ELLSON combination plain and hollow concrete block machine[edit | edit source]
Description
The ELLSON Combination Plain and Hollow Concrete Block Machine, produced in India since 1958, is an ail-steel welded device, which is manually operated and produces both plain (solid) and hollow (twin rectangular cavitied) concrete blocks of the same overall size using the same mould. Apart from the mould, the machine comprises a hopper tray, a lid plate which is used to compact the block, and a lever to eject the block. The cores for forming the cavities of hollow blocks are fixed to the bed of the mould.
In addition to the concrete block machine, a wooden pallet is required for each block produced, ie plain pallets for solid blocks, and pallets with two rectangular cavities for hollow blocks.
With special inserts in the mould box, the height of the blocks can be decreased, but modified versions of the machine are available on request to produce four bricks at a time on a common pallet or solid blocks of different thicknesses using the same mould.
Operating the Combination Block Machine
The machine is first adjusted to the desired block height by placing suitable inserts into the mould, and before each new block is made, a wooden pallet is oiled and dropped into the mould. The tamper plate (which enters the mould box) can be adjusted to enter the mould box to different depths, depending on the block size, that is, the loose mix is usually compacted to about 75 % of its original volume.
A large variety of fine and coarse aggregate can be used for the concrete mix, hence the mix proportions of cement and aggregate will vary according to the type and quality of ingredients. However, the mix should not be richer than one part (by volume) of cement to six parts of mixed fine and coarse aggregates.
The fresh concrete mix is loaded onto the hopper tray, from which the machine operator feeds the mould. The surplus material is scraped off with a trowel and, using both hands, the tamper lid plate is brought down with a few sharp blows on the top of the mould box, tamping the block to the required density. By pulling down the lever, the block is ejected together with the wooden pallet, such that the pallet and block can be carried away to a level, shaded drying area. When the block is sufficiently hardened, the block is fumed onto one side and the pallet is removed, cleaned and oiled for the production of a new block, while the previous one is left to cure by keeping it moist (by regularly spraying water) for at least 7 days. Before using the block in wall construction, it must be completely dried.
Other ELLSON Equipment
A third member of the ELLSON family of machines for blockmaking is the ELLSON Blockmaster Soil Block Press (described in detail in GATE Product Information: Soil Block Presses). It is a manually operated, allsteel construction, manufactured in India since 1959, and is one of the oldest soil block presses that is still being produced.
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Technical Details |
ELLSON Combination Block Machine | |
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Size of machine (length x width x height) |
95 x 75 x 100 cm (37 x 29 x 39 in) | |
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Weight of machine, |
220 kg | |
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Size of crate for shipment |
110 x 88 x 103 cm (43 x 35 x 41 in) | |
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Weight of packed machine |
310 kg | |
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Standard block size (l x w x h) |
a |
40 x 20 x 20[15] cm (16 x 8 x 8[6] in) |
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Other block sizes |
b |
40 x 15 x 20[15] cm (16 x 6 x 8[6] in) |
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c |
40 x 10 x 20[15] cm (16 x 4 x 8[6] in) | |
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Energy input |
manual |
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No. of blocks per cycle/output rate |
1 /50 - 75 blocks per hour | |
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Labour force required (incl. mixing, carrying away blocks, etc) |
6 - 7 men | |
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Price (ex works) valid June 1991 |
Combination Machine (incl. I mould, scoops, sample wooden pallets, packing) |
13500 Rs (» 675 US0 |
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Rs = Indian Rupees |
Same as above, but with 2 moulds |
16500 Rs(» 825 US0 |
<TOC2>> Jesson Super D.I.Y. brick & block makers
Manufacturer
SARANICH Close Corporation
P.O. Box 243
Port Elisabeth 6000
South Africa
Tel. [ . . 27] 41 -413173 /413152
Fax.[ . . 27] 41 - 41 3154
Description
The Super D.I.Y. Machines, developed by Harold and Richard Jesson, are all-steel constructions, designed for do-it-yourself concrete brick and blockmaking by a single operator. Four machines are available, one for making bricks (6 at a time) and the others for making single hollow blocks of three different widths (22, 15 and 10.4 cm), but the same design can be modified to produce other brick or block sizes, if there is sufficient demand for them, that is, minimum 50 units of each modified design.
The production process, including the compaction of the concrete, is entirely manual, extremely simple to carry out and permits a high output rate, as the blocks and bricks are left to dry where they were moulded ("egg-laying" principle), saving the time and effort otherwise needed to carry away the fresh products.
No aluminium or alloys are used in the construction, which is made to last for about 24 months, if used daily and maintained reasonably well. It is painted with steel primer first and then with oil based paint.
Operating the Super D.I.Y. Machines
A level, hard and clean production area of 150 to 200 m2 is required for concrete brick or block production. The whole work can be done by a single person' although far greater efficiency can be achieved, if the operator does not also have to prepare the toncrete mix.
In order to produce 1000 concrete bricks, 2 m3 of crushed stone and/or sand plus 5.5 bags of cement are required. For making concrete blocks, the crushed stone should not be larger than 6 mm and should have a fines content of 25 to 30%, while the sand must be coarse and clean - not plaster sand. 1 m3 of this aggregate plus 3.5 bags of cement are needed for 100 blocks of 22 cm width; the corresponding figures for 15 cm blocks are 0.9 m3 aggregate plus 2.75 bags cement, and for 10.4 cm blocks are 0.8 m3 aggregate plus 2.5 bags cement.
For each batch of mix, 4 wheelbarrows of aggregate are dry mixed with 0.5 wheelbarrow of cement, and just enough water (normally 35 to 40 litres) is added to ensure that binding takes place. These are, of course, recommendations which can be varied to suit the local conditions, requirements and type of material available. Each wheelbarrow load of concrete mix will produce 32 bricks, or 4, 5 and 7 blocks of 22 15 and 10.4 cm width respectively.
When the mix is ready, the mould box is placed in front of the operator at one end of the production line. The mould box is filled with concrete up to the top of the dividing plates for bricks (or up to the top of the mould box for blocks). Into the 2 tubes on the mould box sides, the compactor is fitted and rammed up and down several times until the compactor feet on the sides touch the ground, indicating the correct height of the bricks (block).
While stepping on the compactor feet to hold them down, the operator grasps the yellow mould box handles and, ensuring that the compactor feet do not move, pulls the mould straight up until the hands reach the top of the compactor frame. Then, stepping off the compactor feet, the operator lifts up the whole machine carefully, so that the bricks' (block's) edges are not damaged, and steps back to put the machine down on the new "drop" site. The compactor is removed and the process repeated.
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Super D.I.Y. Brick & Block Makers | ||
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Size of machine (length x width x height) |
85 x 30 x 70 cm (33 x 12 x 28 in) | |
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Weight of machine |
20 kg | |
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Size of carton for shipment |
85 x 30 x 70 em (33 x 12 x 28 in) | |
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Weight of packed machine |
25 kg | |
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Standard brick size (I x w x h) |
a. |
22 x 10.5 x 7.5 em (8.7 x 4.1 x 3 in) |
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Standard block sizes |
b. |
44 x 22 x 22 cm (17.3 x 8.7 x 8.7 in) |
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c. |
44 x 15 x 22cm(17.3x5.9x8.7in) | |
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d. |
44 x 10.4 x 22 cm (17.3 x 4.1 x 8.7 in) | |
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Energy input |
manual | |
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No.of bricks per cycle/output rate (a) |
6/ 240 - 300 bricks per hour | |
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No. of blocks per cycle / output rate (b, c, d) |
1 /40 - 50 blocks per hour | |
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Labur force required (incl. mixing) |
2 men | |
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Price (ex works) valid June 1991 R = South African Rand |
Super D.I.Y. Machine |
450 R (= 170 US0 |
