Design of Hollow Concrete Machine

HOLLOW CONCERTE BLOCK MAKING MACHINE 2015
CHAPTER ONE
1. INTRODUCTION
Construction is not possible without blocks. Since many centuries block making has been
practiced by human beings. Presently, blocks are easily made by using machines using new
technologies. Generally two types of blocks are manufactured by using machines that are
concrete block machines and clay block machines. Different types of automatic machines
use different techniques to make blocks. The raw materials used by the machines for making
hollow blocks are fly ash, sand lime, iron oxide, lime sludge, quarry wastes etc.
The focus of this project is on the production of concrete blocks, specifically hollow
blocks which offer a speedier, cost effective, environmentally sound alternative to conventional
walling materials. It is based on the principle of densification of a lean concrete mix to make a
regular shape, uniform, high performance masonry unit. Concrete Block Technology can be
easily adapted to suit special needs of users by modifying some design parameters such as mix
proportion, water to cement ratio and type of production system. It is an effective means of
utilizing wastes generated by stone crushers, quarrying and [3]stone processing units. The
technology has high potential in areas where raw materials are easily available. The new
technique in producing this interlock block can generate a highly profitable business for micro
and small scale building material producers and construction companies. The market for this type
of block in Ethiopia is not yet growing at a rapid rate, even though there are demands in
construction industries due to low production rate which reflect the cost of block itself.
Producing this interlock block can generate a highly profitable business for micro and small scale
building material producers and construction companies. The specifications and the
characteristics of this block depend on the machine used to manufacture it. The most common
size of block is 400x200x200mm. The basic raw material is cement, fine aggregate and coarse
aggregate. Very little water is used. This is possible only with mechanized compaction and
vibration and gives the block high quality in spite of the lean mix, which uses very little cement.
Weight of this block is about 2 - 3 Kg.. The production systems are - manual molds that require
hand tamping and fully mechanized system that combines compression and manual concrete
filling in mound. The machine also compacts and consolidates the mix so that the blocks are
uniform in size and attain desired physical properties. The blocks are cured for a minimum
period of 14 days, before they are ready to use. On an average 600-800 blocks can be in 8 hours
by 1 skilled and 6-8 semi-skilled workers. In this project, a high quality machines in which
optimize from the current machine design is going to propose according to the feedback and the
need from the hollow block maker.
1.2 Introduction of The block product
JiT, SCHOOL OF MECHANICAL ENGINEERING Page 1

1.2.1 Concrete blocks
Concrete blocks are a basic commodity of the building industry. If you are looking for a great
business with a solid foundation this may be the one for you. Concrete products are used
everywhere for building. There is a constant strong demand. They are always in style unlike here
today gone tomorrow products. They are used to build large buildings. There is a market for
cement blocks around the world and particularly in North America. If you are looking for a good
business, which you can start from home at low cost, making concrete blocks and other concrete
products is a great opportunity. Starting with a part time business, using handmade molds, you
can get going with as little as a few hundred dollars for supplies and materials. You can operate
out of your garage then as business grows and you need more room you can expand to rented
premises. The secret is to keep your costs as low as possible to start with. Too many businesses
fail in the first year because they spend too much money unnecessarily on rents and equipment.
Start with the necessities and add more as you grow in profitability.[1]
Concrete products of all kinds are obviously heavy and bulky. To transport them for long
distances is costly. As a local manufacturer you can supply these products customers in your area
for a lot less than a distant manufacturer can. Your overhead cost, no rent, no staff wages mean
low production cost, again these allows you to price very competitively and still make an
excellent profit.
The only things needed to start up are sheet metal and plywood to make the molds. You can
obtain plans with instructions on how to do this. To manufacture concrete blocks you will need
port land cement, gravel, sand and water. Your local building supply store or lumberyard can
supply these items. With handmade molds one person can make 100 cement blocks in a days’
work. You simply fill the molds with the appropriate concrete mix then turn the blocks out to
dry. This is pretty simple. Then as your business expands you will want to acquire a concrete
block making machine which can turn out many more blocks per day than you can with hand
molds.[2]
You can buy concrete block making machines from various sources. They are very expensive
and do a very good job. If you can afford it go ahead and buy one. It will greatly increase your
productivity and will pay for itself. You can do it for much less however. You can build your
own machine used auto parts and a few available and it is not a difficult project. If you have
welding skills you can do these part of the work yourself, otherwise a local welding shop can do
it for you at fairly low cost.
Making your own machine is not really difficult if you have some mechanical skills. Your home
built machine will make 800 cement blocks per day. A smaller, very simple hand operated
machine can make 200 blocks per day and is quite easy to build. Operating these machines
efficiently is a two person job. One worker runs the machine and the other takes the blocks from

it and stacks them on racks to dry. Obviously you will also need sufficient space to stack
hundreds of blocks.
A concrete block is primarily used as a building material in the construction of walls. It is

sometimes called a concrete masonry unit (CMU). A concrete block is one of several precast
concrete products used in construction.
Today in our country the problems of homeless have been increasing gradually and it appears to
be continuing. The main reason for the cause will be higher cost of construction raw materials,
low income and lack of new technology.
Since the government focus to build thousands of low cost house throughout the country, to meet
the transformation and development goals and achieve significant reduction in homeless the
introduction of compacted block making machine must be essential.
The production of compacted block making machine established in 1988 in South Africa with
joint free India expertise. The CBMM building system replaces conventional blocks and mortar
through the use of compacted blocks, which are hollow and can be dry stacked. The other
components of the conventional building system remain unchanged. These blocks can be made
on construction site or at block yard using hollow block making machines. Today the CBMM
building system and the machines are used in over 50 countries worldwide. This block can be
made with local soil and cement or fly ash (brunt coal ash) and cement.[1]
These eco-friendly blocks are made with combinations of soil-cement, sand –cement which are
durable, but cost effective because they are made using local soil and require low cement content
(about 5%) and fly ash.
Cement concrete hollow blocks have an important place in modern building industry. They are
cost effective and better alternative to burnt clay blocks by virtue of their good durability, fire
resistance, and partial resistance to sound, thermal insulation, small dead load and high speed of
construction. Concrete hollow blocks being usually larger in size than the clay building blocks
and less mortar is required, faster of construction is achieved. Also building construction with
cement concrete hollow blocks provides facility for concealing electrical conduit, water and
sewer pipes wherever so desired and requires less plastering.
1.2.2 Market & demand aspects
Cement concrete hollow blocks are modern construction materials and as such are used in all the
constructions viz. residential, commercial and industrial building constructions. Construction

industry is a growing sector at present day in our country. The demand for this product is always
high in all cities and other urban centers due to construction of residential apartments,
commercial buildings and industrial buildings. Growing public awareness of the advantages of
the product coupled with increase in the government and financial institutions support for
housing which is a basic human necessity would ensure a healthy growth in the demand.
1.2.3 Types of concrete block
1) According to production
Solid concrete block
Hollow concrete block
Fig 1.1 type of block according to production

2) According to its size
400 mm
400×200×150mm
200mm
Fig 1.2. Type of CHB by its size

Advantage or benefits of concrete block
 Uniform shape and size

 High compressive strength
 Fire resistant
 Economical
 Negligible maintenance cost
 Speed in construction
 Due to negligible thickness it will save cement.
 Energy Efficient
 Sound Resistant
 Strong
 Durable
 Will not Warp, Twist or Rot
Table 1.2. Benefits of hollow block V/S block
Hollow blocks Blocks

1. The size and shape of hollow blocks are 1. There is a variation in size and shape i.e. one
uniform and there is no variation. We can side of the wall is in line. Plastering on both
avoid plastering to have even look. sides is essential. Excessive plaster is done on
one side to have even look.
2. Less number of hollow blocks are 2. More number of blocks is used. i.e.(1100 for
required for the given area e.g. (130 100sq.ft wall)
blocks for 100sq.ft walls).
3, Fixing of fencing angle is easy. 3. Wall has to be cut for fixing angle of
fencing.
4. Work is speedy in about 30% more. 4. Work is slower so it needs expensive labor
cost.
5. Less number of joints is found. 5.More number of joints
6. Its room temperature is less due to 6. Inside room temperature is high.
Cavity in blocks.
7. The structure is purely concrete. 7. The structure is purely mud.
8. 7% extra floor space available without 8. No extra space is available.
Compromising on strength of wall.
1.2.4 Raw materials for cement block or block Aggregate
Aggregate is the stone, sand and ash you want to vibrate and compact down and bind together
with the cement. A good aggregate is an aggregate that is free from chemicals, clay and organic
material. A good aggregate will bond well with the cement paste and not react with it. As a rule
of thumb the denser finished block or the stronger block. You must choose your aggregates

according to your needs. To achieve a dense block with an aggregate that can be vibrated and
compacted down easily you need to have an aggregate with evenly graded particles ranging from
fine dust up to larger stone of around 9mm.Blending different aggregates often produces the best
results.
Cement: Cement is your most costly material and by doing trials with different aggregates you
will be able to minimize on cement content and so decrease your costs. Cement should always be
stored in dry place, off the floor and should be use within three months of the date of
manufacture. Never use cement that has lumps in it and only use cement from a well-known
brand that has an SABS mark of approval on it.
Water: Only clean clear potable water should be used in the manufacture of the blocks and
blocks. Any organic material in water will prevent the cement from setting. Chemicals and
impurities could also affect the strength of the end product. Never use salty or break water. It is
advisable to get your water tested for impurities.[3]
1. Cement
2. Sand
3. Water
4. Fly ash
5. Grit (Gravel)
1.2.5 Manufacturing process of blocks
The process of manufacture of cement concrete hollow blocks involves the following 5 stages;
1. Proportioning
2. Mixing
3. Compacting
4. Curing
5. Drying
We can divided manufacturing process blocks currently as follows

Feeding process leveling process
Ready for pressing pressing process
Fig 1.3.manufacturing process of block

1. Proportioning: The determination of suitable amounts of raw materials needed to produce

concrete of desired quality under given conditions of mixing, placing and curing is known as
proportioning.
2. Mixing: The objective of through mixing of aggregates, cement and water is to ensure that
the cement water paste completely covers the surface of the aggregates. All the raw materials
including water are collected in a concrete mixer, which is rotated for about 1 ½ minutes. The
prepared mix is discharged from the mixer and consumed within 30 minutes.
3. Compacting: The purpose of compacting is to fill all air pockets with concrete as a whole
without movement of free water through the concrete. Excessive compaction would result in
formation of water pockets or layers with higher water content and poor quality of the product.
Semi-automatic vibrating table type machines are widely used for making cement concrete
hollow blocks. The machine consists of an automatic vibrating unit, a lever operated up and
down metallic mold box and a stripper head contained in a frame work.[4]
4. Curing: Hollow blocks removed from the mold are protected until they are sufficiently
hardened to permit handling without damage. This may take about 24 hours in a shelter away
from sun and winds. The greatest strength benefits occur during the first three days and valuable
effects are secured up to 10 or 14 days. The longer the curing time permitted the better the
product.
5. Drying: Concrete shrinks slightly with loss of moisture. It is therefore essential that after
curing is over, the blocks should be allowed to dry out gradually in shade so that the initial
drying shrinkage of the blocks is completed before they are used in the construction work.
Hollow blocks are stacked with their cavities horizontal to facilitate through passage of air.
1.3 Block Making process

Batch mixing: For high quality blocks pan mixer should be used. For low quality blocks hand
mixing on the ground can be used. Always run a series of trials with different mixing
proportions. By evaluating your results you can adapt your mixing to be more cost effective.
Start you trial mixes with 1 part cement to 6 parts aggregate. This translates to one bag of cement
to 3 level wheelbarrows of aggregate. Test your block or block strengths at 28 days.
Mixing process: Pan mixer Place half of your aggregate into the pan mixer then add the cement
followed by the remaining aggregate. Allow the cement and aggregate to mix dry until a
consistent even color is produced. Then start adding in water until the correct moisture content is
reached. By hand spread you’re aggregate out over a concrete surface. Then add your cement by
spreading it over your aggregate evenly. Shovel your aggregate up into a pile. Spread the pile out
again and build it up into a second pile. Spread the second pile out again and add water by
sprinkling it evenly over the spread out aggregate. Mix water into aggregate and then pile the

mixture up for a third time. This method usually adequately mixes your batch. Hand mixing is
labor intensive and time consuming. It also tends to be more wasteful.
Water content: The moisture content within you mix is crucial. It is important for the following
reasons: -
 The correct water content allows for good dense compaction by lubricating the aggregate.
Too much water will lubricate the aggregate to such an extent that the block will fall
apart or sag when removed from the mold.
 With the correct water content the block will release easily from the mold. No suction
between the mold and block will be created.
 A very slight water rippling effect can be seen on the sides of the green blocks when the
correct moisture content is reached. Do not allow your mixed batch to stand for more
than half an hour. This will prevent strength loss in your cement and the lubricating water
will not dry off. Your mix and aggregate may need to be adjusted to get a quality looking
block.
1.4. Problem statement

Current machine used to produce blocks are unable to increase productivity. This is mainly due
to; time wasting by doing the cement charging, loading and leveling. The number of workers
doing on the machine is more and blocks produced per cycle is less. Manually obtaining the
lower mold plate as operator needs the device to turn the block. The load applied several time on
the hollow block. Operator need to manually pick-up the block one by one after compaction
process before start the new process cycle. The mold lower plates are manually inserted one by
one.
1.5. Objective of the project

General objective
The main objective of this project is to design a new blocks making machine with new features
and simplifying the machine for one man operation in order to reduce operational cost and
maximize the production rate. Furthermore, the purpose of this is to design the hollow blocks
making machine that suitable for Small Micro Enterprise entrepreneurs.
Specific objective
 To bring building construction of low cost houses effective, easier and faster using the
CBMM.
 To achieve superior finishes and compatible for almost many types of construction.
 To design the machine with in auto block arrangement system.

 To have on site production to reduce transportation cost and to minimize ecological

unbalance caused due to burnt blocks.
 To design machine part with suitable operation, simple and safe handle.
 To achieve lighter conventional masonry and hollow blocks that save mortar & plaster
cost.
 To upgrade the strength of the block then the previous block.
 Generally it aims high strength and technical superiority over conventional methods.
1.6. Scope of project

The machine applies a pressure of 7.93Mpa in order to produce the hollow concrete blocks and
the motor of this machine also uses about 4.24Kw power for this operation. This machine
produce the inter locked type of blocks that is more suitable for construction. And is compact,
less cement and also suitable for electric wire, water pipe type of block.
This project is start with the literature review on product specification in order to satisfy the
project objectives. After obtaining the product Specification, the project is done based on the
scope Project will focus on hollow block making machine. Designing the inter-locking block
making machine that fulfill the project objective. Machine design to suit the regular hollow
blocks. The project goes until detail design of hollow block making machine. The major output
of this project is to produce the detail drawing machine design. The fabrication of the machine is
excluded in this project.
1.7. Expected results

 High production rate,
 Minimum 4 blocks per cycle,
 One-man operation,
 Simple operation,
 Comes with auto arrange block system
 Comes with cement charging system,
 Comes with cooling system,
 automated function,
 Uniform pressure distribution,
 Can be easily maintainable.
 Safe to handle
 Low cost machine,
 Marketable machine
 Comes with alert system

 Eco-friendly,
The analysis of this project is limited to the manufacturing of compacted block making machine.
within the above listed point of view i.e. the main expected result from the new designed HCB
making machine are the point we list above.
1.8. Limitation
 No enough supply of basic need for the project.
 Absence of source that help us to work easily and quickly, our project.
 Getting less information during interview
 The date to submit the project is short and sudden

CHAPTER TWO
BACKGROUND AND LITERATURE REVIEW
2.1. Background
An artificial form called Portland cement was innovated during the industrial revolution in
England, but the national form continued to be marketable until 1890s. UN improved version of
Portland cement was produced in Great Britain though 19thcentury and held share of import to
the United States until 1871. The Construction of the first American company in Pennsylvania,
The American cement industry had organize into professional group by 1900, one of which was
Portland cement association. The obvious function of this group was to advance the use of
Portland cement, which was accomplished through workshop, advertising, catalogs and pattern
books. Concrete block was highly recommended by the association in 1905.
Early production of concrete block in the 19th century was achieved by filling cast iron or
wooden box molds called “side-face machines “with a “dry mix” of concrete mixed with the
minimum amount of water for hardening. The concrete was added in layers and hand-tamped.
The block was removed via the hinged sides of the mold box and laid out to dry for seven to ten
days in an upright position.
Mass production of concrete block buildings did not develop until Hebron palmer patented a
cast-iron hollow block machine in 1900.With this invention, it was claimed that two men could
produce between eighty to one hundred blocks in a machines that rotated up 90 degrees for
release of the block. Hollow blocks were considered superior as they were lighter, insulated
better and were more moisture-resistant. Once the popularity of the concrete block as a building
material was established, competing companies began marketing their own machines. All
followed palmer’s pattern of metal frame and mold box with hand release lever for opening the
sides and removing the finished product. In the year sprier to standardization of the concrete
industry the size of some early block was 24 or 32 long. Blocks were also thicker, sometimes
weighing as much as 180 pounds. With the organization of manufacturing associations the
however, 1/2 or ¼ size block attachments were accessible, as well as gable, bay window, circular
and corner block attachments.
The formation for the blocks was composed of Portland cement, water, sand and stone or gravel
aggregate. it was advocated that the stones for the aggregate be no larger than ½ inch and that the
concrete should be wet but not over-moist, which would cause the block to adhere to the metal to
sag upon removal from the mold. The most common specifications called for one part cement to
two or three parts sand to four or six parts aggregate. When embossing a design on the face of
the block, a fine mix using highly ground sand or aggregate would be placed on the design plate
and then topped with a coarse mix for strength. The face design came in variety of patterns, some

providing a delicate refined look such as egg and dart, rope face, wreath face and scroll face.
These designs were more commonly used as trim in water tables, belt courses, copings, cornices
and sills. Other designs were imitative of cut stone like rock face and panel face which were
most often utilized for contraction of entire house.[4]
The production of compacted block making machine established in 1988 in South Africa with
joint free India expertise .the CBMM building system replaces conventional blocks and mortar
through the use of compacted blocks, which are hollow and can be dry stacked. The other
components of the conventional building system remain unchanged. These blocks can be made
on construction site or at block yard using hollow block making machines. Today the CBMM
building system and the machines are used in over 50 countries worldwide. This block-block can
be made with lo al soil and cement or fly ash (brunt coal ash) and cement.
These eco-friendly blocks are made with combinations of soil-cement, sand –cement which are
durable, but cost effective because they are made using local soil and require low cement content
(about 5%) and fly ash.
2.2 literature review

Cement concrete hollow blocks have an important place in modern building industry. They are
cost effective and better alternative to burnt clay blocks by virtue of their good durability, fire
resistance, and partial resistance to sound, theBirral insulation, small dead load and high speed of
construction. Concrete hollow blocks being usually larger in size than the normal clay building
blocks and less mortar is required, faster of construction is achieved. Also building construction
with cement concrete hollow blocks provides facility for concealing electrical conduit, water and
sewer pipes wherever so desired and requires less plastering. The machines used to produce
HCBs are electrical vibrating machines which have 4.24kw motor to make sure, that the
vibration is strong enough to compact the concrete sufficiently in the molds and to achieve the
required strength. Before starting production the different materials used to produce the HCB
will be dry-mixed thoroughly on a clean and dry ground by hand. Then the mixture will be put in
the mixer with the appropriate amount of water required (water to cement ratio of 0.49 – 0.55).
The mixture is inserted into the mold and vibrated for about 60 seconds before extruded as
HCBs. Except for the slab-HCB, the machines can produce three pieces at a time. The HCB is a
transported by two people on a wooden pallet. The HCB remains on the wooden pallet for 24
hrs. Then it is being cured covered by a plastic sheet to enhance the curing process and
preventing the water from evaporation. Curing-time is at least 10 days before using the HCBs for
construction. It is important to write the date of production on the HCB so that the mason can
easily identify the HCBs, ready for construction. The materials required for the production of
HCBs and their mixing ratio differs from site to site depending on the availability of the building
materials and the ratio that fulfills the required strength. This holds true for all types of HCBs
production. The average overall production is 1200 HCBs per day per machine. [9]

Fig 2.1. The machine used for the production of HCBs
Concrete block technology offers a high speed, cost effective, environmentally sound alternative
to conventional walling materials. Concrete block technology can be easily adapted to suit
special needs of users by modifying design parameters such as mix proportion, water to cement
ratio and types of production system. The technology has high potential in areas where raw
materials are easily available.
Fig 2.2. Filling in concrete while the machine Concrete is filled up during compacting until the
molded is filled is already vibrating

Fig 2.3. Clearing the top removing the mold upwards

CHAPTER THREE
METHODOLOGY AND CONCEPT DESIGN
3.1 Introduction
This chapter consists of methods for completing product development activities. The applied
methods, which are well-structured, provide a step-by-step approach to complete the task of this
project. Based on these methodologies, there are three advantages expected. Firstly, the
decision processes is completely made, reducing the possibility of moving forward with
unsupported decisions. Secondly, by acting as “check list” of the key steps in a development
activity and ensure that the important issues are not forgotten. Third, these structured methods
are largely self-documenting; in the process of executing the method, the record of the decision-
making process can be used for future reference. [5]
Start
Identifying customer needs
Detail
Establishing target Design
specifications
Concept generation
Material
Concept selection
selection
Setting final specification Hydraulic

Process
Product Architecture Schematic
diagram
Finish Detail
Drawing
Diag 3.1 Method of designing the hollow block making machine

3.2. Concept Development Phase

Development process demands the coordination among functions of the integrative development
methods, which is called as the front-end process. The front end process generally contains many
interrelated activities such as;
1. Identifying customer needs: The goal of this activity is to understand customer’s needs (user’s
need) and to effectively communicate them for the optimization job of current machine used.
The output of this step is a set of carefully constructed customer need statement, organized
in a hierarchical list, with importance weightings for many or all of the needs. The data
are obtained mainly by interviewing the user of hollow block making machine and also from
the observation of the current machine design. The identification of the current machine design
weaknesses is really helpful in providing the target specification.
2. Product specifications: Specifications provide a precise description of what a product has to do

is the translation of the customer needs into technical forms. Targets for the specifications are set
early in the process and represent the guide for generating the idea of machine modification.
Later these specifications are refined to be consistent with the product concept. The output of this
stage is a list of target specifications.
3. Concept generation: The goal of concept generation is to thoroughly explore the space of the
product concepts that may address the customer needs. Concept generation includes a mix of
external search, creative problem solving, and systematic exploration of the various solution
fragments. The result of this activity is three generative concepts, each typically represented by a
sketch and brief descriptive text.
4. Concept selection: Concept selection is the activity in which the generated concepts are
analyzed and sequentially eliminated to identify the most promising concept(s). The process is
using the weight age value and a given marks. The highest score can be considered as a chosen
concept. Several iterations may initiate additional concept generation and refinement,
after evaluating three generated concepts in previous.
5. Setting final specification: The target specifications set earlier in the process are revisited after
a concept has been selected and tested. At this point, the specific values of the metrics reflecting
the constraints inherent in the product concept, limitations identified through technical
modeling, and trade-offs between cost and performance.

6. Concept development: This subtopic shows the preliminary result obtained for
completing product development activities.[6]
Table 3.1 shows the finding data from the interviewing of hollow block producers
Question/ Customer Statement Interpretation

Prompt
Director Increase production rate Increase productivity
from 700 block per day
to5000 block per day One man operation
Reduce manpower
Short operation time period Low machine cost
Engineer It all automatic, only by single Simple operation.
touch! Non-stop machining cycle
No waiting time. Minimum 4 mold cavity
Minimum 4 mold cavities per
compaction High compaction rigidity
Uniform pressure distribution, Machine with
Cooling System, No messy complete system
maintenance. Easy maintenance
Labor I don’t like to press the Fool proof operation
compactor several times just
to make sure the block meet
it dimension.
The block is push to the Automated operation
conveyor and have to turn to
obtain the below mold
plate manually
Suggested Nice rigid machine and Marketable machine
Improvement marketable.
An alert system and a safety Effective alert system
feature.
7. Establishing target specifications
Specifications represent an unambiguous agreement in order to satisfy the customer needs. The
target product specifications are meant to describe the precise description of what the product
has to do. Where the most importance is Comes with auto arrange block system and high
production rate. After identifying the customer needs, target specifications are being set.
Customer needs are generally expressed in the language of customer. The primary
customer needs for machine improvement are listed in table 3 as follows.[6]

Table 3.2 Customer needs
NO Need Importance
1 High production rate 5
2 Minimum 4 blocks per cycle 5
3 One man operation 5
4 Simple operation. 5
5 Comes with auto arrange block system 5
6 Comes with cement charging system 5
7 Comes with cooling system 2
8 Fool proof operation 4
9 Automated function 3
10 Uniform pressure distribution 2
11 Can be easily access for maintenance 2
12 Safe to handle 2
13 Low cost machine 1
14 Marketable machine 1
15 Comes with alert system 1
a).High production rate: The machine must be able to increase the productivity of the block
output. The main reason is it can supply the highly demand of hollow block in the construction
industries. This need is very important so that it is highly rated as it is the factor of the need of
optimization the current machine design.
b. Minimum 4 blocks per cycle: The machine must have minimum four (4) mold cavities as it
can produce four hollow blocks in one time. This is one of the factors that can increase
productivity. More mold cavities can rapidly increase the production rate.
c. One man operation: The machine operation must be handled by a single worker only (one
man operation).
d. Simple operation process: A simple on/off button only and no complicated process in
producing the hollow blocks operates machine.
e. Complete with automatic arrangement: Block system Compare with the current machine
system, for producing the hollow block there is no proper process for arrangement of block after
it being produced. The main objective of this system is to arrange the blocks on the pallet
automatically.

f. Complete with concrete charging system: The raw material/concrete is automatically loaded to
the mold cavities before the compression process begins. The process of charging is repeated
automatically after compaction process cycle take place.
g. Equipped with cooling system: The cooling system or cooling unit functions to cool down the
hydraulic system as heat is highly generated by the non-stop compaction process.
h. Infallible operation: The compression process compact the true value of pressure once. No
need for compress repetition
i. Automated function: Machine can run automatically for the process of cement charging/
loading to the mold, compression, and arrangement of block after compression.
j. Easy accessed for maintenance: Machine can be easily maintained and easily accessed for
maintenance area.
k. Complete with vibrate system: Vibrate system sense the need of cement loading/charging and
also detecting the movement of operator’s body part inside the compaction area for safety
precaution.
l. Safe to handle: Standard operation procedure is one of the factors that make the machine
handling is safe.
m. Low cost machine: The cost to build this machine must be reasonable and within the
capability of SME entrepreneurs so that the return of investment time can be shortened.
n. Marketable machine: Machine appearance and performance must be competitive and at

affordable price so that it benefit the SME entrepreneur. The most useful metrics are those
that reflect as directly as possible the degree to which the product satisfies the customer needs.
The relationship between needs and metrics is central to the entire concept of specifications. The
working assumptions is that a translation from customer needs to a set of precise, measurable
specifications is possible and that meeting specifications will therefore lead to satisfaction of the
associated customer needs as shown in table 3.3.

Table 3.3 The relative importance of each metric and the units for the metric are also
Shown “Sub” is an abbreviation indicating that a metric is subjective.
Metric Need Numbers Metric Importance Units

NO
1 1,2,4,5,6,9,11,15 Production rate 5 Cycle/Hour
2 3 Labor 5 Manpower
3 7 Cooling rate 2 Kw
4 8,10 Compression 5 Pa
pressure
5 11 Maintenance 1 Subj.
6 12,15 Safe Standard 3 Subj.
7 13,14 Unit 2 Subj.
price(machine)
8 14 Aesthetic 1 Subj.
3.3. Different concept of machine arrangement
1.Concept generation: After identifying a set of customer needs and establishing the target
product specifications, the concept of modified hollow block making machine can be generated
by identifying the main problem that preventing customer to get their needs and requirement.
1. Concept one Cantilever concept
Table 3.4 Concept description
NO Requirement Description
1 Production rate Automatic charging/loading and block ejecting system
Reducing the waste identified previously.
Productivity increase as production time being reduced.
2 Labor One man operation with the simple control panel
3 Cooling rate The cooling system is inside the panel box
4 Compression Vertical compression hydraulic system
The location of cylinder is beside of machine itself.
5 Maintenance Maintenance is easy due to all critical item are in the
machine control box
6 Safe Standard Machine operation is able to follow the safety standard;
as this machine concept is compact and all moving part
are inside the machine working area.
7 Unit price Safe to handle,
(machine) Automated function,
Marketable machine
8 Aesthetic The machine is compact and suitable for small working area.
Machine is nice and compact.

2. Concept two center cylinder
Table 3.5 Concept 2 description
No Requirement
1 Production Automatic charging/loading and block ejecting system
rate Reducing the waste identified previously.
Productivity increase as production time being reduced.
4 Compression Vertical compression hydraulic system
pressure The location of cylinder at the center of machine itself.
5 Maintenance Maintenance is easy due to all critical item are in the machine control box
6 Safe Machine operation is able to follow the safety standard; as this machine
Standard concept is compact and all moving part are inside the machine working
area.
Marketable machine
3. Concept three Horizontal compaction concept
Table 3.6 Concept three descriptions
No Requirement Description
1 Production rate Automatic charging/loading and block ejecting system (the
blocks are drop as the compaction cylinder retract and conveyor
will transfer the blocks) Reducing the waste identified
Previously. Productivity increase as production time being
Reduced.
4 Maintenance Maintenance is easy due to all critical item are in the
machine control box
5 Compression Horizontal compression hydraulic system
Pressure The location of cylinder is below the charging container.
6 Safe Standard Machine operation is able to follow the safety standard;
as this machine concept is compact and all moving part
are inside the machine working area.

Marketable machine
2. Concept selection: The first step in using Concept Screening is to identify the criteria that will
be use and can generate significant debate itself. Each concept is then being examines and
compares it against each criterion to give it a relative score. The scoring scheme for this is +1, 0
and -1 to show „better, same, worse‟ or may have values to indicate how much better or worse it
is. Each option then has its score totaled to show its overall score relative to the base option. If
one option scores much higher, then this is clearly likely to be the best choice.[5]
a) Concept screening: The purpose of concept screening is to narrow down the concept selection.
In addition, the concepts are analyzed for improvement possibilities. The reference concept for
the analysis has been identified, which is the existing hollow block making machine which is
currently used. The machine is used as reference because it is currently represents the
high production rate block making machine available in Ethiopia. Furthermore, it is a
straightforward and familiar concept which can easily access. There are 3 concepts which are
going to be compared against the reference concept. The comparison will be done with related to
all customer needs. From the evaluation of the concept screening, concept 1 and concept 2
having the same rank (table 3.8). This mean Concept1 in which having a cantilever type
of hydraulic cylinder attachment and Concept 2 in which having cylinder at the center is
fulfilling the customer requirement is rank as the most preferable concept; the second most
preferable concept is concept 3 which used the horizontal compaction system. Concept 3 is
eliminated from the concept selection which means that the concept is below the standard
customer expectation.[9]
Table 3.7 Concept screening matrix
Selection Criteria Current Concept1 Concept2 Concept 3

(Horizontal)
High production rate - + + -

Minimum 4 blocks per cycle - + + +
One man operation - + + +
Simple operation - + + +
Comes with auto arrange block system - + + +
Comes with cement charging system - + + +
Can be easily access for maintenance 0 0 0 0
Comes with cooling system 0 0 0 0
Automated function - + + -
Uniform pressure distribution - + + -
Safe to handle - + + -

Low cost machine 0 - - -

Marketable machine 0 + + +
Comes with alert system - + + +
Sum 0 4 2 2 2
Sum + 0 12 12 8
Sum - 11 1 1 5
Net Score -11 11 11 3
Rank 4 3 2 6
Continue? No Yes yes No
Rate the concept:
Relative Performance Rating
Much worse than reference 1
Worse than reference 2
Same as reference 3
Better than reference 4
Much better than reference 5
b) Concept scoring
A concept-scoring matrix (Table 3.9) relates the concepts chosen from the screening
matrix to customer needs using weights to show the importance of needs. The reference in the
scoring matrix is not only one concept as it is in the screening matrix.
The reference is spread out among concepts for each need, giving better results since one concept
would not be average in all categories. The score rating from one to five is given to each concept
according to their need depending on the importance to the overall design with five being the
most important and one being the least important. This way of scoring makes the concept-
scoring matrix more accurate than the concept screening importance to the overall design
with five being the most important and one being the least important. After all categories and
concepts are scored, the score is multiplied by the weight and added down a column. The weight
percentage is based on the customer requirements priority. From the listed customer needs,
several important needs are valued with high percentage of weight age.
Concept 2 scored higher than concepts 1. This concept has a vertical compression system that
has a bridge to support the hydraulic cylinder. Even though both of concept using the hydraulic
system to compact the block, the structure of how the cylinder being attached to the structure
affecting the process of machine operation. Furthermore, concept 2 has a compact

shape in which having more aesthetic value compare to concept 1. Comparing the safety features
between both concepts, concept 2 due to having a compact shape, moving machine part is
minimize and became more safety to the machine operator, while concept 1 has a moving part
expose to area working area. From the concept selection activities, the hollow block making
machine that bas bridge support cylinder has proved to satisfy most of the customer
requirements. From this selection, Concept 2 has been chosen as the selected concept. However,
it is not a mandatory to follow exactly this concept. This process is just a guideline in designing
the modification that need to improve in order to fulfill the customer requirements and needs.
3.4. Discussions
This type of projects involves a major modification effort to enhance the current design become
automated and high production rate. The new optimized machine must have an excellent
working principle compared to current machine used. This phase begins with the needs of
customer through interviews (site visit), and observing the product in use. From customer, the
statements are interpreted in terms of customer needs. These interpret data are organize into a
hierarchical list where consist of a set of primary needs and a set of secondary needs. The
relative importance of the needs is established in terms of numerical importance weighting for a
subset of the needs. Scale of 1 to 5 (1 not important and 5 highly importance) are used to
summarize the importance data. The target specifications for hollow block making machine are
established after the customer needs have been identified. A good way to generate the list of
metric is to fulfill each need in turn and to consider what precise, measurable characteristic of the
product will reflect the degree to which the product satisfied the need. The units of measurement
are most commonly conventional engineering units.
After identifying a set of customer needs and establishing target product specifications, the
machine modification concept is being generated. Three concepts generated for proposed
modification, which are hollow block making machine that have cantilever structure holding
compaction cylinder (Concept 1), block making machine that have cantilever structure holding
compaction cylinder (Concept 2), and block making machine that have horizontal compression
system (Concept 3).
In concept selection, the concepts being evaluated with respect to customer needs and
other criteria, comparing the relative strengths and weakness of the concepts, for
further investigation. To narrow the number of concepts quickly and to improve the concepts, the
screening matrix is used. The current machine design used has been chosen to become reference
concept, against which all other concepts are rated. In concept scoring, the concepts are weighted
relative to the importance of the selection criteria and focuses on more refined comparisons with
respect to each criterion. The concept scores are determined by the weighted sum of the rating.
Concept 2 is selected as it obtain higher score compare to the concept 1.Final product
specification then being refine according to the chosen concept before developing the

detail design of the hollow block making machine with bridge supporting compaction
cylinder system.[6]
3.2 Conceptual design of hollow concrete block machine (working principle)

The shaft of the motor (prime mover) rotates which is coupled with the shaft of axial piston
pump. Then the axial piston pump rotates clock wise and pressurized fluid enters into the piston
side of double acting synchronized circuit cylinder one from the axial piston pump.
The vibration motor attached on the bottom side of the container (hopper) which is helping to
shake mixture of cement-sand and filling process of mold from container into charger. One
double acting cylinder (actuator) which assembled horizontally by structure base pushes the
mold which within charger into mold cavity and simultaneously push out the wet HCBs into
roller conveyers.
The parallel acting synchronized circuit of double acting cylinder (actuators) at top structure
assembly applying 62.28kN of force for pressing the blocks in mold cavities. In the next process
the bottom synchronized circuit cylinder (actuators) will push the compacted blocks holder by
mold cavities up and lastly the compacted HCBs which is ready to be push out on to roller
conveyors by the block pusher joined to charger head moved by horizontal structure table
assembled with double acting cylinder which is assembled by bolt with table. And the next steps
begin when the bottom cylinder will retract and concrete charging into mold base by horizontal
double acting cylinder (actuators) assembled on horizontal top structure.
Fig.3.1 HCBMM assembly

3.6 HCB Making Machine main components

1 .Actuator one
2. Top stricture one
3. Compacter
4 .Roller conveyors
5. Mold cavity hold base
6. Charger
7. Stricture base
8. Charger pusher cylinder
9. Push button
10. Container
11. Top stricture tow

CHAPTER FOUR
DESIGN ANALYSIS
4.1 Introduction
The designed hollow block making machine consist of four major sub-assemblies in which
having several components or parts that can be classify to standard parts and custom part. The
main feature of this designed machine is that it is purposely design in a compact size with a fully
automatic function in order to produce blocks in four mold cavities. The parallel acting actuators
or cylinders at the top structure assembly applying 62.28KN of force for pressing the blocks in
mold cavities.[5]
4.2. Design consideration

 Cost
 Availability
 Corrosion and wear resistance
 Strength and hardness
 Manufacturability
 durability and effectiveness
 ease of construction and use
 safe production
 long service
4.3. Punching force analysis
This is the force applied from upper structure to the mold when motor rotate the motor shaft the
shaft push the pump connect to it and then the fluid push the hydraulic cylinders connect to this
part this punching force help for best compaction of concrete block. This machine is on fixed
position. The mold and ram are moved by hydraulic cylinders, which creates a much stronger
block and the block maker can use less cement in order to minimize the cost and better strength
of the cement sand ratio 1:10. Any type of blocks can be produced with consistent quality by
affixing the desired mold. This machine applies pressure of 7.93Mpa.Punching force can be
analyzed as follows:[10]
Step-1-we choice the desired pressure to punch the concrete to produce the four blocks per cycle
to be 0.695Mpa the compressive strength of wet hollow concrete cement sand ratio is 1:10 this
means it needs less pressure to punch.
Step-2-to analysis the force we have to calculate the punched surface area.

Where-the thickness, t=20mm the overall dimension mm
The top surface area of one block=total upper area-(area of A+B)
= (400×150)-(340×110)
=22600 since number of blocks produced is four per

cycle, =22600×4=90400
Step-3-the compressive strength or pressure required to punch each wet HCB of sand-cement
ratio 1:10 is 0.1737Mpa.because of our machine produce four blocks per cycle. The required
pressure is 0.695Mpa in order to remove the defect and get high strength block.
=0.695×90400
=62831.85N
=62.832KN
Step-4-this machine is build using simple design, which makes them high on efficiency and low
maintenance. Advanced features and innovation designing make this model to provide quick and
easy production. The force applied by both rod= , the force of each rod
The machine needs to apply the force of KN on the concrete particle inside the mold in
order to produce the hollow block depend on the force, we select the bore diameter of cylinder
from standard table to be d=100mm for cylinder one. The rod diameter of both cylinder is equal
to each other thus to balance the punching force in order to prevent the cracking force and the
mass balance must be equal push the puncher. Cylinder synchronization system, cylinders are
connected in series. Piston area of cyl2=piston area of cyl1-rod area of cyl1 [7]
Fig.4.1. cylinder synchronization

Valve normally closed in un activated position
( )
( )
√( )
√( )
, since the standard bore diameter of any

cylinder is between( )mm the design is safe. Therefore from the standard table the
corresponding rod diameter of cylinder two is 56mm.
( )
( )
But the pressure at rod side of cylinder- ( )
( )
The addition of both forces,
( )
The pressure out from the pump

and used for push down ward the two synchronized cylinder, then the cyliders apply 62.28KN
force to get compacted, with best strength, regular shape block.

4.4. The force analysis of mold holding cavity (up push)

4.4.1. Material selection for mold holding cavity
The material we select for mold holder is ASTM A36 steel because it is the most common
available mild steel. It is also best corrosive resistant, high compressive strength, high heat
resistant. The density of mild steel is .
Table 4.1 material properties of mold holding
ASTM A36 Mild (low-carbon) steel
Minimum Properties Ultimate Tensile Strength, psi 58000-79800

Ultimate Tensile Strength, psi 36300
Elongation 20.0%
Chemistry Iron (Fe) 99%
Carbon (C) 0.26%
Manganese (Mn) 0.75%
Copper (Cu) 0.2%
Phosphorus (P) 0.04% max
Sulfur (S) 0.05% max
4.4.2. Design calculation
The overall volume of mold holder ( ) ( )
The force due to weight of mold base,

This much force is needed to push the mold base up to remove the hollow concrete block by
neglecting the friction force between the mold base and wet block.
In order to push the equal force up the mold base we use double acting synchronized cylinder.
Fig 4.2. Double acting synchronized cylinder push up
So the force should be equally divided to two cylinders, each cylinder rod holding force
is .
Fig 4.3. Division of force between two synchronized cylinders equally
From the standard of cylinder bore selection interval ( ), the load 577.5N holding
the cylinder bore of 50mm and the corresponding rode diameter is 28mm.But the rode diameter
of both cylinder must be equal to each other in order to hold equal amount of force and resist the
bending force.[7]
( )

( )
( )
Therefore the bore diameter of cylinder one is the pressurized fluid comes from the pump
and push the piston side of cylinder one.[8]&[7]
( )
4.5. Design of block push out piston from the mold basis
Fig 4.5a.block pusher piston

The mass of each wet hallow concrete block is 3kg.So for four blocks is 12kg,
F m
Mg
Diag 4.1. total force applied on block push out
The mass the table that carry the blocks is 2kg.So the total mass that are pushed by the piston rod
is Therefore weight of the blocks and table to be pushed is,
The friction coefficient between table and base is nearly zero so friction force is negligible. The
total force that push the wet block is F=137.2N.[8]
D=40mm
Fig 4.4. Double acting cylinder used for push out wet blocks
The pressure required,

( )
Since the pump pressure (7.93) is higher than the required pressure (0.109) the design is safe.
4.6. Pump selection of the system
Requirements of selection,
 determining flow rate

 determining pump speed and select the prime mover
 select pump type based on application
 select system pressure
Piston pump (axial) is selected because its advantage likes,
 high pressure capability(up to 10000psi)

 small-compact size
 high volumetric efficiency
 small change in efficiency through the design pressure range
 great flexibility of performance requirements and speed ranges[12]
Fig 4.5. Axial piston pump
In this type of the pump, the cylinder block and derive shaft are located on the same centerline.

The piston is connected to shoe plate which bears against reciprocating because the piston shoes
flow the angle surface of the swash. The maximums wash plate angle and maximum torque
capability.
Where-
But
The extended length of rod cylinder,
Because the height of mold base is this amount. The time required to extend
200mm length of stroke .
, but
The output power of the pump
4.7. Selection of hydraulic fluid for pump

The hydraulic fluid we are going to select is a type of fluid that transmits power. Even though
there are many type of hydraulic fluid that used for transmit ion of power, we select petroleum
based hydraulic oils because of the following properties of it.
Petroleum Based Hydraulic Oils: These are, by far, the most commonly used hydraulic fluids,
and are used in approximately 95% of all hydraulic systems. They are low to moderate in cost
and, when properly treated with rust inhibitors, oxidation inhibitors, anti-wear agents, anti-foam
agents, and a number of other additives, will pass all pump manufacturers’ tests and
requirements for hydraulic fluids. They generally require little maintenance and give long service
life. Their availability in a broad range of viscosities allows use across a very wide range of

temperatures. Due to the wide variety and quality of additives used by various manufacturers of
petroleum based hydraulic fluids, it is very important to select it. [12]
The symbol representation cylinder circuit
Flow regulation valve
Spring
Double acting piston
Restrictor valve

Pressure reducing valve
4.8. Motor selection

4.8.1. Motor selection consideration
The overall motor performance is related to the following parameters
 Power factor
 Service factor
 Sound level
 Speed
 Start torque
 Acceleration capabilities
 Breakdown torque
 Efficiency
 Enclosure type
 Heating
 Inrush current
 Insulation class
A good motor specification should define performance requirement and describe the
environment within which the motor operates. As the purchase, you should avoid writing design
based specification that would require modification of standard components such as the frame,
bearing, design, rotor design, or insulation.[5]
Specification contents should include:
 Motor horsepower and service factors

 Temperature rise and insulation class
 Efficiency requirement and test standard to be used
 Load inertia and expected number of starts

 Maximum starting current

 Minimum stall time
 Power factor range
Environmental information should include:
 Abrasive or non-abrasive
 Hazardous or non-hazardous
 Humidity level
 Altitude
 Ambient temperature
We should specify special equipment requirement such as the fire protection, space heaters (to
prevent moisture condensation), and whether standard or non-standard are required. Due to the
power output from the motor, there is rotational motion of the pulley. The pulley drives a belt
that are used to transmit power from one shaft to another by means of pulley which rotates at the
same speed or different speed it is very important to obtain all the listed information before
making selection. [10]
 Source of input power

 Types of driven equipment
 Power to be transmitted
 Available lubrication type
 Spare limitations
 Adverse environmental condition.
 Speed and size of driven shaft
 Drive center distance and drive arrangement
 Means of center distance arrangement, if any
4.8.2. The power of the motor
The power of the motor is equal to the power of pump divided by efficiency of axial piston
pump. The efficiency of axial piston pump is between (90-95) %.Taking the average of the two
(94%).
The power of the motor=(power of the pump)/(efficiency of axial piston pump)
=3.986Kw/0.94
=4.24Kw
The revolution per minute (rpm) for this much of power from the standard is 2100rpm.By
considering all the above preconditions of selecting the motor having; the power of 4.24kw is

selected. Depending on the selected motor, which has a power of 4.24kw, used to rotate the
shaft. The revolution per minutes of the shaft of this standard motor is 2100rpm.The torque
applied by the motor can be calculated by using the power equations which is given by ,
4.9. Design of motor shaft

4.9.1. Material Used for Shafts
The material used for shafts should have the following properties:
 It should have high strength.

 It should have good machinability.
 It should have low notch sensitivity factor.
 It should have good heat treatment properties.
 It should have high wear resistant properties.
The material used for ordinary shafts is carbon steel of grades 40 C 8, 45 C 8, 50 C 4 and 50
C 12.Types of shaft: - the following two types of shafts are important. These are transmit ion
shaft and crank shaft .From the subject point of transmission shafts these shafts transmit
power between the source and the machines by absorbing power. The counter shaft, line
shaft, overhead shaft and all factories are transmission the shaft is made of mild steel
Material (steel with Allowable shear stress of=19.3Mpa).

4.9.2. Shaft diameter calculation
We know that that torque transmitted by the shaft (T),
√( )
So the standard diameter of the shaft is 25mm.
Take standard diameter, so we take standard diameter of motor shaft to be,=25mm Because
Standard Sizes of Transmission Shafts are: 25 mm to 60 mm with 5 mm steps; 60 mm to 110
mm with 10 mm steps; 110 mm to 140 mm with 15 mm steps; and 140 mm to 500 mm with 20
mm steps. The standard length of the shafts is 5 m, 6 m and 7 m. the maximum permissible
working stresses in tension or compression of transmission shafts is taken as 112 MP for shafts
without allowance for keyways and the maximum permissible shear stress may be taken as 56
MP for shafts without allowance for key ways.[5]
Shafts Subjected to twisting moment only
When the shaft is subjected to a twisting moment (or torque) only, then the diameter of the shaft
may be obtained by using the torsion equation. We know that
Where T= Twisting moment (or torque) acting upon the shaft
J = Polar moment of inertia of the shaft about the axis of

rotation,
τ= Torsional shear stress, and
R=Distance from neutral axis to outer most fiber
= ⁄ ; where dis the diameter of the shaft.
We know that for round solid shaft, polar moment of inertia,

( )
The twisting moment (T) is obtained by using the following relation:
4.10. Design of upper structure

4.10.1. Material for upper structure
The following factors should be considered while selecting the material:
1. Availability of the materials,
2. Suitability of the materials for the working conditions in service, and
3. The cost of the materials.
4. Strength etc. the steel has been specified on the basis of minimum tensile strength or yield
strength. The minimum tensile strength or yield stress in N/m Fe 290’ means steel having
minimum tensile strength of 290 N/mm.

4.10.2. Force and bending moment analysis
The force applied by both cylinders each having a force of 31.14KN
162.5mm 487.5mm 162.5mm
B D
A E
Diag 4.2 reaction force
The total reaction force,
The bending moment is at,
@point A, the bending moment is zero because the length is zero
@point B ,the bending moment becomes
@point C, the bending moment becomes
( ) ( )

@point D, the bending moment becomes
( ) )
( )
@point E, Note be we use negative sign for dawn ward force and positive sign for
upward force.
BFD
62.28KN
. 31.14 KN
25.3KNm
BMD
-5.06Nm
Diag 4.3.bending moment of diagram

4.11. Design of frame

4.11.1. Material selection
Consideration for the design:
 Cost
 Availability
 Corrosion and wear resistance
 Strength and hardness
 manufacturability
 durability and effectiveness
 ease of construction and use
 safe production
 long service life
Material we select for the frame depending on the above consideration is mild steel metal with
young’s modulus E=0.21 and crushing stress of 330
4.11.2. Frame calculation
The total force exerted by the support frame is combination of mass of mold, upper structure, and
lower structure, motor, wet blocks, mold in the hopper and other hydraulic actuators and other
accessories. The summation of all masses listed above becomes 300kg.assumin factor of safety
to be 5 we can calculate critical load of the frame.
Weight of the total masses,
Critical load of the frame,
Taking the length of frame to be 400mm and from formula of crippling load for the polar
moment inertia (I),

( )
4.12. Bearing selection

4.12.1. Type of bearing
Bearings typically have to deal with two kinds of loading, radial and thrust
Fig 4.6.Types of bearing
a).ball bearing b).roller bearing c).radial ball bearing d).thrust ball bearing
Fig 4.7. Types of bearing
The life of an individual ball (or roller) bearing may be defined as the number of
revolutions (or hours at some given constant speed) which the bearing runs before the

first evidence of fatigue develops in the material of one of the rings or any of the rolling
elements.
Rating life of a group of apparently identical ball or roller bearings is defined as the
number of revolutions (or hours at some given constant speed) that 90 % of a group bearings
will complete or exceed before the first evidence of fatigue develops.[5]
Minimum life is used to denote the rating life. The average life of bearings is 5 times the rating
life (or minimum life). The longest life of a single bearing is seldom longer that the 4 time the
average life and the maximum life of single bearing is about 30 to 50 times the minimum life.
Table 4.2.Life of bearings for various types of machine.
NO Application of bearings. Life of bearing, in

Hours
1 Instruments and apparatus that are rarely used
a) Demonstration apparatus, mechanisms for sliding doors.
500
1000-2000
b) Aircraft engines.
2 Machines used for short periods or intermittently and 4000-8000
Whose breakdown would not have serious consequences
3 Machines working intermittently whose breakdown 8000-12000
Would have serious consequences.
4 Machines working 8 hours per day and not always fully 12000-20000
utilized.
5 Machines working 8 hours per day and fully utilized. 20000-30000
6 Machines working 24 hours per day. 40000-60000
7 Machines required working with high degree of reliability 24 100000-200000
hours per day.
4.12.2. Selection of ball bearing.
1. Basic dynamic radial load is calculated. It is then multiplying for the service factor to get the
design basic dynamic radial load capacity.
2. Selection of the bearing is made from catalogue of manufacturer, according to basic static and
dynamic capacities.

Table 4.3. Values of service factor
NO Type of service. Service factor Ks

for radial ball bearings
1 Uniform and steady load 1.0
2 Light shock load 1.5
3 Moderate shock load 2.0
4 Heavy shock load 2.5
5 Extreme shock load 3.0
4.12.3. Standard Dimensions and Designations of Ball Bearings
The dimensions that have been standardised on an international basis are shown in Fig.4.1.2
these dimensions are a function of the bearing bore and the series of bearing. The standard
dimensions are given in millimetres. There is no standard for the size and number of steel
balls.The bearings are designated by a number. In general, the number consists of atleast three
digits. Additional digits or letters are used to indicate special features e.g. deep groove, filling
notch etc. The last three digits give the series and the bore of the bearing.The last two digits from
04 onwards, when multiplied by 5, givethe bore diameter in millimetres. The third from the last
digit designates the series of the bearing.
Fig 4.8.Standard designation of ball bearings

Lubrication of ball bearing.
They are lubricated for the following purposes:
 To reduce friction and wear between the sliding parts of the bearing
 To prevent rusting or corrosion of the bearing surfaces.
 To protect the bearing surfaces from water, dirt, etc.
 To dissipate heat.[5]
In general, oil and light grease are used for lubricating ball and roller bearings. Too much oil or
grease causes the rise of the temperature of the bearing. Temperatures should be kept below
90oC and in no case; the bearing should operate above 150C.
4.13. Design of welded joint

Types of weld selected: - fillet
Assumption
 The load is distributed uniformly along the entire length of the weld
 Stress is spread uniformly over its effective section.
 Static condition.
Advantages of welded joints over riveted joints.
 Welding structures are usually lighter than riveted joints.

 Welded joints provide maximum efficiency, which is not possible in riveted joints.
 Alteration and additions can be easily made in the existing structures.
 Smooth structure in appearance, therefore its look pleasing.
 Tension member are not weakened as in the case of riveted joints.
 Greater strength often has the strength of the parent metal itself.
 Sometimes, the members are of such shape that the welding is easier.
 Welding provides very rigid joints.
 It is possible to weld any part of a structure at any point.
 The process of welding takes less time than riveting.
Disadvantages of welded joints over rivet joints.
 Members may be distorted or additional stresses may be developed for heating

and cooling during fabrication.
 Requires a highly skilled labor and supervision.
 There is a possibility of crack developing for no provision for expansion and contraction
on the frame.

 Inspection is more difficult.
Types of welded joints.
 But joint - two parts in approximately in the same plane.

 Corner joint: - two parts located approximately at right angle each other.
 Lap joint: - between over lapping parts in parallel plates.
 T- joint: - joints at approximately right angle in the form of “T”.
 Edge joint: - between the edge of two or more parallel parts.
Lap joint: lap joint divided into the following type
1) - Single transverse 2) - Double transverse and 3)- Parallel.
a).Single transverse b).Double transverse c).Parallel

Fig 4.9 welded lap joint
Table 4.4.Stress for welded joints.
Type of weld Bare electrode Coated electrode

Steady load Fatigue load Steady load Fatigue load
Mpa Mpa Mpa Mpa
Fillet weld 80 21 98 35
All types
Butt weld
Tension 90 35 110 55
Compression 100 35 125 55
Shear 55 35 70 35

Table 4.5. Stress concentration factors.
Types of joints Stress concentration factor

1- Reinforcement Butt joint. 1.2
2- Toe of transverse filled weld. 1.5
3- End of parallel filled weld. 2.7
4- T - Butt joint with sharp corner. 2.0
4.14. Design of bolt

4.14.1. Material selection for bolt
 So the material we chose for bolt has to have high wear resistance, good machine ability,
tensile strength and toughness.
 The material is SG 500/7, minimum tensile strength.
 This metal is graphite cast iron.
4.8.2. Design analysis of bolt
During design of bolt the following included:
 Tensile stresses due to stretching of the bolt

 Torsional shear stress due to frictional resistance at the threads.
 Shear stress across threads.[9]
 Compressive or crushing stress on the threads.
 Bending stress if the surfaces under the bolt head are not perfectly.
The resultant axial load on a bolt depends upon the following factors:
 The initial tension due to tightening of the bolt,

 The external load, and
 The relative elastic yielding (springiness) of the bolt and the connected members.
Assumption:-
 The shear loads are carried by friction.

 The attached members are rigid and do not deflect with loads.

Fig 4.10 .Bolted joint.
According to Indian Standard Thread designation M20 x 2.5C indicates a metric bolt of nominal
diameter 20 mm and a course pitch of 2.5 mm.
Based on the above standard bolt initial tightening load is given by:
External load on each load bolt is,
Where n=number of bolts
P=pressure of hydraulic pump

( )

The constant K value range from 0.5-0.75.taking an average value of K=0.625 the total
resultant load
( )
From the above calculation the area becomes .the bolt stress becomes,
Factor of safety 3
To be the bolt design is safe the load ( )
Which is ( )
4.15. Design of hopper (concrete container)

4.15.1. Material selection for the hopper
Since the hopper carry wet cement that can corrode the material the hopper must resist this
action. Due to this we select aluminum sheet metal with yield stress (90-150) Mpa which is best
corrosion resistive metal.[8]
4.15.2. Hopper design analysis
Fig 4.6.hopper

To calculate the volume of the hopper we have to know the weight that it carries. Assuming the
maximum mass to be 40kg the weight becomes,[11]
350mm
700mm
Diag 4.4.force applied by hopper
The force applied by hopper along x- axis,
Force along y- axis,
( )
( )
The height of the hopper is 581mm,

CHAPTER FIVE
COST ANALYSIS AND MANUFACTURING
In today’s competitive business environment, pricing strategy can be a critical factor that can
make the difference between success and failure. Organizations that are cost efficient would
have a clear competitive advantage, therefore accurate and timely cost information can go a long
way in helping these organizations become successful. Organizations also need to control their
cost through effective budgeting and variance analysis. This will enable them to quickly take
corrective action and steer the organization back on track. In the same way we also try to
calculate the cost analysis of the machine of our project.[9]
5.1 Guidelines for Calculating the Block Selling Price
The data presented in this sub topic is meant to help entrepreneurs to estimate the production cost
of compressed block with a view to identifying the lowest costing technology and size of
production. A methodological framework for the estimation of production costs is described in
the following sections. It should be noted that the cost of producing compressed block will
vary a great deal from country to country and even from one area to another within the same
country. Unit production costs will differ in relation to local conditions. Causes for cost
variations include:
 Availability of soil, whether it is available on site or has to be transported to the site.

 Suitability of the soil for stabilization, and thus the type, quality and quantity of
stabilizer needed. It may also be necessary to buy sand if the soil has an
excessively high linear shrinkage,
 Current prices of materials.
 Whether the blocks are to be made in rural or urban areas, size and type of equipment
used and quality required.
 Current wage rates and productivity of the labor force.
It is important to note that block making can be carried out on a „self-help‟ basis, where
labor Costs are eliminated. Furthermore, soil is often available at no cost. The
methodological Costing technique consists of 12 steps that may be sub-divided into two
main parts:
(a) Determining quantities of the various inputs (Steps 1 to 6),

(b) Estimation of the cost of each input and computation of unit production costs (Steps 7
to 12). These steps are briefly described in the remaining part of this section.
Steps 1 - Determining the quantity of blocks to be produced in a given period of time. The
number will be a function of market demand, availability of finance, acquired production
techniques, etc.
Step 2 - Calculate amount of material inputs required for the chosen scale of production. The
basic materials are suitable soil, sand (if needed for linear shrinkage modification), stabilizer and
water. Some oil, for example used engine oil, will be needed as a mold release agent.
Step 3 - List of equipment required. This will include items for digging and moving soil,
preparing soil with a crusher or sieving screen, mixing, a device for molding the blocks, a
covered yard for curing the blocks and an office. Provision should also be made for soil
investigation and testing equipment. Chapters 2 to 4 provide information on the type of
materials, equipment and infrastructure needed. The cost of industrial pieces of equipment may
be acquired from equipment suppliers and manufacturers or from local workshops in cases where
the equipment is produced locally.
Step 4 - List of labor requirements. The productivity of the labor force may not only vary from
one country to another, but also from one site to another within the same country. It is
important to specify the length of the working day, the number of days worked per week and the
number of working weeks per year, taking into account an allocation of time for leave of absence
during the year. The level of skill requirements must also be determined.
Step 5 - Other local services and facilities may be required, such needs may include:
 land for quarrying soil for block making,

 land for production area,
 land for curing area and storage of raw materials,
 Provision of access to working area for delivery of materials and dispatch of products.
Step 6 - Computation of working capital requirements. In addition to funds required for

purchase of equipment and land as itemized in the preceding steps, it will be necessary to have
sufficient financial resources for the purchase of raw materials and payment of wages for a
period of two months, since there can be no income from the sale of blocks until they have been
made and cured. If difficulties are anticipated in obtaining any particular commodity, it might be
necessary to maintain enough stocks for a period longer than one month. It may also be desirable
to use some of the first products in the construction of the covered area, offices, etc., in order to
reduce the cost of items under Step 3. It will then be necessary to slightly increase the working
capital to allow for the number of blocks that will be used for this purpose, rather than sold.

Step 7 - Annual cost of materials identified in Step 2 must be calculated. Clay, sand and water
are often extremely cheap items. The mold-releasing agent will not be needed in large amounts.
So its cost should very little. Reject engine oil may be acquired at a very low price or obtained
free in some cases.
Step 8 - Computation of depreciation costs of equipment and buildings. Whatever type of

equipment used, it will have a limited life-span. An estimate must be made of the annual
depreciation costs for separate equipment items. The depreciation cost of buildings must also be
estimated. These costs will depend on the original purchase cost, the life-span of equipment and
buildings and the prevailing interest rate. It should be noted that the longer the useful life of
equipment or building the lower the annual depreciation cost.
Step 9 - Reasonable value must be given for the cost of labor in the area where blocks are to be
produced. Local wage levels for different skills must be applied and fringe benefits included in
the estimation of labor costs.
Step 10 - Land has an infinite life, and the area from which soil is obtained may be restored to
its original use in some instances. Thus the annual cost of land may be assumed to be equal to the
annual rent of the same or equivalent piece of land. If the land is already owned by the investor,
a hypothetical annual rental rate should be used when estimating the annual land cost, since this
is the income the investor might have obtained by renting it out instead of using the land
themselves.
Step 11 - Working capital raised on loan for the block-making project will need to be accounted
for in the annual cost for interest payments on borrowed capital.
Step 12 - The unit production cost may be calculated by summing up the separate cost items
from Steps 7 to 11 in order to get the total annual cost. The latter is then divided by the
number of blocks manufactured annually to obtain the unit production cost.
Therefore: Total annual production cost= Material costs (7) + Depreciation (8) + Labor cost (9) +
Land rental (10) + Interest on loan [9]
Unit production cost
5.2. Machine component and Raw Material Cost
In order to calculate the cost of building this machine, the list of parts or component must be
clearly identify by referring to the bill of material generated upon the final stage of design. This
hollow block making machine consist of four sub-assemblies and each component in the sub-
assembly consist of several components which can be classify as standard part and custom
part. These can be clearly understood by referring to the bill of materials figures shown.

Bill of Materials
 Total assembly drawing

 Mold assembly drawing
 Table assembly drawing
 Top structure assembly drawing
 Charging system assembly drawing
5.2.1. Material Cost
a) Estimation Material cost
Table 5.1. Material cost
NO Part Quantity Price(birr) Total price(birr)

1 Parallel Flange
152 1 97.00 97.00
1 300.00 300.00
260 1 340.00 340.00
305 1 480.00 480.00
2 Angle Bar
60 70 522 2 25.00 50.00
60 70 740 6 35.00 210.00
102 102 480 2 70.00 140.00
100 73 748 2 160.00 320.00
3 Steel Plate
530 780 30 1 1400.00 1400.00
100 725 40 1 990.00 990.00
160 44 23 4 160.00 640.00
125 300 15 4 60.00 240.00
500 750 40 1 1400.00 1400.00
60 489 10 2 111.00 222.00
120 750 20 1 550.00 550.00
610 1267 20 1 1000.00 1000.00
1127 50 20 1 450.00 450.00
4 Round Bar
Ø15 120 1 6.00 6.00
Ø20 190 1 4.00 32.00
Ø30 250 2 23.00 46.00
Ø60 720 4 230.00 920.00
Ø100 160 4 70.00 280.00
5 Square Bar
25.4 x 25.4 8364 1 160.00 160.00
50.8 x 50.8 11320 1 1102.00 1102.00

6 Sheet Metal (2mm)

4‟x 8” 2 210.00 420.00
7 Steel Block
300 x 125 x 52 1 330.00 330.00
610 x 350 x 165 1 600.00 600.00
TOTAL 12725.00
b) Screws and nuts
Table 5.2 Screw and nuts cost
NO Part Quantity Price(birr) Total price(birr)

1 M12 x 130 12 2.00 24.00
2 M12 Nut 12 2.50 30.00
3 M16 x 40 24 2.50 60.00
4 M16 Nut 24 2.00 48.00
5 M20 x 70 37 4.00 148.00
6 M20 Nut 37 3.50 129.50
7 M24 x 100 4 9.00 36.00
8 M4 x 15 34 1.00 34.00
9 M10 x 40 58 2.00 116.00
TOLAL 625.50

c) Mechanical System Equipment Cost Estimation
Table 5.3 Mechanical system and equipment cost
NO Parts Quantity Price(birr) Total price(birr)

1 Top Hydraulic System
Hydraulic 2 1350.00 2700.00
cylinder
Power pack unit 1 3500.00 3500.00
2 Horizontal Hydraulic System
Hydraulic cylinder 1 550.00 550.00
Power pack unit 1 3300.00 330.00

3 Bottom Hydraulic System
Hydraulic cylinder 1 420.00 420.00
Power pack unit (share with

horizontal hydraulic system) - - -
4 Vibrator Motor
PL15E QD 1.8HP 2 950.00 1900.00
PL20E QD 2.4HP 1 1000.00 1000.00
5 Bearing Bush
LHFCWM30 2 42 84.00
LHFCWM50 4 115 460.00
TOTAL 10944.00
5.2.2. Manufacturing cost

Table 5.4.Manufacturing cost
NO Machine Hour ⁄ TOTAL(birr)
1 Milling 14 60 840.00
2 Drilling 40 40 1600.00
3 Wire EDM 45 90 4050.00
4 Welding 8 50 400.00
5 Turning 10 55 550.00
6 Assembly 30 65 1950.00
9390.00

Estimation of total machine cost= Manufacturing Cost + Material Cost+ Screws and nuts +
Mechanical System Equipment =9390.00+12725.00+625.50+10944.00
=33684.50(birr)
Therefore, roughly, total machine cost including the mechanical system is BIRR
48800.00. However, this value may change relatively as a time goes by.
5.3. Product design specification

Product Design Specification (PDS) is the basis for all design decisions, it may serve as
a contract that must be fulfilled; PDS is dynamic rather than static; PDS must be established with
consideration of all aspects of the product and it’s interactions; systematic and through in
formulating PDS; Poor PDSs lead to poor designs; good PDSs are necessary, but not sufficient
for a good design. At the first stages of design it is essential to cover all the aspects of the
product even if at a superficial level. The specificity of details can be honed as more is learned
about the product and the interactions of different aspects of the PDS. From internal market
research, it has been decided that this machine need to be designed as simple as possible so
that it can be sell to the hollow block making machine construction sector. The machine
should be automated so it can have a shorter lead time in making a blocks. Below is the
product design specification that has been generated according to the development of the
final design. However, as long as this design become a real product, it still can be considered as
not yet a final PDS as it can be change parallel with the fabrication of this machine.[6]&[5]

Table 5 .4. Final product design specification
NO METRIC VALUE
1 Performance
Production rate Cycle/Hour 125>
Maximum force kN 62.28
Charging container capacity m3 1.5
Operating period Hour/Day 8(three shift)
Compression pressure Maintenance MPa 7.93
1 Maintenance
Maintenance free except for light lubricant
Parts requiring lubrication should be accessible within 15 minutes
Without the use of special tools or equipment.
All fasteners used should comply with machine system.
No special tools should be required for maintenance.
3 Size and weight
Weight Kg 300
Length M 1.8
Width M 1
Height M 2.5
4 Product life span year 11>

5 Labor manpower 1
6 Unit price (machine) 33684.50

5.4 Manufacturing and process selection [8]
Table 5.5 manufacturing process and process selection
No Part Material Manufacturing

process
1 Steel (mild Cutting process by
steel) hacksaw
Cut by shearing
machine ;laser
cutting
Assemble by welding
process.
block pusher
2 Cutting process by
hacksaw, laser
cutting
Assembly by welding
process.
charger

3 Cutting process by
hacksaw, laser
cutting
Assembly by welding
process.
compacter
4 Aluminum Laser cutting, turret
sheet metal punching and
welding
Process for joining.
container
5 Sheet metal Laser cutting, turret
punching and
welding
Process for joining.
cover

6 Steel bar Milling and drilling

Join on the top of
compactor by
welding process.
hinge
7 Steel bar Cut by sawing
process, drilling and
tapping.
middle bar
8 Mild steel Drilling and wire
cutting
mold base

10 Steel Milling, drilling,

plate(mild counter boring and
steel) wire.
movable base
11 Steel Milling, drilling and
plate(mild counter boring.
steel)
planar base
12 Angle bar Cut by sawing and
sawing
Assemble by welding
process.
plate structure

13 Steel plate Milling, drilling and

counter boring.
pusher base
Steel rod Cut by sawing
process, drilling and
tapping process.
pusher shaft
14 Steel rod Cut by sawing
process, turning,
drilling and tapping
process.
rode

15 Steel plate Steel plate cut into

several parts, then
further with milling
and drilling process.
The parts then join
by welding process.
slider base
process drilling.
slider compactor
17 Angle bar Cut by sawing
process drilling.
table structure 1

18 Parallel Cut by sawing

flange process drilling.
table structure2
19 Steel bar Cut by sawing
process drilling and
welding.
structure base
20 Angle bar Cut by sawing
Parallel process drilling,
flange milling and welding.
table

21 Parallel Cut by sawing

flange process drilling and
Steel bar milling.
top
structure1
process drilling and
tapping.
pusher slider
23 Cylinder Standard hydraulic
diameter of cylinder with side
40mm mounting.
horizontal cylinder

24 Cylinder Standard hydraulic

diameter of cylinder with bottom
57.306mm mounting.
bottom cylinder
25 cylinder of Custom hydraulic
diameter with special
mounting
top cylinder
26 Parallel Standard hydraulic
flange cylinder with side
Steel bar( mounting.
steel)
top structure2

27 motor having Standard vibration

power of motor for heavy duty.
4.24KW

CONCLUSSION
Starting from many years ago people are using blocks those have different shape for
construction. In Ethiopia, many of us still use wood and mud for making construction. This is
due to the less access and high cost of blocks that comes from backward system of block
production. The aim of our project is just to decrease such problem by using more advanced
machine that produce more numbers of HCBs per cycle and also reduce number of workers on
the machine.
Shorter operation time (30 - 40 seconds) and automatic machine with less maintenance required
is the ideal machine dreamed by the block manufacturer. The target specifications are established
after the customer needs have been identified but before product concepts have been generated
and the most promising ones selected. This process is done in the first part of this project until
the best generated concepts is selected. The chosen concept is being refined its value until the
detail design is generated (mechanical, electrical, and hydraulic) in reflecting on this project all
objectives were successfully met. The design product engineered that help a user to maximize
the production of the hollow blocks in the minimum cost.
The main use of the new design of hollow block making machine was to be able to ensure that
the block productivity increase compare to the current machine design.

RECOMMENDATION
The hollow concrete block will continue to evolve as block manufacturers develop in new shape
and sizes. These new blocks promise to make building construction faster and less expensive, as
well as result in structures that are more durable and energy efficient. Some of the possible block
designs for the future include a mold pattern that are available for interlocking mechanisms of
one block with the other block. This reduces the amount of cement used and it is more
comfortable for construction. So we recommend that the local enterprise to produce HCBs by
using this machine in order to become more productive and serving the society. It is also better if
someone wants to make construction uses this type of blocks that are inter locked and save
amount of cement used.it is also good if School of Mechanical Engineering facilitate to change
this project to practical for the future.

REFERENCE
[1] H.C. Sump, Block Machine, United States Patent Office, Application December 16, 1946,
Serial No. 716,564, Cl. 25-41.
[2] Judson A. Hereford, Block making apparatus, United States patent, Application January
1991, Serial No. 636,726, Cl. B29C 43/00.
[3] Nicholas Lyons and C.K George, Inverter for block mold, United States Patent, Application
February 1989, Serial No. 313,067, Cl. B28B 5/02.
[4] Vernon C. Duff, Machine for manufacturing hollow concrete blocks, Application July 1928,
Serial No. 293,882.
[5] Mechanical Engineering Shipley’s Mechanical Engineering Design, Eighth Edition Text: by
Budynas−Nisbett.R.S. Khurmi, J.K. Gupta, a text book of machine design, 2002, 13th Edition.
[6] Bralla james g.”Handbook of product design for manufacturing: a practical guide to low cost
production,”mc garw hill 1986 USA
[7] Anthony Esposito, Fluid Power,4th Edition.
[8] Helsel jay d, Cecil Jensen”engineering drawing and design,” 5th edition glencoe/mc graw
hill USA, 1996
[9] www.google.com,www.HCB pdf, local block maker and also local construction material
seller
[10] KhuBirri r s, gupta j k:”a text book of machine design,”13th edition, Eurasia publishing
house (pvt) ltd, ran nagar, new delhi, 2002
[11] Mischke charless r, joseph e shigley “standrad handbook of machine designs”, 2nd
edition, mc graw hill USA, 1996
[12] Nelik lev “centrifugal pump and rotary pump: fundamentals with application,”1stedition,
USA 1999.

APPENDIX

Design of Hollow Concrete Machine

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Design of Hollow Concrete Machine

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HOLLOW CONCERTE BLOCK MAKING MACHINE 2015

1.2 Introduction of The block product

JiT, SCHOOL OF MECHANICAL ENGINEERING Page 1

1.2.1 Concrete blocks

JiT, SCHOOL OF MECHANICAL ENGINEERING Page 2

A concrete block is primarily used as a building material in the construction of walls. It is

1.2.2 Market & demand aspects

JiT, SCHOOL OF MECHANICAL ENGINEERING Page 3

1.2.3 Types of concrete block

Solid concrete block

Hollow concrete block

Fig 1.1 type of block according to production

JiT, SCHOOL OF MECHANICAL ENGINEERING Page 4

2) According to its size

Fig 1.2. Type of CHB by its size

JiT, SCHOOL OF MECHANICAL ENGINEERING Page 5

Advantage or benefits of concrete block

 Uniform shape and size

Table 1.2. Benefits of hollow block V/S block

Hollow blocks Blocks

1.2.4 Raw materials for cement block or block Aggregate

JiT, SCHOOL OF MECHANICAL ENGINEERING Page 6

1.2.5 Manufacturing process of blocks

We can divided manufacturing process blocks currently as follows

JiT, SCHOOL OF MECHANICAL ENGINEERING Page 7

Feeding process leveling process

Ready for pressing pressing process

Fig 1.3.manufacturing process of block

JiT, SCHOOL OF MECHANICAL ENGINEERING Page 8

1. Proportioning: The determination of suitable amounts of raw materials needed to produce

1.3 Block Making process

JiT, SCHOOL OF MECHANICAL ENGINEERING Page 9

1.4. Problem statement

1.5. Objective of the project

JiT, SCHOOL OF MECHANICAL ENGINEERING Page 10

 To have on site production to reduce transportation cost and to minimize ecological

1.6. Scope of project

1.7. Expected results

 Comes with alert system

JiT, SCHOOL OF MECHANICAL ENGINEERING Page 12

JiT, SCHOOL OF MECHANICAL ENGINEERING Page 13

2.2 literature review

JiT, SCHOOL OF MECHANICAL ENGINEERING Page 14

Fig 2.1. The machine used for the production of HCBs

JiT, SCHOOL OF MECHANICAL ENGINEERING Page 15

Fig 2.3. Clearing the top removing the mold upwards

JiT, SCHOOL OF MECHANICAL ENGINEERING Page 16

Identifying customer needs

Setting final specification Hydraulic

Diag 3.1 Method of designing the hollow block making machine

JiT, SCHOOL OF MECHANICAL ENGINEERING Page 17

3.2. Concept Development Phase

2. Product specifications: Specifications provide a precise description of what a product has to do

JiT, SCHOOL OF MECHANICAL ENGINEERING Page 18

Question/ Customer Statement Interpretation

7. Establishing target specifications

JiT, SCHOOL OF MECHANICAL ENGINEERING Page 19

Table 3.2 Customer needs

JiT, SCHOOL OF MECHANICAL ENGINEERING Page 20

n. Marketable machine: Machine appearance and performance must be competitive and at

JiT, SCHOOL OF MECHANICAL ENGINEERING Page 21

Metric Need Numbers Metric Importance Units

1. Concept one Cantilever concept