08 2011

Construction by stacking blocks

Concrete BlockTest bench

Item Code: 560-762

TECHNOLOGY

Why are there different types of blocks?

A model/test benchTo test and understand basic construction principles-How are buildings and structures built?- What are the characteristics of buildings where we are?-Why don’t buildings fall down?

How to build a structure?The different types of lintel

Why must the blocks be intersected?Why is there vertical chaining? Is it necessary?The role of the foundations

assembly and dismantling using

“dry” blocks, test different

techniques, easily tidy the materials

away at the end of class.

Real material

Real appearance

Scale 1:10

Grooved base to help set-up,

to show why foundations

are useful

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SUMMARYTest BenchGeneral Presentation 02 to 03

Product presentation 02Main teaching objectives 03

Activity 1: Build a simple wall using the blocks 04 to 06Student worksheet 04Example of student work 05Student resource sheet 06

Activity 2: Build a wall using chaining 07 to 11Resource sheet 07Student worksheet 08Example of student work 09

Activity 3: Installing a lintel 10 to 11Student worksheet 10Example of student work 11

Activity 4: Construction of a lintel 12 to 13Student worksheet 12Example of student work 13

Activity 5: Building a wall with a door and a window 14 to 15Student worksheet 14Example of student work 15

Activity 6 Extra Activity: Horizontal chaining 16 to 17Student worksheet 16Example of student work 17

Examples of information sheets 18 to 20Activity 1 information sheetActivity 2 information sheetActivity 3 information sheet

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Making mini blocks by themselves

This booklet and CDRom may be copied for students for internal school use**This booklet may be copied as many times as necessary within school establishments for educational use only, on the condition that thepublisher’s name is included: A4. Copying or distribution for commercial use is not permitted without agreement from A4. Any copying ordistribution of all or part of this booklet outside of school use is not permitted without agreement from A4.

March 2011Etienne Bernot - Gérald Guillaume

For more information contact:Technology Supplies LimitedPhoenix House, Stafford Park, BattlefieldEnterprise Park, Shrewsbury, SY1 3FE

Published by A4 Company

Concrete Block Test Bench

The CDROM The CDRom for this project is available in the Ste catalogue (Ref “CD PARP”)It contains:- The folder in FreeHand (.FH9), PDF and illustrator (.ai) formats- Photos of the product, drawings in DXF format- 3D model with 3D files for SolidWorks, Parasolid et eDrawings formats.

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Teacher documentTest bench - construction with blocks

Presentation of the Test bench

Door sill Window sill Rods for chaining

Block 25 x 25 x 50

Multi-functionalblock Half-block

Block Chaining

(x 44) (x 6) (x 12) (x 6)

(x 1) (X 2)(x 2)

Wooden lintel

Base (x 1)

(x 1) (X 2) (X 2) (X 1)

The concrete block test bench allows students to work on basic construction principles using stacked blocks. First the student builds a wall at an angle using a base as a foundation. The construction is then modified to include a window and a door. The building will be done with dry blocks so that material can be reused straight away. You can also use the the special mortar which is water soluble (Ref COL-BRIQ) if there is time (it has to be prepared, installed then left to dry). This allows in particular for the “chaining” blocks and the steel rods provided to build a lintel and test with or without an iron framework (If not you can use the wooden lintel provided).

The test bench comes with:- 1 grooved base which acts as the plot of land with the function of a trench.- Blocks scale 1 : 10 - 44 blocks 25 x 25 x 50 cm on the scale 1 : 10- 26 multifunctional blocks for chaining and table - 12 half-blocks,- 6 blocks of horizontal chaining and lintel- 1 doorsill - 1 window sill - 2 wooden lintels 25 x 25 x 150 cm on the scale 1/ 10- 2 steel rods Ø 4 length 140 acting as reinforcement for the lintel framework- 2 PVC Ø 10 length 125 rods as vertical chaining bars for the window frame.- 2 PVC Ø 10 length 230 rods as vertical chaining bars for the door frame.- 1 PVC Ø 10 length 270 rods as vertical chaining bar for the wall angle.

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Teacher document

Test Bench PresentationTest bench - construction with blocks

Educational interest

Activities, changes

- Activity 1: By building a wall angle, the students will realise the need to havefoundations and overlapping blocks in order to produce a wall which issufficiently sturdy. They will answer questions and do some drawings.

- Activity 2: Students will learn about force and chaining. They could carryout experiments on the strength needed to destruct a wall depending onthe chaining.

- Activities 3 and 4: Cast a lintel with or without metal structure. Reflect onlintel construction and installation.

- Activity 5: Build a wall angle with a door and a window. Learn some technicalvocabulary.

- Activity 6: Extra: Horizontal chaining

Building very realistic models using mini-blocks

Solution 1 Solution 2

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With some simple experiments, the test bench permits the following interests: building environment, technical functions and solutions, stability of a structure, building a structural model. It lets some functions and constraints be identified and tests some specific solutions of the concrete blocks. In the field of habitat and structures, students can learn about the following: foundations, chaining, functions of different blocks, wooden or cast lintels, technical vocabulary, bricklayer’s tools.

Other activities include the materials used to make blocks, industrial fabrication of concrete blocks, history of building with stacked bricks (history of concrete and its advantages).

Useful links and support:http://www.ducotedespros.tv/videos/lhistoire-du-beton - http://www.3mdb.com/http://www.pointp.fr/documentation/maison-de-a-a-z-X39S686r471 - http://www.infociments.fr/

The suggested changes are simple and quick to make; the blocks are easily dry assembled on top of each other. They can also be glued together using mortar (Ref: COL-BRIQ) available in our catalogue. In this case the time taken for the mortar to set should be taken into account during the activities.

The test bench can be used to create a very realistic model with mini-blocks using the scale 1: 10. Sets of blocks are available, as are moulds to make them yourself.See our offers in the catalogue or on www.a4.fr

The constructions are ambitious, very realistic and allowseveral experiments to be done, using a range of skills tosolve real and simplechallenges. The modelsproduced can be kept asclass materials fordevelopment activities orequipment (alarm, homeautomation). See page 18: Some usefulmaterials

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Activity 1 - Foundation and constructionStudent WorksheetTest bench - construction with blocks

Complete the following two sketches below to show 2 different ways to stack blocks

What are the foundations used for? (represented on the test bench by the grooved rigid base)

Describe how you tested the strength of two different walls and give your conclusions

What are the qualities of a well-built wall and what tools should a bricklayer use?

Base

Wall of bricks Wall of bricks

Solution 1 Solution 2

Base (concrete footing)

Build a double wall that will act as a windbreak so that a barbecue can be installed. On the base acting as the foundation, put six rows of blocks (25 x 25 x 50) to make a wall angle as illustrated below.

Experiment with different ways of stacking theblocks and find a way to test the wall strength.

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Activity 1 - Foundation and constructionTest bench - construction with blocks

Complete the following two sketches below to show 2 different ways to stack blocks

What are the foundations used for? (represented on the test bench by the grooved rigid base)

Describe how you tested the strength of two different walls and give your conclusions

What are the qualities of a well-built wall and what tools should a bricklayer use?

Base

Wall of bricks Wall of bricks

Base (concrete footing)

Build a double wall that will act as a windbreak so that a barbecue can be installed. On the base acting as the foundation, put six rows of blocks (25 x 25 x 50) to make a wall angle as illustrated below.

Experiment with different ways of stacking theblocks and find a way to test the wall strength.

Solution 1 Solution 2

Example of student work

The blocks must be well aligned, walls must be vertical. The top of the wall must be

horizontal. The bricklayer will use a plumb-line, a level and a ruler. He will also use mortar

to stick blocks together.

We can see that when blocks are placed on top of each other without being intersected the

wall is very fragile. However if blocks are intersected (the vertical joints are staggered in

each row) the wall is much more cohesive, even without mortar, and is more resistant.

To test the strength of the walls we pushed on them with a plate or a ruler to test the

surface and not just one block. After several tries, we can estimate the compared strength

of each construction attempt.

The foundations allow the structure to be anchored to the ground and position the

structure.

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Resource document

Activity 1: Foundation and construction: A bricklayer’s toolsTest bench - construction with blocks

The trough and trowel forthe mortar

Trowel for laying mortar

The level to verify if the surface is horizontal or vertical

The plumb line to check if the wall is vertical

The rule to verify an alignment

The chalk line (blue) The chalk line string

The hammer to cut and adjust blocksThe cement mixer to mix the mortar

The pencil to draw marks

The laser level

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Activity 1: Foundation and Construction: Testing the Wall ResistanceTest bench - construction with blocks Resource document

Two solutions to test a wall resistance

Solution 1 - Cut a PVC plate using the dimensions below.230

115

141

175

Ø3

Pass a string through the hole in the wall,pull on it as shown below.

Solution 2 - Hold a ruler at one end and use the weight to assess the pushing force on the wall.

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Activity 2 - Construction and chainingStudent WorksheetTest bench - construction with blocks

Here are the different blocks and the red PVC rods which act as the iron framework.

Carry out strength tests on the corner of a wall built with or without a framework (vertical chaining). Seethe drawing below. The wall corner must be rebuilt several times and test it until it is destructed. Explain how a framework can make a wall more rigid?

Complete this drawing by drawing inthe framework put in

block25 x 25 x 50

multi-functional block half-block

The plastic rodsreplace the vertical

framework

or

Two ways of testing the strength of a wall

You can interlock the PVC rods with the holes in the multifunctional blocks (in the corner) and

the half blocks (at the ends).This vertical chaining joins various rows of blocks together and

makes the vertical blocks at the corner and end of the wall very strong. The middle of each wall is

weak but it is well supported by the vertical side ‘blocks’.

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Activity 2 - Construction and chainingTest bench - construction with blocks

Here are the different blocks and the red PVC rods which act as the iron framework.

Carry out strength tests on the corner of a wall built with or without a framework (vertical chaining). Seethe drawing below. The wall corner must be rebuilt several times and test it until it is destructed. Explain how a framework can make a wall more rigid?

Complete this drawing by drawing inthe framework put in

block25 x 25 x 50

multi-functional block half-block

The plastic rodsreplace the vertical

framework

or

Two ways of testing the strength of a wall

You can interlock the PVC rods with the holes in the multifunctional blocks (in the corner) and

the half blocks (at the ends).This vertical chaining joins various rows of blocks together and

makes the vertical blocks at the corner and end of the wall very strong. The middle of each wall is

weak but it is well supported by the vertical side ‘blocks’.

Example of student work

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Activity 3: Casting a lintelTest bench - construction with blocks Student Worksheet

What are the constraints or difficulties experienced?

Complete the drawings to show the test to determine break strength.What conclusion can you make from our experiments?

Mixing the mortar:7 parts powder for 1 single volume of water

Lintel 1 Lintel 2

Load lintels

Filled in with mortar

We have to build a wall like the one shown opposite, with a door and awindow. Lintels are needed above the door and window to support the partsabove them. The test bench includes wooden lintel and materials to make masonry lintels: chaining blocks and metallic rods used to make frameworks.

To make the masonry lintels, the block chainings are placed side by side and are joined together using mortar that is poured into the gutter they form. For our experiments we will use the special mortar which can be re-diluted (ref COL-PARP).

Think of and describe an experiment to prove the need for using a metal rod framework. Complete the following drawings (include a caption) and describe your experience.

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Activity 3: Casting a lintelTest bench - construction with blocks

What are the constraints or difficulties experienced?

Complete the drawings to show the test to determine break strength.What conclusion can you make from our experiments?

Mixing the mortar:7 parts powder for 1 single volume of water

Load lintels

We have to build a wall like the one shown opposite, with a door and awindow. Lintels are needed above the door and window to support the partsabove them. The test bench includes wooden lintel and materials to make masonry lintels: chaining blocks and metallic rods used to make frameworks.

To make the masonry lintels, the block chainings are placed side by side and are joined together using mortar that is poured into the gutter they form. For our experiments we will use the special mortar which can be re-diluted (ref COL-PARP).

Think of and describe an experiment to prove the need for using a metal rod framework. Complete the following drawings (include a caption) and describe your experience.

Example of student work

Only mortar

Chaining blockLintel 1 Lintel 2

Metal rod

Filled in with mortar

We made two lintels; one with a metal rod and one without. To test the resistance we will support the

lintels on the exterior blocks and suspend an increasingly heavy mass on the middle block until it

breaks.

The first difficulty was deciding the right amount of mortar to fill the lintels.

The mortar needed to be pushed into the hollow of the lintel using a tool (a spatula or mini trowel)

We had to wait for the mortar to set (one day) before doing the tests

The lintel without the metal

rod breaks under the strain of

a 4kg mass. More than 7 kg

are necessary to start to affect

the lintel with a metal rod.

The lintels with the rods are always more resistant, almost doubly resistant.

Masonry lintels always have a metal rod.

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Activity 4: Installing a lintelTest bench - construction with blocks Student Worksheet

Make a wall at angles with openings like the one illustrate

What are the possible technical solutions to make lintels?

Illustrate the two solutions on the drawings below.

Explain what you need to do to be able to install a lintel directly from 3 lintel blocks. (You could preparethe ground lintels and install them once the mortar is ready but this would delay the construction andrequire lifting heavy masses).

Illustrate your explanation on the drawing to the right, adding a caption if necessary.

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Full part above an opening (dooror window)

Lintel

How to supportthe lintel without

mortar?

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Activity 4: Installing a lintelTest bench - construction with blocks

Make a wall at angles with openings like the one illustrate

What are the possible technical solutions to make lintels?

Illustrate the two solutions on the drawings below.

Explain what you need to do to be able to install a lintel directly from 3 lintel blocks. (You could preparethe ground lintels and install them once the mortar is ready but this would delay the construction andrequire lifting heavy masses).

Illustrate your explanation on the drawing to the right, adding a caption if necessary.

?

??

Full part above an opening(door or window)

Lintel

How to supportthe lintel without

mortar?

Example of student work

We have two possibilities using the material provided: Masonry lintels with lintel blocks or wooden lintels.

To be able to install the lintels, they must be supported with props, then insert the framework and fill with mortar. If the support is solid enough, we can continue the construction without waiting for the mortar to completely set and the full strength of the lintel.

Support board

Support legs

Student Worksheet

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Activity 5: Technical vocabularyTest bench - construction with blocks

Number Definition

01

Linking element surrounding walls. It can be horizontal or vertical

0506

020304

070809

Chaining

Name

A slightly sloped sill for drainageBay sill

Element located in the lower part and slightly sloped for drainage10

Framework Metal structure included in the construction to ensure strength

Work to do:

Other solutionWooden lintel

Foundation material made from strengthened concreteVertical part of the structure, along a door or windowFull part above an opening (door or window)Lintel

Door jambSlab

Opening Opening in a wall filled with a window

Wall element between the floor and opening supportApron Wall

SillLateral face, toward the opening, of a door jamb.Frame

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Fill in the drawing below based on either the wooden lintel or the cast lintel solution and use the vocabulary resource table at the bottom of the sheet. Then complete the drawing using the correct numbers (Example 1).Use different colours to highlight the blocks that have a particular technical function:- the horizontal and lintel chaining blocks in blue,- the vertical chaining blocks in red,- the table blocks in green,- the window sill in yelllow,- the door sill in brown.

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Activity 5: Technical vocabularyTest bench - construction with blocks

Number Definition

01

Linking element surrounding walls. It can be horizontal or vertical

0506

020304

070809

Chaining

Name

A slightly sloped sill for drainageBay sill

Element located in the lower part and slightly sloped for drainage10

Framework Metal structure included in the construction to ensure strength

Work to do:

Foundation material made from strengthened concreteVertical part of the structure, along a door or windowFull part above an opening (door or window)Lintel

Door jambSlab

Opening Opening in a wall filled with a window

Wall element between the floor and opening supportApron Wall

SillLateral face, toward the opening, of a door jamb.Frame

Fill in the drawing below based on either the wooden lintel or the cast lintel solution and use the vocabulary resource table at the bottom of the sheet. Then complete the drawing using the correct numbers (Example 1).Use different colours to highlight the blocks that have a particular technical function:- the horizontal and lintel chaining blocks in blue,- the vertical chaining blocks in red,- the table blocks in green,- the window sill in yelllow,- the door sill in brown.

Example of student work

Other solutionWooden lintel

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6: Extra activity: Horizontal chainingStudent WorksheetTest bench - construction with blocks

Use horizontal chaining blocks to build an eighth row. Use the metal rods of about 170 length or morefor the chaining. To connect the horizontal chaining to the vertical one, you must drill the PVC Ø 3.5bars at 185 and 190 from the end (See figure below).

Look at the vertical poles. Why do we make holes in them?

Assemble the wall as shown below.

Test the strength of the wall. What can you see?

Chaining block 2 chaining steel rods Ø 3 length170 mm

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6: Extra activity: Horizontal chainingTest bench - construction with blocks

Use horizontal chaining blocks to build an eighth row. Use the metal rods of about 170 length or morefor the chaining. To connect the horizontal chaining to the vertical one, you must drill the PVC Ø 3.5bars at 185 and 190 from the end (See figure below).

Look at the vertical poles. Why do we make holes in them?

Assemble the wall as shown below.

Test the strength of the wall. What can you see?

Chaining block 2 chaining steel rods Ø 3 length170 mm

Example of student work

The holes allow the vertical and horizontal chaining to connect. Therefore, the wall should become stronger.

We can see that the wall is much more rigid now, with the horizontal structure connected to the vertical one. The wall forms a whole, one part cannot be destructed unless all of it is. Everything is connected, which makes the construction very strong.

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Activity 1: Foundation and ConstructionTest bench - construction with blocks

Foundations.

Continue footing isolated footing Slab Posts or Well

Construction technique: Stacking blocks to make a wallConcrete blocks are bonded with mortar

1: Overlapping blocks must be more than 1/3 of the block length. 2: The horizontal joint should be distributed on the whole contact surface3: Vertical joints are made by filling gaps with mortar.

4: Blocks are always bonded with the hollow part at the bottom.

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NO YES

A beam and postconstruction technique

Example of

information sheet

The foundation of a house or a structure corresponds to the part in contact with the ground.- It must receive and be resistant to loads that will press on it. It must not lose its shape too much.- It transmits these loads to the ground which must be as stable as possible. A study of this is therefore important before any foundation is built.

Different types of foundation:Considering the above information, we can see that the foundation type will depend on the type of ground. Shallow foundations are used when ground is stable, otherwise deep foundations are used.

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Activity 2: Construction and chaining

Test bench - construction with blocks

Chainings:They are made from metal rods embedded in the mortar. They let you link different parts or differentblocks to ensure the structure of the house is rigid.

Vertical chaining Horizontal chaining

The chaining has several functions.When it’s vertical:- It will ensure the wall has a certain mechanical rigidity, strengthens wall angles and the ends. - It will help the wall to support the load of elements above.

When it’s horizontal:- the load of the elements located above will be distributed across the width - it fights pressure on the wall (wind, beams) it stops the wall from ‘opening’- it also acts as a lintel above doors and windows.

Horizontal and vertical chaining are connected in order to ‘bind’ all the materials used in theconstruction.

Mortar

Metal bars

Example of

information sheet

Casted Post

Angle chaining blocks

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Activity 3: Casting a lintelTest bench - construction with blocks

MortarThe mortar is used to ‘bond’ blocks together, like the two blocks in the example. It’s a mixture of sand,cement and water.

Concrete is a mixture of mortar and gravel.

Mortar is particularly resistant to pressure but has low tensile strength. Reinforcement is added to the mortar(for tensile strength) to produce construction materials which need to have a good resistance to bending (slabs,beams, columns ...).

RESISISTANCE TO COMPRESSION in MPaHardening starts when it has set...45

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1 hour 3 h 5 h 24 h 28 days 91 days

Mortar

Mortar

Metal rods

Example of

information sheet

The maximum concrete strength is reached progressively over time. It relates to the time taken to set, which depends on the cement used, weather conditions, the quality of the materials (sand, gravel) and their quantities. After 7 days, and ordinary concrete has reached 40 to 60 % of its final resistance (only !). and from 60 to 80% after 28 days. It’s therefore not recommended to remove the formwork too quickly; the concrete slabs for example. It hardens when it’s not moving (not because it becomes dry...) The cement itself doesn’t have much resistance. It’s the gravel, in the case of concrete, that gives some resistance (sand in the case of mortar). It’s therefore of prime importance to choose good materials.

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Making blocks yourselfTest bench - construction with blocks

The polyester synthetic plasterIt is used as plaster but gives a very hard material that resists water.Dilution : 1/4 water + 3/4 powder. Before setting, the liquid mixture allows the moulds to be filled easily.It sets in less than 15 minutes. They are white in colour but they may be stained easily with a dye.Ref: RESI-PLAPE-1K25-BC.

Sand mortarMixture of sand and food resin that dissolves in water. It can be made into cement but presents no risks to skin and canbe re-diluted in water, which allows you to recycle all the model’s materials. Ref. : COL-BRIQ-5K

Réf: COLO-N

The mouldA flexible silicon mould to make blocksRef: MOUL-PARP-A.

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Black dye to colour the blocks

Mini trowell. Réf. : TRU-MIN-9CM Mortar pan

CUV-MORT-D13

As explained in the test bench presentation (page 3), it’s possible to use mini blocks to make models. A4 can provide mini-blocks ready to be used but also materials to make them yourself. (Moulds, synthetic plaster, but also silicon fluid to make flexible moulds (indoor fluid, skin contact)

Refer to the catalogue to see all materials and products available.Download “Realizations in mini-bricks” and “Parpens and bricks models”

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Test bench - construction with blocks