Index For The Hydraform Manual Index Page No.:: PG 3 PG 4

INDEX FOR THE HYDRAFORM MANUAL
INDEX PAGE NO.:

Disclaimer Pg 3
1. Hydraform safety instructions & warranty information Pg 4
1.1. Safety instructions Pg 4
1.2. Set up of machine on site Pg 5
1.3. Hydraform warranty Pg 6
2. The layout and parts of the Hydraform machine Pg 7
2.1. M7 Hydraform blockmaking machine Pg 7
2.2. Parts list Pg 8
2.3. Drawing: corner and side view of M7 Pg 9
3. Operating and maintenance of the Hydraform machine Pg 10
3.1. Machine operation Pg 10 - 11
3.2. How to produce one Hydraform block Pg 12
3.3. Maintenance of machine Pg 13
3.4. Diesel engine maintenance Pg 14
3.5. Diesel motor Pg 15
3.6. Hydraulic maintenance Pg 16
3.7. Changing of wearplates on all machines Pg 17
4. Tools for production and construction Pg 18 -19
5. Soil selection Pg 20
5.1. The visual test Pg 20
5.2. The wash test Pg 21
5.3. The jar test Pg 22
5.4. Shrinkage test Pg 23
6. Mix design & selection Pg 24
6.1. Diagram of: cross section of wall and roof Pg 25
7. Block production Pg 26
7.1. Sieving Pg 26
7.2. Mixing by hand Pg 27
7.3. Hydraform pan mixer blockmaking machine Pg 28
7.4. Mixing by pan mixer Pg 29
7.5. Checking the moisture in the mix Pg 30
7.6. Checking the water content in the mix, block length Pg 31
7.7. Hydraform blocks can vary in length due to the following three cases Pg 32 - 33
7.8. Stacking and curing Pg 34
Hydraform training manual copyright 2005 Page 1 Revision 31/10/05
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(INDEX contd.) PAGE NO.:
8. Quality checks on blocks Pg 35 - 36
9. The Hydraform block tester Pg 37
10. Important definitions & points before starting construction Pg 38

10.1. The Hydraform block Pg 38 - 39
10.2. General points on construction Pg 40 - 41
10.3. Corners Pg 42
10.4. T-junctions Pg 42
10.5. Cross-junctions Pg 43
10.6. Joints and angles Pg 43
10.7. Preparing the blocks and masonry Pg 44
11. Construction process Pg 45

11.1. Foundations Pg 45
11.2. Floor / surface bed Pg 46
11.3. Leveling the first course of bricks Pg 47
11.4. Beginning the first course Pg 48
11.5. Above the first course Pg 49
11.6. Above lintel level Pg 50
12. Services and finishes Pg 51

12.1. Agrément specifications for finishes Pg 52
13. Trouble shooting – construction Pg 53 - 56
14. Method for producing ± 1 500 Hydraform blocks per day Pg 57 - 58
15. Blockyard layout for one machine Pg 59
16. Agrément Certificate procedure and certificate extract Pg 60 - 63

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Disclaimer
Machine, Training and Building Manual
Hydraforms manual has been prepared for clients use to advise on the best
possible use of the machine, blockmaking and building system incorporating
years of experience in the field.
“Other Factors” to be considered
Soils, cements, mix preparations, material codes, building materials, building
codes, local regulations, external conditions and more are all important to
produce a quality block and achieve acceptable building standards.
Disclaimer
Hydraform cannot be held responsible for not achieving acceptable quality levels
in block production and building as the “Other Factors” are out of our control

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1. HYDRAFORM SAFETY INSTRUCTIONS AND
WARRANTY INFORMATION
1.1 SAFETY INSTRUCTIONS

Injuries can be costly
Read these few points thoroughly
When towing or moving the Hydraform machine.
· Do not speed.
· Make sure mobile machines are connected to the towing vehicle
correctly.
· Secure all machines on the pick-up or trailer.
· Do not hit top ram and bottom ram together. Do not operate without soil
in the machine. Never produce blocks shorter than 100 mm.
Cleaning the Hydraform machine.

· Do not clean the machinery if the motor is idling or the electricity power
is on.
DANGER
· Beware of TOP RAM opening and closing during blockmaking. It can
cause damage to your hands, fingers and body
· Only a trained operator should operate the machine
Top ram
Top arm

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1.2 SET UP OF MACHINE ON SITE
The Hydraform machine must be in a level position resting on

the four corner stands or legs.
Check list before block production or starting the machine
· Check hydraulic oil level gauge on tank (on all machines)
· Check air filter for cleanness (on diesel machines only)
· Check engine oil (diesel machines only)
· Check electric connections (electric machines only)
· Check mixer for free movement (M7ExM or mixer machines only)

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1.3 HYDRAFORM WARRANTY
HYDRAFORM
ESTABLISHED 1988
WARRANTY REGISTRATION CERTIFICATE
The manufacturers guarantee that the machine is free from defects of design,
workmanship, and material for a period of 6 months from the date of delivery.
The guarantee is confined to defects, which render the machine unusable or
materially impair its function due to faulty materials, workmanship or design.
Defects of this nature should be notified at once in writing to the nearest
Hydraform office, and substantiated. Replaced parts become the property of the
manufacturers. The manufacturers will meet all reasonable costs of the
replacements in all cases of expressly admitted claims. Repairs require the prior
permission of the manufacturers. The guarantee does not apply to natural wear
and tear, nor to defects resulting from negligence or misuse. The guarantee
becomes null and void in the event of failure to observe the operating instructions
or if the machine is repaired by the purchaser or third parties without
authorization by the manufacturers.
MACHINE TYPE______________________DELIVERY DATE______________
SERIAL NUMBER_________________________
ACCEPTED CLIENT_______________________
DATE_________________

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2. THE LAYOUT AND PARTS OF THE HYDRAFORM
MACHINE
2.1. M7 HYDRAFORM BLOCKMAKING MACHINE
Soil loader Top ram

Top arm
Top cylinder
Block cutter
Compression
chamber
(wear plates
inside Diesel engine
– 4 Pieces = 1
set)
Tow hitch
Pressure
gauge
Hydraulic oil tank

Control levers
Bottom cylinder
Legs/stands
(4 No)

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2.2 PARTS LIST
NO. DESCRIPTION
1. SOIL HOPPER
2. SOIL HOPPER SUPPORT
3. VALVE CONTROL
4. TOP ARM CYLINDER LEVER (TOP RAM)
5. BOTTOM CYLINDER LEVER (BOTTOM RAM)
6. CHAMBER
7. WEAR PLATES 4 PER SET
8. TOP RAM
9. TOP ARM
10. REAR PIN AND BEARINGS
11. MAIN CYLINDER (80MM)
12. FRAME (FIXED OR MOBILE)
13. PIN
14. BOTTOM RAM
15. TOP ARM CYLINDER
16. TOP RAM EXTENSION
17. CLEVIS

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2.3 DRAWING: CORNER AND SIDE VIEW OF M7

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3. OPERATING AND MAINTENANCE OF THE
HYDRAFORM MACHINE
3.1 MACHINE OPERATION
It is important that only one person, (the trained operator) is in charge and
responsible for the machine and the block production.
Two lever operation
The are two levers to operate the machine, each lever must be
moved separately.
By letting go of any of the two, the spring-loaded lever goes back
into the neutral position.
Lever: Nr.4. This is the left hand lever when standing in front of machine, this
controls the top ram (top arm), when pushed forward, top ram (top
arm) opens, when pulled back, top ram (top arm) closes.
Lever: Nr.5. This is the right hand lever when standing in front of machine, this
controls the bottom ram, when pushed down bottom ram moves
down, when pushed up bottom ram moves up.
Lock and system pressure
1. Adjustment bolt for pressure setting.

2. Lock nut.
3. Double bank valve body.
4. Top ram lever.
1
5. Bottom ram lever.
2
4
5 3

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How to change hydraulic system pressure
Your machine will be delivered with the system pressure pre-set to 90 – 100 BAR
(9-10 MPa).
It is not necessary to reset the pressure.
If you are working with high sand content soils, then you will need to increase the
system pressure to 120 – 130 BAR (12-13 MPa).
If you are working with high clay content soils you may need to decrease the
system pressure to 60 – 80 BAR (6 – 8 MPa).
1. Loosen locknut (Nr. 2).

2. Loosen adjustment bolt (Nr. 1) for lower pressure.
3. Tighten adjustment bolt (Nr. 1) for higher pressure.
To take the reading on the pressure gauge open the top ram and hold the bottom
ram in the down or up position.
NB!! Make sure the top ram is in the open position, when changing
the pressure.

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3.2 HOW TO PRODUCE ONE HYDRAFORM BLOCK
STEP BY STEP INSTRUCTIONS
1. Bottom ram in down position.
2. Top ram open.
3. Fill mix into hopper.
4. Push hopper across chamber and return to original position.
5. Close top ram.
6. Move bottom ram upwards to compact the soil-cement mixture.
7. Open top ram.
8. Move bottom ram upwards until the produced block is

completely out of the chamber.
9. Take block away to be cured.
10. Move main cylinder downward until the end.
11. Stop.
REPEAT STEP 1 TO 11 FOR FURTHER BLOCKS

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3.3 MAINTENANCE OF MACHINE
MAINTENANCE TO BE DONE EVERY DAY

· Machine must be cleaned overall.
· If production is stopped make sure bottom ram is down and the top ram is
closed.
· After stopping the engine release the pressure in the hydraulic hoses by
moving the hydraulic levers in the respective directions.
· (See section 3.4 and 3.6)
WEEKLY MAINTENANCE
· Once a week check machine for wear and tear, leaks, loose bolts, clean
machine thoroughly, check engine, and hydraulic system.
WEARPLATES MAINTENANCE
· Wearplates may need changing after 40 000 – 80 000 blocks. The
wearplates need to be changed when the block height is 118 mm
(See section 3.7 and section 8.7)

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3.4 DIESEL ENGINE MAINTENANCE (Antor - Lombardini)
For diesel engine maintenance refer to engine manual, which is

supplied with all new machines.

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3.5 DIESEL MOTOR
(Diesel powered machines only)
Hydraform backs up our customers with technical advice on all kinds of service
questions, spare parts and engine repairs.
CONTACT HYDRAFORM
Johannesburg
220 Rondebult Road

Libradene
Boksburg
1459
P.O. Box 17570

Sunward Park
1470
Tel: +27-11 913 1449

Fax: +27 -11 913 2840
Email: sales@hydraform.com
Internet: www.hydraform.com

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3.6 HYDRAULIC MAINTENANCE
Service instructions
Main points to check are as follows:
1. Visually checking correct oil level of hydraulic tank, hydraulic oil must
always be visible in sight glass. Top up hydraulic oil with oil grade 68 if
required.
2. Visually checking all hydraulic hoses connection points for leaks – tighten if
necessary.
3. Every 1000 hours (6 months of operation) the suction filter must be removed
and cleaned. To do this, first remove reservoir lid, then reach into the tank
and loosen filter. Wash filter with cleaning fluid (paraffin or equivalent), blow
dry and replace filter, close lid ensuring seals are intact.
The above checks should be done on a regular basis to ensure

safe operation of the machine.
Hydraulic Maintenance Schedule
DAILY: Check hydraulic oil level in tank. Check for external

leaks
Worn hoses.
EVERY 6 MONTHS: Change return – line filter element.
YEARLY: Change suction strainer (inside the tank).
Change breather.
Change return – line filter element.
Remove tank lid and clean tank.

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3.7 CHANGING OF WEARPLATES ON ALL MACHINES
Wearplates
There are four wearplates in the machine, which give the shape of the block.
These are of special material to achieve wear resistance. However, depending
on the working conditions and the soil abrasion wearplates must be changed
when necessary.
When the block height reaches 118 mm, the wearplates must be changed. The
blocks will show signs of cracking and no longer fit together properly. (See
section 8.7)
Important note:
1. Wearplates must always be replaced as a set.
2. Every time wearplates are changed new bolts, washers and spring
washers must be used.
3. All bolts are high tensile materials.
4. After wearplates have been fitted check bottom ram and top ram for free
movement, (top ram is designed to have free play).
Taking out wearplates
· Open the top ram and move bottom ram down to its lowest position.
· Stop engine.
· Switch off Diesel motor or electric motor.
· Front and back wearplates are bolted into the compression chamber with
six bolts.
· Side wearplates are bolted into the compression chamber with four bolts.
· Take out front and rear wearplates bolts.
· Take out front and rear wearplates (if you have difficulty in taking them
out, use a block of wood and a hammer to loosen the plates).
· Take out left and right side wearplates bolts.
· Take out side wearplates.
Fitting the new wearplates
· Use new bolts and spring washers whenever possible.
· The wearplate compression chamber form must be cleaned and lightly
oiled.
· Fit side plates first, ensuring that the top of the plate is level with the top of
the compression chamber, tighten bolts.
· Fit front and rear plate ensuring that they are level with the chamber.
· Tighten bolts.
· Start machine and move top ram up and down slowly to ensure free
movement, into the block chamber.
· Move bottom ram up and down to ensure free movement, tighten all bolts
again.
· Proceed with blockmaking.

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4. TOOLS FOR PRODUCTION AND CONSTRUCTION

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TOOLS FOR PRODUCTION AND CONSTRUCTION
(contd.)

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5. SOIL SELECTION
A Hydraform block is produced from a soil and cement mixture. The soil type is
classified as a sandy – loam. The soil should contain more sand than clay and
silt (fines). If the clay content is too high, sand will need to be blended in with the
soil.
The clay keeps the block together so it is easy to carry the block during
blockmaking. The sandy portion is what binds with the cement to give the block
its ultimate strength.
Too little clay will make block handling difficult, too much clay will make the block
shrink and crack during curing.
Hydraform blocks are made from sub-soil 1 metre below ground level, never top
soil, which contains organic material.
There are 4 field tests in the field to test the soil:
5.1 The visual test
· Dig a hole 1m deep.
· Look at the different soil layers.
· Does the soil look sandy or does it

have lumps?
a. If it is has lumps and cracks in

the soil then there is clay.
b. If it is very sandy then dig

deeper to find a more clayey
soil.
· DO NOT USE TOPSOIL!
5.2 The wash test

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· Take some soil in the hand, pour
water on it and rub and squeeze
it.
· Does it feel gritty or soapy?
a. If it is gritty there is a lot of

coarse sand.
b. If it is soapy then there is clay.
· Wash the hand with water. If

soil washes off easily then it is
mostly sand or silt. If it is difficult
to wash off and leaves colour on
your hand, then there is a lot of
clay.
5.3 The jar test

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· Fill a straight sided, flat bottomed jar
¹/³ with soil.
· Fill to ²/³ with water
· Shake well (1 minute).
· Leave to stand for 24 hours.
· Measure the thickness of the layers

of clay and sand.
Note: There must be between 10%

and 50% clay and silt to make
a block, ideally 15-35% silt
and clay.
Clay and silt – upper layer

Sand and gravel – lower layer
5.4 Shrinkage test

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· Fill a shrinkage box 60cm long
x 4cm deep x 4 cm wide with
wet soil.
· Scrape it level and leave to

dry in the sun for 5 days.
· After 5 days in the sun

measure the shrinkage.
· If shrinkage is no more than

10mm then the soil is sandy.
It might be difficult to handle
the block, during
blockmaking.
· If shrinkage is more than

60mm then the soil has too
much clay. Sand must be
added or find another soil.
· An ideal soil should shrink

around 20 mm – 40 mm.

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6. MIX DESIGN & SELECTION
Brick Cement Soil Blocks per

Strength (Parts) (Parts) 50kg bag of
cement
Mix 1
X1 X20
5% cement
(± 4MPa) 70 – 75
X1 X12
Mix 2
8% cement 40 - 45
(± 7MPa)
Never exceed more than 80 blocks from one bag of cement,

the cement content and block strength will be low.
1 MPa (Mega Pascal) = 10kg/cm² = 1000 kPa = 145 psi
6.1 Mixed design and selection (contd.)

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Cross section of wall and roof
Mix 1 – Plastered
Mix 2 – Unplastered
Mix 2
7. BLOCK PRODUCTION

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7.1 Sieving
Strong steel frame 2 m long

X 1m wide
Stand
8-10mm strong mesh
7.2 Mixing by hand

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Note: The soil-cement mix must be used within one hour of mixing
never leave a mix unused for more than one hour.
Batch the soil and cement
Mix three times

until the cement &
soil are mixed
thoroughly
Add water with watering can
· Do not pour the water onto a single spot creating

a pool of water.
· Water must be sprinkled onto the mix slowly

while mixing.
Mix three times

until the water is
spread evenly
throughout the mix
7.3 Hydraform pan mixer (Do not allow blades to touch drum)

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Hydraulic motor
White Hydraulics -
USA
Bearing housing
and motor support
Drum
U bolts
Middle blade
Inner blade
Outer blade
7.4 Mixing by pan mixer

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Note: The soil-cement mix must be used within one hour of mixing
never leave a mix unused for more than one hour.
· Empty wheelbarrow into mixer

from ramp.
· Add soil first.
· Add cement second.
· Dry mix for 1 minute.
· Add water slowly and mix for 1
minute.
Note: water must be sprinkled in

slowly.
DO NOT pour the water onto one

spot.
· Empty mixer by pulling lever after

soil-cement is well mixed.
NOTE: If the mixer struggles to mix, the soil may contain too much
clay, add sand or reduce the mixing volume. The mixer
operates best with 100 – 110 litres of soil and cement.

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7.5 Checking the moisture in the mix
The Drop Test
Too Dry
Ö Good
Too Wet
1. Squeeze the soil – cement mix into a ball.
2. Drop ball from waist height.
3. - If ball shatters into many small pieces it is too dry.

- If ball breaks into 5-6 lumps then the water content is right.
- If ball does not break or only breaks into a few lumps it is too wet.
NOTE: A dry mix will produce a poor quality block. The mix should be close to
the optimum water content of the soil. The water content will vary block
length. When the soil – cement mix is too dry the block length will be
longer than when the water content is correct.

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7.6 Checking the water content in the mix, block length
Too wet, block is short and has cracks
Too dry, block is long and difficult to handle
Operator must maintain block length by maintaining a consistent water content in the mix

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7.7 Hydraform blocks can vary in length due to the following
three cases.
Note: If you are getting more than 100 – 108 blocks from one cubic metre
of mix, then there are 3 possibilities for this error.
Firstly the operator is not filling the chamber fully with the required 10 litres of
soil per block. The hopper will automatically level the chamber when the soil
hopper is pulled back after filling.
Secondly the water content in the soil-cement mixture is not consistent.
Thirdly the operator might not be returning the bottom ram to the very bottom
during block manufacture. The ram must go all the way to the bottom before
making every block.
Also ensure the quantities of soil being mixed is in fact the same every time. The
person mixing the soil may heap the soil on some mixes and then under fill the
wheelbarrow on other mixes.
1) Under filling the mould / chamber: Note: one full length block is 10 litre
before compaction. Normally one cubic metre of mix should produce 100 –
108 blocks per cubic metre. When measuring out the mix it is important to
ensure the wheelbarrow being used or buckets are leveled every time,
ensuring the same quantity of soil and cement is being used. Length may
be intentionally varied when producing half blocks or special length blocks.
5 litres of soil put into the chamber will give a half block of approx 110-
120mm length. Never produce a block with a length of less than 100mm or
4 litres of soil, this may cause damage to the top gate arm during
compaction of the soil cement mix.
2) Water content in the mix: First we need to establish the ideal block
length for a given soil type. This is done by preparing a mix of soil and
cement and a little water (The first mix should be slightly dry).
· Mix thoroughly and produce a block.
· Measure the 1st block.
· Add water to the mix and mix thoroughly again, produce a 2nd block and
note the length. The block length will reduce as the water content is
increased.
· Repeat the process adding more water to each mix and make new blocks
noting the length.
· Finally fine cracks will begin to show on the bottom of the block, this
indicates there is too much water and the mix is too wet. Note the length
of the block for this mix.
· The best average length would be a little longer than the block length
when fine cracks start to show. Assuming this length is 230mm instruct the
machine operator to manufacture blocks in the range of 225mm – 235mm.

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Give the operator a steel rod of length 235mm with a marking at 225mm.
The average block length should always be between the upper marking
and lower marking.
· If the soil is a little dry the block will be longer than the average length, the
operator then simply adds a little water to the mix and continues producing
blocks.
· The steel rod gives a visual and easy check for the operator to check and
maintain the water content of all blocks being produced.
Consistency in mixing and water content in the mix is the key to good
block quality.

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7.8 Stacking and curing
Curing gives the block its durability and strength
· Stack the blocks 5 high and 7

wide (depending on the width of
the plastic).
· Cover the blocks, as they are

stacked.
· Never leave the blocks in the sun

or wind uncovered.
· Even when producing blocks in

shade, plastic must be used.
· Uncover the blocks and water

the blocks twice a day – once in
the morning & once in the
evening, and cover again
immediately. This is curing.
· The blocks are cured for 7-14

days. The longer curing the
stronger the block.

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8. QUALITY CHECKS ON BLOCKS
Note: If blocks are cracking from excessive vibration from chamber
during extrusion. Lower the system pressure (see 3.1) and
increase the water content of the soil cement mixture
PROBLEM CAUSE REMEDY
1. Rough surface on -Mix too dry -Add more water to mix

blocks
-Rough plates -Inspect plates and
change if necessary
-Soil build up in joints or -Clean excess soil from

on wearplates joints and plates
2. Cracking blocks
2.1 Horizontal cracks -Too much water in mix -Use less water in mix
seen as block ejected Add cement to mix
from chamber already made to dry out
-Compression pressure -Reduce pressure

too high (see section 3.1)
2.2 Cracks developing -Blocks losing too much -Cover blocks properly
during 7 day curing water too fast during with plastic and water
period curing twice daily as per
Hydraform
recommendations
-High clay content -Add coarse sand to mix
-Add more cement

(see section 6)
- wearplates worn out (see point 7 below)

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3. Blocks being damaged -Careless handling of
and broken during blocks -Closer supervision of
stacking and storage stacking
-Blocks too weak
-Check production
process and/or add
more cement to mix
4. Blocks shorter than -Too much water in mix
chosen length -Use less water in mix
-Compression pressure
too high -Reduce pressure
(see section 7.5, 7.6 & 7.7)
5. Blocks longer than -Mix too dry

chosen length -Add more water to mix
-Compression pressure
too low -Increase pressure
(see section 3.1)
(see section 7.5, 7.6 & 7.7)
-Water content changing

6. Block length changing
continuously -Keep water in mix
continuously
constant. Check water
(see section 7.5, 7.6 & 7.7) content by checking
length of block with ruler
-Soil properties changing
continuously -Use same soil source
for all production
7. Block height is - Wearplates are worn.

different -Replace wearplates
-New wear plates produce when block height is
a block height 118 mm
of 115 mm

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9. THE HYDRAFORM BLOCK TESTER
This is a simple tool designed to give rough indication of the strength of the
blocks being produced.
Take care when the block breaks that it does not fall onto the operator’s hand
and cause injury.
Jack head
· Lower jack by turning nut

anticlockwise and pushing
down on jack.
· Turn nut clockwise.

Nut
· Reset gauge to zero.
Gauge
Handle
Hydraform block
· Place block in tester and jack

slowly until block fails and
gauge reaches a maximum.
· Evaluate strength for use

(see section 6).
· Always ensure the block is

properly level and touching
the top and bottom pad
evenly.

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10. IMPORTANT DEFINITIONS AND POINTS BEFORE
STARTING CONSTRUCTION
10.1 The Hydraform Block

An Interlocking Compressed Earth Block made on the Hydraform press is
referred to as a block.
Interlocking
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 it is called
Interlock.
Bed
The recessed under surface of the block is referred to as the bed.
Ridge
The raised top surface of the block is called the Ridge.

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Male Face
The side face of the block with an extension is called the Male face.
Female face
The side face of the block with a recess is called the female face.
Course
One (horizontal) layer of Hydraform blocks is called a course.
Height of a course = 115 mm (with a new set of wear plates).

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10.2 General points on construction
Masonry should be started at the corners and therefore corners should be built
first, so that ½, ¼ or cut blocks can be used to fill in the masonry.
To start the first layer lay mortar at the corners and adjust corner blocks in
position. Ensure that the first layer is truly vertical by checking with a level.
All corners must start with a ½ block.
The male face must point outwards and corners must be built in a cyclic order as
below.
Also ensure that the first layer is truly horizontal by checking with a spirit level
over at least 3 simultaneous joints.

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Slide blocks one on top of another to interlock them in place leaving no gaps
between them.
Block laying must proceed in one direction only so that male and female faces
can interlock.
Blocks must be lightly hammered in place using a rubber hammer to achieve

‘true interlock’ to avoid gaps between blocks.
The aim is to make the corner an integral part of the structure.
Vertical poles must be in place to ensure straight vertical corners.

Check plumb at every course and check level at each joint across the entire
length of the wall.

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10.3 Corners
For a corner, you will require:
Shaved ½ blocks.
Shaved full blocks.
You must start the first course with a ½ block.
Also remember to shave off the ridge and male face of the corner block, as
shown. Ensure that the shaved ridge points upward and the shaved male face
point’s outwards.
10.4 T Junctions
For a T Junction of n courses, you will require:
Shaved ½ blocks.
Shaved full blocks.
You must start the first course with a ½ block.
Ensure that the shaved faces point upwards.

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10.5 Cross-Junctions
For a cross junction you require only full blocks with ridges shaved off, as shown.
Make sure that there are no straight joints. Ensure that the junction is an integral
part of both the walls.
10.6 Joints and Angles
Each course will have to be connected at the corner with a brick force as shown.
Always start with large blocks. Always nail the brick force in the centre of the
block and not near the edge.

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10.7 Preparing the blocks and masonry
Cleaning
Before using the top and bed surfaces of the block must be cleaned using a
brush.
Cutting and Shaving

You can cut your block with a block cutter or a blaster chisel and hammer. Use
“used” hacksaw blades or chisel and hammer to shave your blocks for corners if
you don’t have a block shaver.
Cleaning
Use a used hacksaw blade to remove any stubborn soil lumps inside any of the
recesses, ridges or flanges so that they are directly in contact to ensure ‘true’ and
safe load transfer.
Remember
Blocks must be clean and free of all soil lumps sticking to the block surface
otherwise blocks will not truly interlock. Therefore achieving plumb and level
would be very difficult and time consuming.

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11. CONSTRUCTION PROCESS
11.1 Foundations
Below is one recommendation. Alternately seek advice from local engineers or
follow common building practice.
Mortar is used in the foundation brickwork
Direction of bricks
Mortar
Concrete footing
Note: If it is necessary to step the foundations, use the
Hydraform brick height in the step.

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11.2 Floor / Surface bed
Concrete floor
Concrete
Compacted backfill Completed foundation

block work

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11.3 Leveling the first course of bricks
Profile (50 x 50 mm Timber or Steel)
Water level

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11.4 Beginning the first course
Set up corners first – always start

with a half block Builders line
Mortar

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11.5 Above the first course

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11.6 Above Lintel Level
Roof tie downs
Mortar between
blocks above lintel
levels Mortar above and
below lintel
Roof: Follow the normal local practice for roof design and construction

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12. SERVICES AND FINISHES
For laying electrical conduits and wiring in your building, you may either have
exposed casing running along the wall or run your conduits within the conduits
within the conduit blocks. Conduit blocks are special blocks with semi – circular
recesses in the top and bottom surfaces of the block.
You may however chase the masonry in order to fit conduiting as in conventional
masonry, but you will have to plaster the chased area.
Other services such as plumbing and sewerage could be exposed. All pipes must
be coated with water repellent paints and must have all joints sealed perfectly to
avoid damage to blocks due to water leakage from the pipes.
Plaster all edges and corners externally. It is important to plaster the corner well
beyond the joint.

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Skirting should be higher than the first joint from the finished floor.
Skirting top should slope outwards – away from the wall. They should not be
finished flat, and never sloping inwards.
12.1 Agrément specifications for finishes
· When building in South Africa with NHBRC approval, construction and

finishes will need to be done in accordance with the Agrément
specification. Agrément recommend both internal and external walls be
plastered and painted.
· A full Agrément certificate is available from the www.agrement.co.za
website under active certificates

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13. TROUBLE SHOOTING - CONSTRUCTION
13.1 If blocks are not sitting flush on each other and the interlock is not
perfect when checked with a spirit level and plumb bob.
· The blocks have not been cleaned well enough.

· The blocks must be cleaned with a brush & foreign particles scraped
with a blade. The interlock will thus be much easier.
· The wearplates may need changing (block height must never exceed
118 mm see section 8, point 7)
Also check the blocks for dimensional accuracy.
13.2 In spite of all the precautions the masonry is not in plumb.
· If it is possible, remove the blocks and redo the masonry.

· Otherwise take a flat hard plate of rubber, wood or steel, align it along
the wall and hammer against the wall to get the blocks in plumb.

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13.3 If you find that some blocks appear to have sheared on loading.
· Probably the blocks have not been made to interlock (well) with each
other: therefore the blocks are not in plumb necessary for safe load
transfer.
· Re-do the masonry and make sure that the blocks safely transfer the
load by being perfectly in level and plumb.
· Wearplates may need replacing, replace wearplates when block height
is more than 118 mm, (see section 8, point 7).
13.4 If you find chunks of blocks coming off at places where the brick
force was hammered.
· Probably the brick force has not been nailed in the center of the blocks.
Instead the brick force has been hammered towards the edges. If this
occurs along the entire vertical length of the joint such as a joint
between a 220mm wall & a 115mm wall the masonry should be
redone.
· If it is only one or two odd joints, the blocks should be repaired by
pointing with a cement soil mortar.

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13.5 If you find that some of your blocks in the masonry have got
damaged on the surface even after having done the masonry with
utmost care.
· The blocks probably got damaged during shuttering / deshuttering

procedure or ladders were probably made to rest against them.
· Chisel out the damaged part and repair with cement – soil mortar.
· However, in order to avoid such an occurrence altogether, it is a good
idea to cover the ends of the ladder & scaffolding material with a cloth.
13.6 If you find water seeping in especially near the skirting.
· The skirting has been finished at a joint in the masonry very close to
ground level so the water manages to seep in.
· Increase or decrease the height of skirting so that it is not flush with the
joint.
Otherwise, slope the top of the skirting away from the joint and seal the
joint with a sealant or point it with soil cement mortar.
13.7 If you find water seeping in through the masonry joints
· The blocks are probably not interlocked properly in the enthusiasm to

build faster.
· Re-do the leaking joints, Make sure to hammer the blocks in position.
· Seal the joints with a sealant or point with soil-cement mortar.

· Avoid water running directly from the roof onto the walls, use correct
roof overhang or a gutter.

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13.8 If you want to build another room next to an existing one.
· A planned expansion is much easier as you can use full blocks in the
corners instead of half. These full blocks can also then become a part
of the expansion.
· If your expansion is unplanned, chip off the plaster from the corner.
Replace each ½ block in the corner with a full block with the ridge
shaved. You now have a corner to start expanding from.
13.9 Precautions
As shown, when two block interlock one over another, the central recess
and ridge of both the blocks do not touch while the side flanges of both the
blocks touch each other transferring the load coming on the top block to
the bottom. Hence, it is important that blocks are stacked “truly” so that
actual load transfer can happen through both the side flanges.
Precautions
The first course is like a base or foundation for all the upper courses.
Slight errors in the first course would compound in subsequent courses. It
is therefore important that the first course is done to desired levels of
perfection even at the cost of increase in time.

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14. METHOD FOR PRODUCING ± 1500 HYDRAFORM
BLOCKS PER DAY
An 8 man team (excluding sieving and curing) can produce 1 500 blocks per day
if the following procedure is followed. A full team with curing and sieving is
normally 9 – 11 people.
14.1 The soil must be sieved with a minimum of 2 days lead-time i.e. 1m³ per
100 blocks or 15 m³ sieved soil for one day production of 1 500
blocks/day. 2 men can sieve 15 m³ soil per day.
14.2 The water must be available close to the operation. Preferably by

hosepipe from either a gravity fed tank or by municipal pipeline.
14.3 Cement must be stacked next to the operation. The full days’ supply must
be stacked before any production begins.
· 5% cement = 21 bags for 1 500 blocks.
· 8% cement = 36 bags for 1 500 blocks.
14.4 The labour employed should not be weak old men or old women and most
definitely not young girls. The labour should be healthy, strong men that
are willing to work hard.
Mixing by hand:
To run one machine, 8 men are required. This excludes the carrying of the
cement to the production area, curing of the blocks, stockpiling and
sieving of the soil. All activities other than running of the machine must be
done by separate personnel. The block production team and function of
each of the 8 men area as follows:
- Machine operator.
- Soil loading by bucket.
- Carrying blocks 2 persons.
- Mixing of first mix.
- Mixing of first mix.
- Mixing of second mix.
- Mixing of second mix.
The second mix is the most crucial mix, if the second mix is not always
100% ready, the machine will have to stop, and wait for the mixing to be
completed. If the machine stops, production will fall by 4 blocks per
minute. Therefore if the machine stops, between each and every mix for
only 7 minutes to catch up, the production will fall by 30 blocks per mix.
To produce 1 500 blocks per day 15-20 mixes are normally done. The
production would drop by almost 600 blocks per day if there were a 7-
minute delay per mix waiting for the second mix to catch up.

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Pan mixer:
If a pan mixer is being used then the labour complement numbers 7 as
follows:
- Machine operator
- Soil loader
- Stacker/block carrier x 2 persons
- Mixer soil loader
- Cement and water loader
- Mixer discharger
14.5 Production pay is normally the most effective method of paying the block
production team. The team is paid a fixed amount per good quality
finished blocks. The incentive will ensure production is maximized while
ensuring the team will always have a goal to increase their daily pay.
Example: 8 men X daily labour rate/1 500 blocks = value of labour for 1
block.
14.6 Curing is extremely important and should be done by a responsible person

who is separate from the 8-man team. This person should also be used to
carry the cement bags before production begins and also to prepare the
ground for the newly stacked blocks.
14.7 Tools should be of good quality and there should be no shortage of tools
forcing people to share.
14.8 Lunchtime- before the team goes on lunch, they should prepare the mix
for after lunch, the cement bags should be placed on top of the soil ready
to be opened and spread out over the soil. No mix must be left unused
before lunch, if the cement has been mixed into the soil it must be used
before lunch. The lunchtime must be strictly monitored, keeping in mind
that 4 blocks production is lost per minute when the machine is not
running. After lunch the full team should help to get the first mix ready.
14.9 End of the day- before packing up, the soil must be measured out for the
following days first two mixes (without adding cement). The machine must
be filled with Diesel and cleaned. The next morning there must be no
delay, the machine should be ready to run within 10 minutes after work
begins.
14.10 The blockyard should be set out properly with sufficient space to move
freely. The blocks should be set out neatly to not waste space. 1500
blocks should take up approximately 1,8m x 12m.

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15. BLOCKYARD LAYOUT FOR ONE MACHINE
HYDRAFORM MIDRAND BLOCKYARD (not to scale)
BLOCK PACKING AREA
BLOCK PACKING AREA

B B B B
L L L L
O O O O
C C C C
K K K K
P P P P
A A A A
1 1 1 1 1 1 1 1
C C 5 5 5 5 5 5 5 5 C C
K K 0 0 0 0 0 0 0 0 K K
I I 0 0 0 0 0 0 0 0 I I
N N B B B B B B B B N N
G G L L L L L L L L G G
C O O O O O O O
A A K C C C C C C C A A
R R S K K K K K K K R R
E E S S S S S S S E E
A A A A
M7 ½ BLOCKS
CEMENT
STORE
COVERED W T
MIXING A A
AREA T N
6 X 2 METERS E K
R
6 X 3 METERS
± 50M³

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For the Hydraform Engine specifications and
maintenance please contact the office and
quote your engine number
Tel: +27 11 913 1449

Email: sales@hydraform.com

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Index For The Hydraform Manual Index Page No.:: PG 3 PG 4

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Index For The Hydraform Manual Index Page No.:: PG 3 PG 4

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INDEX FOR THE HYDRAFORM MANUAL

INDEX PAGE NO.:

9. The Hydraform block tester Pg 37

10. Important definitions & points before starting construction Pg 38

11. Construction process Pg 45

12. Services and finishes Pg 51

13. Trouble shooting – construction Pg 53 - 56

14. Method for producing ± 1 500 Hydraform blocks per day Pg 57 - 58

15. Blockyard layout for one machine Pg 59

16. Agrément Certificate procedure and certificate extract Pg 60 - 63

Hydraform training manual copyright 2005 Page 2 Revision 31/10/05

Machine, Training and Building Manual

possible use of the machine, blockmaking and building system incorporating

years of experience in the field.

“Other Factors” to be considered

Soils, cements, mix preparations, material codes, building materials, building

produce a quality block and achieve acceptable building standards.

Hydraform training manual copyright 2005 Page 3 Revision 31/10/05

1.1 SAFETY INSTRUCTIONS

Cleaning the Hydraform machine.

Hydraform training manual copyright 2005 Page 4 Revision 31/10/05

The Hydraform machine must be in a level position resting on

Check list before block production or starting the machine

· Check hydraulic oil level gauge on tank (on all machines)

· Check air filter for cleanness (on diesel machines only)

· Check engine oil (diesel machines only)

· Check electric connections (electric machines only)

· Check mixer for free movement (M7ExM or mixer machines only)

Hydraform training manual copyright 2005 Page 5 Revision 31/10/05

MACHINE TYPE______________________DELIVERY DATE______________

Hydraform training manual copyright 2005 Page 6 Revision 31/10/05

2.1. M7 HYDRAFORM BLOCKMAKING MACHINE

Soil loader Top ram

Hydraulic oil tank

Hydraform training manual copyright 2005 Page 7 Revision 31/10/05

Hydraform training manual copyright 2005 Page 8 Revision 31/10/05

Hydraform training manual copyright 2005 Page 9 Revision 31/10/05

Two lever operation

Lock and system pressure

1. Adjustment bolt for pressure setting.

Hydraform training manual copyright 2005 Page 10 Revision 31/10/05

It is not necessary to reset the pressure.

1. Loosen locknut (Nr. 2).

Hydraform training manual copyright 2005 Page 11 Revision 31/10/05

STEP BY STEP INSTRUCTIONS

1. Bottom ram in down position.

2. Top ram open.

3. Fill mix into hopper.

4. Push hopper across chamber and return to original position.

5. Close top ram.

6. Move bottom ram upwards to compact the soil-cement mixture.

7. Open top ram.

8. Move bottom ram upwards until the produced block is

9. Take block away to be cured.

10. Move main cylinder downward until the end.

REPEAT STEP 1 TO 11 FOR FURTHER BLOCKS

Hydraform training manual copyright 2005 Page 12 Revision 31/10/05

MAINTENANCE TO BE DONE EVERY DAY

· (See section 3.4 and 3.6)

Hydraform training manual copyright 2005 Page 13 Revision 31/10/05

For diesel engine maintenance refer to engine manual, which is

Hydraform training manual copyright 2005 Page 14 Revision 31/10/05

(Diesel powered machines only)

MACHINE TYPE________DELIVERY DATE