CA2283263C

CA2283263C - Construction element and process for its preparation

Info

Publication number: CA2283263C
Application number: CA002283263A
Authority: CA
Inventors: Ivan Vasilievich Sitnikov
Original assignee: Individual
Current assignee: Individual
Priority date: 1997-03-19
Filing date: 1998-03-18
Publication date: 2004-11-02
Anticipated expiration: 2018-03-18
Also published as: WO1998041707A1; CA2283263A1; CZ295209B6; PL335681A1; AU7241398A; CZ328899A3

Abstract

The invention relates to construction and can be used to prepare construction items of various shapes and sizes for decorative finishing. A construction element comprises a construction block made of either foam concrete, gas silicate concrete, expanded-clay concrete, heavy concrete, or otherwise of a thermal insulating material selected from the group comprised of foam polystyrene, foam polyurethane, gas silicate, or foam concrete, or another material with similar thermal conductive qualities, or in the form of a ceramic or silicate brick. A decorative coating is formed by placing at least one side of the construction block in a mold containing the decorative finishing mixture. A process includes preparation of the decorative mixture by mixing cement and sand according to a ratio ranging from 1:1 to 1:3. During the mixing of the sand, and depending on its fraction, the following sand fractions are added: firstly, a coarse fraction, followed by a medium one and finally, a tine fraction.

Water and plasticizer are added at the same time as the sand, and the prepared mixture is poured in a mold. A layer of the resulting decorative finishing mixture can range in thickness from 5 mm to 50 mm. A construction block is then placed onto the layer of the prepared mixture, and maintained long enough for the mixture to harden.

Description

Field of the Invention The invention relates generally to construction, and more particularly to production of decorative finishing construction items of various shapes and sizes for decorative external and internal lining of buildings, and for interior finish to satisfy high aesthetic, ecological, heat-insulating and thermotechnical requirements. Owing to ecologically pure decorative finishing coating, the invention can be widely and successfully employed both in monolithic concrete works and laying of face walls, and in interior finishing works.
to Background of the Invention A construction element comprising a decorative finishing layer jointed with a construction block and disposed on one of the construction block sides is known in the prior art (SU, No.837958, Int.Cl. C04B 28/04, 1978).
A problem with the prior art element is its inferior technological effectiveness and poor physical and mechanical properties, including compressive strength, cold endurance, weather resistance and adhesion strength of the decorative coating, this substantially reducing consumption properties of articles.
A conventional method for making a construction finishing coating includes the steps of applying a leveling undercoat layer and a protection decorative layer, wherein one or more of the layers include a composition comprising, taken in parts of weight:
butadiene styrene latex 100, 5% aqueous solution of sodium salt of carboxymethyl cellulose 2.0-4.0, limestone flour 35-40, liquid polyethyl hydrosiloxane 3.5-4.0, chemical water purification sludge comprising alkaline-earth metals 25-34, oxyethylized alkyl phenols 0.34-0.6.
3o The composition can further contain a pigment.
In production, prior to applying a construction finishing coating, the conventional method for making a construction finishing coating on articles or constructions provides for producing an article or construction by mixing components of a raw mixture, shaping the mixture, heat treatment and preparing a surface (RU Patent No.2055032 C1, 1996).
Most closely approaching the present invention by its principle and the result achieved is a method for making a construction element including the steps of preparing a decorative finishing mixture, pouring the prepared mixture in a mold, placing an article base onto the mixture and hardening (SU Inventor's Certificate No.742409, 1980).
Disadvantages of the prior art methods include their inferior technological effectiveness, labor-consuming operations, expensive accessories used in production, unstable qualitative characteristics of the article produced, short service life of the coating, poor adhesion, inferior resistance to weather, water, cold and cracks. All this is caused, in particular, by the fact that to provide an enhanced adhesion between a decorative layer or tile and the article base, additional operations are required to clean a surface of the article base, to moisten the surface and to introduce additional adhesive, binding and filling agents, etc.
SUMMARY OF THE INVENTION
2o It is an object of the present invention to provide a construction element exhibiting reasonably high physical and mechanical properties, including compressive strength and cold endurance, which is easy in production and does not require a dedicated equipment, and has a high thermal conductivity factor, this enabling to efficiently use the element in erected and reconstructed buildings and constructions.
The object of the invention is achieved in a conventional construction element comprising a construction block and a finishing coating located on at least on side of the construction block, wherein in accordance with the invention the construction block is made of foam concrete, or gas silicate concrete, or expanded-clay concrete, or heavy-3o weight concrete, or of a heat-insulating material selected from the group consisting of foam polystyrene, foam polyurethane, gas silicate, foam concrete or other materials having similar thermal conductivity properties, or in the form of a ceramic or silicate brick, the finishing coating being formed by placing at least one side of the construction block in a mold filled with a decorative finishing mixture which is obtained by mixing cement with sand in the ratio ranging from 1:1 to 1:3, using sand with fractions of 0.03-0.1 mrn, 0.3-1.2 mm and 2-4 mm that are added during the mixing in the amount, by weight percent, of 20-25, 25-30 and 55-70, respectively, and adding water and a plasticizer, with a layer of the decorative finishing mixture poured in the mold having a thickness in the range from 3 mm to 50 mm.
Further, a face surface of the finishing coating can be colored and have a decorative relief pattern.
A layer of heat and/or water resistant material having good adhesion to the finishing coating can be positioned between the finishing coating and the construction block, a thickness of said layer not exceeding a thickness of the construction block.
The finishing coating can be further connected to the construction block by anchor extensions provided in the construction block and/or in the finishing coating.
A height and/or length of the finishing coating can be greater than a height and/or length of the construction block, respectively, at least in one direction.
Further, the finishing coating can be C-shaped in a lateral and/or longitudinal section, with a width of flanges positioned on side walls of the construction block being no less than 3 mm.
The construction block can be further made of several parts connected with each other by a binding solution so that to form a bearing plane on which a layer of a heat-insulating material with the finishing coating is secured.
It is an object of the invention to provide a method for making decorative and lining articles and construction elements using decorative and lining construction elements which are easy to produce and have a reasonably low production cost, with a decorative coating having increased durability owing to improved adhesion to the construction block.
The method also provides an improvement in water, cold and crack resistance.

The above object is achieved in a conventional method for making a construction element, including the steps of preparing a decorative finishing mixture, pouring the prepared mixture in a mold, placing a construction block onto the mixture layer and hardening, wherein the decorative finishing mixture is prepared by mixing cement with sand in the ratio ranging from l: l to 1:3, respectively, using sand with fractions of 0.03-0.1 mm, 0.3-1.2 mm and 2-4 mm in the amount, by weight percent, of 20-25, 25-30 and 55-70, respectively, adding water and a plasticizer simultaneously with the sand, the prepared mixture being poured in the mold in a layer having a thickness in the range from 3 mm to 50 mm, placing the construction block onto the layer of the prepared mixture and 1o maintaining long enough for the mixture to harden.
Upon placing the construction block onto the decorative finishing layer, the element is advantageously maintained for 24-48 hours at a temperature of 20-23°C.
During the mixing, a pigment can be added to the decorative finishing mixture.
Brief Description of the Drawings Fig.l shows a general view of a construction element in accordance with the invention;
Fig.2 is a cross sectional view ofthe construction element in Fig.l;
Fig.3 is a schematic view of an anchor used in the construction element with a 2s heat/water insulation layer; and Fig.4 is a schematic view illustrating the relationship among geometric dimensions in the construction element.
3o Detailed Description of Preferred Embodiment A method for making a construction element in accordance with the present invention can be implemented in the following manner.

A decorative finishing mixture is prepared by mixing and agitating cement with sand in the ratio from 1:1 to 1:3, the sand being successfully added during the mixing depending on its fraction: first, a coarse fraction, followed by a medium one and finally, a fine fraction. Specifically, the following sand fractions are used: coarse fraction of 2-4 mm, medium fraction of 0.3-1.2 mm, and fine fraction of 0.03-0.1 mm, taken in the amount of 55-70, 25-30, 20-25 weight percent, respectively. Water and a plasticizer are added simultaneously with the sand. Water/cement (W/C) ratio is 0.28-0.30. The prepared decorative finishing mixture is then poured in a plain mold exhibiting a high degree of adhesion in a layer from 5 mm to 50 mm in thickness. A construction block, such as a to brick, is then placed onto the layer of the prepared decorative finishing mixture. The construction element is maintained long enough for the mixture to harden. The best conditions to be followed are to hold the construction element for 24-48 hours at a temperature of 20-23°C.
To impart a definite color to the decorative finishing mixture, a pigment evenly mixed with the sand is added to the mixture.
Example of implementing the method. A decorative finishing mixture is prepared of following components: Portland cement of "400" grade; fine filling agent, such as 2o quartz sand, with fractions of 2-4 mm, 0.3-1.2 mm, 0.03-0.1 mm, natural building sand, a plasticizer such as super plasticizer of C-3 grade, a pigment such as iron oxide Fez03 giving a red color to the article.
Specific effective activity of natural radioactive nuclides in the raw materials is no greater than 370 Bq/kg.
Cement and sand are taken in the proportion of 1 part cement to 2 parts sand, superplasticizer from 1.0 to 2.0 %, pigment may range from 0.1 to 5%. The plain mold is a mold made of a material exhibiting low adhesion to the decorative finishing layer, this 3o enabling to easily separate the article when hardened. W/C is 0.28-0.30.
Portland cement is mixed with sand in an agitator, first adding to the agitator the sand of 0.03-0.1 mm fraction, next 2-4 mm fraction, and finally 0.3-1.2 mm fraction. The pigment, water and superplasticizer C-3 are added simultaneously with the sand of 2-4 mm fraction. The mixture is blended to homogeneous state.
The so-prepared mixture is poured on a plain surface of the mold in a layer having a thickness in the range from 5 to 50 mm. Next, a construction block, such as a brick, is placed onto the decorative finishing mixture. The assembled element is held for 24-48 hours at a temperature of 20-23° until the mixture fully hardens.
The addition of sand having the aforementioned fineness to the mixture and the mixing of the mixture components in the given sequence provide close laying, reduce 1o initial shrinkage stresses in the article structure, improve adhesion of the decorative finishing layer to the article base, increase durability of the finishing layer, owing to placing the article base directly onto the decorative finishing layer prepared in accordance with the procedure above.
The test results are: cold endurance M = 200 cycles; water resistance V = 8;
adhesion greater than 0.6-0.8 MPa.
Application of the invention makes it possible to substantially simplify the process for making construction elements, to reduce cost per unit of product and to 2o improve service performance.
A construction element produced using the method disclosed above comprises a construction block 1 and a finishing coating 2 made of the aforementioned decorative finishing mixture. A face surface of the finishing coating 2 may be provided with a decorative relief pattern or be plain as defined by the mold relief.
Dependant on the purpose and specification, the construction block may be made of foam concrete, or gas silicate concrete, or expanded-clay-concrete, or heavy-weight concrete, or of a heat-insulating material selected from the group consisting of foam 3o polystyrene, foam polyurethane, gas silicate, foam concrete or another material having similar thermal conductivity.
The construction block may be made in the form of a ceramic or silicate brick, either common or heavy, with the brick grade no less than M 100 by strength and G 25 by cold resistance. When used as a construction element, a decorative facing building stone may be produced from brick.
The decorative coating 2 can have a thickness from 3.0 mm to 50 mm depending on technical and process conditions. Length "L" and height "H" of the coating 2 (Fig.4) exceed length "1" and height "h" of the construction block, respectively. As an example, blocks 1 made of sand and heavyweight concrete measure 20 x 20 x 40 cm with minor deviations to the smaller side mainly. Blocks of a lightweight concrete, such as foam 1o concrete, or gas silicate concrete, or clay-expanded concrete, are frequently made of a greater length.
A heat and/or water resistant layer 3 of a material, e.g. on the basis of foam polystyrene, exhibiting good adhesion to the finishing coating 2, may be positioned between a finishing coating 2 having a C-shaped cross section and a construction block 1.
To improve bearing properties of the element, anchor extensions 4 may be provided in the block 1 and/or in the finishing coating 2.
2o Such structures of the decorative finishing construction elements feature cold endurance of M 200 cycles, water resistance of B 8 and adhesion of 0.6 MPa.
In one embodiment, at least one additional layer 3 of a heat and/or water-resistant material can be provided between the finishing coating 2 and the construction block 1, a thickness of the additional layer not exceeding a thickness of the block 1, while a height and/or length of the finishing coating 2 exceeds a height and/or length, respectively, of the block 1 and the additional layer 3.
A decorative lining construction element for the use as a retained form can be 3o formed by at least one row of the finishing coating 2 connected to a layer 3 of heat-resistant material secured on parts of the construction block 1 so as to form a bearing structure. In this case, the construction element can be made in the form of a retained form, with the decorative coating 2 secured on parts of the block 1 by anchors 5 connected thereto.
The employment of the invention provides a reduction in the manufacture cost of decorative and lining articles, increased durability of the finishing coating, and enhanced water, cold and crack resistance. Addition of sand of the indicated fractions in the listed amounts to a decorative finishing mixture when producing decorative and facing construction elements, while observing a given sequence of the mixture preparation and process conditions, imparts dense structure to the mixture, reduces initial shrinkage stresses, enhances adhesion of the finishing coating both to the construction block and to to the heat-insulating layer material, this resulting in reliability and durability of the construction element and superior aesthetic, physical and mechanical properties thereof.
Industrial Applicability The present invention observes the industrial applicability condition as it can be implemented using available production means.

Claims

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:

I . A construction element comprising a construction block and a finishing coating located on at least one side of the construction block, wherein the construction block is a ceramic or silicate brick, or is made from a material selected from the group consisting of:

a) foam concrete, b) gas silicate concrete c) expanded-clay concrete, d) heavy-weight concrete, and e) a heat insulating material selected from the group consisting of:
i) foam polystyrene, ii) foam polyurethane, iii) gas silicate, iv) foam concrete, and v) other materials having similar thermal conductivities, wherein the finishing coating is obtained by mixing cement with sand in a ratio ranging from 1:1 to 1:3 by weight percent, said sand having fractions of 0.03-0.1 mm, 0.3-1.2mm and 2-4mm, which are added during said mixing in the amounts of 20-25, 25-30 and 55-70 by weight percent, respectively, and adding water and a plasticizer, and wherein said construction element is prepared by placing at least one side of the construction block into a mold and pouring a layer of the finishing mixture having a thickness of 3mm to 50mm into the mold.
2. The element of claim 1, wherein said finishing coating is colored.
3. The element of claim 1, wherein a face surface of the finishing coating has a decorative relief pattern.
4. The element of claim 1, wherein a layer of heat resistant, water resistant or heat and water resistant material having good adhesion to the finishing coating is further positioned between the finishing coating and the construction block, a thickness of said layer not exceeding a thickness of the construction block.
5. The element of claim 1, wherein said finishing coating is further connected to the construction block by anchor extensions provided in the construction block, the finishing coating or the construction block and the finishing coating.
6. The element of claim 1, wherein a height of the finishing coating is greater than a height of the construction block.
7. The element of claim 1, wherein a length of the finishing coating is greater than a length of the construction block, at least in one direction.
8. The element of claim 1, wherein a height and length of the finishing coating is greater than a height and length of the construction block, at least in one direction.
9. The element of claim 1, wherein said finishing coating is C-shaped in a lateral, longitudinal or lateral and longitudinal section, with a width of flanges positioned on side walls of the construction block being no less than 3 mm.
10. The element of claim 1, wherein said construction block is comprised of several parts connected with each other by a binding solution so that to form a bearing plane on which a layer of a heat-insulating material with the finishing coating is secured.
11. A method for making a construction element as set forth in claim 1, including the steps of preparing a decorative finishing mixture, pouring the prepared mixture in a mold, placing a construction block on the mixture layer and hardening, wherein the decorative finishing mixture is prepared by mixing cement with sand in the ratio ranging from 1:1 to 1:3, respectively, using sand with fractions of 2-4mm, 0.3-1.2 mm and 0.03-0.1 mm in the amount, by weight percent, of 55-70, 25-30 and 20-25, respectively, adding water and a plasticizer simultaneously with the sand, the prepared mixture being poured in the mold in a layer having a thickness from 3mm to 50mm, the construction block being placed onto the layer of the prepared mixture and maintained long enough for the mixture to harden.
12. The method of claim 11, wherein upon said placing of the construction block on the decorative finishing layer, the assembled element is maintained for 24-48 hours at a temperature of 20-23 °C.
13. The method of claim 11, wherein during said mixing step, a pigment is added to the decorative finishing mixture.