Industry Overview
Interlocking Concrete Block Pavement (ICBP) is a specialized pavement construction technique used in locations where conventional hot bituminous mix or cement concrete pavements may be less durable or desirable because of operational, environmental, geological, traffic, and other constraints. The technology was introduced in India about a decade ago for applications such as footpaths and parking areas and has since been adopted for a wider range of uses.
Concrete paver blocks were first introduced in Holland in the fifties as a replacement for paver bricks, which had become scarce following the post-war building construction boom. Their designs subsequently evolved from non-interlocking blocks to partially, fully, and multiply interlocking shapes. Accordingly, pavements using non-interlocking blocks are known as Concrete Block Pavement (CBP), while those using interlocking forms are known as ICBP.
ICBP consists of small-element, solid, unreinforced precast concrete paver blocks placed over a compacted bedding layer, a properly profiled base course, and suitable edge restraints. The joints between blocks are filled with appropriate fine material. When properly designed and constructed, ICBP can provide durable performance for non-traffic, light, medium, heavy, and very heavy traffic applications. Its principal benefits include dimensional consistency, durability, rapid opening to traffic, ease of maintenance, access to underground utilities, resistance to fuel and oil spillage, and suitability for heavy vehicle loads. However, factory quality control, accurate base-course profiling, appropriate bedding and joint-filling materials, and effective drainage are essential for satisfactory performance.
Cost Estimation
| Particular | Value |
|---|---|
| Plant Capacity | 14,000 Nos/Day |
| Land & Building (4000 sq.mt.) | Rs. 15 Lac |
| Plant & Machinery | Rs. 46 Lac |
| Working Capital for 1 Month | Rs. 24 Lac |
| Total Capital Investment | Rs. 92 Lac |
| Rate of Return | 45% |
| Break Even Point | 64% |
Content Index
- INTRODUCTION
- ADVANTAGES AND LIMITATIONS
- HOWEVER, IMPORTANT LIMITATIONS OF THE TECHNIQUE ARE THE FOLLOWING:
- PHYSICAL REQUIREMENTS
- APPLICATION OF ICBP TECHNOLOGY
- SHAPES AND CLASSIFICATIONS
- MATERIALS
- \PAVING BLOCKS
- BEDDING AND JOINT FILLING SAND
- BASE AND SUB BASE MATERIALS
- CONSTRUCTION OF INTERLOCKING CONCRETE BLOCK PAVEMENT
- SEQUENCING OF OPERATIONS
- PAVEMENT TYPES
- PAVER PROPERTIES
- PAVER DIMENSIONS
- PAVING STRENGTH
- MINIMUM BREAKING LOAD
- COMPRESSIVE STRENGTH OF PAVERS
- DURABILITY
- SLIP RESISTANCE
- ABRASION RESISTANCE
- MOISTURE EXPANSION
- EFFLORESCENCE
- PITTING DUE TO LIME
- COLD WATER ABSORPTION
- ADVANTAGES AND LIMITATION OF PAVERS BLOCKS
- THE MORTAR USED IN PRODUCING PAVING BLOCKS
- SHAPES AND APPLICATION OF PAVERS BLOCKS
- APPLICATIONS OF CONCRETE PAVING BLOCKS
- 1. NON-TRAFFIC AREAS:
- 2. LIGHT TRAFFIC AREAS:
- 3. MEDIUM TRAFFIC AREAS:
- 4. HEAVY TRAFFIC AREAS:
- RAW MATERIALS FOR CONCRETE PAVER
- DETAILS AND COMPARISON OF PAVER BLOCKS
- PAVER BLOCKS
- COMPARISON OF PAVERS TO IPS
- B.I.S. SPECIFICATION
- SPECIFICATION OF PRECAST CONCRETE BLOCKS FOR PAVING
- 1 SCOPE
- 2 REFERENCES
- 3 TERMINOLOGY
- FIG. 1 EXAMPLES OF ARRIS (BEVELLED, ROUNDED, CHAMFERED) CHASED SIDE FACE AND DRAW
- 4 MATERIALS
- 5 GRADE DESIGNATIONS OF PAVER BLOCKS AND DESIGN OF CONCRETE BLOCK PAVEMENT
- TABLE 1: RECOMMENDED GRADES OF PAVER BLOCKS FOR DIFFERENTTRAFFIC CATEGORIES (CLAUSES 5 AND 9.1.4)
- 6 PHYSICAL REQUIREMENTS
- TABLE 2: RECOMMENDED DIMENSIONS AND TOLERANCE FOR PAVER BLOCKS (CLAUSES 6.2.2.1, 6.2.2.2, 6.2.3 AND 9.1.2)
- TABLE 3: COMPRESSIVE STRENGTH REQUIREMENTS OF CONCRETE PAVER BLOCKS (CLAUSES 6.2.5.2 AND 9.L.4)
- 7 TEST METHODS
- 8 SAMPLING
- TABLE 4: SAMPLING REQUIREMENTS (CLAUSE 8.5)
- 9 ACCEPTANCE CRITERIA
- 10 MARKING
- OVERVIEW OF CONSTRUCTION INDUSTRY IN INDIA
- 1. HIGH BUDGETARY ALLOCATION FOR INFRASTRUCTURE
- 2. INCREASING PRIVATE SECTOR INVOLVEMENT
- 3. IMPROVEMENT IN LOGISTICS
- 4. RISING FOREIGN DIRECT INVESTMENT (FDI) IN THE SECTOR
- ADVANTAGE INDIA
- 1. ROBUST DEMAND
- 2. ATTRACTIVE OPPORTUNITIES
- 3. POLICY SUPPORT
- 4. INCREASING INVESTMENT
- PERFORMANCE OF EIGHT CORE INFRASTRUCTURE INDUSTRIES
- GROWTH IN INFRASTRUCTURE RELATED ACTIVITIES
- STRONG MOMENTUM IN EXPANSION OF ROADWAYS
- STRONG REVENUE GROWTH FOR INDIAN RAILWAYS
- POWER GENERATION CAPACITY HAS INCREASED AT A HEALTHY PACE
- THE NATIONAL INFRASTRUCTURE PIPELINE (NIP)
- GOVERNMENT INITIATIVES
- CONCLUSION
- MARKET OVERVIEW OF PAVER BLOCKS
- PRODUCT MARKETING
- SECTOR & INDUSTRY ANALYSIS
- SECTOR CHARACTERISTICS AND OVERVIEW
- UNORGANIZED SECTOR – MACHINE BLOCKS
- UNORGANIZED SECTOR – HAND MADE BLOCKS
- ENVIIRONMENTAL & PROTECTION ASPECTS
- MARKET INFORMATION
- MARKET POTENTIAL
- EXPORTS AND IMPORTS OF PREFAB CONSTRUCTION BLOCKS
- TECHNICAL DETAILS FOR PAVERS BLOCKS
- DESIGN MIX CONCRETE:
- PAVER BLOCK MAKING MACHINE:
- WEIGH BATCHING & MIXING EQUIPMENT:
- CURING:
- LABORATORY
- RAW MATERIALS
- CEMENT
- AGGREGATES
- WATER
- OTHER MATERIALS
- PAVERS BLOCK CHARACTERISTICS
- PAVER BLOCK DIMENSIONS
- TESTING OF PAVER BLOCKS
- FOR 80MM PAVER TILES
- FOR 60MM GRASS PAVER TILES
- LAYING OF PAVER BLOCKS
- PRIMING
- BEDDING SAND COURSE
- LAYING OF INTERLOCKING PAVER BLOCK:
- INITIAL COMPACTION
- JOINT FILLING AND FINAL COMPACTION
- EDGE RESTRAINT USING KERB BLOCK
- UNIFORM INTERLOCKING SPACES
- SKILLED LABOUR
- LAYING PATTERN:
- TECHNICAL SPECIFICATION AND GRADE OF PAVER BLOCKS
- TECHNICAL SPECIFICATIONS OF PAVERS
- PRODUCT-WISH WEIGHTS AND DIMENSIONS
- PRODUCT DIMENSIONS AND WEIGHT
- RECOMMENDED GRADES OF PAVERS BLOCKS FOR DIFFERENTTRAFFIC CATEGORIES AS IS 15658-2006
- COMPRESSIVE STRENGTH REQUIREMENTS OF CONCRETE PAVER BLOCKS
- CORRECTION FACTORS FOR THICKNESS AND ARRIS/CHAMFER OF PAVER BOCK FOR CALCULATION OF COMPRESSIVE STRENGTH
- DESIGN OF PAVNG BLOCK
- DESCRIPTION OF LAYERS AND BASIC ENGINEERING DESIGN REQUIREMENTS
- SUBGRADE
- BASE COURSE
- TYPICAL GRADING FOR BASE COURSE MATERIALS
- BEDDING COURSE
- TYPICAL GRADING FOR BEDDING COURSE MATERIALS
- SURFACE COURSE
- RECOMMENDED SPECIFICATIONS FOR CLAY PAVERS
- EDGE RESTRAINTS
- DRAINAGE
- PAVER LAYING PATTERNS
- JOINTS BETWEEN PAVERS
- TYPICAL GRADING FOR JOINTING SANDS
- TOLERANCE ON COURSE LEVELS
- CROSSFALLS
- STEEP GRADIENTS
- MANUFACTURING PROCESS OF PAVERS BLOCKS
- WET CAST TECHNIQUE
- HYDRAULICALLY PRESSED TECHNIQUE
- RAW MATERIAL REQUIRED FOR THE MAKING OF PAVER BLOCKS
- MANUFACTURING PROCESS OF CONCRETE PAVERS
- WET CAST TECHNIQUE
- HYDRAULICALLY PRESSED TECHNIQUE
- PROCESSING DETAILS OF PAVERS BLOCKS
- MANUFACTURING PROCESS OF FLY ASH BRICKS
- TECHNICAL SPECIFICATION:-
- 1. COMPRESSIVE STRENGTH
- 2. DRYING SHRINKAGE
- 3. WATER ABSORPTION
- 4. EFFLORESCENCE TEST
- FORMULATION OF PAVERS BLOCKS
- QUALITY CONTROL AND STANDARDS
- A) INDIAN STANDARD SPECIFICATION
- B) QUALITY REQUIREMENTS
- PROS AND CONS OF WET CAST AND HYDRAULIC PRESS TECHNIQUES
- WET CAST PRODUCTION
- IMAGE COURTESY OF ARMCON LTD.
- OTHER WET CAST LANDSCAPE PRODUCTS
- MULTI-TONED TRAVERTINE EFFECT FLAG FROM BRADSTONE
- WET-CAST CHANCERY WALLING FROM MARSHALLS
- WET-CAST SLEEPER-EFFECT PAVING FROM ATLAS/BRETT
- HYDRAULIC PRESS PRODUCTION
- PIMPLE TEXTURE
- SIMPLIFIED MANUFACTURING PROCESS
- CURING AND PACKING
- REKERS CONCRETE BLOCK MACHINE
- PRESS AND MOULD FROM CHANDLA INDUSTRIES
- HOMOGENOUS AND FACE MIX PRODUCTS:
- TYPICAL "THROUGH-COLOUR "BRITISH BLOCK
- FACE-MIX BLOCK
- PAVING TEXTURES
- BARFACE PAVING IN RED
- DIAMOND PATTERN CLAY PAVERS
- HOBNAIL PAVING
- RIVEN SANDSTONE FLAGS - INDIAN IMPORTS
- RIVEN-EFFECT CONCRETE FLAGS FROM WESTMINSTER STONE
- RIVEN-EFFECT CLAY PAVERS FROM BAGGERIDGE
- NATURAL TEXTURES:
- SAWN YORKSTONE FLAGS
- HEAVILY RIVEN STONE FLAGS
- CROPPED GRANITE SETTS
- STANDARD TEXTURES:
- CONCRETE
- CHAMFERED EDGE AND SPACER LUGS MOULD-FORMED ON SMALL ELEMENT PAVER
- VARIOUS SHAPES AND DECORATIVE SURFACE TEXTURE ON MOULDED CONCRETE BLOCK
- BULL-NOSE AND HALF-BATTERED PROFILE TO MOULDED CONCRETE ROAD KERB
- CLAY:
- HANDMADE CLAY PAVERS
- MOULDED STAR-PATTERN CLAY PAVERS
- WIRECUT MIXED-SIZE CLAY PAVERS
- SECONDARY PROCESSES:
- TUMBLED-TYPE PAVERS
- HEAVILY TEXTURED PAVERS
- SECONDARY PROCESSES:
- TUMBLING
- TYPICAL TUMBLED CONCRETE PAVER
- LAID IN COURSES, THE EFFECT IS A 'TRADITIONAL' LOOK
- NEWLY-LAID DIRTY TUMBLED PAVERS
- SHOT BLASTING:
- SHOT-TEXTURED FLAG (MARSHALLS' SAXON)
- SHOT-TEXTURED KERB (MARSHALLS' CONSERVATION)
- SHOT-TEXTURED FLAGS IN 3 COLOURS
- SHOT-TEXTURED BLOCK PAVER
- DISTRESSED MEDITERRANEAN RUSTIC PAVERS FROM STONE & STYLE
- TUMBLED CHINESE GRANITE ON MESH BACKING
- TUMBLED RED GRANITE SETTS
- TUMBLED YORKSTONE SETTS
- BUSH HAMMERING:
- BUSH-HAMMERED GRANITE
- BUSH-HAMMERED CONCRETE
- BUSH-HAMMERED DECO FLAG
- BUSH-HAMMERED "CORNISH" BLOCK PAVERS FROM FORMPAVE
- BUSH-HAMMERED CONCRETE PAVERS LAID TO FOOTPATH
- POLISHING:
- MILANO GROUND/POLISHED PAVING FROM ACHESON-GLOVER
- VERONA GROUND/POLISHED PAVING
- "PERFECTA" HEXAGONAL GROUND PAVING FROM MARSHALLS
- POLISHED GRANITE FLAGS 450X450MM
- POLISHED GRANITE BLOCKS 200X100MM
- WASH-TO-EXPOSE:
- SPECIFICATIONS FOR ORDINARY CONCRETE
- FINE AGGREGATES
- COARSE AGGREGATES
- PRESCRIBED MIXES FOR ORDINARY STRUCTURAL CONCRETE
- FREE WATER: CEMENT RATIO
- PROCESS FLOW DIAGRAM
- PROCESS OUTLINE OF PAVERS BLOCK (MANUAL PROCESS)
- PRINCIPLES OF PLANT LAYOUT
- MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
- PLANT LOCATION FACTORS
- PRIMARY FACTORS
- 1. RAW-MATERIAL SUPPLY:
- 2. MARKETS:
- 3. POWER AND FUEL SUPPLY:
- 4. WATER SUPPLY:
- 5. CLIMATE:
- SPECIFIC FACTORS
- 6. TRANSPORTATION:
- A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES
- 7. WASTE DISPOSAL:
- 8. LABOR:
- 9. REGULATORY LAWS:
- 10. TAXES:
- 11. SITE CHARACTERISTICS:
- 12. COMMUNITY FACTORS:
- 13. VULNERABILITY TO WARTIME ATTACK:
- 14. FLOOD AND FIRE CONTROL:
- EXPLANATION OF TERMS USED IN THE PROJECT REPORT
- 1. DEPRECIATION:
- 2. FIXED ASSETS:
- 3. WORKING CAPITAL:
- 4. BREAK-EVEN POINT:
- 5. OTHER FIXED EXPENSES:
- 6. MARGIN MONEY:
- 7. TOTAL LOAD:
- 8. LAND AREA/MAN POWER RATIO:
- PROJECT IMPLEMENTATION SCHEDULES
- INTRODUCTION
- PROJECT HANDLING
- PROJECT SCHEDULING
- PROJECT CONSTRUCTION SCHEDULE
- TIME SCHEDULE
- SUPPLIERS OF PAVING BLOCK
- SUPPLIERS OF PORTLAND CEMENT
- SUPPLIERS OF STONE CHIPS
- SUPPLIERS OF DG SETS
- SUPPLIERS OF WATER PUMP
- SUPPLIERS OF PALLETS
- SUPPLIERS OF MOULDS
- PLANT AND MACHINERY SUPPLIERS FOR PAVERS BLOCKS
- CHINA SUPPLIER OF AUTOMATIC PAVING BLOCK MAKING MACHINE
- PROJECT SYNOPSIS
Appendix
- APPENDIX – A:
- 01. PLANT ECONOMICS
- 02. LAND & BUILDING
- 03. PLANT AND MACHINERY
- 04. OTHER FIXED ASSESTS
- 05. FIXED CAPITAL
- 06. RAW MATERIAL
- 07. SALARY AND WAGES
- 08. UTILITIES AND OVERHEADS
- 09. TOTAL WORKING CAPITAL
- 10. TOTAL CAPITAL INVESTMENT
- 11. COST OF PRODUCTION
- 12. TURN OVER/ANNUM
- 13. BREAK EVEN POINT
- 14. RESOURCES FOR FINANCE
- 15. INSTALMENT PAYABLE IN 5 YEARS
- 16. DEPRECIATION CHART FOR 5 YEARS
- 17. PROFIT ANALYSIS FOR 5 YEARS
- 18. PROJECTED BALANCE SHEET FOR (5 YEARS)
Frequently Asked Questions
Interlocking Concrete Block Pavement (ICBP) is a pavement system made from precast concrete paver blocks laid over a compacted bedding layer and properly prepared base course.
The blocks are placed within edge restraints and their joints are filled with suitable fine material. Depending on their shape, paver blocks can interlock along some or all of their vertical faces. The report describes ICBP as an alternative where conventional bituminous or cement-concrete pavement may be less suitable because of traffic, environmental, geological, operational, or service-life considerations.
ICBP offers durability, easy maintenance, rapid opening to traffic, and resistance to several operational stresses.
Factory production can provide consistent quality and dimensional accuracy when suitable quality control is maintained. The pavement can tolerate deflections without structural failure and is not affected by thermal expansion or contraction in the same manner as conventional rigid pavement. It can provide ready access to underground utilities, is resistant to fuel and oil spillage, and can accommodate heavy vehicle maneuvering loads. Coloured blocks can also provide permanent traffic markings.
ICBP requires strict quality control, accurate base preparation, suitable bedding and jointing materials, and effective drainage.
The report identifies factory quality control as a prerequisite for durable pavement. Any deviation in the base-course profile can appear on the finished pavement surface, making accurate preparation important. High-quality, properly graded bedding sand and joint-filling material are also necessary. Where an unbound granular base is used, poor drainage can accelerate deterioration. The report also states that ICBP is not suited for high-speed roads with speeds above 60 km/h.
ICBP can be used across non-traffic, light-traffic, medium-traffic, heavy-traffic, and very-heavy-traffic applications.
Examples in the report include building premises, footpaths, malls, pedestrian plazas, landscaped areas, parking areas, housing colony roads, office driveways, rural roads, city streets, service stations, container and bus terminals, ports and dockyards, mining areas, industrial-complex roads, factory floors, airport pavements, and heavy-duty roads on expansive soils. Selection should consider the expected traffic category and the structural and environmental conditions of the site.
The report classifies concrete paver blocks into four generic types according to their face geometry and interlocking characteristics.
Type A blocks have plain vertical faces and do not key into one another. Type B blocks have alternating plain and curved or corrugated faces that provide interlocking along the shaped faces. Type C blocks have curved or corrugated faces throughout and interlock along all vertical faces. Type D blocks include L- and X-shaped forms with curved or corrugated faces that interlock along their vertical faces.
Paver-block quality depends on the concrete materials, mix design, production equipment, compaction, curing, handling, supervision, and quality control.
The report notes that zero-slump concrete is used in paver-block production and that block performance is influenced by cement grade, water content, aggregate quality and gradation, mix design, additives, machine compaction and vibration capacity, handling equipment, curing practices, supervision, and workmanship. Dimensional accuracy, concrete strength, durability, and appropriate material quality are important for satisfactory pavement performance.
Bedding and joint-filling materials, together with proper drainage, are essential to maintaining the performance of an ICBP system.
The bedding layer provides the supporting interface between the paver blocks and the prepared base, while joint-filling material contributes to the functioning of the block assembly. The report emphasizes the importance of appropriate quality and gradation for both materials. It also notes that ICBP over an unbound granular base can deteriorate more rapidly when drainage is poor. Consequently, pavement design and construction should maintain the required profile, drainage provisions, bedding quality, and properly filled joints.
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