Affordable Housing Technologies
Mortarless Block
Housing System
Unlike traditional
cinder block or brick, the mortarless block does not require mortared joints for
structural integrity and does not need skilled bricklayers in the construction except in
laying the first course in mortar on a concrete slab or footing to insure that the
structure will be perpendicular and level.
The blocks are
hollow and interlock, which allows them to be laid four times faster than conventional
block masonry. This process also alleviates the requirement of mortar to connect each
block. Traditional exterior and interior finishes may also be applied such as stucco,
plaster, siding, paint and paneling. Colorants can be added to the mix to simulate brick
or other materials and the molds can be varied to add different surface textures/patterns.
Unlike construction materials that rely on man-made materials, such as styrofoam and
plastic or specially treated metals, the block can be produced with materials that are
readily available. A typical aggregate mix required to produce the blocks is: sand
(washed) 66%, gravel 20%, cement 10% and water 4%.
The block is
particularly suited to areas where there is little skilled labor and enables local labor
to be used extensively throughout most phases of the project.
Mortarless block is
superior to wood frame construction where climatic conditions would cause extensive wood
rot or insect infestation. It also spares our ever-decreasing forests. Mortarless block
construction is also superior to the various steel frame designs that are prone to rust in
humid/wet climates. Metal frame also requires special fabricating equipment and/or milling
process.
| To the left shows how
the blocks stack precisely and interlock to create true and straight courses. |
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This construction
method requires no special masonry skills making it ideal for quick deployment and the
creation of jobs in any area. |
| A two-bedroom
mortarless block house under construction. Local contractors and laborers will be utilized
in the construction of the homes and paid competitive wages based on regional salary
structures. |
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The blocks may be
produced on conventional concrete block machines, using conventional pallets, and without
alterations to the machine or block making equipment. However to save manufacturing and
shipping costs, the blocks will be manufactured on-site utilizing a transportable
block-making factory.
Transportable
Block Factory
A transportable
block factory (shown below) is used at the construction site to save on the manufacturing
and shipping costs of transporting pre-cast cement blocks to the project location. The
machine is capable of producing up to 1000 blocks per hour. The trailer cab is unhitched
and the factory becomes semi-permanent while making the blocks. When a sufficient number
of blocks are made as required by the housing subdivision, the factory is easily
transported to be in close proximity to the next phase of the housing development, or
moved on to the next project after all the blocks are made for the current project.
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