EP0378217B1 - Brick with vertical hollow passages and method of erecting a sound insulation wall - Google Patents

Abstract

In order to provide a completely novel concept for a sound insulation wall and sound insulation block, permitting economical manufacture of sound insulation masonry blocks made of brick in a block size which is economical and competitive as regards laying, according to the invention the sound insulation brick is constructed in large size in the manner of a shuttering block and is equipped with at least four rows (6, 7, 8), arranged one behind the other in the longitudinal direction of the sound insulation brick, of vertically extending filling channels (5). In this arrangement, each row has at least two filling channels (5), each filling channel being square or rectangular in cross-section. To obtain the apparent density necessary for sound insulation, the filling channels are filled with mortar during the laying process. <IMAGE>

Description

The present invention relates to a perforated brick and a method for creating a soundproof wall.

So far, noise protection walls have been manufactured with small or medium-sized perforated bricks.

Both small and medium-sized perforated bricks have the disadvantage that they have to be made from a clay with a very high body density. If clay with a low cullet density is used, the soundproof walls made from such small or medium-sized perforated bricks do not meet the stricter values of at least 53 db required in the new DIN 4109 (Soundproofing in Building Construction; Issue 89).

Clay with a high cullet density is not available in every brickworks and therefore has to be transported in many cases, which incurs transport costs that increase the basic material price for such bricks. In the production of small and medium format Perforated bricks also have very high drying and fire times, which requires a relatively high amount of energy and, as a result, leads to relatively high energy costs.

Soundproof walls made of small or medium-sized bricks are therefore not competitive in terms of material and manufacturing costs for the bricks compared to soundproof walls made of concrete, sand-lime brick or the like. This cost ratio, which is already unfavorable with regard to the material and manufacturing costs of the bricks, becomes even more unfavorable when taking into account the construction costs for such brick walls. In such brick walls, the bearing and butt joint lengths are system-dependent, for example relatively large compared to walls made of sand-lime brick. In the cost calculation, therefore, a wage expenditure of about 6.5 hours per m³ for small-format bricks to erect the walls and a wage expenditure of about 4.5 to 5 hours per m³ for medium-format bricks.

In order to reduce the construction costs, at least the height of the bricks would have to be increased and in this way the length of the bearing and butt joints would have to be reduced. Such an enlargement of the brick dimensions is, however, not feasible in practice, since it is impossible to produce cracks due to the shrinking phenomena during the drying process. The drying and fire times required for such large-format bricks would also lead to a further increase in the energy costs that are already very high for medium-sized bricks. In addition, the recommendations of the employer's liability insurance association and the labor inspectorate, which are applicable for the relocation of large-format bricks, have a maximum weight of 25 kg prescribe, are no longer adhered to. The increase in the size of medium-sized bricks to large format is therefore ruled out.

The object of the present invention is to provide a completely new type of soundproofing wall and soundproofing stone concept which enables economical production of soundproofing masonry blocks from brick material in a stone size that is economical and competitive for laying.

This object is achieved by a perforated brick with the features of claim 1.

Thanks to the features according to the invention, a completely new wall and brick concept for soundproof walls, in particular for interior walls and apartment partitions in apartment buildings, has been created for the first time.

For example, perforated bricks of the type according to the invention have a comparatively low proportion of brick due to their design as large-sized formwork blocks and the special arrangement of the filling channels. The material costs and the costs for the production of the bricks, including the energy costs for the firing and drying, are therefore very low.

By filling the filling channels with mortar, the wall made with bricks according to the invention only receives the bulk density required for the soundproofing behavior on the spot. Since the required bulk density is mainly due to the mortar filling, i.e. is achieved with relatively cheap, non-combustible material, the material costs of a wall according to the invention per unit volume are lower than for soundproof walls made of small-sized soundproofing bricks.

Due to the backfilling with mortar on the spot, there are lower freight costs for the transport of the bricks according to the invention due to the comparatively low transport weight. Small-format soundproofing bricks with a bulk density of 1.8 have a transport weight per m³ of 1,800 kg, while for large-format bricks of the type according to the invention only 830 kg have to be estimated per m³.

The low individual weight of large-format bricks according to the invention of a maximum of 16 kg simplifies moving and is far below the maximum weight of 25 kg recommended by the professional association and the trade inspectorate.

Due to the large-format design, there is automatically a reduction in the length of the bearing and butt joints, which can save considerable wage costs compared to small and medium-sized soundproofing tiles of the known type.

Due to the special formwork block design, only the walls and webs of the brick take on the supporting function.

If the outer walls of a building are also made of bricks, there are also no different physical changes in shape, so that there is no risk of cracking in such cases, as is practically unavoidable in the case of mixed masonry.

Due to the design according to the invention as a large-sized formwork block with a special arrangement of vertically extending filling channels, it is possible to fill a brick layer in one operation and to open the bed joint. Conventional mortar slides are particularly suitable for the simultaneous filling and opening of the bed joint.

To create a soundproofing wall according to the invention, such perforated bricks are suitable in which a total of five rows of filling channels are provided, the middle row and the respective rows on the end faces each having three filling channels, and the two rows lying between these rows each having two filling channels.

A particularly advantageous embodiment is achieved in perforated bricks according to the invention when the rows of filling channels are arranged symmetrically over the length of the brick and the webs between the filling channels have a thickness that corresponds approximately to the thickness of the side and end walls of the brick. Such an arrangement has a favorable effect both statically and during the filling process, for example by means of a mortar slide. Such an embodiment during production also has the advantage that the molds are relatively easy to manufacture and the fire is completely unproblematic because of the relatively large cross section of the filling channels. About that In addition, the dimensional accuracy of such bricks is very good and the blank stability due to the high web portion in the fresh state is relatively high.

In terms of statics and in connection with the filling process, it is also advantageous if the soundproofing tiles are equipped with filling channels which, measured in the longitudinal direction of the tile, each have the same width.

In principle, the toothing in the area of the end faces of the bricks according to the invention can be designed in different ways. However, it is advantageous for the installation and the soundproofing behavior if the toothed end faces are each equipped with four trapezoidal and vertical teeth.

For the adhesion of plaster and other layers, it is also advantageous if the soundproofing brick has structured side surfaces. With a wall thickness of 24 cm with a plaster layer on both sides, a soundproofing wall according to the invention meets the DIN requirements for a fire wall.

• a. daß eine erste untere Reihe von Ziegeln in eine Mörtelschicht eingebettet wird und die Zwischenräume zwischen den benachbarten Ziegeln mit einer Mörtelschicht ausgefüllt werden,
• b. daß im Anschluß daran die Füllkanäle der ersten Ziegelreihe mit Mörtel vollständig gefüllt und auf die ebene obere Auflagerfläche der ersten unteren Reihe von Ziegeln eine Mörtelschicht als Lagerfuge aufgezogen wird,
• c. daß dann eine weitere Reihe von Ziegeln auf die erste Reihe jeweils um eine halbe Ziegellänge versetzt aufgesetzt und in die Mörtelschicht der Lagerfuge eingebettet wird und die Zwischenräume zwischen den benachbarten Ziegeln mit einer Mörtelschicht ausgefüllt werden,
• d. daß im Anschluß daran die Füllkanäle der weiteren Ziegelreihe mit Mörtel gefüllt und auf die ebene obere Auflagerfläche der weiteren Reihe von Ziegeln eine Mörtelschicht als Lagerfuge aufgezogen wird,
• e. daß dann die Verfahrensschritte c. und d. so lange wiederholt werden, bis die Schallschutzwand in ihrer vorgegebenen Höhe fertiggestellt ist.

An advantageous method for creating a soundproofing wall according to the invention using large-format bricks according to the invention is characterized in that

• a. that a first lower row of bricks is embedded in a layer of mortar and the spaces between the adjacent bricks are filled with a layer of mortar,
• b. that the filling channels of the first row of bricks are then completely filled with mortar and a layer of mortar is laid as a bed joint on the flat upper support surface of the first lower row of bricks,
• c. that another row of bricks is then placed on the first row, offset by half a brick length, and embedded in the mortar layer of the bed joint, and the spaces between the adjacent bricks are filled with a mortar layer,
• d. that the filling channels of the further row of bricks are subsequently filled with mortar and a layer of mortar is laid as a bed joint on the flat upper support surface of the further row of bricks,
• e. that then the process steps c. and d. be repeated until the soundproof wall is completed at its predetermined height.

Large-format bricks made of bricks with toothed end faces and vertically running channels are basically already known (see DE-A 3400907 and DE-U 8504737.6). However, such bricks are already filled with insulating material, such as synthetic foam or other insulating materials, such as inflated lime-cement mixture, during the manufacture, and are used exclusively for external masonry with improved thermal insulation.

In addition, large-format bricks made of brick or other materials are known (see DE-A 2719860 and DE-B 2739409). These known bricks are also designed exclusively for exterior walls and each have vertically extending cavities next to each other, some of which are made of heavier materials, such as Sand, mortar or the like may be filled in, but some may not be filled in for thermal insulation. However, the arrangement of different cavity systems, some of which are to be filled and some of which may not be filled, leads to a relatively complex procedure when creating a wall. Such bricks are also used exclusively for external walls.

DE-A-27 19 860 discloses a brick, in particular a brick, having a plurality of cavities extending from a first surface side of the stone to an opposite second surface side, the first cavities of smaller cross section adjacent to an edge line of the surface sides and at least one removed from this edge line lying second cavity are arranged with a larger cross section.

The document shows that it is possible to fill the cavities with concrete or with mortar or with sand to produce sound-absorbing walls.

Furthermore, it is known that this heat-insulating material is either introduced into the second cavity or into the second cavities during the manufacture of the brick according to the invention, or only when the stone is processed, mineral fibers, slag, ash being used to fill the cavities. Pumice hard stone or foamed plastic are suitable, according to which this publication discloses that filling the cavities with mortar during the processing of the stone is not advantageous and desirable.

The brick known from this publication does not have the size of a multiple of a normal-sized brick.

Fig. 1

zeigt in einer perspektivischen Ansicht den prinzipiellen Aufbau eines erfindungsgemäßen Schallschutzziegels,

Fig. 2

zeigt eine mit einem Schallschutzziegel gemäß Fig. 1 erstellte Schallschutzwand mit Eckverband, und

Fig. 3

zeigt einen Schnitt in der Ebene III-III der Fig. 2.

In the following a preferred embodiment of a large-format soundproofing brick according to the invention and a soundproofing wall according to the invention created with such bricks is described and explained in more detail with reference to the accompanying drawings for further explanation and for a better understanding of the invention.

Fig. 1

shows in a perspective view the basic structure of a soundproofing brick according to the invention,

Fig. 2

shows a soundproofing wall created with a soundproofing brick according to FIG. 1 with corner bandage, and

Fig. 3

shows a section in the plane III-III of FIG. 2nd

As can be seen from FIG. 1, the large-format soundproofing brick according to the invention is in principle constructed in the manner of a formwork block. It has two toothed end faces 1, each of which is equipped with four vertically extending teeth 2 with a trapezoidal cross section. The upper and lower bearing surfaces 3 and 4 (only the upper bearing surface 3 can be seen in FIG. 1) are flat.

In the preferred embodiment shown, five rows of filling channels 5 are provided one behind the other, viewed in the longitudinal direction of the brick. The middle Row 6 and the respective front rows 7 each have three filling channels 5. The rows 8 lying between rows 6 and 7 are each equipped with two filling channels 5.

In the present exemplary embodiment, the rows 6, 7 and 8 — viewed over the length of the brick — are each arranged symmetrically and each have the same width. This results in the filling channel arrangement shown in FIG. 1, in which the filling channels of the rows 6 and 7 each have a square cross section and the filling channels of the rows 8 each have a rectangular cross section. The webs 13 between the filling channels are dimensioned such that their thickness corresponds approximately to the thickness of the side walls 9 and the end walls 14 (without teeth 2).

In the exemplary embodiment shown, the side walls 9 are also structured by vertically running grooves 10 which are semicircular in cross section.

Fig. 2 shows a corner tape made with soundproofing tiles of the type according to the invention. The bed joint 15 between the adjacent bearing surfaces 3 and 4 is completely filled. In the corner area, the inner two of the overall vertically extending teeth 2 are knocked out with the mason hammer at the connecting tile 11, which runs at 90 ° to the corner tile, whereby a mortar pocket 12 is created which can be filled with the trowel without difficulty.

When building a wall, one layer is completely filled with mortar and the bedding mortar is applied before the next layer is put on. As can be seen from Fig. 3, the bottom two layers are already filled with mortar, while the upper layer still has to be filled.

Due to the special arrangement of the filler channels 5 shown in FIG. 1, in which three square filler channels in one row each connect to two rectangular filler channels in the adjacent row, a web constellation results in a cut in the plane III-III in the wall, as shown in FIG Fig. 3 is shown.

Claims (7)

1. Vertically perforated brick of the size of a multiple of a wall brick of normal format, with plane lower and upper bearing surfaces (3, 4) as well as end faces (1) comprising denticulations and with through-channels (5) which are open before installation of the wall brick and which have a rectangular cross-section of such a size that a mortar applied to the upper bearing surface on installation of the wall brick can flow into the channels and completely fill them, wherein five rows (6, 7, 8) of channels (5) are provided in the longitudinal direction of the wall brick, wherein the middle row (6) and the end rows (7) each have three channels (5) having a square cross-section and the rows (8) located between these rows (6, 7) each have exactly two channels (5) having a non-square rectangular cross-section and the webs of the side walls (9) have a constant thickness over the whole length of the wall brick and wherein the channels (5) designed as filling channels as measured in the longitudinal direction of the vertically perforated brick each have the same width.
2. Vertically perforated brick according to claim 1, characterised in that the rows (6, 7, 8) of filling channels (5) are arranged symmetrically over the length of the brick.
3. Vertically perforated brick according to claim 1 or 2, characterised in that the brick is provided with webs (13) between the filling channels (5), of which the thickness roughly corresponds to the thickness of the side walls (9) and the end walls of the brick.
4. Vertically perforated brick according to claim 1, characterised in that the end faces (1) are provided with in each case four trapezoidally shaped and vertically extending teeth.
5. Vertically perforated brick according to claim 1, characterised in that it comprises structured side faces (9).
6. Method for the manufacture of a sound insulating wall using vertically perforated bricks according to claims 1 to 5, characterised

   a) in that a first lower row of vertically perforated bricks are embedded in a mortar layer and the gaps between the adjacent vertically perforated bricks are filled with a mortar layer,

   b) in that subsequently the filling channels of the first row of vertically perforated bricks are completely filled with mortar and a mortar layer is applied as a coursing joint to the plane upper bearing surface of this first row of vertically perforated bricks,

   c) and in that then a further row of vertically perforated bricks are placed on the first row in each case offset by half a brick length and embedded in the mortar layer of the coursing joint and the gaps between the adjacent vertically perforated bricks are filled with a mortar layer,

   d) in that subsequently the filling channels of the further row of vertically perforated bricks are filled with mortar and a mortar layer is applied as a coursing joint to the plane upper bearing surface of the further row of vertically perforated bricks,

   e) in that then steps c) and d) are repeated until the sound insulating wall is finished in its predetermined height.
7. Method according to claim 6, characterised in that filling of the filling channels and application of the coursing joint take place by means of a mortar board.

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