Hydraform International

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Hydraform International Pty Ltd. is a manufacturer of brick and blockmaking machines. It was founded in Johannesburg, South Africa. [1] The company specialises in brick and blockmaking machines and accessories that enable the development of a stabilised soil cement block or a compressed earth block (CEB). Their products include stabilised soil blockmaking machines, pan mixing machines that are used to create the mixture for the blockmaking mixtures and accessories for these machines. The brick that is created by their machines is an interlocking stabilised soil cement block that is made using a mixture of soil, water and Portland Cement.

Contents

Hydraform International sells their products to both a local and international market with both commercial and residential uses. These equipment is presently used in 50 countries. [2] It also provides a training program and conducts training academies on how to use their machines and maintain them. [3]

History

Hydraform International Pty Ltd. was founded by Jochen Kofahl in 1988. Jochen Kofahl partnered with Robert Plattner. Hydraform International first operated in Jochen Kofahl’s garage. Hydraform International is now headquartered in Johannesburg with offices in India, Nigeria and Uganda. The first Hydrafrom machine created was the M1 machine. The company offers blockmaking machines and training services.

Notable projects

In 2007, a post-conflict strategy by the Ugandan Government was implemented. This strategy was launched in response to the political and rebel conflicts in Uganda. [4] This was called the Peace, Recovery and Development plan. Hydraform International was contracted to help rebuild communities through a low-cost housing project [5] and stimulating the local economy through job creation.

In 2009, construction on Rogbere School of Excellence in Sierra Leone began. This project was funded by Irish NGO Emmaus and NGO, A Call to Business. Hydraform technology was procured for its mobility and cost-savings advantages. [6]  The junior was completed by September, 2010. In 2012, A Call to Business funded the construction of an orphanage within the same village. Construction was completed in 2013 using Hydraform interlocking blocks. [7]

In 2010, all 20 buildings for the Ongutoi Health Centre in Uganda were built using Hydraform International’s blockmaking systems. [8] The project was funded by a charity organisation, High Adventure Gospel Communications Ministers, who praised Hydraform International for the cost advantages obtained that would not have occurred had standard building methods been chosen. The cost advantages stemmed from not having to import materials as the block were made on site with materials that were sourced on site and not needing mortar to bond the bricks. Hydraform International was also praised for the training of unskilled labourers in Uganda on Hydraform machines. Hydraform International facilitated skills transfer to labourers within the local community.

In 2010, Hydraform International machines were procured for a resettlement project by the Endeavour Mining Corporation. Endeavour Mining Corporation needed to resettle 2,200 residents in Ghana before opening a mine. [9] Hydraform International provided two machines which saw the projects being completed by 2013.

In 2010, Aumazo Inc., a non-profit organisation, acquired a Hydraform International blockmaking machine that is capable of producing 1,500 bricks per day. [10] By 2012, the machine manufactured 26,000 blocks which were used to finish a library for boarding school in Cameroon. Hydraform International also organised a technician to train labourers on machine usage and maintenance on site.

In 2010, the Krizevac Project, a NGO started the construction of the Mother Teresa Children’s Centre North in Malawi. The centre was completed in 2013 using Hydraform blocks. [11] Krizevac Project formed the Beehive Centre for Social enterprise. The Beehive Centre acquired Hydraform machines and now offers vocational training and produces Hydraform bricks.

Another project is the Giba Business Park in South Africa. The project was completed in 2011. The developers of Giba Business Park aimed for the use of sustainable business practices and cost-saving advantages. [12] Two Hydraform blocking making machines were used for this project. By using the Hydraforrm Machines, the Green Building Council of South Africa were able to lessen their carbon footprint because blockmaking process could happen on site unlike standard bricks that would need to transported to the site. Alongside this, Hydraform International enabled the construction costs to be reduced because there were no mortar costs as the blocks did not need to be cemented together. [12]

In 2012,  the Department of Public Works in South Africa elected Hydraform International building systems for a rural housing development located in the Gombani Village in Zimbabwe. The remoteness of the village meant that Hydraform’s mobile blockmaking systems were suitable solutions. The mobile building systems also resolved the issue of transportation costs to a remote village.

In 2012, the Savannah Accelerated Development Authority (SADA) acquired 50 Hydraform machines as a solution to a sustainable housing scheme in under-developed regions. Hydraform technicians conducted training on how to select soil, use the machines and construct public buildings . Hydraform International was selected to promote ecologically sustainable building methods. [13]

In 2015, Hospital Saint Jean-Baptiste was inaugurated in Côte d’Ivoire. [14] The development of the hospital had a focus on job and skills creation. Hydraform International was contracted to train local labourers on how to use their machines and facilitate blockmaking skill transfers to the local community. [15] The project also aimed to utilise locally-sourced materials.

In 2016,  the Department of Rural Development and Land Reform unveiled 27 new low-cost homes built using Hydraform machines [16] and bricks. The homes were built for displaced families in the Eastern Cape. Hydraform International supplied machinery and trained members of the Radway Green Farm community on the usage of the machine which enabled community members to employed for the construction of the homes.

In Tanzania, Hydraform International enabled the construction of 201 houses for the Kibada project by the National Housing Corporation Tanzania (NHC). In 2017, Hydraform International provided their M7MI range machines which produced 2000 blocks per day [17] and resulted in the project being finished for 30% fewer than the cost anticipated for a project using non-interlocking bricks and mortar.

Training academy

Hydraform International also provides businesses who have procured their machines with training of skilled and unskilled labourers. Hydraform sends technicians to projects with Hydraform building systems to train labourers on site and conducts training academies to ensure that clients succeed at block formation. Both unskilled and skilled labourers are trained on how to select soil as input for the block formation and how to construct Hydraform blocks. [15] Hydraform trains labourers on how to conduct soil tests and curing of blocks [15] to ensure clients who have contracted Hydraform International are earning a return on their investment . Training is also provided on machine maintenance. The training academy has both theoretical and practical components. Hydraform’s training services have been contracted on projects such as the Radway Green Farm project [16] to promote skill transfer within rural communities. The training academy seeks to address job creation through skills transfer and community engagement.

Hydraform Blocks

The Hydraform Interlocking Soil Block (hydraform block) is an interlocking earth block used in many countries for construction purposes. The hydraform block is made from soil cement which is a mixture of soil, cement and water, and is hydraulically compressed to form a high quality interlocking soil block. Soil from the building site can be used to manufacture building blocks. Sandcrete and landcrete are similar materials but are not compressed.

Hydraform interlocking blocks. Hydraform bricks (6394665491).jpg
Hydraform interlocking blocks.

The Hydraform compressed earth block is very popular due to the cost savings that are involved during the construction process as only around 30% of the structure requires mortar between the blocks. Due to the interlocking nature of the stabilized soil block, unskilled labour can be utilised in construction thereby empowering rural communities and creating jobs.

The blocks interlock top to bottom and front to back. Blocks dimensions are 220 millimetres (8.7 in) wide, 115 millimetres (4.5 in) high and 230 millimetres (9.1 in) long. It weighs approximately 12 kilograms (26 lb). Once blocks are manufactured it is "wet cured" for a period of 14–21 days to reach desired strength. [18] [19] [20] [21] [22] [23]

Hydraform Blockmaking process

Hydraform International has a product range of six machines that can develop stabilised soil cement blocks. The block is made out of a mixture of soil, water and 5% to 10% Portland Cement [24] is required and placed in a Hydraform pan mixer. The mixture has to be an equal balance of moist and dry to have the structural integrity of a brick. To determine whether the mixture is satisfactory, a drop test can be done, this is where the user drops a segment of the brick on the floor from a height of one metre to see how it shatters. The user can identify whether the brick is too moist or too dry based on the number of segment it shatters into. The mixture must be consistently used to ensure that the blocks do not have surface irregularities. [25] When the mixture has set, it is poured into a Hydraform series blockmaking machine. Hydraulic pressure is used to compress the mixture into a mould of a block with interlocking depressions on its sides. The depressions on the outsides of the block allow for a “lock-and-key” [26] mechanism where each block can be connected to another with the same depression. As a result of being able to connect the blocks, the need for mortar is diminished as the blocks do not have to be cemented together like a standard brick. This process can occur on-site as Hydraform machines are mobile . After the blocks have been developed, a labourer can connect using the grooves in each brick in a vertical and horizontal direction. The dimensions of the blocks created by a Hydraform series machine are generally 220mm, [24] however they can be moulded to a block that is 150mm. [24]

Benefits of Hydraform blocks

Hydraform blockmaking equipment can be powered by electric motors or by diesel, this allows the equipment to be mobile and to be used onsite. As production can occur onsite, transportation costs can be minimised. The process of interlocking blocks is also cost-effective as the blocks are dry-stacked [27] to create a wall as opposed to the standard masonry practices where the blocks are laid and cemented by mortar. Hydraform blocks are interlocked instead of laid and pasted together using mortar as seen in standard brickwork. By being dry-stacked, the amount of mortar required is reduced and this can waive the cost of mortar that is generally required in masonry work. Interlocking blocks produced by Hydraform can allow for the recycling of materials. Any remaining mixture of the blocks can be used as an input for the Hydraform machine while on site.[ citation needed ] High-waged skilled labour is not required for the production of the Hydraform blocks. Hydraform International can provide a base course to train users of Hydraform equipment and after this course, the masons are qualified to construct and dry stack the interlocking blocks. The length of the process to create a wall using the interlocking blocks is shorter than standard brickwork as the blocks do not have to be laid and individually cemented by mortar. The materials needed for the block mixture can be sourced locally as the mixture is made up of water, soil and Portland Cement so there is no impending risk of scarcity and on-site soil can be utilised for the soil component of the mixture. A potential benefit is that structural integrity of buildings using interlocking blocks cannot be damaged by termites like timber constructions are in rural Africa. Hydraform has also been contracted by developers who were motivated to reduce their carbon footprint [28] by reducing their transport costs from transporting materials.

Criticisms of Hydraform blocks

The mixture of the interlocking blocks must be a specific consistency. If the mixture is too dry, it will collapse after it has been hydraulically pressed and if the mixture has too much water, it cannot be solidified. This means that the process of construction will be lengthened if the mixture is not the required consistency. For the blocks to be successfully interlocked, each block must be uniform in size so users of the Hydraform blockmaking machine must be aware of how much mixture is being poured into the blockmaking machine each time to avoid over or under-pouring. [26] Standard brickwork continues to be used over interlocking masonry, this means that the workforce trained to produce and construct interlocking blocks is limited. As the walls built with interlocking blocks are not reinforced by plaster or mortar, reinforcement using plaster might be required to ensure that wall is durable in weather conditions such as rain and wind. [29] The Hydraform machines used to develop these interlocking blocks on site need constant maintenance to ensure that they are powered and are regularly monitored for any defects. To successfully build a dry-stacked wall with interlocking blocks, the blocks must interlock in perfect horizontal and vertical alignment. This cannot be achieved if the machine is not producing uniform-sized blocks. Interlocking masonry is still not the common form of masonry in construction so it is a relatively new as opposed to standard brickwork, [29] this means that the durability of these blocks has not been seen in environments other than rural developments. There is also the risk of erosion from weather conditions such as winds or rain that could threaten the stability of the blocks. [27]

Related Research Articles

<span class="mw-page-title-main">Adobe</span> Building material made from earth and organic materials

Adobe is a building material made from earth and organic materials. Adobe is Spanish for mudbrick. In some English-speaking regions of Spanish heritage, such as the Southwestern United States, the term is used to refer to any kind of earthen construction, or various architectural styles like Pueblo Revival or Territorial Revival. Most adobe buildings are similar in appearance to cob and rammed earth buildings. Adobe is among the earliest building materials, and is used throughout the world.

<span class="mw-page-title-main">Brick</span> Block or a single unit of a ceramic material used in masonry construction

A brick is a type of construction material used to build walls, pavements and other elements in masonry construction. Properly, the term brick denotes a unit primarily composed of clay, but is now also used informally to denote units made of other materials or other chemically cured construction blocks. Bricks can be joined using mortar, adhesives or by interlocking. Bricks are usually produced at brickworks in numerous classes, types, materials, and sizes which vary with region, and are produced in bulk quantities.

<span class="mw-page-title-main">Concrete</span> Composite construction material

Concrete is a composite material composed of fine and coarse aggregate bonded together with a fluid cement that hardens (cures) over time. Concrete is the second-most-used substance in the world after water, and is the most widely used building material. Its usage worldwide, ton for ton, is twice that of steel, wood, plastics, and aluminium combined. Globally, the ready-mix concrete industry, the largest segment of the concrete market, is projected to exceed $600 billion in revenue by 2025. This widespread use results in a number of environmental impacts. Most notably, the production process for cement produces large volumes of greenhouse gas emissions, leading to net 8% of global emissions. Other environmental concerns include widespread illegal sand mining, impacts on the surrounding environment such as increased surface runoff or urban heat island effect, and potential public health implications from toxic ingredients. Significant research and development is being done to try to reduce the emissions or make concrete a source of carbon sequestration, and increase recycled and secondary raw materials content into the mix to achieve a circular economy. Concrete is expected to be a key material for structures resilient to climate disasters, as well as a solution to mitigate the pollution of other industries, capturing wastes such as coal fly ash or bauxite tailings and residue.

<span class="mw-page-title-main">Masonry</span> Building of structures from individual units of stone, bricks, or blocks

Masonry is the craft of building a structure with brick, stone, or similar material, which are often laid in and bound together by mortar; the term masonry can also refer to the building units themselves. The common materials of masonry construction are bricks and building stone such as marble, granite, and limestone, cast stone, concrete blocks, glass blocks, and adobe. Masonry is generally a highly durable form of construction. However, the materials used, the quality of the mortar and workmanship, and the pattern in which the units are assembled can substantially affect the durability of the overall masonry construction. A person who constructs masonry is called a mason or bricklayer. These are both classified as construction trades.

<span class="mw-page-title-main">Stonemasonry</span> Creation of buildings, structures, and sculpture using stone

Stonemasonry or stonecraft is the creation of buildings, structures, and sculpture using stone as the primary material. Stonemasonry is the craft of shaping and arranging stones, often together with mortar, to form structures.

<span class="mw-page-title-main">Mortar (masonry)</span> Workable paste which hardens to bind building blocks

Mortar is a workable paste which hardens to bind building blocks such as stones, bricks, and concrete masonry units, to fill and seal the irregular gaps between them, spread the weight of them evenly, and sometimes to add decorative colors or patterns to masonry walls. In its broadest sense, mortar includes pitch, asphalt, and soft mud or clay, as those used between mud bricks, as well as cement mortar. The word "mortar" comes from Old French mortier, "builder's mortar, plaster; bowl for mixing." (13c.).

<span class="mw-page-title-main">Building material</span> Material which is used for construction purposes

Building material is material used for construction. Many naturally occurring substances, such as clay, rocks, sand, wood, and even twigs and leaves, have been used to construct buildings. Apart from naturally occurring materials, many man-made products are in use, some more and some less synthetic. The manufacturing of building materials is an established industry in many countries and the use of these materials is typically segmented into specific specialty trades, such as carpentry, insulation, plumbing, and roofing work. They provide the make-up of habitats and structures including homes.

<span class="mw-page-title-main">Rammed earth</span> Technique for constructing foundations, floors, and walls by compacting a damp mixture of sub soil

Rammed earth is a technique for constructing foundations, floors, and walls using compacted natural raw materials such as earth, chalk, lime, or gravel. It is an ancient method that has been revived recently as a sustainable building method.

<span class="mw-page-title-main">Cordwood construction</span>

Cordwood construction is a term used for a natural building method in which short logs are piled crosswise to build a wall, using mortar or cob to permanently secure them. This technique can use local materials at minimal cost.

<span class="mw-page-title-main">Concrete masonry unit</span> Standard-sized block used in construction

A concrete masonry unit is a standard-size rectangular block used in building construction. The use of blockwork allows structures to be built in the traditional masonry style with layers of staggered blocks.

<span class="mw-page-title-main">Repointing</span> Repair of exterior mortar

Repointing is the process of renewing the pointing, which is the external part of mortar joints, in masonry construction. Over time, weathering and decay cause voids in the joints between masonry units, usually in bricks, allowing the undesirable entrance of water. Water entering through these voids can cause significant damage through frost weathering and from salt dissolution and deposition. Repointing is also called pointing, or pointing up, although these terms more properly refer to the finishing step in new construction.

<span class="mw-page-title-main">Autoclaved aerated concrete</span> Lightweight, precast building material

Autoclaved aerated concrete (AAC) is a lightweight, precast, foam concrete building material suitable for producing concrete masonry unit like blocks. Composed of quartz sand (SiO2 with impurities), calcined calcium sulfate (CaSO4, a.k.a. plaster of paris), lime (CaO), cement, water and aluminum powder, AAC products are cured under heat and pressure in an autoclave. Invented in the mid-1920s, AAC simultaneously provides structure, insulation, and fire- and mold-resistance. Forms include blocks, wall panels, floor and roof panels, cladding (façade) panels and lintels.

<span class="mw-page-title-main">Lime mortar</span> Building material

Lime mortar or torching is composed of lime and an aggregate such as sand, mixed with water. The ancient Egyptians were the first to use lime mortars, which they used to plaster their temples. In addition, the Egyptians also incorporated various limes into their religious temples as well as their homes. Indian traditional structures built with lime mortar, which are more than 4,000 years old like Mohenjo-daro is still a heritage monument of Indus valley civilization in Pakistan. It is one of the oldest known types of mortar also used in ancient Rome and Greece, when it largely replaced the clay and gypsum mortars common to ancient Egyptian construction.

<span class="mw-page-title-main">Earth structure</span> Building or other structure made largely from soil

An earth structure is a building or other structure made largely from soil. Since soil is a widely available material, it has been used in construction since prehistoric times. It may be combined with other materials, compressed and/or baked to add strength.

<span class="mw-page-title-main">Compressed earth block</span>

A compressed earth block (CEB), also known as a pressed earth block or a compressed soil block, is a building material made primarily from an appropriate mix of fairly dry inorganic subsoil, non-expansive clay, sand, and aggregate. Forming compressed earth blocks requires dampening, mechanically pressing at high pressure, and then drying the resulting material. If the blocks are stabilized with a chemical binder such as Portland cement they are called compressed stabilized earth block (CSEB) or stabilized earth block (SEB). Typically, around 3,000 psi (21 MPa) of pressure is applied in compression, and the original material volume is reduced by about half.

Sandcrete is a yellow-white building material made from a binder, sand in a ratio of circa 1:8, and water. Sometimes other ingredients may be added to reduce the amount of expensive Portland cement such as pozzolanas and rice husk ash. Sandcrete is similar but weaker than mortar, for which the ratio is circa 1:5. Soil cement and landcrete are similar materials but use other types of soil and hydraform blocks which are compressed, stabilized, earth blocks.

<span class="mw-page-title-main">Structural material</span>

Structural engineering depends on the knowledge of materials and their properties, in order to understand how different materials resist and support loads.

<span class="mw-page-title-main">Types of concrete</span> Building material consisting of aggregates cemented by a binder

Concrete is produced in a variety of compositions, finishes and performance characteristics to meet a wide range of needs.

This glossary of structural engineering terms pertains specifically to structural engineering and its sub-disciplines. Please see glossary of engineering for a broad overview of the major concepts of engineering.

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