THEORY: To build a building block for home construction out 80% local material and 20% cement. Using polymers as a binding agent (Polycem). building blocks that snap together without the use of mortars.
DATE of ORIGIN: September, 1998.
DESCRIPTION: By using local materials like sugar cane, corn stocks, mangrove and waste wood as base agents. Mixed together with concrete, water and polymers to make a light weight cinder block. By using locally based materials the blocks could be made local to the use, with 80% material savings in cement volume. Making the cost much lower than a standard concrete cinder block.
Polycem blocks with be impervious to rot, insects, weather and storms. It can also be cut with a hand saw and nailed to hold a fastener. It can also be painted adding pride of ownership. It is also possible to put a textured finish on the outside surface.
These products were first meant for roofing products such as shingles or roofing tiles. However, the roofing market is over represented with products and this technology is better suited for mortar-less snap together cinder blocks.
The polymer gives the concrete a memory. Meaning that it will take a force and come back to its original shape. Unlike standard concrete cinder blocks that would simply crack and break.
The concept here is to sell one, two and three room houses that have all the blocks needed to build that particular home. All the homeowner has to do is put down a cement slab with 9′ rebar sticking out around the perimeter. The blocks are slipped over the re bar and then are snapped together with a ten pound hammer. Using a piece of wood between the hammer and the polycem block as to not damage the finished product. Once the blocks are all assembled the homeowner installs the rafters and bends the re bar over the rafters. Now the home is tied together from the slab to the rafters.
The different block molds required would be 13, as follows, Standard blocks, full block, 1/4 block, 3/4 block. Door/window jamb blocks, LH full block, LH 1/4 block, RH full block, RH 1/4 block. Head and Sill blocks, LH top block, center top block, RH top block and LH bottom block, center bottom block, RH bottom block.
Here a 12″ L x 8″ H x 3″ T, hollow block is used to save money on material. Using a three-part rubber mold. One for the base and inside walls and the other two as outer side and top portions of the mold. Split down the length of the mold. By using a 3″ thick block to save on material required a 1/4 and 3/4 block. Unlike standard cinder blocks which are half as thick as they are long.
If Haiti had these kind of homes all of them would have survived the last storm instead of the massive destruction that took place.
Cheap, strong, rot-proof, locally made homes. That can be assembled by everyone with no fasteners and no tools other a one hammer. But the key is to keep it inexpensive, so locals can have work and housing.
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