
blocks are made. Every fifth row is mortared with
cement.

Novice block layers can quickly learn to build

straight, level walls.
INTERLOCKING BLOCK
TECHNOLOGY

Insertion of the electric box in the walls

Finished house

INTERLOCKING BLOCK CONSTRUCTION TECHNOLOGY

DEVELOPED BY AUROVILLE
A technology using reinforced hollow concrete block has been developed all over the
world since a while. Its principle is to reinforce the masonry by grouting a concrete
into the holes of the blocks where stands a steel rod at the critical locations (Corners,
ends, near openings, etc,). Horizontal reinforcements are also cast in blocks with a U
shape.
The technology using Hollow Interlocking Compressed Stabilised Earth Blocks (HI
CSEB) is based on the same principle: to reinforce horizontally and vertically the masonry
with Reinforce Cement Concrete (RCC) members.
The advantage of hollow interlocking CSEB, compared to hollow concrete blocks, is
that they offer keys, which interlock in the other blocks. Thus these walls offer more
resistance to shear and buildings would be even stronger. They would better resist
earthquakes and without major damages.
Compressed stabilised earth blocks have another advantage: they are in most cases
cheaper and they are always more eco-friendly than concrete blocks.
Compressed stabilised earth blocks have a poor bending strength but this is not so critical
because the block itself will not bend but the masonry will do. CSEB have very poor shear
strength, which is critical in the
case of earthquakes. Interlocking blocks will not have a stronger shear strength compared
to ordinary CSEB. But the key effect will increase the shear strength of the masonry if the
cohesiveness of the material is
high enough to keep the link between the key and the body of the block. (Especially
shocks and vibrations of an earthquake)
INTERLOCKING BLOCK
TECHNOLOGY

Particular requirements for hollow interlocking blocks

Interlocking blocks can resist disasters (Cyclones, earthquakes, tsunamis and floods),
provided that they are hollow, so as to be reinforced with Reinforced Cement Concrete
(RCC), at regular intervals. A hollow interlocking CSEB for earthquake resistance must
satisfy these requirements:
Extreme consistency in height (1 mm difference maximum is allowed).
Self-aligning to reduce time-wasting adjustments.
Blocks should be hollow and the vertical holes and U shaped blocks should allow casting
RCC, according to requirements: To reinforce regularly the masonry vertically and
horizontally.
The interlocking keys must interlock transversally and longitudinally to the wall. They
should interlock especially well in the length of the wall, which is subject to the shear
stress of the earthquake.
Every course must interlock with each other as well as the header of every block in
length: to increase the shear strength of the masonry.
Good seating of the blocks on top of each other for properly transmitting the load bearing:
All the block area, including the key, must transmit the load.
The binder should be a cement-soil-sand (1: 1: 3) mortar of 5 mm thick. It should be quite
fluid in order to be workable.
The mould must allow manufacturing full size blocks and 3/4 and 1/2 sizes. The blocks
must not be cut to match the bond pattern, which will be detrimental to the accuracy,
strength and quality of the masonry.

Hollow Interlocking
block 245 (245 x 245 x
95 mm) Running
block

Hollow Interlocking block

295 (295 x 145 x 95 mm)
Running block

Hollow Interlocking block

D300 (299 x 150 x 100 mm)
Running block

This block 245 can be used up to two storey

buildings. The block is laid with a stabilised earth
mortar of 5 mm. A concrete grout is cast later on into
the holes. The module of the block (dimension
including the mortar thickness) is 25 x 25 x 10 cm.

INTERLOCKING BLOCK
TECHNOLOGY

This block 295 can be used for single

storey buildings only. The block is laid
with a stabilised earth mortar of 5 mm. A
concrete grout is cast later on into the
holes. The module of the block
(dimension including the mortar
thickness) is 30 x 15 x 10 cm.
This block D 300 can be used for single
storey buildings only. This block is dry
stacked and a concrete grout is cast later
into the holes. This grout flows in all the
holes as well as the vertical and horizontal
joints due to the special profile of the
block. The module of the block (dimension
including the mortar thickness) is 30 x 15
x 10 cm
The accuracy of the Auram press allows a very regular block height: only 0.5 mm
difference in height. This allows the block to get the ideal mortar thickness of 5 mm or to
have dry stacked blocks which are then grouted with a concrete. The holes have been
maximized (regarding the size of the block and the press design) at 5 cm diameter to allow
a proper concrete cover for the steel.
The area of the key has been maximized at 9 cm diameter for the blocks 245 and 295, so
as to ensure the maximum adhesiveness of the key on to the block body, so as to resist the
shear effect. The height of the key has been determined by having the maximum friction
area between blocks to resist the shear and by having the minimum friction on the mould
while de-moulding the block from the press. The chamfer angle of the key seeks to be
optimum. The keys of the hollow interlocking block Dry 300 are square so as to get an
effective interlocking.
The hollow interlocking block technology developed by the Auroville Earth Institute
has been approved by three governments
The government of Gujarat, India, as a suitable construction method, up to two floors high,
for the rehabilitation of the zones affected by the severe earthquake of January 2001 in Kutch
district.
The Government of Iran (Housing Research Centre) as a suitable construction method, up
to 8 m high (two floors), for the rehabilitation of the zones affected by the 2003 earthquake
of Bam.
The Government of Tamil Nadu, India, (Relief and Rehabilitation) as a suitable
construction method for the rehabilitation of the zones affected by the 2004 tsunami of
Indonesia.

INTERLOCKING BLOCK
TECHNOLOGY

Bibliography
15th International Brick and Block Masonry Conference Florianpolis Brazil 2012
Sustainable Dry Interlocking Block Masonry Construction.
Interlocking Soil Soil-Cement Brick Technology Habitech Centera Research and
Development unita unit for thefor theHousing and Building Housing Components.
Interlocking Block Construction Technology developed by Auroville.

INTERLOCKING BLOCK
TECHNOLOGY