Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B28—WORKING CEMENT, CLAY, OR STONE
  • B28C—PREPARING CLAY; PRODUCING MIXTURES CONTAINING CLAY OR CEMENTITIOUS MATERIAL, e.g. PLASTER
  • B28C7/00—Controlling the operation of apparatus for producing mixtures of clay or cement with other substances; Supplying or proportioning the ingredients for mixing clay or cement with other substances; Discharging the mixture
  • B28C7/04—Supplying or proportioning the ingredients
  • B28C7/06—Supplying the solid ingredients, e.g. by means of endless conveyors or jigging conveyors
  • B28C7/08—Supplying the solid ingredients, e.g. by means of endless conveyors or jigging conveyors by means of scrapers or skips
  • B28C7/0835—Supplying the solid ingredients, e.g. by means of endless conveyors or jigging conveyors by means of scrapers or skips using skips to be hoisted along guides or to be tilted, to charge working-site concrete mixers
  • B28C7/0847—Supplying the solid ingredients, e.g. by means of endless conveyors or jigging conveyors by means of scrapers or skips using skips to be hoisted along guides or to be tilted, to charge working-site concrete mixers the skips being hoisted along vertical or inclined guides
• • 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
  • B28B15/00—General arrangement or layout of plant ; Industrial outlines or plant installations
• • 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
  • B28B3/00—Producing shaped articles from the material by using presses; Presses specially adapted therefor
  • B28B3/02—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein a ram exerts pressure on the material in a moulding space; Ram heads of special form
  • B28B3/022—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein a ram exerts pressure on the material in a moulding space; Ram heads of special form combined with vibrating or jolting

Definitions

• the present invention relates to a mobile plant for the manufacture of masonry building products, such as masonry blocks, and to the construction of walls and other building structures using such building products, without the use of mortar.
• Masonry block has for a long time been attributed as one of the best building materials available for building construction, especially in tropical and sub-tropical zones. Masonry buildings, however, appear expensive when compared to other forms of construction. This is not only due to the fact that the base material requires energy usage in its product but also that there is a high degree of skill required in the assembly and construction of buildings using masonry block.
• a mobile plant for the manufacture of shaped building products, comprising a motorised mixer for mixing a batch of sand, aggregate and cement, a skip container associated with said mixer for receiving predetermined amounts of materials and discharging the materials into the mixer, means for discharging mixed concrete from the mixer, conveyor means so disposed in relation to said mixer for receiving concrete discharged from said mixer and for conveying same to a hopper adjacent to said mixer, and mould means disposed below said hopper for receiving a charge of concrete from the hopper and adapted to mould said charge of concrete into a predetermined shape, wherein the component parts of said plant are mounted on a rigid platform whereby the plant is adapted for transportation from one site to another as required.
• Fig. 1 is a perspective view of a platform-mounted mobile masonry block plant
• Fig. 2 is a side elevation view of the plant of Fig. 1;
• Fig. 3 is a plan view of the plant;
• Fig. 4 is an end elevation view of the plant taken from the mixer end;
• Fig. 5 is an end elevation view of the plant taken from the hopper/block moulding end;
• Figs. 6-8, inclusive, illustrates some of the masonry blocks manufactured by the mobile plant and utilized in mortarless building construction according to the method disclosed herein;
• Fig. 19 represents a cross-section taken through the foundation and part of a vertical wall of a building structure constructed in accordance with one embodiment of the invention.
• Fig. 20 represents a cross-section similar to Fig. 18 showing starter bar reinforcements extending from the wall into the floor slab.
• Fig. 21 represents a perspective view of the formation of reinforced beam or foundation blocks
• Figs. 22, 23 and 24 represent perspective views of a wall under construction, laying courses of masonry blocks without mortar one above the other;
• Fig. 25 represents a perspective view of the completed wall structure with the top reinforced trough beam partly cut away;
• Fig. 26 represents a perspective view of a building structure with the roof frame attached
• Fig. 27 is a cross-sectional view through an embodiment of a vertical wall of a single storey structure constructed in accordance with the invention.
• Fig. 28 is a cross-sectional view through vertical walls of another embodiment of the invention, being a two storey building structure.
• the mobile masonry block plant 1 comprises a motor-driven concrete mixer 2 mounted on a platform 3 with an adjacent block-moulding machine 4.
• a skip bucket 5 is mounted on rails 6 and 7 to one side of the mixer
• the skip bucket 5 is lowered to its lowest point for the filling operation. This is preset according to requirements; in some embodiments the skip 5 is adapted to be lowered to a point lower than the platform 3 of the plant (as depicted in phantom in Figs. 2-4), whereby the open top of the skip 5 is at ground level for ease of filling. In one preferred embodiment, the skip 5 is designed with a capacity of 0.4m 3 , but can be varied as required.
• the cam-operated gate 9 on the bottom outlet of the mixer is closed, and with the skip bucket hoisted to its highest point the aggregate mix is discharged from the skip 5 into the mixer 2 and then mixing operations are commenced.
• the bottom cam-operated gate 9 is opened and the gate is moved to one side of the outlet.
• the concrete mixture is discharged from the mixer onto the conveyor 10 disposed beneath the mixer outlet and the mixture is then conveyed to the conical-shaped hopper 11 above the block moulding machine 12.
• the hopper 11 is designed to be of a capacity similar to that of the skip 5 (e.g. 0.4m 3 ).
• the block moulding machine 12 is designed to manufacture concrete blocks 13 in accordance with local requirements or standards, e.g. in Australia blocks are preferably manufactured in accordance with Australian Standard 1500-1974, or the equivalent thereof. Prior to manufacture in any one location, analysis is carried out on the locally available materials (e.g. aggregates and cements) to allow a mix to be formulated that will satisfy the abovementioned standards.
• local requirements or standards e.g. in Australia blocks are preferably manufactured in accordance with Australian Standard 1500-1974, or the equivalent thereof.
• analysis is carried out on the locally available materials (e.g. aggregates and cements) to allow a mix to be formulated that will satisfy the abovementioned standards.
• the block moulding machine 12 by means of simultaneous unilateral vibration and compression produces blocks 13 of an accuracy of plus or minus 1mm.
• the mould box 14 is up, the pressure plate is inside the mould box, and the scraper frame is forward.
• a wooden pallet is placed and positioned on the vibration plate.
• the mould box 14 is lowered onto the pallet using pneumatic or hydraulic means, such as a pneumatic double-acting cylinder 15 and 16.
• the scraper frame is then pushed back as far as possible.
• Concrete mix is then discharged from the hopper 11 into the mould box 14, which is simultaneously vibrated to facilitate settlement of the mix.
• the scraper frame is pulled forward so that the pressure plate is above the mould box; this clears all excess material from above the mould box.
• the pressure plate is then lowered while the mould box 14 is vibrated until the block is compacted and moulded to a predetermined vertical size.
• the mould box 14 is then raised, by pneumatic or hydraulic means in the preferred apparatus, and the manufactured block remains on the timber pallet.
• the block and pallet are then removed and the blocks are stacked for curing.
• the blocks are allowed to cure by natural processes for about 14-21 days, during which time they are preferably covered with plastic and kept moist to slow hydration.
• the blocks can be cured by either low or high-pressure steam curing to reduce the curing time.
• the mobile plant 1 is preferably of dimensions which make it adaptable (i.e. when partly disassembled) to transport in a standard sized container.
• a preferred plant has dimensions of about 5.4 metres (length) x 2.2 metres (width) x 3.7 metres (height). Disassembled, it is possible to fit two such plants into a standard sized container.
• These blocks 17 are shown in Figs. 6, 10-12 and 18 designed with a projecting nib 18 at one end and an inverted nib 19 at the other. Some of these blocks are designed with an inverted nib 19 at each end as in Figs. 10 and 12. This allows horizontal tying to take place.
• the blocks are mostly of hollow construction with a rectangular hole or cavity 20 therethrough, but at the projecting end of the block a solid fill is inherent through which a vertical hole 21 of just over 10mm diameter passes. This is to allow vertical reinforcement to pass through while eliminating concrete filling of cores.
• the laid size of the preferred block of this embodiment is 400mm long x 200mm high x 150mm wide. 2. Corner Blocks Embodiments of corner blocks 22 are illustrated in Figs. 13, 14, 16 and 17. Although most embodiments are basically a hollow block they have provisions close to each nib to allow a steel bar to be passed through in the same manner as the stretcher.
• These blocks 23 are illustrated in Figs. 7, 8 and 9 and are designed in both 'male' and 'female' mode. These blocks are used at every opening and each has a rod passing through every block. The end of the block has a groove 24 which will allow the flashing nib at the side of the window to slide into it. The nib is held firm using a clip.
• the following dimensions for end blocks are given by way of example only: 400mm long x 200mm high x 150mm wide 200mm long x 200mm high x 150mm wide. 4. Beam Blocks
• Beam blocks 25 are illustrated in Figs. 19, 20, 21 and 25.
• Beam blocks are preferably "trough" blocks 26 and are used both below (Figs. 19-21) and above the wall (Fig. 25). They may also be used below any opening. They are designed to allow reinforcement steel to be laid into their trough and be concrete filled.
• the troughs 26 have performed holes to allow the passage of 10mm steel rod from below. The following dimensions of one embodiment are given by way of example only. 400mm long x 200mm high x 150mm wide 200mm long x 200mm high x 150mm wide.
• a trench 27 is excavated to expose sub strata 28 of even load bearing material.
• the trench bottom is levelled as accurately as possible and lined with damp-proof course plastic sheeting.
• Two 12mm reinforcement rods 30 are laid into the blocks trough spaced at a minimum about 40mm apart. Overlapping at joins should be a minimum of about 600mm and wired with 10 gauge wire.
• starter bars 31 are wired to these rods and left vertically protruding from the trough; see Figs. 19 and 21 .
• These starter bars are intended to provide the first section of a vertical tie rod 32 to tie together vertical courses of blocks forming the wall (as illustrated in Figs. 19 and 22-28), or to provide a tie from the wall 33 for the floor slab 34 (as illustrated in Fig. 20). They should therefore project sufficiently to allow them to be bent at right angles at the estimated floor height and to project into the floor slab a minimum of 300mm.
• the first course of stretchers 35 are laid on it (see Fig. 22).
• the stretchers have had inserted in the reinforcement hole a starting rod and concrete anchor.
• This starting rod is threaded and is of sufficient length to finish at least 300mm above the top of the beam block.
• Each starter block is individually levelled and is kept at equal level to its immediate blocks. The blocks are laid against a string line to ensure straightness.
• the reinforcement rods 31 are bent at right angles and a chip taken out of the side of the blocks (as at 40 in Fig. 20) to allow passage of the rods to proceed without affecting the level sitting of the block above.
• the blocks through which these reinforcement rods pass are concrete filled 41 when the floor slab 34 is being poured.
• the temporary tensioning is released and laying is continued as previously described.
• the blocks are stopped one course below and the beam blocks are laid in their stead.
• These beam blocks will have reinforcement rods laid in them and be concrete filled. Prior to the concrete filling however, tension will be applied to the rods as described below.
• the projecting rods 32 Upon completion of each day's laying the projecting rods 32 have a temporary tension applied to them to ensure overnight stability of the wall.
• a beam block 46 is laid around the wall, as in Fig. 25. Where openings are encountered, the beam block is allowed to pass over the opening by using temporary formwork.
• the beam blocks 46 have holes in their base which allow the rods 32 to pass through. It is necessary for sufficient rod to be available to allow it to project a minimum of 100m above the top of the beam block. Nuts and washers 47 are then run down the threaded rod until the bottom of the trough of the beam block is reached.
• each of these nuts are tightened using a socket spanner and applying maximum force permissable with a lever handle. Notwithstanding the fact that there is no mortar between the blocks, the blocks are rigidly held together to form the wall. A wall so formed is structurally a beam and is in fact very much stronger than a conventional masonry wall. If during the process of laying, the wall has tended to move out of line either vertically, or horizontally, this is corrected by tapping the blocks into position using a rubber mallet prior to the full tightening process.
• the floor is laid quite early in the construction process. There are a number of reasons for this:
• Reinforcement rods are then laid in a grid pattern.
• the rods are wired together at every intersection and the rods that line up with the starter bars are allowed to overlap these bars by a minimum of 300mm and are then firmly wired thereto.
• windows are specified as having fins at each side, then these are inserted during the construction of the wall. If, however, the windows do not have side nibs, these may be inserted in a later period in the manner recommended by the manufacturer. (e) DOORS
• Doors are installed in the normal manner of fixing jambs direct to the block openings.
• the jambs fully cover the groove in the end blocks.
• ROOF FRAMING At the commencement of the roof framing a wall plate (e.g. 100mm x 38mm) is run around the top of the walls 33, as shown at 50 in Fig. 26. At positions where the block threaded reinforcement rod 32 is projecting, the plate 50 is drilled to allow the rod to pass through. A nut and washer 51 is run down and tightened, this now ties the wall plate directly through to the foundation.
• a wall plate e.g. 100mm x 38mm
• Roof trusses 52 are preferred although conventional roofing can be constructed according to local requirements and/or specifications.
• Eaves are prepared for lining in the conventional manner.
• Fig. 27 is a cross-section through a vertical wall 33 of a single storey dwelling illustrating that the wall comprises a plurality of rows of blocks rigidly held between top and bottom beam blocks 26 and 46. Notwithstanding the fact that there is no mortar between the blocks, the blocks are rigidly held together to form the wall 33. A wall so formed is structurally a beam and is in fact very much stronger than a conventional masonry wall.
• Fig. 28 illustrates the principal of construction of the present invention when applied to a two storey building.
• the ground floor comprises a concrete raft or slab 53 which is rebated around its peripheral edge to provide a seat for the bottom beam or bond block 26 on a bed of mortar 54.
• the blocks are then laid in a plurality of rows to provide a mortarless wall as described above.
• an intermediate bond beam or beam block 55 is laid and the intermediate rows of blocks forming the external walls 33 are clamped between bond beam blocks 26 and 55.
• Galvanized steel saddles are attached to the inside edge of the intermediate bond beam to provide support for the first floor joists 57.
• first floor bond beam 55 The external walls of the second storey of the building are then built up from first floor bond beam 55 in the previously described manner, with the first floor bond beam being reinforced with steel rods and concrete filled for extra rigidity. Subsequent rows of blocks are threaded onto the vertically extending rods as previously described until the walls of the second storey reach the required height. This wall is held rigidly in place by the addition of the top beam block 46 in the manner as previously described. The plate 50 is then secured in position and the roof structure 52 is added.
• the building construction system of the present invention has the following advantages: 1. Elimination of filling a foundation trench with concrete. Trenches vary in width. The deeper one excavates by hand, the wider the trench. In conventional construction, the sides of the trench are used as formwork and therefore far more concrete than is useful is poured to cater for this.

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• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Ceramic Engineering (AREA)
• Mechanical Engineering (AREA)
• Dispersion Chemistry (AREA)
• Manufacturing & Machinery (AREA)
• Conveying And Assembling Of Building Elements In Situ (AREA)

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• 1985
  • 1985-06-07 BR BR8506822A patent/BR8506822A/pt unknown
  • 1985-06-07 AU AU44346/85A patent/AU4434685A/en not_active Abandoned
  • 1985-06-07 ZA ZA854349A patent/ZA854349B/xx unknown
  • 1985-06-07 EP EP19850902932 patent/EP0183805A4/fr active Pending
  • 1985-06-07 WO PCT/AU1985/000123 patent/WO1986000043A1/fr not_active Application Discontinuation

Patent Citations (3)

Non-Patent Citations (1)

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