The fertile topsoil is removed from the site, and the earth soil is spread out on the surface and allowed to dry under the sun, before being moved to a dry storage place. At this stage the earth should be checked with regard to its binding quality. In some cases, it may be desirable to supplement with other soil types in order to enhance this binding quality, to avoid shrinkage, or simply to increase the strength of the compressed earth blocks CLAYGAR. The raw earth must be of a homogeneous consistence before pressing, and to ensure this, the earth is passed through a specially designed pulverizer.
Depending on the composition of the earth, sand, fine gravel, or other soil types can be added in a mixing machine designed specially for this purpose. During this process, the mixer measures with great precision the required amounts of the various soil types while at the same time adding the precise volume of water to enable optimal pressing.
The actual pressing procedure is automatic and PLC controlled. The compressed earth blocks CLAYGAR are left to dry out in a sheltered and well-ventilated place, and will be ready for use in about 1-2 weeks. This means in other words that the blocks are dried as opposed to fired. Furthermore, if the weather at the time of pressing is warm and dry, then the blocks may be put to use immediately.
This well planned manufacturing process whereby pulverizing, mixing and pressing are carried out continually means that four persons are sufficient to maintain production.
The first person ensures that the raw material, the dry stored earth is carried to the pulverizer by conveyer belt. The earth powder and other eventual additives such as sand or gravel are carried to the mixer on their own individual conveyer belt. The second person mans the mixer and supervises the dosage of the various constituents.
This final mixture is then transported via a mass dosering to the press, which on account of the dosering is able to press compressed earth blocks CLAYGAR of a highly homogenous nature. As the press emits
compressed earth blocks CLAYGAR in a continual stream, the third person places them on pallets while carrying out a visual control. Finely the fourth member of the team alternates between supplying the necessary raw materials and transporting the pallets with completed blocks to the dry storage area. It is essential that this manufacturing procedure is well organized, since the production capacity is dependent on a continuous supply of raw material.
The compressed earth blocks CLAYGAR are usually laid using an
earth mortar CLAYMALT prepared on site.
The earth mortar CLAYMALT consists of pulverized earth mixed with coarse sand and water. This earth mortar is also available in bags, in which case the mortar can be prepared simply by adding water to the mix in a mixer, or a stavmixer.
Compressed earth blocks CLAYGAR should be kept dry during the laying procedure. The blocks should be pressed down into the moist mortar, as opposed to being knocked down whereby the earth mortar joints may become too thin. Furthermore, harsh use of a sharp trowel can cause additional damage to the blocks. The thickness of the joint can vary from 0,5 to 1,5 cm, and the
earth mortar CLAYMALT should be applied liberally so that it is pressed out of the joint. The excess mortar should be scraped off on completion of the first meter in height. In order to achieve a brushed sand effect this excess mortar can be removed with the use of a wet broom/brush in a circular motion.
If a clean brick finish is required, traditional earth mortar CLAYGAR may be used.
Similarly, it is also possible to plaster with clay plaster CLAYGAR, and finally the blocks may be finished with a coat of mineral paint CLAYGAR HH 00.