WO2017007435A1 - A multi-hollow, cement based, lightweight building block and its manufacturing method - Google Patents
A multi-hollow, cement based, lightweight building block and its manufacturing method Download PDFInfo
- Publication number
- WO2017007435A1 WO2017007435A1 PCT/TR2016/000085 TR2016000085W WO2017007435A1 WO 2017007435 A1 WO2017007435 A1 WO 2017007435A1 TR 2016000085 W TR2016000085 W TR 2016000085W WO 2017007435 A1 WO2017007435 A1 WO 2017007435A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- building block
- manufacturing
- mortar
- mold
- cement
- Prior art date
Links
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
- E04B2/14—Walls having cavities in, but not between, the elements, i.e. each cavity being enclosed by at least four sides forming part of one single element
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B7/00—Moulds; Cores; Mandrels
- B28B7/16—Moulds for making shaped articles with cavities or holes open to the surface, e.g. with blind holes
- B28B7/18—Moulds for making shaped articles with cavities or holes open to the surface, e.g. with blind holes the holes passing completely through the article
- B28B7/183—Moulds for making shaped articles with cavities or holes open to the surface, e.g. with blind holes the holes passing completely through the article for building blocks or similar block-shaped objects
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B7/00—Moulds; Cores; Mandrels
- B28B7/28—Cores; Mandrels
- B28B7/30—Cores; Mandrels adjustable, collapsible, or expanding
- B28B7/306—Cores; Mandrels adjustable, collapsible, or expanding pliable or extensible
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B7/00—Moulds; Cores; Mandrels
- B28B7/34—Moulds, cores, or mandrels of special material, e.g. destructible materials
- B28B7/348—Moulds, cores, or mandrels of special material, e.g. destructible materials of plastic material or rubber
Definitions
- This invention relates to new type building blocks that are used for making interior and exterior walls and ribbed slabs of constructions and their manufacturing method.
- Some building blocks like clay bricks, autoclaved aerated concrete blocks (and several types of lightweight concrete blocks), panels-boards, clay hollow blocks, concrete hollow blocks or expanded polistyrene block slabs, lintels and some composite elemets are being used for masonry works of building walls and slabs as pre-fabrication elements.
- the binders of those blocks are clays, cements, limes, gypsum and several chemicals, polimers etc.
- filler materials except of those binders are natural and artificial aggregates, powdered mineral additives, several fibers and reinforcement materials.
- the methods specifically can be mechanical production procedures providing macro hollow or lightness (pressing, molding, extrusion, optimization of dimensions, forming panel shape etc.), using natural/artificial lightweight filling materials and some chemical materials led to cellular holes (pores).
- macro hollow or lightness pressing, molding, extrusion, optimization of dimensions, forming panel shape etc.
- natural/artificial lightweight filling materials and some chemical materials led to cellular holes (pores).
- pores There are some limitations about increasing the ratio of empty in design of building blocks. The total hole or pore content in the building block should not be so much to cause unacceptably deformations due to manufacturing, warehousing, transporting, environmental exposures and constructive loads in application site)
- the ratio of empty as in concrete bricks obtained by the way of pressing are not generally exceeded approximately 35-40% of the total block volume.
- Their wall thicknesses have to be kept a bit thicker for self-standing of stiff fresh concrete element after pressing without collapsing/breaking off, thus the material integrity is preserved, but the weight of block cannot to be reduced as required.
- Pumice-mixed concrete blocks together with large empties made by pressing method could highly reduce the block unit weight. But lightweight aggregates like pumice do not exist in all regions or the transportation to other regions can not be economic.
- the unit weight of the clay blocks manufactured by extrusion could be reduced highly because of less wall thickness and distance between hollows compared to pressed bricks, although this, sizing irregularities can occur due to extrusion and heating process.
- masonry mortar much more than enough can ooze thru hollows of clay blocks, that is, cost of construction may increase, purposed insulation properties cannot be ensured and construction loads can increase instead of reducing.
- Several textures are generally formed on clay blocks' surfaces, thus cement or gypsum based plasters are available to stay on the wall although the material or moisture absorption differences.
- Two-coat plasterwork to ensure smoothness on the wall should be done due to either these planned textures or sizing irregularities from manufacture process of the burned clay bricks, this also can cause to bring extra loads to construction and inflate manpower and material costs furthermore.
- cement-based plasters can be difficult to stay on that wall, spraying cement slurry can be applied onto the wall before plasterwork, thus can also increase coating thickness and manpower of plaster.
- manufacturing process of autoclaved aerated and cellular (foam) concrete blocks residual moisture in the blocks can not be refused for a long time and can diffuse to finished wall surface in future.
- a purpose of the invention is to obtain building blocks in which are easy to supply constituent materials everywhere, lightweight, insulation properties, environmentally neutral and economic.
- Main topic of the invention is related to get smaller diameter of hollows and narrower the solid part between these adjacent mini hollows (up to 1 mm wide) than it has been made hitherto, in result, to get higher the total ratio of empty (up to 70%) in cement-based building blocks, thus to achieve lightness of blocks by using mechanical methods instead of using chemical agents/admixtures or porous materials, to reduce or end using of these expensive materials, to reduce the costs of block manufacturing.
- the other purpose of the invention is to reduce masonry and plasterwork costs compared to the other building blocks have.
- Another purpose of the invention is to present an optimal solution by selecting the strong sides of all the different types of building blocks.
- Figure 2 A perspective view of the rubber strip set to be located into the mortar.
- Figure 3 A view after the rubber strip set is placed and the mortar is poured into the mold
- Figure 4 A perspective view of the finished building block after the mortar is hardened and then the rubber strip set/the mold are removed
- the subject of invention is cement-based and economic building blocks in which consist of numerous longitudinal mini scale independent hollows, thus its strenght, lightness, insulation properties got more reinforced.
- the manufacturing method of the mentioned building blocks is to place the rubber strip set (2) and the cement mortar (3) into the mold (1), after the mortar is hardened then the rubber strip set/mold are removed out, finally to obtain the hollow block (5).
- Hollow blocks can be manufactured in several shape and dimensions by using suitable molds types and sufficient amount of rubber strip sets and sized by cutting according to request.
- these building blocks' main constituent materials are cement, sand and water.
- the following materials and its combinations can be mixed too:
- Powdered mineral additives fly ash, microsilica, ground blast furnace slag etc.
- Fiber and reinforcement materials (PP fibers, glass fibers, carbon fibers, steel fibers and bars etc.)
- the invention is an alternative building block and its manufacturing method, to be used in interior/exterior walls (brick, panel and lintel blocks) and ribbed slabs (hollow block slab)
- cement-based cement-based masonry mortars and plasters, fireproofing property, resistant to environmental exposures, external loads, no-contain harmful chemicals and gases, its availability everywhere and cheaper comparing to other binders.
- This new building block is designed with optimal hollow diameter providing mortar filling holes neither more nor less, for example, while bricklaying, enough locking is being possible between blocks as a few amount of mortar getting into holes, on the other hand, while concrete pouring in ribbed slabs, fresh concrete oozings into hollows are not allowed too much.
- Oppositely large hollows in clay bricks formed by extrusion provide lightness of block, but in application, brick laying mortar costs can be higher and foresights like reducing loads and strenghtening insulation features can not be realized in construction project.
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- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Chemical & Material Sciences (AREA)
- Ceramic Engineering (AREA)
- Mechanical Engineering (AREA)
- Architecture (AREA)
- Physics & Mathematics (AREA)
- Electromagnetism (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Manufacturing Of Tubular Articles Or Embedded Moulded Articles (AREA)
Abstract
This invention is about a designed multi-hollow, cement based building block (wall bricks, window/door masonry lintels, wall boards and hollow brick slabs) that is used for making interior and exterior walls and slabs and its manufacturing method. The manufacturing method of building blocks: The materials are the mold (1), the cement mortar (3) and the rubber strips set (2) and the procedure consists of the stages; firstly casting the mortar into the mold and placed the rubber strip set previously and after hardening of fresh mortar, removing the mentioned rubber set and the mold from block and finally obtaining the lightweight and economic building block (5) that contains the numerous mini longitudinal hollows (4).
Description
DESCRIPTION
A MULTI-HOLLOW, CEMENT BASED, LIGHTWEIGHT BUILDING BLOCK AND ITS MANUFACTURING METHOD Field of the Invention
This invention relates to new type building blocks that are used for making interior and exterior walls and ribbed slabs of constructions and their manufacturing method. Background of the Invention
Some building blocks like clay bricks, autoclaved aerated concrete blocks (and several types of lightweight concrete blocks), panels-boards, clay hollow blocks, concrete hollow blocks or expanded polistyrene block slabs, lintels and some composite elemets are being used for masonry works of building walls and slabs as pre-fabrication elements.
The binders of those blocks are clays, cements, limes, gypsum and several chemicals, polimers etc.
As filler materials except of those binders are natural and artificial aggregates, powdered mineral additives, several fibers and reinforcement materials.
For last decades, user demand preferences that motivates manufacturers to make building blocks more lightweight are less application/mounting labor, less dead load to construction, better thermal insulation properties (theoretical in general, thermal insulation property of a material is getting better as reducing its unit weight) and more economic.
To reduce unit weight of blocks, the methods specifically can be mechanical production procedures providing macro hollow or lightness (pressing, molding, extrusion, optimization of dimensions, forming panel shape etc.), using natural/artificial lightweight filling materials and some chemical materials led to cellular holes (pores). (There are some limitations about increasing the ratio of empty in design of building blocks. The total hole or pore content in the building block should not be so much to cause unacceptably deformations due to manufacturing, warehousing, transporting, environmental exposures and constructive loads in application site)
The ratio of empty as in concrete bricks obtained by the way of pressing are not generally exceeded approximately 35-40% of the total block volume. Their wall thicknesses have to be kept a bit thicker for self-standing of stiff fresh concrete element after pressing without collapsing/breaking off, thus the material integrity is preserved, but the weight of block cannot to be reduced as required.
Pumice-mixed concrete blocks together with large empties made by pressing method could highly reduce the block unit weight. But lightweight aggregates like pumice do not exist in all regions or the transportation to other regions can not be economic.
The unit weight of the clay blocks manufactured by extrusion could be reduced highly because of less wall thickness and distance between hollows compared to pressed bricks, although this, sizing irregularities can occur due to extrusion and heating process. Meanwhile, at the time of brickwork application in site, masonry mortar much more than enough can ooze thru hollows of clay blocks, that is, cost of construction may increase, purposed insulation properties cannot be ensured and construction loads can increase instead of reducing. Several textures are generally formed on clay blocks' surfaces, thus cement or gypsum based plasters are available to stay on the wall although the material or moisture absorption differences. Two-coat plasterwork to ensure smoothness on the wall should be done due to either these planned textures or sizing irregularities from manufacture process of the burned clay bricks, this also can cause to bring extra loads to construction and inflate manpower and material costs furthermore.
Autoclaved aerated concrete blocks, cellular lightweight (foam) concrete blocks and their combinations with or without using artificial lightweight agregates (expanded polystyrene etc.) possess higher cost components and/or manufacturing processes. In masonry applications of the autoclaved aerated concrete blocks, cement-based plasters can be difficult to stay on that wall, spraying cement slurry can be applied onto the wall before plasterwork, thus can also increase coating thickness and manpower of plaster. In manufacturing process of autoclaved aerated and cellular (foam) concrete blocks, residual moisture in the blocks can not be refused for a long time and can diffuse to finished wall surface in future.
Other lightweight blocks produced by using artificial lightweight aggregates or polymer binders generally cause to toxic gas emission during life-cycle or accidental fire especially.
Purpose of the Invention
A purpose of the invention is to obtain building blocks in which are easy to supply constituent materials everywhere, lightweight, insulation properties, environmentally neutral and economic.
Main topic of the invention is related to get smaller diameter of hollows and narrower the solid part between these adjacent mini hollows (up to 1 mm wide) than it has been made hitherto, in result, to get higher the total ratio of empty (up to 70%) in cement-based building blocks, thus to achieve lightness of blocks by using mechanical methods instead of using chemical agents/admixtures or porous materials, to reduce or end using of these expensive materials, to reduce the costs of block manufacturing.
The other purpose of the invention is to reduce masonry and plasterwork costs compared to the other building blocks have.
Another purpose of the invention is to present an optimal solution by selecting the strong sides of all the different types of building blocks.
Brief Description of the Drawings Figure 1 : A perspective view of the mold for the building block
Figure 2: A perspective view of the rubber strip set to be located into the mortar.
Figure 3: A view after the rubber strip set is placed and the mortar is poured into the mold
Figure 4: A perspective view of the finished building block after the mortar is hardened and then the rubber strip set/the mold are removed
Reference Numbers in the Figures
1 : The mold
2: The rubber strip set
3: The mortar
4: The numerous and frequent longitudinal mini hollows
5: The multi-hollow, cement-based lightweight building block Detailed Description of the invention
The subject of invention is cement-based and economic building blocks in which consist of numerous longitudinal mini scale independent hollows, thus its strenght, lightness, insulation properties got more reinforced.
The manufacturing method of the mentioned building blocks is to place the rubber strip set (2) and the cement mortar (3) into the mold (1), after the mortar is hardened then the rubber strip set/mold are removed out, finally to obtain the hollow block (5). Hollow blocks can be manufactured in several shape and dimensions by using suitable molds types and sufficient amount of rubber strip sets and sized by cutting according to request.
When referred to the building blocks, the following items can be considered ;
a) Brick-type blocks (for laying with mortar)
b) Panel-type blocks (for installing to a base construction)
c) Window/Door lintel blocks
d) Hollow blocks for slabs
The mentioned invention is an alternative building block and its fundamental manufacturing method for above all block types.
As the invention subject, these building blocks' main constituent materials are cement, sand and water. In addition, the following materials and its combinations can be mixed too:
a) Powdered mineral additives ( fly ash, microsilica, ground blast furnace slag etc.)
b) Chemical admixtures (porosing-foaming-air entainment agents, admixtures to increase strenght etc.)
c) Artificial and natural ieightweight aggregates (granular EPS, perlite, pumice etc.)
d) Fiber and reinforcement materials (PP fibers, glass fibers, carbon fibers, steel fibers and bars etc.)
Industrial Applicability
The invention is an alternative building block and its manufacturing method, to be used in interior/exterior walls (brick, panel and lintel blocks) and ribbed slabs (hollow block slab)
It presents to facilitate labor of brick laying application through its lightness. It consists of hollows which reduce thermal bridges, thus provides thermal and noise insulation.
The advantages of the building block being "cement-based" are compatible with the other cement-based masonry mortars and plasters, fireproofing property, resistant to environmental exposures, external loads, no-contain harmful chemicals and gases, its availability everywhere and cheaper comparing to other binders.
This new building block is designed with optimal hollow diameter providing mortar filling holes neither more nor less, for example, while bricklaying, enough locking is being possible between blocks as a few amount of mortar getting into holes, on the other hand, while concrete pouring in ribbed slabs, fresh concrete oozings into hollows are not allowed too much. Oppositely large hollows in clay bricks formed by extrusion provide lightness of block, but in application, brick laying mortar costs can be higher and foresights like reducing loads and strenghtening insulation features can not be realized in construction project.
Claims
1. A lightweight building block, comprising:
numerous and frequent longitudinal mini hollows (4).
2. The building block in accordance with claim 1 , wherein: constituent material is cement-based mortar (3).
3. A manufacturing method to produce lightweight concrete building block, comprising:
to make the numerous longitudinal frequent hollows (4), the rubber strip set (2) is used in the mortar (3).
4. A manufacturing method according to claim 3, comprising the following steps: a) Preparing the mold (1) and the rubber strip set (2)
b) Pouring the cement-based mortar (3) into the mold (1) and the rubber strip set (2)
c) Removing the rubber strip set (2) and the mold (1) from the hardened cement-based mortar (3) and obtaining the multi-hollow cement-based lightweight building block (5)
d) Cutting the block (5) for sizing as required.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| TR201508417 | 2015-07-07 | ||
| TR2015/08417 | 2015-07-07 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| WO2017007435A1 true WO2017007435A1 (en) | 2017-01-12 |
Family
ID=57133393
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/TR2016/000085 WO2017007435A1 (en) | 2015-07-07 | 2016-06-09 | A multi-hollow, cement based, lightweight building block and its manufacturing method |
Country Status (1)
| Country | Link |
|---|---|
| WO (1) | WO2017007435A1 (en) |
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN108274597A (en) * | 2018-04-19 | 2018-07-13 | 宁夏千秋墙体材料有限公司 | Poling core pulling equipment and wallboard laminator |
| CN109053045A (en) * | 2018-08-30 | 2018-12-21 | 广州大学 | A kind of alkali-activated carbonatite fly-ash slag piezoelectricity floor tile and preparation method thereof |
| CN114905604A (en) * | 2022-01-13 | 2022-08-16 | 华北水利水电大学 | Laboratory manufacturing method for autoclaved aerated concrete porous building blocks |
| CN115849944A (en) * | 2022-12-21 | 2023-03-28 | 江苏恒尚节能科技股份有限公司 | Aerated concrete block for building curtain wall and preparation method thereof |
Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB536431A (en) * | 1939-12-04 | 1941-05-14 | William Small | Improvements in or relating to cavity wall construction and bricks and blocks therefor |
| FR978606A (en) * | 1948-11-23 | 1951-04-16 | Stup Procedes Freyssinet | prefabricated building elements, their manufacturing process and constructions made with these elements |
| CN2571753Y (en) * | 2002-10-08 | 2003-09-10 | 常全生 | Light hollow thermo-insulation brick made of solid refuse |
| FR2928946A1 (en) * | 2008-03-21 | 2009-09-25 | Cogestone France Sarl | Parallelepiped insulating block i.e. bond stone, for constructing e.g. house external wall, has cores arranged in staggered rows and aligned in row between two tangents, where tangents of two contiguous rows pass through cores of other row |
| FR2989981A1 (en) * | 2012-04-30 | 2013-11-01 | Edouard Serras | Parallelepiped construction elements for use as e.g. bricks, to construct thermally insulating bearing walls of low energy consumption building, have internal air circulation channels communicated with internal channels of adjacent elements |
-
2016
- 2016-06-09 WO PCT/TR2016/000085 patent/WO2017007435A1/en active Application Filing
Patent Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB536431A (en) * | 1939-12-04 | 1941-05-14 | William Small | Improvements in or relating to cavity wall construction and bricks and blocks therefor |
| FR978606A (en) * | 1948-11-23 | 1951-04-16 | Stup Procedes Freyssinet | prefabricated building elements, their manufacturing process and constructions made with these elements |
| CN2571753Y (en) * | 2002-10-08 | 2003-09-10 | 常全生 | Light hollow thermo-insulation brick made of solid refuse |
| FR2928946A1 (en) * | 2008-03-21 | 2009-09-25 | Cogestone France Sarl | Parallelepiped insulating block i.e. bond stone, for constructing e.g. house external wall, has cores arranged in staggered rows and aligned in row between two tangents, where tangents of two contiguous rows pass through cores of other row |
| FR2989981A1 (en) * | 2012-04-30 | 2013-11-01 | Edouard Serras | Parallelepiped construction elements for use as e.g. bricks, to construct thermally insulating bearing walls of low energy consumption building, have internal air circulation channels communicated with internal channels of adjacent elements |
Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN108274597A (en) * | 2018-04-19 | 2018-07-13 | 宁夏千秋墙体材料有限公司 | Poling core pulling equipment and wallboard laminator |
| CN108274597B (en) * | 2018-04-19 | 2023-09-19 | 宁夏千秋墙体材料有限公司 | Poling core pulling equipment and wallboard plate making machine |
| CN109053045A (en) * | 2018-08-30 | 2018-12-21 | 广州大学 | A kind of alkali-activated carbonatite fly-ash slag piezoelectricity floor tile and preparation method thereof |
| CN114905604A (en) * | 2022-01-13 | 2022-08-16 | 华北水利水电大学 | Laboratory manufacturing method for autoclaved aerated concrete porous building blocks |
| CN115849944A (en) * | 2022-12-21 | 2023-03-28 | 江苏恒尚节能科技股份有限公司 | Aerated concrete block for building curtain wall and preparation method thereof |
| CN115849944B (en) * | 2022-12-21 | 2023-08-11 | 江苏恒尚节能科技股份有限公司 | Aerated concrete block for building curtain wall and preparation method thereof |
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