NL2020151B1

NL2020151B1 - Prefab Concrete Building Element and Method of Manufacture of the Same

Info

Publication number: NL2020151B1
Application number: NL2020151A
Authority: NL
Inventors: Henricus Brood Govardus
Original assignee: Byldis Prefab B V
Priority date: 2017-12-21
Filing date: 2017-12-21
Publication date: 2019-07-01

Abstract

A process of manufacturing a building element comprising at least a first slab, the first slab comprising building blocks that are attached to one another by a cured mortar provided between the building blocks and to be generally put, in use, in a vertical position to expose a facing side of the building blocks is described. The process comprises providing a supporting surface to allow supporting the building blocks with their facing side downwards on the supporting surface, providing a layer offoam treated with a retardant agent onto the supporting surface, the retardant agent allowing for a retardation ofa curation time ofa mortar, arranging the building blocks with their facing side on the supporting surface with the layer offoam treated with the retardant agent and with gaps between the building blocks; providing uncured mortar into the gaps between the building blocks; allowing the uncured mortar between the building blocks to cure; and removing the building element from the supporting surface while the mortar in contact with the retardant agent ofthe layer of foam is still uncured.

Description

Prefab Concrete Building Element and Method of Manufacture of the Same

FIELD OF THE INVENTION

[01] The present invention relates to a method of manufacture of a prefabricated concrete building element, particularly for use in the construction of residential or commercial properties.

BACKGROUND OF THE INVENTION

[02] Construction and fabrication of both commercial and residential properties is of increasing importance. Many countries have a need to build more properties to house more people, with an ever-decreasing area of foundational land. Population density is increasing, and cities are becoming home to more and more people. The increase in population density has also led to an increase in the amount of required office space and commercial space. The construction of high-rise structures, which exploit vertical space, has therefore become increasingly popular.

[03] Tall structures such as high-rise buildings and complexes are often more susceptible to environmental conditions, such as heavy winds and inclement weather, than their smaller counterparts. Other factors, such as fire safety, play an integral role in the construction and design of such buildings.

[04] There is therefore a need to provide components used to construct a building where the structural and safety requirements can be met.

[05] The construction of such properties may take a considerable amount of time. This results in high costs, not only due to materials, but due to labour. The time during which construction is in progress often impacts the surrounding area, and may negatively affect trade and commercial activities of neighbouring businesses. There is therefore a need to provide a process through which components of a building may be manufactured efficiently.

[06] US 3,629,384, US 2006/180731 A1, WO 2011/085447 A1 and US 4,957,685 generally disclose some aspects of manufacturing a prefabricated building element on a supporting surface.

SUMMARY OF THE INVENTION

[07] It is an objective of the invention to provide a process of manufacturing a building element comprising at least a first slab, the first slab comprising building blocks that are attached to one another by a cured mortar provided between the building blocks and to be generally put, in use, in a vertical position to expose a facing side of the building blocks, the process comprising providing a supporting surface to allow supporting the building blocks with their facing side downwards on the supporting surface; providing a layer of foam treated with a retardant agent onto the supporting surface, the retardant agent allowing for a retardation of a curation time of a mortar; arranging the building blocks with their facing side on the supporting surface with the layer of foam treated with the retardant agent and with gaps between the building blocks; providing uncured mortar into the gaps between the building blocks; allowing the uncured mortar between the building blocks to cure; and removing the building element from the supporting surface while the mortar in contact with the retardant agent of the layer of foam is still uncured. [08] The above objective enables a highly reproducible manufacturing process of a building element, with design flexibility and conforming to structural requirements. The use of a supporting surface with a layer of foam treated with a retardant agent facilitates straightforward arrangement of building blocks in a building element. The mortar, disposed into gaps between the building blocks, provides the required strength to the building element. A foam layer treated with a retardant agent, provides a convenient manner by which to apply the retardant agent. Foam is easily manipulated and fitted. The use of foam also prevents residue from adhering to the supporting surface, facilitating an easy clean-up, and enables the use of a positive surface retardant. This is advantageous over conventional methods in that the supporting surface can easily be re-used with little cleaning and maintenance efforts, and there is a reduced risk of damage to the outer surface (the facing side) of the building element during removal of the retardant agent.

[09] In some embodiments, spacer strips are provided on the supporting surface. The spacer strips correspond to a width of the gaps between the building blocks to allow the spacer strips to penetrate into the gaps when the building blocks are provided onto the supporting surface.

[10] The use of spacer strips provided on the supporting surface enable the building blocks to be arranged in a reproducible manner, and ensures a gap between the building blocks into which mortar can then be applied. This therefore ensures that a suitable amount of mortar is applied, in accordance with relevant structural and safety requirements. [11] In some embodiments, the spacer strips have a height in the range of 0.5 to 3 cm, optionally of 0.5 to 2 cm, optionally 1 cm. [12] The height of the spacer strips is one of the factors that determine the depth of the inlaid joint between building blocks. In a finished building element, the mortar between building blocks is inset a distance from the facing side of the building blocks. The height of the spacer strips contributes to the distance in which the mortar is inset. [13] In some embodiments, the supporting surface comprises wood, the wood optionally being treated with an oil-based agent. [14] A wood-based supporting surface provides an easily adaptable and buildable surface on which to construct a building element. Wood can be treated with oil to protect the wood from moisture and to facilitate removal of a constructed building element. It is straightforward to fasten components, such as spacer strips, to a wooden surface. [15] In some embodiments, the operation of providing the layer of foam treated with the retardant agent comprises an operation of treating a layer of foam with the retardant agent. [16] A retardant agent can be developed according to performance requirements and environmental conditions, and then applied to pre-cut foam. This enables a high level of adaptability. Prior to being applied to the foam, the retardant agent can be diluted with water, if required. [17] In some embodiments, the retardant agent is applied in an aqueous form to the foam layer, and wherein the foam layer comprises an open-cell foam.

[18] An aqueous retardant agent is easily dilutable and distributable, as it can be applied via a spray in an even fashion. An open-cell foam at least partially absorbs the retardant agent such that it can be easily and conveniently applied to supporting surface during the manufacturing process. [19] In some embodiments, after the application of the aqueous retardant agent, the treated foam layer is left to dry for a predetermined time prior to being provided to the supporting structure. [20] By leaving the foam layer to dry for a predetermined time, further tuning of a depth of exposure of the retardant agent may be achieved. The foam, being at least partially dry, is then able to absorb water, which assists in its eventual removal from the building element. [21] In some embodiments, the layer of foam is treated with the retardant agent at a remote location. [22] Treating the foam layer with the retardant agent at a remote site may be a safety requirement of the retardant agent, depending upon the formulation used. It is also convenient to prepare large quantities of foam in one location prior to distribution across a large manufacturing plant. [23] In some embodiments, the retardant agent is an aqueous surface retarder. [24] The use of an aqueous surface retarder facilitates straightforward and even distribution over a layer of foam. Moreover, an aqueous surface retarder can be diluted with water, enabling fine tuning of a depth of exposure. This can be used to compensate for environmental factors that affect the observed depth of exposure of a surface retarder, and provides flexibility in design of a building element. The depth through which a joint of mortar between building blocks can be finely adjusted by altering the concentration of the surface retarder. [25] In some embodiments, the retardant agent enables a delay in hydration of the mortar. [26] Delaying the hydration of the mortar provides an effective timeframe in which the layer of foam treated with the retardant agent can be removed, whilst a reduced risk of damage to the facing side of the building blocks and therefore the outer surface of the building element. [27] In some embodiments, the retardant agent comprises a 1,2-benzisothiazol-2(3H)-one composition, a benzene, mono-C10-13-alkyl derivatives, distillation residues composition, and a mixture of 5-chloro-2-methyl-4-isothiazolin-3-one and 2-methyl-2hisothiazol-3-one. [28] This composition of retardant agent has a practical safety level and is not generally environmentally harmful, making it a suitable and effective choice in a manufacturing plant. [29] In some embodiments, the mortar comprises cement, filler, sand, additives, water and optionally, pigment additives. [30] Mortar comprising these elements can be produced to meet relevant requirements, such as structural standards. The relative amounts of these elements can be determined at least partially in view of the type of building block used. [31] In some embodiments, the mortar has a compressive strength of 55 N/mm2 after 28 days. [32] A mortar with a high compressive strength facilitates the production and assembly process, and also adheres to the structural requirements of the building element. During the manufacture of the building element, building blocks bonded with mortarwith such a compressive strength may be handled in an effective manner. [33] In some embodiments, the layer of foam comprises a polyether layer. [34] Polyether is an open-cell foam that can be easily handled. It is well-suited to partially absorbing the retardant agent and can be easily removed from the building element. [35] In some embodiments, the layer of foam is between 1,5mm and 2.5mm in thickness, and preferably 2mm in thickness. [36] This thickness range results in an easily managed and distributed material. A foam layer meeting this requirement can partially absorb the retardant agent and is sufficiently thin to conform to the profile of the supporting surface, optionally with the spacer strips. The foam can also be easily distributed to the required areas of a production facility. [37] In some embodiments, the process further comprises removing the layer of foam treated with the retardant agent from the facing side of the building blocks when the building block has been removed from the supporting surface. [38] Removing the layer of foam treated with the retardant agent ensures a clean outer surface of the building element. The facing side of the building blocks are cleaned. As the retardant agent is provided in the layer of foam, its removal is straightforward and complete, with a reduced risk of damage to the facing side of the building blocks. [39] In some embodiments, the operation of removing the layer of retardant agent is a rinsing process. [40] The layer of foam treated with the retardant agent can absorb a rinsing agent, enabling the foam to easily remove itself from the outer surface of the building element, taking with it the retardant agent. This further reduces a risk of damage to the outer surface of the building element. [41] In some embodiments, the building blocks comprise bricks. [42] Bricks are strong and often impermeable. The use of bricks also enables bespoke masonry designs and enables building elements in a wide range of shapes and sizes to be created.

BRIEF DESCRIPTION OF THE DRAWINGS

[43] Further features and advantages of the invention will become apparent from the description of the invention by way of non-limiting and non-exclusive embodiments. These embodiments are not to be construed as limiting the scope of protection. The person skilled in the art will realize that other alternatives and equivalent embodiments of the invention can be conceived and reduced to practice without departing from the scope of the present invention. Aspects and features disclosed in the description are provided to assist in the understanding of the embodiments. It will become apparent to the skilled person that the exemplary embodiments may be carried out without those specifically defined features. Well-known operations and concepts are not described in detail, so as to avoid obscuring the description with unnecessary detail. Embodiments of the invention will be described in greater detail with reference to the accompanying drawings, in which like or same reference symbols denote like, same or corresponding parts, and in which

Fig. 1A shows a front view of a building element.

Fig. 1B shows a side view of a building element.

Fig. 2 shows a profile view of a supporting surface used in the production of a building element.

Fig. 3 shows a profile view of a plurality of building blocks being arranged on a supporting surface.

Fig. 4 shows a flowchart of method of manufacturing a building element.

DETAILED DESCRIPTION OF EMBODIMENTS

[44] In the present description, several examples and embodiments of a process through which a building element is constructed are described. The process generally describes the use of a supporting structure to support the arrangement of a plurality of building blocks, to which a mortar is added. As the mortar hardens (cures), the building blocks become bonded together. The process described in detail below enables the fabrication of building elements in a horizontal fashion, enabling a high degree of reproducibility and providing an efficient construction process. [45] Figure 1A shows a front view of a building element. Referring to Figure 1A, an outer surface of a prefabricated building element 10 is shown. Building element 10 comprises a plurality of building blocks 101. The building blocks may be bricks or stone or a combination thereof, although the present application is not limited thereto. The building blocks may be uniform in size and shape, or they may differ in at least one of size and shape. The building blocks 101 are bonded together by mortar disposed between said building blocks 101. [46] The building element 10 generally is a single component for use in the construction of a prefabricated structure. Multiple building elements 10 are then connected to form a shell of a structure, such as a residential or commercial building. [47] The building element 10 comprises an outer leaf. The building element may be used as a component in an outer wall of, for example, a residential or commercial structure. The outer leaf may comprise masonry components, such as brickwork, designed to comply with both safety and performance requirements and, optionally, aesthetic requirements. The outer leaf may be impermeable and weather-proof, or may be treated with an agent rendering the outer leaf impermeable. [48] Figure 1B shows a side view of the building element. Referring now to Figure 1B, building element 10 is shown, comprising a plurality of building blocks 101 bonded together by mortar 111. The building blocks 101 bonded by the mortar 111 is referred to as the outer leaf of the building element 10. The building element 10 may additionally comprise an inner leaf 141. The inner leaf 141 may comprise a concrete layer and may serve as an inner wall. The outer leaf may serve as an exterior wall. The inner leaf 141 is generally designed according to structural and safety standards. An insulating layer 131 may be disposed between the outer leaf and the inner leaf 141. The insulating layer 131 is generally selected to comply with performance requirements. The inner leaf 141, outer leaf, and optionally the insulating layer 131 may be assembled in a sandwich-like fashion. That is, the outer leaf, optional insulating layer 131 and inner leaf 141 may be assembled to form a building element such as building element 10.

[49] Additionally, the building element 10 may comprise an air cavity 121 separating insulation layer 131 from the outer leaf. During the production of building element 10, at least one cavity spacing element (not shown) may be disposed on the layer of building blocks 101 bonded by mortar 111. The at least one cavity spacing element may be used to provide air cavity 121. Additionally, a layer of watertight material (not shown) may be applied to the layer of building blocks 101 bonded by the cured mortar 111 priorto the placement of the at least one cavity spacing element. The layer of watertight material is generally provided to improve the impermeability of the outer leaf of building element 10. [50] It can be seen in Figure 1B that the cured mortar 111 is inlaid from the building blocks 101. That is, in the fabricated building element 10, the mortar 111 is inset a predetermined depth 151 from the facing side of the building blocks 101. The predetermined depth 151 is associated with the manufacturing process and is described in further detail with reference to Figures 2 and 3. [51] Inner leaf 141 may provide structural support to the building element 10. In some embodiments, the inner leaf 141 comprises a layer of concrete. The inner leaf 141 may form an inner wall of a structure. The materials and composition of the inner leaf 141 may be designed according to structural requirements and/or safety standards. [52] Inner leaf 141 may be added to the building element 10 during its construction. In an example, the at least one cavity spacing element is disposed on the bonded building blocks 101 and cured mortar 111 whilst the building element 10 is being constructed. The insulation layer 131 is then disposed on top of the at least one cavity spacing element, creating air cavity 121. Concrete in liquid form is subsequently provided on top of the insulation layer 131 and left to harden, forming the inner leaf 141. [53] Figure 2 shows a profile view of a supporting surface used in the production of the building element. Referring now to Figure 2, a horizontal supporting surface 210 is shown with a plurality of spacer strips 220. The supporting surface 210 is used to facilitate the assembly or construction of the building element 10. In the embodiment shown, the supporting surface 210 is made of a wood material, Alternatively, it could be made of metal, steel, a plastic or any other suitable material.. In some embodiments, the supporting surface 210 may be built in a bespoke manner using a hardwood frame. The supporting surface 210 provides the shape and size of the building element 10 and is used to facilitate its construction. In some embodiments, the wooden components of the supporting surface 210 may be treated with an oil. The use of oil can be used to facilitate the removal of a constructed building element 10 from the supporting surface 210 upon its completion. [54] The supporting surface 210 is provided with a plurality of spacer strips 220 in the embodiment shown. The spacer strips 220 may be made of, for example, wood, plastic, metal, or steel. In some embodiments, each spacer strip 220 has a width W of 1 cm. The spacer strips 220 may have uniform width, or a plurality of different widths may be used. The length of the individual spacer strips 220 generally corresponds to the length of the gaps between the building blocks, but may be determined to meet aesthetic and/or structural requirements. The spacer strips 220 are separated by a distance D, corresponding to the width of a building block 101. The spacer strips 220 may correspond to a desired arrangement of building blocks 101.

[55] The spacer strips 220 are used to assist in the positioning of building blocks 101 on the supporting surface in the fabrication of an outer leaf of building element 10. The building blocks 101 may be arranged according to an aesthetic design or according to structural requirements for the building element 10. [56] The spacer strips 220 ensure a spacing between building blocks 101, into which a bonding agent, such as mortar, is provided. The height H of the spacer strips 220 may then be used to create laid-back joints between building blocks 101 shown in Figure 1B. In a laid-back joint, the surface of the mortar 111 between building blocks 101 is inset from the facing side surface of the building blocks. [57] Supporting surface 210 may be re-used to produce multiple identical building elements 10. The use of spacer strips 220 on the supporting surface 210 then improve the uniformity of a plurality of building elements 10 and enable reliable reproducibility of building elements 10.

[58] Figure 3 shows a profile view of a plurality of building blocks 101 being arranged on a supporting surface. Referring to Figure 3, supporting surface 210 is shown, upon which spacer strips 220 are disposed. A layer of retardant agent 350 is shown overlaid upon the supporting surface 210 and spacer strips 220. Building blocks 101 are placed over the layer of retardant agent 350. The building blocks 101 are thus arranged such that they are separated by the spacer strips 220. Supporting surface 210 and spacer strips 220 are described with reference to Figure 2. Further description of these elements has therefore been omitted.

[59] The layer of retardant agent 350 retards a curation time of mortar in contact with the layer of retardant agent 350. The layer of retardant agent 350 comprises a foam layer impregnated or treated with a retardant agent. The retardant agent may be applied to the foam layer in an aqueous form. Conventionally, the retardant agent is be applied as a paste on the supporting surface, however this results in residue left in the supporting surface, resulting in considerable cleaning and maintenance efforts, and can cause damage to the building element when the retardant agent is removed. [60] In some embodiments, the foam layer comprises a layer of polyether. The foam layer is an open-cell foam, capable of at least partially absorbing the retardant agent. The foam layer is preferably 1mm to 3mm in thickness. In some embodiments, the foam layer may be 2mm in thickness. [61] In some embodiments, the foam layer is treated with the retardant agent at a remote site. Alternatively, the foam layer can be treated with the retardant agent onsite. [62] The retardant agent enables a delay in hydration of a mortar. In other words, when in contact with a cement or mortar, the retardant agent interacts to delay the curation time of the cement or mortar. The retardant agent therefore impedes the curation of the mortar for a predetermined depth, delaying the hardening of the mortar. [63] In some embodiments, the retardant agent may comprise a 1,2-benzisothiazol-2(3H)-one composition, a benzene, mono-C10-13-alkyl derivatives, distillation residues composition, and a mixture of 5-chloro-2-methyl-4-isothiazolin-3-one and 2-methyl-2hisothiazol-3-one. [64] The retardant agent may be basic, preferably having a pH level of approximately 9. The depth of exposure of the retardant agent may be dependent on the composition and/or the concentration of the retardant agent. A variety of types of retardant agent are available, each providing a different depth of exposure. The depth of exposure can be further tuned by diluting the retardant agent with water. The observed depth of exposure may be further influenced by environmental conditions, such as weather and temperature. A depth of exposure of approximately 4mm is preferable. The depth of exposure may be within a range of 1 to 7mm. The height H of the spacer strips and the depth of exposure of the retardant agent contribute to the depth 151 of the inlaid joint shown in Figure 1B. [65] The retardant agent is a positive surface retardant in the embodiment shown. A positive surface retardant is, for instance, provided to a top surface of fresh concrete, which is allowed to dry. Once hardened, the concrete, along with the applied positive surface retardant, is removed from a mould or supporting surface, and the positive surface retardant is rinsed off. In contrast, a negative surface retardant is generally provided to an inner surface of a mould, into which concrete is added. The negative surface retardant adheres to the concrete as the concrete dries, and facilitates the removal of the dried concrete from the mould (in other words, the concrete is prevented from bonding to the mould). Upon removal, the negative surface retardant remains adhered to the concrete until it is washed off. After removal of the concrete, however, the mould is left with residue from the negative surface retardant. Prior to re-use, the mould must therefore be cleaned. [66] In an embodiment of the present disclosure, a positive surface retardant, applied to a layer of foam, may be used to reduce the amount of cleaning required. The foam layer partially absorbs the positive surface retardant, preventing the surface retardant from adhering to supporting surface 210 and thereby preventing residue. Instead, the positive surface retardant, along with the foam layer, adheres to the concrete until it is removed, for example, via a rinsing process. [67] Building blocks 101 are arranged on the supporting surface 210 on top of the layer of retardant agent 350. The building blocks 101 are arranged according to the spacer strips 220, as previously described. The layer of retardant agent 350 conforms to the profile created by the spacer strips 220 on the supporting surface 210. The spacer strips 220, covered by the layer of retardant agent, thereby protrude between the building blocks 101, creating gaps between the building blocks 101. The gaps between the building blocks 101 created by the spacer strips 220 provide space in which mortar is added to bond the building blocks 101 together. [68] Figure 4 shows a flowchart of method of manufacturing a building element. Referring now to Figure 4, supporting surface 210, is provided in operation 410. As described with reference to Figures 2 and 3, a plurality of spacer strips 220 may be disposed on a working surface of the supporting surface 210. The supporting surface may be treated with oil or a similar substance to facilitate the eventual removal of a completed building element 10 from the supporting surface.

[6θ] In operation 420, a layer of retardant agent 350 is provided onto the supporting surface 210. If a plurality of spacer strips 220 are disposed on the supporting surface 210, the layer of retardant agent 350 is arranged on top of the spacer strips 220. The layer of retardant agent 350 conforms to the profile created by the plurality of spacer strips 220.

[70] In operation 430, a plurality of building blocks 101 are arranged on the supporting surface. The building blocks 101 are placed on top of the layer of retardant agent 350. The building blocks 101 may be placed such that they are separated by the spacer strips 220. The building blocks 101 are separated by gaps, which may be formed by the spacer strips 220. [71] In operation 440, uncured mortar is provided to fill the gaps between the building blocks 101. Thus, the layer of retardant agent 350 is in direct contact with the provided uncured mortar. The layer of retardant agent 350 delays the curation time of the mortar with which it is in contact, and is effective for a predetermined depth. The mortar may be a high-performance, selfcompacting concrete. The mortar preferably has a processability in the range of 295mm to 345mm (preferably 320mm) via the Haegerman cone. The mortar preferably has a weight correction factor in the range of 0.48 to 0.52 (preferably 0.5) from the weighed materials. In some embodiments, the mortar is formulated to have a high compressive strength, preferably 55N/mm2. Traditionally, the compressive strength of mortar used in construction is in the region of 2 to 12N/mm2. In some embodiments, the mortar is formulated to be impermeable or effectively impermeable. The mortar is preferably formulated to have a flexural bond strength of at least 5.0N/mm2 after 28 days and a bending tensile strength of 5N/mm2 after 28 days. The choice of building blocks 101 has an effect on the observed physical properties of the hardened mortar. For example, stinger stones, hand shape stones and mold bricks each have an associated water wicking property. Different types of building blocks 101 therefore absorb water from the applied and as yet uncured mortar, and should therefore be considered when preparing the mortar. In some embodiments, after 28 days, pressure strength values of the mortar are maintained to correspond to the compressive strength of concrete in an inner leaf of building element 10. Such correspondence ensures that the inner and outer leaves of a completed building element 10 react equally to weather conditions during construction of a building. [72] In an embodiment, the mortar comprises cement, filler (such as limestone powder), sand, additives (such as base modified polycarboxylic ethers and/or base polycarboxylate ether-shrink reducing plasticizer), water, and optionally, pigment additives. The ratio between these ingredients affects the processability, strength, and colour of the mortar. The additives are used to improve processability, reduce shrinkage of the mortar, and for water restriction because of the strength development. [73] In operation 450, the uncured mortar is allowed to cure. The mortar within a predetermined depth from the layer of the retardant agent 350 remains uncured, whilst the mortar located more than the predetermined depth from the layer of the retardant agent 350 hardens, forming a bond between the building blocks 101. [74] The predetermined depth through which the mortar remains uncured is associated with the exposure depth of the retardant agent. In some embodiments, the predetermined depth is approximately 1cm, and mortar more than 1cm from the layer of the retardant agent 350 is allowed to cure. The mortar within 1cm from the layer of the retardant agent 350 interacts with the retardant layer, and may remain uncured. The uncured mortar is removed once the building element 10 is assembled. [75] Once the mortar 111 between the building blocks 101 has cured, the building blocks 101 are bonded together, forming the outer leaf of building element 10. In operation 460, building element 10 is removed from the supporting surface 210. During the removal of the building element 10 from the supporting surface 210, the layer of the retardant agent 350 may remain coupled to the building element 10. [76] Optionally, an air cavity, an insulating layer and/or an inner leaf is formed on the building element 10 priorto its removal from the supporting surface at operation 460. In an example, at least one spacing element is optionally disposed on top of the cured mortar to create air cavity 121. A layer of insulating material 131 is then disposed on the at least one spacing element, following by a layer of concrete. The layer of concrete is then allowed to harden, forming the inner leaf 141. These layers have been described in detail with reference to Figure 1B. These layers are not essential, and one or more of these layers may be used. [77] Once the building element 10 has been removed from the supporting surface 210, the layer of the retardant agent 350 and any uncured mortarwithin the predetermined depth from the layer of the retardant agent 350 may be removed. The layer of the retardant agent 350 and uncured mortar may be removed via a rinsing process. The rinsing process may comprise rinsing an outer facing edge of the building element 10 with a pressurized jet, preferably water-based. The foam layer treated with the retardant agent absorbs the aqueous rinse and, due to the additional weight of the absorbed material, the foam layer, along with the retardant agent, falls off the surface of the building element 10. The layer of retardant agent 350 is thereby removed from the outer facing edge of the building element 10. After the retardant agent and foam has been removed from the surface of the building element 10, the mortar between the building blocks 101 may continue to hydrate to a closed state. The outer facing edge of the building element 10, exposing a facing side of the building blocks 101, is thereby clean of any residual retardant agent. [78] Once the layer of retardant agent has been removed from building element 10, building element 10 is ready for use as a single component in the erection of a structure, such as a commercial or residential building. Multiple building elements 10 can then be joined together to form the structure.

Claims

1. Een werkwijze voor het vervaardigen van een bouwelement (10) die ten minste een eerste blad omvat, welke eerste blad bouwblokken (101) omvat die met elkaar zijn verbonden door een uitgeharde mortel (111) die tussen de bouwblokken is aangebracht en in het algemeen, bij gebruik, in een verticale positie wordt gebracht voor het blootstellen van een zichtzijde van de bouwblokken, welke werkwijze omvat: - het verschaffen van een steunoppervlak (210) om het ondersteunen mogelijk te maken van de bouwblokken met de zichtzijdes daarvan neerwaarts op het steunoppervlak; - het verschaffen van een met een vertragingsmiddel behandelde laag schuim (350) op het steunoppervlak, welk vertragingsmiddel een vertraging van een uithardingstijd van een mortel bewerkstelligt, waarbij deze werkwijzestap een stap omvat van het behandelen van een laag schuim met het vertragend middel, en waarbij het vertragend middel in een waterige vorm wordt aangebracht in de laag schuim, en de laag schuim een open-celschuim omvat; - het verschaffen van de bouwblokken met de zichtzijdes daarvan op het steunoppervlak met de laag schuim behandeld met het vertragingsmiddel en met tussenruimtes tussen de bouwblokken; - het aanbrengen van niet-uitgeharde mortel in de tussenruimtes tussen de bouwblokken; - het toestaan dat de niet-uitgeharde mortel tussen de bouwblokken uithardt; - het verwijderen van het bouwelement van het steunoppervlak terwijl de mortel in contact met het vertragingsmiddel van de laag schuim nog niet is uitgehard.A method of manufacturing a building element (10) comprising at least a first blade, which first blade comprises building blocks (101) connected to one another by a cured mortar (111) arranged between the building blocks and in the generally, in use, is brought into a vertical position to expose a view side of the building blocks, the method comprising: - providing a support surface (210) to enable support of the building blocks with the viewing sides thereof down on the supporting surface; - providing a layer of foam (350) treated with a retardant on the support surface, said retardant causing a curing time of a mortar, said method step comprising a step of treating a layer of foam with the retardant, and wherein the retarding agent is applied in an aqueous form to the foam layer, and the foam layer comprises an open-cell foam; - providing the building blocks with the visible sides thereof on the support surface with the layer of foam treated with the retarder and with gaps between the building blocks; - the application of uncured mortar in the interstices between the building blocks; - allowing the uncured mortar to cure between the building blocks; - removing the building element from the supporting surface while the mortar in contact with the retardant of the layer of foam has not yet hardened.

2. De werkwijze volgens conclusie 1, waarbij afstandstrips (220) worden aangebracht op het steunvlak (210), welke afstandstrips overeenkomen met een breedte van de tussenruimtes tussen de bouwblokken (101) om mogelijk te maken dat de afstandstrips insteken in de tussenruimtes wanneer de bouwblokken op het steunoppervlak (210) worden verschaft.The method of claim 1, wherein spacer strips (220) are provided on the support surface (210), which spacer strips correspond to a width of the interstices between the building blocks (101) to allow the spacer strips to penetrate into the interstices when the building blocks are provided on the support surface (210).

3. De werkwijze volgens conclusie 2, waarbij de afstandstrips (220) een hoogte hebben in het bereik van 0,5-3 cm, optioneel van 0,5-2 cm, optioneel van 1 cm.The method of claim 2, wherein the spacer strips (220) have a height in the range of 0.5-3 cm, optionally of 0.5-2 cm, optionally of 1 cm.

4. De werkwijze volgens willekeurig welke van de voorgaande conclusies, waarbij het steunoppervlak (210) hout omvat, waarbij het hout optioneel is behandeld met een op olie gebaseerd middel.The method of any one of the preceding claims, wherein the support surface (210) comprises wood, wherein the wood is optionally treated with an oil-based agent.

5. De werkwijze volgens willekeuring welke van de voorgaande conclusies, waarbij, na het aanbrengen van het waterige vertragingsmiddel, de behandelde laag schuim (350) een vooraf bepaalde tijd mag drogen voorafgaand aan het verschaffen op het steunoppervlak (210).The method according to any one of the preceding claims, wherein, after applying the aqueous retardant, the treated foam layer (350) is allowed to dry for a predetermined time prior to providing on the support surface (210).

6. De werkwijze volgens willekeurig welke van de voorgaande conclusie, waarbij de laag schuim op een op afstand liggende plaats wordt behandeld met het vertragend middel.The method of any one of the preceding claim, wherein the layer of foam is treated with the retarder at a remote location.

7. De werkwijze volgens willekeurig welke van de voorgaande conclusies, waarbij het vertragend middel een waterige oppervlaktevertrager is.The method of any one of the preceding claims, wherein the retarding agent is an aqueous surface retardant.

8. De werkwijze volgens willekeurig welke van de voorgaande conclusies, waarbij het vertragend middel een vertraging in de hydratatie van de mortel bewerkstelligt.The method according to any of the preceding claims, wherein the retarding agent causes a delay in the hydration of the mortar.

9. De werkwijze volgens willekeurig welke van de voorgaande conclusies, waarbij het vertragend middel omvat een 1,2-benzisothiazol-2(3H)-on samenstelling, een benzeen, mono-Cio-n-alkyl afgeleiden, destillatieresiduesamenstelling, en een mengsel van 5-chloor-2-methyl-4-isothiazoline-3-on en 2-methyl-2hisothiazol-3-on.The method of any one of the preceding claims, wherein the retarding agent comprises a 1,2-benzisothiazole-2 (3 H) -one composition, a benzene, mono-C10-n-alkyl derivatives, distillation residue composition, and a mixture of 5-chloro-2-methyl-4-isothiazolin-3-one and 2-methyl-2-isothiazol-3-one.

10. De werkwijze volgens willekeurig welke van de voorgaande conclusies, waarbij de mortel omvat cement, vuiler, zand, additieven, water en, optioneel, pigmentadditieven.The method according to any of the preceding claims, wherein the mortar comprises cement, dirt, sand, additives, water and, optionally, pigment additives.

11. De werkwijze volgens willekeurig welke van de voorgaande conclusies, waarbij de mortel een druksterkte heeft van 55 N/mm2 na 28 dagen.The method according to any of the preceding claims, wherein the mortar has a compressive strength of 55 N / mm 2 after 28 days.

12. De werkwijze volgens willekeurig welke van de voorgaande conclusies, waarbij de laag schuim een polyetherlaag omvat.The method of any one of the preceding claims, wherein the foam layer comprises a polyether layer.

13. De werkwijze volgens willekeurig welke van de voorgaande conclusies, waarbij de laag schuim tussen 1,5 mm en 2,5 mm dik, en bij voorkeur 2 mm dik is.The method according to any of the preceding claims, wherein the foam layer is between 1.5 mm and 2.5 mm thick, and preferably 2 mm thick.

14. De werkwijze volgens willekeurig welke van de voorgaande conclusies, verder omvattende het verwijderen van de met het vertragend middel behandelde laag schuim van de zichtzijde van de bouwblokken wanneer het bouwelement verwijderd is van het steunoppervlak (210).The method of any of the preceding claims, further comprising removing the layer of foam treated with the retardant from the visible side of the building blocks when the building element is removed from the support surface (210).

15. De werkwijze volgens de voorgaande conclusie, waarbij de werkwijzestap van het verwijderen van de met het vertragend middel behandelde laag schuim een spoelwerkwijze is.The method of the preceding claim, wherein the method step of removing the layer of foam treated with the retardant is a rinsing method.

16. De werkwijze volgens willekeurig welke van de voorgaande conclusies, waarbij de bouwblokken (101) bakstenen omvatten.The method of any one of the preceding claims, wherein the building blocks (101) comprise bricks.