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SupaBlok™

Our SupaBlok™ interlocking block molds consist of metal components that are quickly assembled by hand to form trays of eight block cavities. Trays consist of a base plate, a pair of side plates and nine divider plates. Each divider plate has a pair of holes which, once assembled will accommodate two plastic tubes running the length of the tray. Two types of block are produced; regular interlocking and bond beam. Regular blocks can be cut in half to produce half blocks needed at the ends of walls and around windows and doors. Bond beam blocks can be used as lintels above doorways and windows and at the tops of walls.

Regular blocks have a pair of circular knobs on top and a corresponding recess on the bottom. There is a hole between each knob and recess. When placed on the ground the blocks lay flat and level with it. Another block can then be stacked upon the first in a brick like interlocking pattern. A special flat top configuration can be cast that has a recess on the top (rather than a knob) and the bottom such that when stacked it offers a flat top surface. Such a block is useful at the bottom of window openings. The bond beam block has a deep U shaped cavity at the top allowing a builder to insert horizontal rebar. Lines on cast blocks indicate where to cut to create half blocks and where to cut the corners to make 45° degree angled walls.

Lightweight

Energy Efficient

Affordable

Environmentally Friendly

User Friendly

Termite Resistant

Noise Reducing

Excellent Indoor Air Quality

Fire Resistant

Versatile

Durable

Crack Resistant

SupaBlok™ is the ultimate green building block. It is precision molded, interlocking, mortarless and requires little skill to lay. It is made with cellular lightweight concrete (CLC). A non-toxic chemical foam (see photo) is introduced into regular concrete leaving a multitude of air pockets within the mixture. This wet mixture is poured into block molds and allowed to cure. No heat is employed during the manufacturing process. The molds are disassembled revealing lightweight blocks comprised of sand and cement filled with non-interconnected air pockets. The interlocking SupaBlok™ design was created by and is exclusive to Greentec.

During construction, reinforced steel (rebar) and grout are introduced into some of the holes within the blocks to form columns. It is these columns that provide the support for the structure. The structure essentially represents a basic column and beam system with the columns and beams being made out of materials that structural engineers are already familiar with. The mortarless design creates gaps between blocks which act as expansion joints that may eliminate the need for such. Although SupaBlok™ walls are structural, the blocks themselves are not structural elements. SupaBlok™ is a form that contains the structure.

The ease of assembly makes SupaBlok™ ideal for “do it yourself” home builders and professional builders alike. SupaBlok™ has high insulation values, is fireproof and termite resistant. SupaBlok™ built structures are strong and perform well in high winds and during seismic activity. SupaBlok™ is very different from all other concrete products on the market and should not be confused with Insulated Concrete Forms (ICF) or Autoclaved Aerated Concrete (AAC).

Long lasting, affordable, energy efficient homes can be  built with non-toxic materials that generate minimal job site waste. SupaBlok™ can be used in both residential and commercial construction. Applications include interior and exterior walls in homes and buildings, fire walls, fences, sheds, and retaining walls.

Typical Rates

Block material cost: About 50-80% of regular dense concrete material cost per unit volume depending on mix design and local raw material costs

Production rate: Typically 20 to 80 blocks can be produced per man hour depending on the efficiency of the operation

Installation rate: Typically 2 to 10 square meters can be installed per man hour (including mixing and pouring of grout and placement of mortar and rebar) depending on the size and efficiency of the construction crew

Installed SupaBlok™ walls are as much as 40%  less than regular concrete block walls

 

The regular SupaBlok™ precast is 15 cm deep by 15 cm tall by 30 cm wide with a pair of holes. The bond beam block has the same dimensions but also has a deep horizontal cavity (U shape).

SupaBlok™ Features

  • Lightweight
  • Interlocking
  • Mortarless
  • Can easily make 45° corners
  • Self aligning
  • Molded-in-place electrical boxes
  • Cut and shaped easily with hand tools
  • Accepts nails by nail gun (600 kg/cu m density)
  • Easily create double walls, buttresses and ledges
  • Form for column and beam structural system
Although a wide range of mix densities are possible, for blocks, two standard densities are recommended:

The SupaBlok™ 600 is a 600 kg/m3 density mix (lighter mix)

The SupaBlok™ 1100 is a 1100 kg/m3 density mix (heavier mix)

Blocks can be cut in half to form half blocks which are usually selected to fill openings around doors and windows and at ends of walls. Electrical boxes and plumbing fixtures can be cast in place.

The SupaBlok™ bond beam block can be used for bond beams and lintels. A bond beam is a continuous beam, usually constructed of concrete and reinforced horizontally with rebar, on top of supporting walls. The purpose of the bond beam is to tie walls together and distribute weight evenly to the walls below. The bond beam blocks are interlocking and mortarless and allow for vertical and horizontal steel reinforcement. The vertical rebar from blocks below (and above) can be tied to the horizontal rebar running through the blocks creating a strong structure with evenly distributed loads.

A lintel is a support beam above windows and doors. The SupaBlok™ bond beam blocks are used in cases where regular SupaBlok™ will not suffice.

The lighter mix design has very good insulating properties and is best for those applications requiring very good thermal insulation or a low density. The heavier block is harder and is targeted at applications where abrasion resistance is important or where thermal insulation and light weight are less of a priority. The lighter block is used for home and building construction in temperate climates where it can be treated as a mass wall absorbing heat during warm days and radiating that warmth into the interior of the home or building during cool evenings. The heavier block is used in more tropical climates where mass walls are not effective due to the relatively small change in day and evening temperatures.

SupaBlok™ 600                         

Applications for the lighter block include:

  • Fire and demising walls
  • High rise buildings (as infill)
  • Offices and warehouses
  • Homes (external and internal walls)
  • Sound rooms and studios

The lightweight quality of the block and the discrete nature of the air pockets within are evident by the fact that SupaBlok™ 600 will float on water. Significant savings in heating and cooling expenses can also be achieved. SupaBlok™ 600 exceeds the energy efficiency requirements that many communities require.                        

High thermal mass systems such as SupaBlok™ 600 contribute to energy efficiency not only by virtue of their thermal insulating performance but also by their ability to store energy.  SupaBlok™ structures are very energy efficient; SupaBlok™ reduces heating and cooling loads and the size of air conditioning (A/C) systems.

Wood frame, concrete block and other traditional methods of construction tend to be very labor intensive, SupaBlok™ is designed to simplify and quicken construction.

Long lasting, durable and affordable structures can be built with SupaBlok™. Its light weight means significantly less cement is consumed and reduced freight loads result in less energy consumption and pollution during transport. It does not rot, is not attacked by vermin, and does not absorb moisture into its core resulting in a lower maintenance requirement. Minimal job site waste is generated during construction. Lightweight cellular concrete absorbs sound (while dense concrete reflects sound) and significantly reduces indoor noise resulting in quieter rooms and little to no sound transmission to adjoining rooms.

SupaBlok™ is a very healthy and environmentally friendly green building material. No ozone depleting or hazardous chemicals are normally used during manufacture. Heavy use of pesticide is not required prior to construction. SupaBlok™ is a breathable material that removes toxins from the air and naturally maintains a low relative humidity within the home. Mold growth is inhibited by the lack of moisture and organic material (such as wood or paper) combined with the alkaline environment of the cement based system. Because SupaBlok™ is a clean breathable material it is ideal for those suffering from asthma, allergies and chemical sensitivities.

To take advantage of the modular design and to avoid cutting the blocks, walls and openings are typically dimensioned in multiples of whole or half blocks.

                              

Benefits

Owner/ Developer Benefits

  • Low cost SupaBlok™ system works best for modular low income housing
  • Better performance per unit wall cost than competing systems
  • Great choice for building yourself as the lightweight, interlocking, dry stacked design requires mostly unskilled labor
  • Great for those with chemical sensitivities as SupaBlok™ is a breathable material that is not typically produced with and does not contain any toxins, plastics, flyash, VOCs, or other potentially harmful materials
  • Superior thermal insulation reducing heating and cooling loads and air conditioning system size
  • Much less sound transmission than wood frame and far better sound absorption than regular concrete. While regular dense concrete reflects sound back into a room, SupaBlok™ absorbs the sound in its walls creating quieter rooms
  • SupaBlok™ does not rot or warp and does not absorb moisture into its core resulting in lower annual maintenance costs
  • Termites and other vermin will not attack, burrow, or nest within SupaBlok™ cellular concrete
  • Rodents and other vermin cannot enter the wall cavity and attack electrical wiring and plumbing
  • Mold requires warm temperatures, moisture, and organic nutrients such as wood and paper to grown and leave mildew. SupaBlok™ is totally inorganic and is mold resistant
  • SupaBlok™ is fire resistant and will not burn or produce harmful fumes during a fire. Its fire resistance is superior to concrete block walls
  • Resistant to seismic activity and shifting soils. Unlike traditional concrete wall systems, crack causing stresses in one block are unlikely to propagate through the wall
  • Inexpensive to finish, blocks are smooth and tight fitting requiring only a thin render to finish prior to applying stucco, siding, brick or veneer
  • Unlike regular concrete, because of its insulating properties SupaBlok™  600 is not prone to sweating of the walls
  • SupaBlok™ homes and buildings are comfortable, long lasting and easy to maintain
  • Opportunity for preferential government fees and taxes due to the use of a green building material

Architect/ Engineer Benefits

  • Excellent thermal resistance provides LEED energy efficiency credits
  • Low density gives designers an option for a lightweight, inorganic wall with lower foundation, column, and support requirements
  • LEED credits for being fully recyclable as aggregate at the end of its life
  • Very low embodied energy resulting from reduced cement usage and absence of external heating during manufacture
  • Reduced freight loads and less energy consumption and pollution during transport compared to concrete blocks
  • No hazardous chemicals or volatile organic compounds (VOCs) typically used in manufacture or construction contributing to LEED credits for indoor air quality
  • Sound absorbing walls (as much as eight times more absorbing than concrete block) providing LEED credit opportunities for acoustical performance
  • Innovative lightweight, interlocking, mortarless design creates opportunities for Innovation in Design LEED credit opportunities
  • Modular design leads to minimum construction site waste
  • Ductile wall design resists seismic action
  • Flexible system allows engineers to design walls to meet wind speed requirements
  • Walls are a column and beam structure made from materials that engineers already know
  • Long lasting affordable structures can be built with lower wall costs than regular concrete block

Builder/ Installer Benefits

  • Blocks can be manufactured on the construction site reducing freight and delays and offering better control over the building process
  • Can be built with mostly unskilled workers
  • Speed and ease of construction means fewer workers can build larger wall areas more quickly than competing systems
  • Projects completed faster thanks to precise fit of interlocking dry stacked system
  • Easily accommodates plumbing and electrical wiring, electrical boxes and water taps can be cast in place
  • Self-aligning, requires little bracing or special supports during construction
  • Lightweight forms are safer for workers to handle
  • System is versatile with ledges and double walls possible. Supablok™ can even be carved and shaped
  • Blocks can be cut with a hand saw and require no special tools, mortars, plasters, or reinforcement. They will not corrode steel
  • Nail gun can be used to install trim, molding and siding

Typical Block Properties


*Fully cured full size regular SupaBlok™

 

SupaBlok™ 1100                        

Applications include:

  • Barns, sheds and storage facilities
  • Basements and foundation walls
  • Dumpster/ skip enclosures
  • Fences
  • Fireplaces
  • Freestanding garages and carports
  • Homes (internal and external walls)
  • Offices and warehouse
  • Outdoor kitchens, barbeques and fire pits
  • Parapet walls
  • Retaining walls and raised beds
  • Safe rooms
  • Sign and monument supports
   

Significant cost and time savings can be had by building with SupaBlok™ 1100 versus bricks or conventional concrete blocks. These close fitting forms are interlocking and self-aligning. They stack quickly without the use of mortar or highly skilled labor. Traditional building materials tend to be very labor intensive but SupaBlok™ is designed to simplify and quicken construction.

Building efficiencies are significantly better as the wall area built per worker per hour is far greater with SupaBlok™ than with brick or concrete block. SupaBlok™ cavities (holes) are also much smaller than typical concrete block openings resulting in the need for much less concrete (or grout) and rebar.

Unlike brick and concrete block walls, the dry stacked design of SupaBlok™ creates a crack resistant wall which can eliminate the need for expansion joints . Thin stucco or textured paint is all that is needed to create a smooth wall free of mortar joint lines.Unlike regular concrete, the unique properties of SupaBlok™ allow it to withstand direct contact with flames from a fire. SupaBlok™ 1100 is ideal for fireplaces and outdoor barbeque pits.


Benefits

Owner Benefits

  • Unlike brick or concrete block walls, the dry stacked SupaBlok™ design keeps any stress induced localized cracking from propagating
  • Thin stucco or textured paint can create smooth walls free of visible mortar joint lines
  • SupaBlok™ is typically a very clean material, there are no toxins or chemicals present that may leach out into plant soil
  • SupaBlok™ raised beds will not rot or warp and are not attacked by vermin or termites. They are very cost competitive with cedar, copper and landscape block systems
  • SupaBlok™ retaining walls are about half the cost of typical landscaper installed walls and are much lighter and easier to handle than the typical 36 kg retaining wall block
  • SupaBlok™ fences are faster, easier and more cost effective to erect than brick or concrete block walls
  • Reduce noise from your surroundings with a SupaBlok™ fence. It will absorb sound while regular concrete block walls reflect it back
  • Regular concrete will crack and explode into pieces under direct flame, SupaBlok™ can withstand a direct flame for extended times without any damage. This quality makes it ideal for use in constructing outdoor kitchens, fireplaces, barbecues and fire pits. Unlike regular concrete blocks, when used to build barbeques, with fire on the inside, SupaBlok™ remains cool to the touch on the outside

Builder Benefits

  • Requires far fewer workers to build the same wall area compared to concrete block or brick
  • Projects completed faster thanks to precise fit of interlocking dry stacked system
  • Very little installation material (e.g. grout and rebar) required compared to concrete block or brick
  • Self-aligning forms require little bracing or special supports during construction
  • No heavy equipment or electricity needed on site
  • Can be installed in confined spaces

 

Typical Block Properties


*Fully cured full size regular SupaBlok™

 

Similar block styles of a different design were used in the past and they are included in the photo examples below.

Examples