Brick and Mortar vs. Injection Moulded Construction System - moladi
Brick and Mortar vs. Injection Moulded Construction System - moladi
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moladi Construction Process - Video LinkDisrupting the Mould
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The inefficiencies of moulding a brick or block in a mould
then tasking an artisan to lay them. Then chase the walls for water and
electrical services. Then relying on another artisan to plaster the walls. Depending
on the skills and ability of artisans to produce a house vs. casting a house in
a mould employing unskilled workers – eliminating the need to chase and plaster,
in a day, at a known cost. This we refer to as the moladi "injection moulding construction process".
Brick production: Pollution and Carbon emissions - CO2
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| Brick production: Pollution and Carbon emissions - CO2 |
Molding or Moulding Process:
Molding or moulding is the process of manufacturing by shaping liquid or pliable raw material using a rigid frame called a mold or matrix. This itself may have been made using a pattern, a model or formwork of the final object.
A mold or mould is a hollowed-out block (cavity) that is filled with a liquid or pliable material such as plastic, glass, metal, ceramic raw material or mortar (sand and cement). The liquid hardens or sets inside the mold, adopting its shape. A mould is the counterpart to a cast.
Hennie Botes CEO of moladi highlights the smooth
of shutter finish of the classroom wall. The reusable modular lightweight
plastic formwork (mold or mould) is removed the day after casting.
No need to plaster - No
need to chase – No beam filling - No waste.
moladi Injection Moulding Construction Process #MIMCP
Disruptive Innovation:
A disruptive innovation is
an innovation that helps create a new market and value network, and
eventually disrupts an existing market and value network (over a few years or
decades), displacing an earlier technology
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Injection moulded construction process |
Modern building methods using modern building materials:
moladi
Construction System aims to address the challenge by providing a scalable,
low-tech and low-skilled affordable building solution using in-situ casting.
Founded in 1986 by South African social entrepreneur Hennie Botes, the company
aims to replace the classic brick-and-mortar construction with an easier
method: using a patented lightweight, removable and re-usable plastic injection
moulded formwork system that is filled with fast setting aerated mortar to cast
entire houses on-site. The process is deliberately designed to be labour intensive to boost local employment and local production without requiring prior construction experience or skills. The moladi construction process mostly uses local supplies apart from the reusable formwork and a special additive to aerate the mortar (concrete without stone) to reduce the density, thereby enhancing the thermal properties of the structure. The other function of the additive is to water proof the wall and enhance the flow ability of the mortar within the formwork eliminating the need to vibrate.
Through creative engineering and
sophisticated manufacturing, moladi
aims to advance living standards and spaces affordably. moladi is an advanced
building technology that utilises an innovative re-usable plastic formwork system to reduce the required skills to produce quality affordable homes and other structures that are socially acceptable by speeding up delivery and thus
reducing cost. By emulating the methodology of the automotive assembly line, moladi implements the
principles applied by Henry Ford; reducing cost by increasing production output
by de-skilling the production operation, making homes affordable.
The advantage that moladi brings to the
“production process” is that the process can measured and maintained, ensuring
consistent speed and quality within budget.
Conventional brick and mortar construction:
- How many bricks or blocks are laid per day?
- Are the quantity of bricks or blocks laid per day the same for every day of the week?
- What happens when the bricklayer does not come to work?
- Is the dagha (mortar) mix to lay the bricks or blocks consistent?
- How many bricks or blocks are wasted or broken or stolen?
- Are walls straight plumb and square?
- How long to chase for electricity piping?
- How long to chase for water piping?
- How long does it take to do beam filling?
- How long does it take to plaster window reveals?
- Is plaster thickness consistent or does it vary?
- Is the plaster mix consistent?
- Any rework?
- Rubble to clear?
This leads to the question: Are the inefficiencies of the brick and mortar construction process making homes unaffordable for most?
It all comes down to efficiency of producing a cost effective, socially acceptable wall for people (knock test), then fixing all the other components, like door, windows, roof, ceiling, bathroom fixtures etc., onto the "chassis" (the wall). So in reality, who can produce a wall on a stand the quickest, and millions of them? We simply use a cost per square meter of a wall (chassis) on a foundation (in position), ready for "assembly" as a yardstick of efficiency. This is method compares "Apples to Apples"?
By applying moladi the above variables are excluded from the equation.“If you can't measure it, you can't manage it.” - Peter Drucker
moladi Construction Process:
- Erecting the formwork is constant.
- No stays
- No propping
- No consumables
- Formwork holds a constant precise volume.
- Mortar a known cost.
- Mortar is a known consistent compressive strength.
- Reinforcing a known weight/cost.
- Time to position and bind reinforcing constant.
- Filling the formwork is consistent.
- Removing the formwork is constant.
- Labour is not skilled.
Injection Moulding Process:
Mould closes – Material injected – Cools – Ejects the finished component. A known cycle time at a known cost.
Speed reduces cost - A
“lean construction” principal.
Erect Formwork (Clamp) - Fill Formwork (Inject) - Mortar Sets (Cools) - Remove Formwork (Eject)
Lean Construction - Lean Production:
One of the important principles under a
lean production paradigm is termed ‘lean assembly’. This refers to simplifying
the process of assembly through industrialisation, modularisations,
standardisation, and continuous flow processes. The reduction of operations
required for a production process means less chance of the occurrence of
errors, waste and rework.
This follows from the same logic that the
fewer the number of operations, the higher the quality of the product and a
predictive timeline, resulting in cost savings. moladi formwork system
provides and assists with the full range of requirements involved in the
transfer and use of a proven low-cost construction technology.
Jobs Food through Shelter:
moladi
supplies technology and supports transfer of know-how to empower individuals to
achieve self-worth, by meaningful action to raise those at the “bottom of the
pyramid” to a higher level, supplying a proven technology with an impressive
track record (Est. 1986). This is how moladi
can address the delivery of quality homes in less time, creating jobs by
employing unskilled local labour - developing skills and entrepreneurs.
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moladi designed to create - Jobs for the unemployed - Food for the hungry - Shelter for the homeless |
moladi - A Technology Supplier:
We skill entrepreneurs, contractors,
business owners and construction companies how to “produce” using moladi construction
technologies - “What if we told you the solution to the 25% national
unemployment statistic (36% youth unemployment) and the million-plus housing
backlog was already in our back yard? And what if we told you jobless,
unskilled South Africans could become entrepreneurs in the house building
sector and be able to build homes in their communities at a fraction of the
cost and in less than a week? What would you say if we told you there is a
company that is not only prepared to certify you, but to empower you too and
give you a market, technology and the opportunity to grow personally and
professionally?" - Link
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| moladi-Cooperatives-jobs-food-shelter |
“We can fight poverty, hunger, unemployment and associated social ills like crime through housing. “It’s a matter of connecting the dots. - Hennie Botes
Empower community co-operatives to lead mass housing programme and food production. - Link
References:
How Elon Musk and other pioneers (moladi) are shaking up
the construction industry | World Economic Forum #WEF #Tesla #moladi
The only structures, built as a show unit after the
earthquake that struck in 2010, standing in the show village after Hurricane
Matthew in 2017
Brick and Mortar vs. Injection Moulded Construction System - moladi
Brick and Mortar vs. Injection Moulded Construction System - moladi
Certification:
SABS | Agrément Certification | NHBRC | Bank Approved (1993)
Awards:
2017 –World Economic Forum - Boston Consulting
Group – Future of Construction – World Bank Project
2016 – Best of African Design - moladi showcased for a year at
the Cube Museum in the Netherlands
2014 – Africa is Now - moladi displayed at Design Indaba
Cape Town
2012 – moladi selected as a finalist of the international Frost & Sullivan Green Excellence Award for Sustainable Development.
2012 – International Case Study conducted by FSG
and the Rockefeller Foundation - Shared Value in Emerging Markets.
2012 – Nominated by the Europe Business Assembly
for the International Socrates Prize in economy and business category.
2012 – Co-operative Finalist with Kingston
University in the international Hult Global Case Challenge in association with
the Clinton Global Initiative.
2011 – moladi selected by the Smithsonian Institute to exhibit
the technology in association with its Cooper Hewitt Museum at the UN
Headquarters in New York.
2010 – International Case Study on moladi conducted by the UNDP
(United Nations Development Programme) - Growing Inclusive Markets.
2010 – Hennie Botes, CEO of moladi, is awarded South Africa’s
Science and Technologies best man by Men’s Health magazine.
2009 – moladi named winner of the Affordable Housing Competition
held by Data Bank in Accra, Ghana.
2006 – Housing Innovation Award Winner of the ABSA
Bank and NHBRC (National Home Builders Council) national competition in South
Africa.
2005 – Finalists in the TT100 (Top 100 Technology
Awards), South Africa.
1997 – Winner of the prestigious SABS - South
African Bureau of Standards - Design for Development Award, South Africa.
1991 – Winner of the International PRW Award for Excellence – United Kingdom
Brick Mortar vs Injection Moulded Construction System cast in-situ cast insitu construction Hennie Botes masonry modern moladi mortar moulded new plastic formwork process
