Catalogue draft 1 by Qais Tabib

NATIONAL BLOCKS & INTERLOCK FACTORIES

PA V I N G

Introductio Applications Rectangular Block

KERBSTONE

Introduction 16 Kerbstone 18

MASONRY

Salient features Solid Blocks Hollow Blocks

B LO C KS

CATALOGUE

04 07 15

23 27 28

Patterns 30 Gallery 52

Contents

NATIONAL BLOCKS & INTERLOCK FACTORIES

Statement of our management We are one of the leading manufacturers of concrete products in assorted colors, shapes and thicknesses in Qatar. The full generations. Our Products are patently designed and manufactured in precise compliance. With the said norms and specifications in order that the product may last long as well as carry the aesthetic attraction. Our Products are regularly tested for compressive strength, water absorption, abrasion resistance, Tension strength and color lasting by recognized laboratories in accordance with the international specifications. We receive positive test results from the testing laboratories.

We pleased to inform you that the quality of our management system products and services have been assessed and found to be in accordance with the requirement of quality standard and also we are totally complying with the environmental management system for manufacturing of tiles and blocks.

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PAVING

INTRODUCTION

CONCRETE BLOCK PAVING

The Concrete block is widely used for roads and other paved areas intended for pedestrian or low-speed vehicular traffic.

is a traditional concept. Small units are bedded on sand, and locked together and sealed by sand in the joints between the units. Its aesthetic appeal and versatility make it a natural choice and it is undoubtedly assured a prominent position in modern day and future environmental planning.

It is attractive, functional and economical; it can enhance the appearance of a residential or shopping area through its colour, texture and pattern. In an industrial area, it can resist the high stresses imposed by point loads associated with trailer jacks or heavyduty racking, and is undamaged by oil spillage. It can be used on its own or in combination with other surfacing materials.

Research indicated that at the 1.5 Million “Standard Axle” level, the load supporting abilities of concrete paving blocks on 50mm of sand are equal to – a) 225mm of dry lean-mix concrete b) 170mm of dense macadam c) 160mm of hot-rolled asphalt CONCRETE BLOCK PAVING is for any areas where STRENGTH, FLEXIBILITY and ECONOMY are essential.

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WHAT IS CONCRETE BLOCK PAVING? Concrete block paving consists of small individual high strength concrete units manufactured to accurate dimensional standards. The blocks are one hand sized and are laid without mortar on a sand laying course. The blocks are formed from a “no-slump” concrete mix comprising of Portland Cement and 3-9mm limestone and from 0-3mm lime-stone sand which is compressed under extremely high pressure by millions of high frequency vibrations. In the 2,000 years between PAVIMENTUM and PAVEMENT, something got lost in the translation.

WHAT IS THE LINK? What is the link between the durability and lasting beauty of PAVIMENTUM, and the economy and flexibility of PAVEMENT? The link between form, function and aesthetic integrity? The link between tradition and technology? THE LINK IS THE INTERLOCKING CONCRETE PAVING BLOCK.

The basic composition and state-of-the-art manufacturing techniques produce paving blocks with an extraordinarily high compressive strength that exceeds 49N/mm², and water absorption will never exceed 5%. In the 2,000 years between PAVIMENTUM and PAVEMENT, something got lost in the translation.

NATIONAL BLOCKS & INTERLOCK FACTORIES The engineers responsible for the design and maintenance of Pavements have for many years, been searching for a surface with the following properties: • • • • • • • • •

Durability Surface stability with tyre pressures up to1.4 MN/M² Good frictional characterists Good standard of rid ability Rapid removal of surface water Capacity of rapid repair and maintenance Resistance to thermal movements Resistance to high jet engine exhaust velocities and to thermal shock Resistance to aviation fuels and hydraulic oils

The Concrete Block Paving, once laid and vibrated into the sand laying course, and the joints filled by sand, from a durable, flexible surface that appears to satisfy most of the properties.

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APPLICATIONS Concrete block paving offers designers an immediately useable, flexible, load bearing surface. When manufactured to BS 6717: Part 1, the blocks have excellent durability, skid resistance and strength, long life, attractive appearance and factory controlled quality. Concrete block paving is suitable for virtually all types of pavement. Some of them are as follows:

A. LIGHT DUTY: 1. Residential 6. Parking Lots (Light Traffic) 2. Driveways 7. Bicycle Paths 3. Patios 8. Erosion Control 4. Pool Decks 9. Temporary Paving 5. Walkways B. MEDIUM DUTY: 1. Sidewalks 10. Maintenance 2. Mobile Home Parks 11. Service Roads 3. Shopping Malls 12. Warehouses 4. Parks 13. Cross Walks 5. Residential Streets 14. Farm Equipment 6. Canal Lining 15. Storage Yards 7. Public Parking 16. Camping Areas 8. Safety Zones 17. Parking Lots (Heavy Traffic) 9. Bus Stops C. HEAVY DUTY: 1. City Streets 5. Gas Stations 2. Loading Ramps 6. Industrial Floors 3. Stables 7. Loading Docks 4. Intersections And for all aircraft pavements which are subject to slow moving aircraft.

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Some of the main advantages of concrete paving blocks are: 1.

MORE STRENGTH, MORE LIFE:

Centimeter for centimeter (inch for inch), concrete paving blocks are stronger than (49N/mmÂ˛-minimum) and more durable than conventional paving materials. Concrete block paving can handle the weight of heavy construction equipment or fully loaded tractor trailers, plus it offers an exceptionally long product life.

LESS ABSORBENT:

Concrete block paving has less than five percent absorption, which is considerably lower than both asphalt and poured concrete, providing for substantial resistance to oil and salt, common destructive agents to the life and appearance of other paving surfaces.

MORE ATTRACTIVE:

Because concrete paving blocks are available in a variety of shapes and colours, an endless number of beautiful patterns and designs can be created which simply cannot be achieved with asphalt or poured concrete.

LESS MAINTENANCE:

Concrete block paving requires far less maintenance than other paving materials. Concrete block pavingâ&#x20AC;&#x2122;s strength and durability eliminates costly patching and surfacing, while concrete paving blocks range of colours make it possible to create a mosaic of parking space lines and directional signs, and eliminate painting.

EASILY REUSABLE:

Unlike asphalt and poured concrete, concrete paving blocks can be removed for access to underground utilities and reinstalled after repairs are completed.

COOLER IN SUMMER:

Concrete block paving remains cooler than asphalt and poured concrete in summer making it the ideal choice for parks, patios, around swimming pools and pedestrian areas.

EASIER TO INSTALL:

The installation of concrete paving blocks requires neither the specialised equipment nor the intensive skilled labour of asphalt and poured concrete installations.

YEAR-ROUND ALL-WEATHER INSTALLITION:

Concrete block paving can be installed any time of the year, in practically any type of climate or weather. Unlike asphalt and concrete, concrete block paving does not require favourable weather and temperature for successful installation, avoiding costly construction delays.

MAJOR COST SAVINGS:

The initially higher cost concrete block paving is recouped many times over through longer product life, reduced maintenance, repair, sealing and stripping costs, making concrete block paving the most economical material available for your next paving job.

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SPECIFICATIONS OF CONCRETE PAVING BLOCKS 1. DIMENSIONS Cement or coloured blocks shall be 60mm or 80mm or 100mm thickness from Starline Block Factory or similar and approved. The shape, size, thickness and colour will be subject to approval from the Engineer and complying to BS 6717 : Part 1.

2. REQUIREMENTS This specification specifies requirements for precast concrete paving blocks intended for construction of low speed roads, and industrial and other paved surfaces subjected to all categories of static and vehicular loading and pedestrian traffic.

3. CEMENT The cement used in the manufacture of concrete paving blocks shall, unless stated otherwise, be ordinary Portland Cement which complies with the requirements of BS12 “Ordinary Portland Cement”. If Sulphate Resisting Cement be used, it shall comply with the requirements of BS 4027 “Sulphate Resisting Cement”.

4. THE CEMENT CONTENT The Cement Content should not be less than 400 Kg/Cu.M. concrete.

5. COLOURED BLOCKS The coloured concrete paving blocks shall have a minimum content of inorganic pigment of 5% by weight of the Cement Content and according to manufacturer’s instructions. All pigments to comply with BS-1014.

6. AGGREGATES Aggregates used are crushed lime stone complying with BS - 882: 1983, free from earth, clay, loam and soft clay. Sampling and testing in accordance with BS - 812: 1975. The amount of material passing a BS 75 micron sieve in the combined aggregates, when tested in accordance with BS 812 (wet sieving method), shall not exceed the following limits. Fine aggregates : 3% by weight Coarse aggregate : 1% by weight

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7. CRUSHED SAND The sand for concrete shall be capable of passing through a 5mm BS test sieve and it shall be so graded that when mixed with coarse aggregates and cement it shall produce concrete of the maximum density. The fine aggregates shall not contain more than 25% by weight of soluble Calcium Carbonate in either the fraction restraint on, or the fraction passing a 600 micron BS sieve.

8. MIXING WATER For mixing concrete, water shall be potable and free from all sediments and dissolved or suspended matter which may be harmful to the manufacture of concrete as specified and shall be tested in accordance with BS 3148.

9. SIZES AND TOLERANCES Concrete paving blocks have a work size thickness of 100mm, 80mm and 60mm, and shall have a peripheral chamfer on the top edge. The maximum dimensional deviations from the stated work size are as follows – Length : ± 2mm Width : ± 2mm Thickness : ± 3mm 10. COMPRESSIVE STRENGTH The average compressive strength of blocks, when tested in accordance with the BS 6717: Part 1, 1986, should not be less than 49 N/mm² (average crushing strength)

11.WATER ABSORPTION The concrete paving blocks when tested upon as specified in ASTM C140 – the maximum limits of water absorption shall be as follows: 5%absorbed after 10 minutes, 7%absorbed after 24 hours.

12. ADMIXTURES Admixtures will be permitted to used in the concrete only with the full approval from the Engineer and complying to BS 5075 if specified.

13. COLOUR FADING Pigments are to comply to BS 1014 and tested for Alkali Resistance and Light Resistance according to ASTM C979.

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HOW TO LAY CONCRETE PAVING BLOCKS 1.SELECTION OF BLOCKS Although block shape and colour are purely subject to taste, the thickness should be considered depending on the application and performance required. (Refer to item 6 below, and the illustration on page 10)

2. ASSESSMENT OF SUB-GRADE Following the removal of top-soil materials, the quality of the Sub-grade should be ascertained prior to construction of the Sub-base. The quality determines the thickness of Sub-base required, and is normally classified as a CBR value (California Bearing Ratio). Soils with low CBR values 2 or 3% require more substantial covering construction in order to distribute loads over greater areas. Low CBR values are found in clays, with higher values being more applicable to sandy gravels.

3. PREPARATION OF SUB-BASE The Sub-base thickness is required for different CBR values of the Sub-grade and different cumulative numbers of Standard Axle (SA) loads (See Table 3, Page 13)

4.INSTALLATION OF EDGE RESTRAINTS Edge restraint is essential to prevent the blocks from moving sideways and becoming loose. It is normally provided by standard precast concrete kerbs or insitu concrete edge strips or existing paving or building or some other design feature.

5. LAYING COURSE This is 50mm thick layer of clean sharp sand containing not more than 3% silt and clay, and with not more than 10% by weight retained on a 5mm sieve.

For best results, the moisture content of the laying course sand should be within 1% of the optimum, as determined by Test 12 of BS 1377. The sand should be spread over the area to be paved. The actual thickness will vary according to the tolerance of the Sub-base layer. Sub-bases to the Specification are allowed a tolerance of Âą 25mm.

6. SURFACE COURSE The concrete blocks forming the surface courses should be of the following recommened thickness: 60mm for drive-ways, patios, pool-decks, walkways, parking, bicycle paths, erosion control surfaces. 80mm for side-walks, shopping malls, residential streets, public parking, bus-stops, service roads, cross walks, parking lots, camping areas, mobile home parks, canal lining, safety zones, maintenance areas, farm equipment storage. 100mm for city streets, inter-sections, gas stations, loading docks, loading ramps, industrial floors, stables.

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WALKWAYS

LIGHT TRAFFIC ROADWAYS

ESTATE ROADWAYS, “A” CLASS ROADS & ALL OTHER INDUSTRIAL SITUATIONS

HEAVY INDUSTRIAL TRAFFIC

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STRUCTURAL DESIGN OF THE PAVEMENT The procedure recommended for the design of lightly trafficked areas are as follows:

DETERMINE THE CALIFORNIA BEARING RATIO OF THE SUBGRADE.

The CBR of the underlying materials may be provided by the Site Investigation Report. If this is not the case, it may be estimated by reference to TABLE 1. Where any doubt exists regarding the validity of the date, the lower of the figures indicated should be assumed. If the site investigation was undertaken during dry period, due allowance for a substantial reduction in CBR during wetter periods must be made.

DETERMINE THE VOLUME OF TRAFFIC AS ‘STANDARD AXLES’

Assess the total amount of traffic to be carried during the design lifetime of the pavement before major maintenance or repair becomes necessary. The volume of traffic to be carried by the pavement is expressed as ‘Standard Axle’ (SA). This theoretical figure is calculated from the number of commercial vehicles using the pavement during its design lifetime and multiplying it by the factor obtained from TABLE 2 to convert to the notional number of axles of a standard vehicle – the ‘Standard Axles’

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DETERMINE THE SUB-BASE THICKNESS REQUIRED

TABLE 3 may be used to determine the required thickness of Type 1 granular Sub-grade material relating to the CBR and traffic volume.

GENERAL NOTES – APPLICABLE TO LIGHTLY TRAFFICKED AREAS AND HIGHWAY USE 1) Sub-base materials should be Type 1 granular materials. The use of Type 2 or inferior materials may lead to the pavement construction becoming excessively sensitive to moisture changes and water movements. 2) Any soft or poorly compacted materials must be removed from the Sub-grade. 3) Laying course materials should meet the specification included in BS 6717 : PART 3 4) Concrete Block paving should be laid in accordance with the recommendations included in BS6717 : PART 3 5) The nominal laying course thickness over a Sub-base of granular material should be 50mm. 6) The minimum block thickness for roads carrying more than an average of 5 commercial vehicles per day should be 80mm. In other cases the block thickness should be 60mm.

EXAMPLE OF DESIGN PROCEDURE

An access road is to be constructed to a small commercial estate to carry no more than five commercial vehicles per day. The design time of the road is to be 20 years before major maintenance is required. From the site investigation a realistic CBR value of 3% revealed, taking into account the likely condition and water table levels at the time of construction. Number of commercial vehicles: 10(5 each way) x 6(days/week) x 48 (working weeks/year) x 20 (years design life) = 57,600 Allowing for traffic growth say – 60,000 Conversion to ‘Standard Axles’: 60,000 x 0.45 (from TABLE 2) = 27,000 Sub-base thickness – From TABLE 3 : 3% CBR; 27,000 SA = 280mm

DESIGN SOLUTION Sub-base: 300mm Type 1 granular material Laying course: 50mm Crushed sand Concrete Block : 80mm Total thickness 430mm

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RECTANGULAR BLOCK For heavy industrial block pavements, we suggest that a block shape with straight sides is the appropriate choice for the following reasons: (1)There is a better chance of a constant quality interlock around all sides of the block. The degree of interlock is less than for profiled blocks but its constancy is of greater importance. (2) A Rectangular block is less prone to stress concentrations than a profiled block under horizontal loads, hence less chance of flexural tensile failure. (3) A Rectangular block pavement behaves better when subjected to traffic wave deformations than profiled blocks as horizontal forces will be transferred as line loads rather than point loads. (4) From a practical point of view, Rectangular blocks are easier to uplift and replace when services need to be installed under the pavement. This happens frequently at industrial sites.

NATIONAL BLOCKS & INTERLOCK FACTORIES

Kerbstone

NATIONAL BLOCKS & INTERLOCK FACTORIES

How we produce our kerbstone: W e do as detailed below produce our K erbstone according to all major B ritish and A meri can standards . Y et as per Q atari standards , we have chosen to produce it according to BS 7263, to ensure that our stones do cross the borders of test available . O ur mix design is as follows : M aterial type 0-2 05 5-10 10-20 C ement W ater

W eight 287 KG 170 KG 152 KG 76 KG 107 KG 100 KG

A ll our laboratory test have shown very good strength results , and supporting documents will be supplied according to customer and consultants requirements .

OUR PROCESS

1- T he mix ( aggregates ) is being prepared in the mixer using computerized dosing system end placed in the mixer

W hile working on the aggregates , the cement is being processed and transferred in

the weighting scale in mixer

3- D ry mix of aggregates and cement ( calculated ) 4- W ater is added according to mix design 5- W et mix will go in process 6- M ix is transferred to the molding area 7- F ilter papers are placed at the bottom of the mold ( ready mix ) 8- C alculated material is placed in the mold ( ready mix ) 9- P ress and vacuum of the mix and water . ( the K erbstone is ready for storing ) 10- C ubing readymade products to storing area A ll finished products will be shifted and laid in the shielded area away from sun ( initial curing ) T hen 12 hours later are shifted for the remaining of the curing period under the sun .

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MASONRY BLOCKS

NATIONAL BLOCKS & INTERLOCK FACTORIES

SALIENT FEATURES Scope of activities • Manufacturer of Concrete Products in assorted color, shapes and thicknesses. • Supply of the manufactured Goods to the Qatar Market as well as buyers in the neighboring countries and overseas countries. • Fixing work on subcontract and / or turnkey basis.

Orientation: We are one of the leading manufacturers of concrete products in assorted colors, shapes and thicknesses in Qatar. The full generations. Our Products are patently designed and manufactured in precise compliance. With the said norms and specifications in order that the product may last long as well as carry the aesthetic attraction. Our Products are regularly tested for compressive strength, water absorption, abrasion resistance, Tension strength and color lasting by recognized laboratories in accordance with the international specifications. We receive positive test results from the testing laboratories. We pleased to inform you that the quality of our management system products and services have been assessed and found to be in accordance with the requirement of quality standard and also we are totally complying to the environmental management system for manufacturing of tiles and blocks. We normally allow visits to our factory from business partners, friends and well-wishers with or with out prior invitation.

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Block Ingredients: The following ingredients are used to in the manufacture of our blocks. - Crushed concretes 0mm to 10mm. - Potable water, free from all chemicals. - Ordinary Portland and Moderate Sulphate Resisting Cement (type2) OR Sulphate Resisting Portland Cement. ( as required by the client). Methods of Productions: The manufacture of procedure of the block is 3 stage processes VIZ. Mixing Pressing and Curing.

Mixing: The mixing plant guided by computer mixes aggregates, cement and water proportioned ratios: - Crushed Concrete 0mm to 10mm. - Potable water, free from all chemicals. - Ordinary Portland and Moderate Sulphate Resisting Cement (type2) OR Sulphate Resisting Portland Cement. ( as required by the client). - Cement Content is 360kg /m³ To begin with Crushed Concrete 0mm to 10mm is transferred from outer hoppers to inner hopper where potable water and cement are mixed. As soon as the process is complete, the mix content is then transferred to press machine where systematic process of filling vibration pressing takes place. The blocks obtained from either of the systems equally yield strength not less than 7N/mm². The products obtained are of high quality. Tests conducted on products give identical results with respect of strength and water absorption. The outer surface of the products is non-slip and yield smooth finish.

Curing: When the pressing process is complete, the tiles are then stacked in steel pallets and transferred to curing chambers and stacked on shelves. The shelves are kept at a distance of 20 cm from each other’s. Later the chamber is immediately closed and heating system is set on. The temperature is slowly raised to reach up to 60 degree Celsius with humidity up to 100% the curing lasts for at least 14 days.

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Packing: The company had, time and again gone to strenuous efforts in the past in order to improve the existing packing system. At present the blocks are bundled by means of rust proof steel strapping being the latest strapping system available in the international market.

Quality Control: • • •

Blocks producers are in accordance with BS Standards. All Blocks are automatically cured in Autoclaved Chambers. All Raw Materials are supplied from government certified Suppliers.

Laboratory Quality Control: Starline Do Make Third Party Laboratory tests on accordance with any Standards required by the End user. Yet, Starline do have quality control material testing reports to maintain quality control system. Third Party Lab: Two Labs are certified that do the third party testing. • •

Al- Tayseer Laboratories P.O Box 1556 Doha Qatar. Lab Tech Laboratories P.O Box 39019 Doha Qatar.

Our Products: 1. 2. 3. 4. 5.

8” Hollow and Solid Block. 6” Hollow and Solid Block. 4” Hollow and Solid Block. Interlock (All Shape and Colors). Hurdy Blocks.

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Capacity: Our Daily Products are, 1. 52’000 Blocks of 8” blocks. 2. 80’000 Block of 6” blocks. 3. 98’000 Blocks of 4” blocks. 4. 3000 meter squared 5. 64’000 Solid 4” 6. 50’000 Solid 6” 7. 40’000 Solid 8” 8. 2000pc Kerb stone

Raw Material Sources: Cement : Qatar Cement Company. Aggregate : Qatar Quarry. Sand : Government Sand Quarry in Um Saed.

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Paving patterns

NATIONAL BLOCKS & INTERLOCK FACTORIES