PAVERS BLOCK AND BRICKS MANUFACTURING PLANT

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Interlocking Concrete Block Pavement (ICBP) has been extensively used in a number of countries for quite some time as a specialized problem-solving technique for providing pavement in areas where conventional types of construction are less durable due to many operational and environmental constraints. ICBP technology has been introduced in India in construction, a decade ago, for specific requirement viz. footpaths, parking areas etc. but now being adopted extensively in different uses where the conventional construction of pavement using hot bituminous mix or cement concrete technology is not feasible or desirable. The paper dwells upon material, construction and laying of concrete block pavement as a new approach in construction of pavement using Interlocking Concrete Paver Blocks.

Concrete paver blocks were first introduced in Holland in the fifties as replacement of paver bricks which had become scarce due to the post-war building construction boom. These blocks were rectangular in shape and had more or less the same size as the bricks. During the past five decades, the block shape has steadily evolved from non-interlocking to partially interlocking to fully interlocking to multiply interlocking shapes. Consequently, the pavements in which non-interlocking blocks are used are designated as Concrete Block Pavement (CBP) or non-interlocking CBP, and those in which partially, fully or multiply interlocking blocks are used are designated as ‘Interlocking Concrete Block Pavement (ICBP).

CBP/ICBP consists of a surface layer of small-element, solid un-reinforced pre-cast concrete paver blocks laid on a thin, compacted bedding material which is constructed over a properly profiled base course and is bounded by edge restraints/kerb stones. The block joints are filled using suitable fine material. A properly designed and constructed CBP/ICBP gives excellent performance when applied at locations where conventional systems have lower service life due to a number of geological, traffic, environmental and operational constraints [1-8]. Many number of such applications for light, medium, heavy and very heavy traffic conditions are currently in practice around the world.

Advantages and Limitations

There are many distinct features of ICBP as compared to the conventional methods of pavement construction and hence make it a suitable option for application in the specified areas [7 & 10]. Some of these are:

• Mass production under factory conditions ensures availability of blocks having consistent quality and high dimensional accuracy.

• Good quality of blocks ensures durability of pavements, when constructed to specifications.

• ICBP tolerates higher deflections without structural failure and will not be affected by thermal expansion or contraction.

• ICBP does not require curing, and so can be opened for traffic immediately after construction.

• Construction of ICBP is labor intensive and requires less sophisticated equipment.

• The system provides ready access to underground utilities without damage to pavement.

• Maintenance of ICBP is easy and simple and it is not affected by fuel and oil spillage.

• Use of coloured blocks facilitates permanent traffic markings.

• ICBP is resistant to punching loads and horizontal shear forces caused by maneuvering of heavy vehicles

• Low maintenance cost and a high salvage value ensures low life cycle cost.

However, important limitations of the technique are the following:

• Quality control of blocks at the factory premises is a prerequisite for durable “ICBP”

• Any deviations of base course profile will be reflected on the “ICBP” surface. Hence extra care needs to be taken to fix the same.

• High quality and gradation of coarse bedding sand and joint filling material are essential for good performance.

• “ICBP” over unbound granular base course is susceptible to the adverse effects of poor drainage and will deteriorate faster. “ICBP” is not suited for high speed roads (speed above 60 km/h)

Physical Requirements

Since zero slump concrete is used in production of paver blocks, the quality of blocks produced will depend upon various parameters like the capacity of compaction and vibration of machine, grade of cement used, water content, quality of aggregates used, their gradation and mix design adopted, additives used, handling equipment employed, curing method adopted, level of supervision, workmanship and quality control achieved, etc. Recommended grades of paver blocks to be used for construction of pavements having different traffic categories are given in Table 1.

Application of ICBP Technology

Some of the proven areas where ICBP technology is being applied are listed below:

Non-traffic Areas: Building Premises, Footpaths, Malls, Pedestrian Plaza, Landscapes, Monuments Premises, Premises, Public Gardens/Parks, Shopping Complexes, Bus Terminus Parking areas and Railway Platform, etc.

Light Traffic: Car Parks, Office Driveway, Housing Colony Roads, Office/Commercial Complexes, Rural Roads, Residential Colony Roads, Farm Houses, etc.

Medium Traffic: Boulevard, City Streets, Small Market Roads, Intersections/Rotaries on Low Volume Roads, Utility Cuts on Arteries, Service Stations, etc.

Heavy and Very Heavy Traffic: Container/Bus Terminals, Ports/Dock Yards, Mining Areas, Roads in Industrial Complexes, Heavy-Duty Roads on Expansive Soils, Bulk Cargo Handling Areas, Factory Floors and Pavements, Airport Pavement, etc.

Shapes and Classifications

There are four generic shapes of paver blocks corresponding to the four types of blocks as below:

Type A: Paver blocks with plain vertical faces, which do not key into each other when paved in any pattern,

Type B: Paver blocks with alternating plain and curved/corrugated vertical faces, which key into each other along the curve/corrugated faces, when paved in any pattern,

Type C: Paver blocks having all faces curved or corrugated, which key into each other along all the vertical faces when paved in any pattern and

Type D: ‘L’ and ‘X’ shaped paver blocks which have all faces curved or corrugated and which key into each other along all the vertical faces when paved in any pattern.

The generic shapes and groups of paver blocks identified to four types are illustrated in Figures 1 & 2.

Materials

The quality of materials, cement concrete strength, durability and dimensional tolerance of paving blocks, etc. is of great importance for the satisfactory performance of block pavements. These aspects and the block manufacturing process itself, which immensely affect the quality of paving blocks, have been outlined in the Indian Roads Congress Special Publications. The Central Road Research Institute (CRRI) has prepared the specifications for ICBP.

Paving Blocks

The quality of materials, strength of cement concrete and durability as well as dimensional tolerances etc. are of great importance for satisfactory performance of block pavement. The recommended thickness of block and grades of concrete for various applications and specification for paving in which materials used for preparation of blocks, physical requirements, physical test methods, sampling and acceptance criteria has already been formulated in BIS Code.

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Description

INTRODUCTION
ADVANTAGES AND LIMITATIONS
HOWEVER, IMPORTANT LIMITATIONS OF THE TECHNIQUE ARE THE FOLLOWING:
PHYSICAL REQUIREMENTS
APPLICATION OF ICBP TECHNOLOGY
SHAPES AND CLASSIFICATIONS
MATERIALS
PAVING BLOCKS
BEDDING AND JOINT FILLING SAND
BASE AND SUB BASE MATERIALS
CONSTRUCTION OF INTERLOCKING CONCRETE BLOCK PAVEMENT
SEQUENCING OF OPERATIONS
PAVEMENT TYPES
PAVER PROPERTIES
PAVER DIMENSIONS
PAVING STRENGTH
MINIMUM BREAKING LOAD
COMPRESSIVE STRENGTH OF PAVERS
DURABILITY
SLIP RESISTANCE
ABRASION RESISTANCE
MOISTURE EXPANSION
EFFLORESCENCE
PITTING DUE TO LIME
COLD WATER ABSORPTION
ADVANTAGES AND LIMITATION OF PAVERS BLOCKS
THE MORTAR USED IN PRODUCING PAVING BLOCKS
SHAPES AND APPLICATION OF PAVERS BLOCKS
APPLICATIONS OF CONCRETE PAVING BLOCKS
1. NON-TRAFFIC AREAS:
2. LIGHT TRAFFIC AREAS:
3. MEDIUM TRAFFIC AREAS:
4. HEAVY TRAFFIC AREAS:
RAW MATERIALS FOR CONCRETE PAVER
DETAILS AND COMPARISON OF PAVER BLOCKS
PAVER BLOCKS
COMPARISON OF PAVERS TO IPS
B.I.S. SPECIFICATION
SPECIFICATION OF PRECAST CONCRETE BLOCKS FOR PAVING
1 SCOPE
2 REFERENCES
3 TERMINOLOGY
FIG. 1 EXAMPLES OF ARRIS (BEVELLED, ROUNDED, CHAMFERED) CHASED SIDE FACE AND DRAW
4 MATERIALS
5 GRADE DESIGNATIONS OF PAVER BLOCKS AND DESIGN OF CONCRETE BLOCK PAVEMENT
TABLE 1: RECOMMENDED GRADES OF PAVER BLOCKS FOR DIFFERENTTRAFFIC CATEGORIES (CLAUSES 5 AND 9.1.4)
6 PHYSICAL REQUIREMENTS
TABLE 2: RECOMMENDED DIMENSIONS AND TOLERANCE FOR PAVER BLOCKS (CLAUSES 6.2.2.1, 6.2.2.2, 6.2.3 AND 9.1.2)
TABLE 3: COMPRESSIVE STRENGTH REQUIREMENTS OF CONCRETE PAVER BLOCKS (CLAUSES 6.2.5.2 AND 9.L.4)
7 TEST METHODS
8 SAMPLING
TABLE 4: SAMPLING REQUIREMENTS (CLAUSE 8.5)
9 ACCEPTANCE CRITERIA
10 MARKING
OVERVIEW OF CONSTRUCTION INDUSTRY IN INDIA
1. HIGH BUDGETARY ALLOCATION FOR INFRASTRUCTURE
2. INCREASING PRIVATE SECTOR INVOLVEMENT
3. IMPROVEMENT IN LOGISTICS
4. RISING FOREIGN DIRECT INVESTMENT (FDI) IN THE SECTOR
ADVANTAGE INDIA
1. ROBUST DEMAND
2. ATTRACTIVE OPPORTUNITIES
3. POLICY SUPPORT
4. INCREASING INVESTMENT
PERFORMANCE OF EIGHT CORE INFRASTRUCTURE INDUSTRIES
GROWTH IN INFRASTRUCTURE RELATED ACTIVITIES
STRONG MOMENTUM IN EXPANSION OF ROADWAYS
STRONG REVENUE GROWTH FOR INDIAN RAILWAYS
POWER GENERATION CAPACITY HAS INCREASED AT A HEALTHY PACE
THE NATIONAL INFRASTRUCTURE PIPELINE (NIP)
GOVERNMENT INITIATIVES
CONCLUSION
MARKET OVERVIEW OF PAVER BLOCKS
PRODUCT MARKETING
SECTOR & INDUSTRY ANALYSIS
SECTOR CHARACTERISTICS AND OVERVIEW
UNORGANIZED SECTOR – MACHINE BLOCKS
UNORGANIZED SECTOR – HAND MADE BLOCKS
ENVIIRONMENTAL & PROTECTION ASPECTS
MARKET INFORMATION
MARKET POTENTIAL
EXPORTS AND IMPORTS OF PREFAB CONSTRUCTION BLOCKS
TECHNICAL DETAILS FOR PAVERS BLOCKS
DESIGN MIX CONCRETE:
PAVER BLOCK MAKING MACHINE:
WEIGH BATCHING & MIXING EQUIPMENT:
CURING:
LABORATORY
RAW MATERIALS
CEMENT
AGGREGATES
WATER
OTHER MATERIALS
PAVERS BLOCK CHARACTERISTICS
PAVER BLOCK DIMENSIONS
TESTING OF PAVER BLOCKS
FOR 80MM PAVER TILES
FOR 60MM GRASS PAVER TILES
LAYING OF PAVER BLOCKS
PRIMING
BEDDING SAND COURSE
LAYING OF INTERLOCKING PAVER BLOCK:
INITIAL COMPACTION
JOINT FILLING AND FINAL COMPACTION
EDGE RESTRAINT USING KERB BLOCK
UNIFORM INTERLOCKING SPACES
SKILLED LABOUR
LAYING PATTERN:
TECHNICAL SPECIFICATION AND GRADE OF PAVER BLOCKS
TECHNICAL SPECIFICATIONS OF PAVERS
PRODUCT-WISH WEIGHTS AND DIMENSIONS
PRODUCT DIMENSIONS AND WEIGHT
RECOMMENDED GRADES OF PAVERS BLOCKS FOR DIFFERENTTRAFFIC CATEGORIES AS IS 15658-2006
COMPRESSIVE STRENGTH REQUIREMENTS OF CONCRETE PAVER BLOCKS
CORRECTION FACTORS FOR THICKNESS AND ARRIS/CHAMFER OF PAVER BOCK FOR CALCULATION OF COMPRESSIVE STRENGTH
DESIGN OF PAVNG BLOCK
DESCRIPTION OF LAYERS AND BASIC ENGINEERING DESIGN REQUIREMENTS
SUBGRADE
BASE COURSE
TYPICAL GRADING FOR BASE COURSE MATERIALS
BEDDING COURSE
TYPICAL GRADING FOR BEDDING COURSE MATERIALS
SURFACE COURSE
RECOMMENDED SPECIFICATIONS FOR CLAY PAVERS
EDGE RESTRAINTS
DRAINAGE
PAVER LAYING PATTERNS
JOINTS BETWEEN PAVERS
TYPICAL GRADING FOR JOINTING SANDS
TOLERANCE ON COURSE LEVELS
CROSSFALLS
STEEP GRADIENTS
MANUFACTURING PROCESS OF PAVERS BLOCKS
WET CAST TECHNIQUE
HYDRAULICALLY PRESSED TECHNIQUE
RAW MATERIAL REQUIRED FOR THE MAKING OF PAVER BLOCKS
MANUFACTURING PROCESS OF CONCRETE PAVERS
WET CAST TECHNIQUE
HYDRAULICALLY PRESSED TECHNIQUE
PROCESSING DETAILS OF PAVERS BLOCKS
MANUFACTURING PROCESS OF FLY ASH BRICKS
TECHNICAL SPECIFICATION:-
1. COMPRESSIVE STRENGTH
2. DRYING SHRINKAGE
3. WATER ABSORPTION
4. EFFLORESCENCE TEST
FORMULATION OF PAVERS BLOCKS
QUALITY CONTROL AND STANDARDS
A) INDIAN STANDARD SPECIFICATION
B) QUALITY REQUIREMENTS
PROS AND CONS OF WET CAST AND HYDRAULIC PRESS TECHNIQUES
WET CAST PRODUCTION
IMAGE COURTESY OF ARMCON LTD.
OTHER WET CAST LANDSCAPE PRODUCTS
MULTI-TONED TRAVERTINE EFFECT FLAG FROM BRADSTONE
WET-CAST CHANCERY WALLING FROM MARSHALLS
WET-CAST SLEEPER-EFFECT PAVING FROM ATLAS/BRETT
HYDRAULIC PRESS PRODUCTION
PIMPLE TEXTURE
SIMPLIFIED MANUFACTURING PROCESS
CURING AND PACKING
REKERS CONCRETE BLOCK MACHINE
PRESS AND MOULD FROM CHANDLA INDUSTRIES
HOMOGENOUS AND FACE MIX PRODUCTS:
TYPICAL “THROUGH-COLOUR “BRITISH BLOCK
FACE-MIX BLOCK
PAVING TEXTURES
BARFACE PAVING IN RED
DIAMOND PATTERN CLAY PAVERS
HOBNAIL PAVING
RIVEN SANDSTONE FLAGS – INDIAN IMPORTS
RIVEN-EFFECT CONCRETE FLAGS FROM WESTMINSTER STONE
RIVEN-EFFECT CLAY PAVERS FROM BAGGERIDGE
NATURAL TEXTURES:
SAWN YORKSTONE FLAGS
HEAVILY RIVEN STONE FLAGS
CROPPED GRANITE SETTS
STANDARD TEXTURES:
CONCRETE
CHAMFERED EDGE AND SPACER LUGS MOULD-FORMED ON SMALL ELEMENT PAVER
VARIOUS SHAPES AND DECORATIVE SURFACE TEXTURE ON MOULDED CONCRETE BLOCK
BULL-NOSE AND HALF-BATTERED PROFILE TO MOULDED CONCRETE ROAD KERB
CLAY:
HANDMADE CLAY PAVERS
MOULDED STAR-PATTERN CLAY PAVERS
WIRECUT MIXED-SIZE CLAY PAVERS
SECONDARY PROCESSES:
TUMBLED-TYPE PAVERS
HEAVILY TEXTURED PAVERS
SECONDARY PROCESSES:
TUMBLING
TYPICAL TUMBLED CONCRETE PAVER
LAID IN COURSES, THE EFFECT IS A ‘TRADITIONAL’ LOOK
NEWLY-LAID DIRTY TUMBLED PAVERS
SHOT BLASTING:
SHOT-TEXTURED FLAG (MARSHALLS’ SAXON)
SHOT-TEXTURED KERB (MARSHALLS’ CONSERVATION)
SHOT-TEXTURED FLAGS IN 3 COLOURS
SHOT-TEXTURED BLOCK PAVER
DISTRESSED MEDITERRANEAN RUSTIC PAVERS FROM STONE & STYLE
TUMBLED CHINESE GRANITE ON MESH BACKING
TUMBLED RED GRANITE SETTS
TUMBLED YORKSTONE SETTS
BUSH HAMMERING:
BUSH-HAMMERED GRANITE
BUSH-HAMMERED CONCRETE
BUSH-HAMMERED DECO FLAG
BUSH-HAMMERED “CORNISH” BLOCK PAVERS FROM FORMPAVE
BUSH-HAMMERED CONCRETE PAVERS LAID TO FOOTPATH
POLISHING:
MILANO GROUND/POLISHED PAVING FROM ACHESON-GLOVER
VERONA GROUND/POLISHED PAVING
“PERFECTA” HEXAGONAL GROUND PAVING FROM MARSHALLS
POLISHED GRANITE FLAGS 450X450MM
POLISHED GRANITE BLOCKS 200X100MM
WASH-TO-EXPOSE:
SPECIFICATIONS FOR ORDINARY CONCRETE
FINE AGGREGATES
COARSE AGGREGATES
PRESCRIBED MIXES FOR ORDINARY STRUCTURAL CONCRETE
FREE WATER: CEMENT RATIO
PROCESS FLOW DIAGRAM
PROCESS OUTLINE OF PAVERS BLOCK (MANUAL PROCESS)
PRINCIPLES OF PLANT LAYOUT
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
SPECIFIC FACTORS
6. TRANSPORTATION:
A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES
7. WASTE DISPOSAL:
8. LABOR:
9. REGULATORY LAWS:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME ATTACK:
14. FLOOD AND FIRE CONTROL:
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
1. DEPRECIATION:
2. FIXED ASSETS:
3. WORKING CAPITAL:
4. BREAK-EVEN POINT:
5. OTHER FIXED EXPENSES:
6. MARGIN MONEY:
7. TOTAL LOAD:
8. LAND AREA/MAN POWER RATIO:
PROJECT IMPLEMENTATION SCHEDULES
INTRODUCTION
PROJECT HANDLING
PROJECT SCHEDULING
PROJECT CONSTRUCTION SCHEDULE
TIME SCHEDULE
SUPPLIERS OF PAVING BLOCK
SUPPLIERS OF PORTLAND CEMENT
SUPPLIERS OF STONE CHIPS
SUPPLIERS OF DG SETS
SUPPLIERS OF WATER PUMP
SUPPLIERS OF PALLETS
SUPPLIERS OF MOULDS
PLANT AND MACHINERY SUPPLIERS FOR PAVERS BLOCKS
CHINA SUPPLIER OF AUTOMATIC PAVING BLOCK MAKING MACHINE
PROJECT SYNOPSIS

APPENDIX – A:

01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)

Additional information

Plant Capacity

14,000 Nos/Day
Land & Building

(4000 sq.mt.)
Plant & Machinery

US$ 65714
Rate of Return

45%
Break Even Point

64%

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