EP0378437A2 - Verfahren zum Auftragen von Mörtel auf eine Formfläche - Google Patents

Verfahren zum Auftragen von Mörtel auf eine Formfläche Download PDF

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Publication number
EP0378437A2
EP0378437A2 EP90300376A EP90300376A EP0378437A2 EP 0378437 A2 EP0378437 A2 EP 0378437A2 EP 90300376 A EP90300376 A EP 90300376A EP 90300376 A EP90300376 A EP 90300376A EP 0378437 A2 EP0378437 A2 EP 0378437A2
Authority
EP
European Patent Office
Prior art keywords
nozzle
mould
mortar material
mortar
outlet
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP90300376A
Other languages
English (en)
French (fr)
Other versions
EP0378437B1 (de
EP0378437A3 (de
Inventor
Abdul Salam Abass Alwash
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
CON-TECH SERVICES Ltd
Original Assignee
CON-TECH SERVICES Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by CON-TECH SERVICES Ltd filed Critical CON-TECH SERVICES Ltd
Publication of EP0378437A2 publication Critical patent/EP0378437A2/de
Publication of EP0378437A3 publication Critical patent/EP0378437A3/de
Application granted granted Critical
Publication of EP0378437B1 publication Critical patent/EP0378437B1/de
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • 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
    • B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/08—Apparatus or processes for treating or working the shaped or preshaped articles for reshaping the surface, e.g. smoothing, roughening, corrugating, making screw-threads
    • B28B11/0818—Apparatus or processes for treating or working the shaped or preshaped articles for reshaping the surface, e.g. smoothing, roughening, corrugating, making screw-threads for roughening, profiling, corrugating
    • 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
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/30—Producing shaped prefabricated articles from the material by applying the material on to a core or other moulding surface to form a layer thereon
    • B28B1/32—Producing shaped prefabricated articles from the material by applying the material on to a core or other moulding surface to form a layer thereon by projecting, e.g. spraying
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F21/00—Implements for finishing work on buildings
    • E04F21/02—Implements for finishing work on buildings for applying plasticised masses to surfaces, e.g. plastering walls
    • E04F21/06—Implements for applying plaster, insulating material, or the like
    • E04F21/08—Mechanical implements
    • E04F21/12—Mechanical implements acting by gas pressure, e.g. steam pressure

Definitions

  • THE PRESENT INVENTION relates to a method of applying a mortar material to a surface, for example for purposes of masonry repair or restoration, or to a mould surface in the fabrication of a product simulating natural stone.
  • cement or concrete products for example in the form of building blocks or slabs, which simulate the appearance of natural stone, such as sandstone, by forcibly compacting a moist mixture of cement and finely divided aggregate, such as sand, into a mould, to cover the mould surface in a layer to which is generally applied a body of ordinary concrete mix as a backing material.
  • the concrete On setting of the compacted mixture the concrete provides the bulk of the product and affords a support for the moulded surface, defined by the compacted layer, once the product has been extracted from the mould.
  • the surface of the product exposed to view in the finished building or the like is the surface of the compacted layer which was in direct contact with the mould surface.
  • the close packing of the sand or other aggregate in the compacted layer reduces the size of the interstices between aggregate particles as compared with a conventional mortar or concrete, for example, so that the product has an appearance somewhat similar to natural sandstone, for example.
  • a method of applying a mortar material to a surface comprising spraying material in finely divided form onto said surface to adhere thereto.
  • mortar material as used herein is intended to refer to a mixture of water, cement and an aggregate, generally of a particle size corresponding with that of sand or shingle, although some larger particles may be incorporated in the mix.
  • the term “mortar material” used herein is not intended to imply that the material must be suitable for use as mortar between building bricks, for example and, indeed, the preferred consistency of the mortar material in carrying out the present invention is somewhat stiffer than would be considered ideal for brick-laying purposes.
  • apparatus for applying a mortar material to a surface comprising a gun comprising a chamber with an inlet to receive a mortar material into said chamber, pumping means for supplying mortar material to said chamber via said inlet, a nozzle providing an outlet from said chamber and a compressed gas pipe extending within said chamber from an inlet for compressed gas, and having an outlet within said chamber, in the region of said nozzle and directed towards said nozzle outlet, whereby mortar material from said chamber can flow past said pipe towards said nozzle outlet to be entrained by gas flowing at high speed from said conduit outlet towards and through said nozzle outlet, thereby to atomise the mortar material and propel it at high speed, in the form of a spray, from the nozzle.
  • items such as architectural cladding panels or stonework, fireplace surrounds or flagstones, of simulated natural stone such as limestone or sandstone are fabricated by spraying the mortar mixture into a mould to form the required product.
  • the product may in certain cases be reinforced by placing a reinforcing structure, such as a reinforcing framework of wire mesh and/or steel rod or wire, in the mould after spraying a first layer of the mixture over the mould surface and before spraying a subsequent layer or layers of the mixture into the mould over and around the reinforcing structure, to unite with the layer first applied.
  • a fibrous reinforcement may be incorporated in the mixture before or during spraying.
  • the product may be built up in the mould by alternately spraying layers of the mixture and applying reinforcement, until the desired thickness is built up.
  • the mixture is caused or allowed to set, after which the moulded product is removed from the mould.
  • the surface of the product which is to be exposed to view may then treated, for example by sand-blasting or chemically, to remove the cement laitance at the immediate surface and expose the natural colour and texture of the aggregate and give the desired stone-like finish.
  • products made in accordance with the invention whilst reproducing the appearance of the desired natural stone, can be made lighter and stronger than corresponding components of natural stone or corresponding known simulated stone products and can withstand substantial natural loads.
  • simulated stone products can be made, by methods embodying the invention, in more complicated shapes than is possible using conventional methods.
  • a mortar material (as herein defined) is pumped to a spray gun which is also supplied with compressed air to discharge, in a blast of air, the mortar material in a finely dispersed or "atomised” spray towards a surface to which the mortar material is to be applied, for example a mould surface or a surface of a piece of masonry which is to be repaired or restored.
  • the spray gun comprises a hollow cylindrical metal body 10 to which is connected, intermediate the ends of body 10, a mortar inlet pipe 12 whereby mortar can pass, via the pipe 12, into the interior of the body 10.
  • a hollow frusto-conical nozzle 14 which, at its forward end, remote from the body 10, carries a replaceable nipple 16 affording the spray outlet of the gun.
  • the interior of the nipple 16 is subjected, in use of the apparatus, to a "sand-blasting" effect which produces a fairly high rate of wear in the nipple.
  • the nipple is screw-threadedly fitted in a screw-threaded bore at the forward end of nozzle 14 so that the nipple 16 can readily be unscrewed when worn and replaced by a new nipple.
  • differently dimensioned nipples might be used for different mortar compositions or for different working conditions, for example.
  • the nozzle 14 is itself detachably secured to the body 10, for example, as shown in Figure 2, by inter-engaging screw-threads on the nozzle 14 and body 10, so that the nozzle 14 can simply be unscrewed from the body 10.
  • the nozzle 14 is equipped with outwardly projecting wings 15.
  • Extending coaxially within the body 10 is a rigid pipe 18, for compressed gas (normally compressed air), the pipe 18 extending from a plug 20 at the rear end of the body 10 and secured at its rear end in this plug 20.
  • the pipe 18 extends forwardly, through the interior of the body 10 into the interior of the conical nozzle 14 and terminates in a free end spaced just rearwardly of the nipple 16 and directed towards the nozzle outlet afforded by the latter so that there is defined between the conical interior surface of the nozzle 14 and the pipe 18 an annular space which becomes progressively narrower radially towards the nozzle outlet.
  • the air pipe 18 is connected, via the plug 20 and a manually operable air valve 26 with a compressed air line 25 extending from a compressor or other source of compressed air, the compressed air line being connected with the valve 26 via a quick release coupling.
  • the mortar inlet point 12 is connected, via a flexible delivery hose 28, with the outlet of a pump 30 driven by a motor 32.
  • the inlet of the pump 30 is connected, via a hose 34, with an outlet opening at the lower end of a storage hopper 36 for the mortar material.
  • the pump 30 is preferably a peristaltic pump in which a flexible hose connected with the inlet and outlet of the pump, is pinched by rollers at positions which move along the path along which the flexible pipe is extended, during operation of the pump, to propel the mortar material through the pump. It has been found that a pump of this type is able to pump a stiff mortar mix reliably over long periods and is easily maintained.
  • the lowermost part of the hopper 36 is in the form of a well or channel having the form of part of a cylinder with a horizontal axis and an agitator paddle 37 is rotated about said horizontal axis, in the bottom of the hopper 36, the vanes 39 of the paddle cooperating closely with the said well or channel to minimise the chance of mortar lodging and setting in "dead spaces".
  • the outlet connected with the hose 34 is disposed in the part-cylindrical well or channel.
  • a mortar mixer 41 Disposed directly above the hopper 36 is a mortar mixer 41 which has a lowermost part which is in the form of part of a cylinder with a horizontal axis.
  • the mixture 41 has an upper part defined by side walls 43 extending tangentially upwardly relative to the cylindrical surface of the lower part and terminating in edges of an upwardly open mouth through which the components of the mortar material may be introduced into the mixer.
  • Both the mixer 41 and the hopper 36 have the cross-sectional shape shown in Figure 6 throughout their lengths and have flat vertical end walls as shown in Figure 4.
  • a further paddle arrangement 45 is also disposed in the mixer and is rotatable about a horizontal axis which is also the axis of curvature of the cylindrical part of the bottom of the mixer 41, the vanes 46 of the paddle 45 being so dimensioned as to cooperate closely with the inner surface of the part-cylindrical portion of the mixer 41.
  • the hopper and mixer paddles 37, 45 have respective horizontal shafts which are journalled in the end walls of the hopper and mixer and extend through said end walls at one end of the apparatus to respective drive pulleys connected by a driving belt, for example a V-belt, or to respective drive sprockets connected by a roller chain.
  • the opposite end of the shaft of paddle 37 carries, outside the hopper 36, a further pulley which is driven, by way of a V-belt by a driving motor 50.
  • FIG. 7 illustrates in more detail the construction of the paddle arrangement 45 for the mixer. (Apart from dimensions, the paddle arrangement 32 for the hopper 36 is similar). As illustrated, the arrangement comprises four arms 45 a extending radially from the shaft at intervals therealong, and each carrying a respective vane 46.
  • the vanes 46 are generally flat, each extending in a plane inclined with respect to the rotary axis of the paddle so that the vane is, in effect, a part of a respective helix about the paddle axis.
  • the vanes 46 have arcuate outer edges to cooperate closely with the cylindrical portion of the mixer 41.
  • the pair of vanes nearer one end of the shaft are oppositely inclined to the pair nearer the other end of the shaft (i.e.
  • Each vane 46 is of composite construction comprising a backing plate 46 a welded to the respective arm 45 a and a sheet 46 b of flexible belting material sandwiched between the backing plate 46 a and a clamping plate 46 c bolted to the plate 46 a through the sheet 46 b .
  • the sheet 46 b like the plates 46 a and 46 c , has an arcuate outer edge but this edge of sheet 46 b projects outwardly beyond the plate 46 a and 46 c slightly for actual rubbing contact with the inner surface of the cylindrical part of the mixer 41.
  • the construction of the paddle 37 for the hopper 36 is similar, including the vane construction, and the belting sheets of the vanes 39 likewise make rubbing contact with the cylindrical inner surface of hopper 36.
  • the vanes 46 are omitted in Figure 3.
  • An opening is provided in the lowermost part of the mixer 41 and is closed by a hinged door 49 which can be opened when mixing of a batch of the mortar material has been completed, to allow the mixed batch to fall into the hopper 36.
  • the air compressor or other source of compressed air connected with the air pipe 18 is capable of maintaining a pressure of several atmospheres in the compressed air hose 25 with the valve 26 open and the gun in operation, so that a jet of air of substantial force and velocity emerges from the forward end of the pipe 18 to pass through the nipple 16.
  • the operation of the pump 30 ensures a steady flow of mortar material into the annular space within the body 10 around the pipe 18 so that there is a steady flow of mortar material through the frusto-conically narrowing annular space within the nozzle so that fresh mortar material is continuously flowing into the region of the air jet emerging from the pipe 18 to pass through the nipple 16 whereby such mortar material can be entrained by the jet and discharged, through the nipple 16, in a fine spray in which, by and large, the individual aggregate particles, each with a cement/water coating, are physically separate from the other such particles in the spray and travel with high velocity towards the surface to which the spray is directed impacting with the said surface with considerable force.
  • the surface of the material is provided to a great extent by the surfaces of the aggregate particles themselves and has far fewer and smaller pores than would be the case with a conventional mortar so that the product has more the appearance of a natural stone than of a product moulded or formed from concrete or cement.
  • the apparatus described allows the mortar material to be deposited, in densely compacted condition on sub­stantially any stable surface in a layer of desired thickness, for example in a layer as thin as 1/16" (1.5mm) in thickness and in any orientation, for example to a vertical surface or to a downwardly facing horizontal surface (i.e. inverted working).
  • novel pro­ducts in simulated stone or concrete can be readily manufactured by spraying the mortar material around the interiors of relatively complex moulds or in a layer of desired thickness over the exterior of a former.
  • the resulting products are strong so that whilst, as noted above, reinforcement may be utilised, such reinforcement is in many cases unnecessary.
  • the aggregate employed would generally be a natural aggregate such as sand or shingle, it will be appreciated that aggregates which are not naturally occurr­ing, for example finely divided ceramic particles or the like, for example pigmented materials, may be utilised to afford any desired effect.
EP90300376A 1989-01-13 1990-01-12 Verfahren zum Auftragen von Mörtel auf eine Formfläche Expired - Lifetime EP0378437B1 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB8900736 1989-01-13
GB898900736A GB8900736D0 (en) 1989-01-13 1989-01-13 Method of fabricating products simulating natural stone

Publications (3)

Publication Number Publication Date
EP0378437A2 true EP0378437A2 (de) 1990-07-18
EP0378437A3 EP0378437A3 (de) 1991-01-16
EP0378437B1 EP0378437B1 (de) 1994-05-18

Family

ID=10649980

Family Applications (1)

Application Number Title Priority Date Filing Date
EP90300376A Expired - Lifetime EP0378437B1 (de) 1989-01-13 1990-01-12 Verfahren zum Auftragen von Mörtel auf eine Formfläche

Country Status (4)

Country Link
EP (1) EP0378437B1 (de)
AT (1) ATE105904T1 (de)
DE (1) DE69008873T2 (de)
GB (1) GB8900736D0 (de)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2676020A1 (fr) * 1991-05-02 1992-11-06 Sogea Procede de fabrication d'un materiau de parement a base de mortier renforce par des fibres de verre.
US5467923A (en) * 1992-02-17 1995-11-21 Burian Gesellschaft M.B.H. & Co. Kg Method and device for the monolithic application of a thermal-insulation and/or fire-protection compound to a surface
EP0847808A1 (de) * 1996-12-10 1998-06-17 Deitermann Chemiewerk GmbH & Co. KG Spritzpistole zum Verteilen und Aufbringen von Massen mit einem hohen Anteil an Bitumen-Wasser-Emulsion
WO2017001734A1 (fr) * 2015-06-30 2017-01-05 Eurl Baumer Damien Système et procédé de projection de béton léger d'isolation
CN107724651A (zh) * 2017-10-10 2018-02-23 火星盛世机械制造有限公司 墙面砂浆打印多喷头装置及建筑墙面砂浆打印一体机器人

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10315956B2 (en) 2014-03-07 2019-06-11 StoneCoat of Texas, LLC Limestone masonry veneer, resurfacing and aesthetic overlay compositions, methods of making and methods of use

Citations (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2004465A (en) * 1930-02-26 1935-06-11 Walker Cement Products Inc Cement shingle
US3708124A (en) * 1968-06-07 1973-01-02 P Kellert Cement spray gun
GB1306793A (en) * 1971-02-05 1973-02-14 British Ceramic Res Ass Apparatus for blasting material such as a column of extruded material
FR2228364A5 (de) * 1973-05-04 1974-11-29 Ippolito Marceau
GB1489604A (en) * 1974-12-02 1977-10-26 Wilce B Moulding of channel sections
GB2011518A (en) * 1977-11-23 1979-07-11 Ibstock Building Products Ltd Cement guns
FR2421679A1 (fr) * 1978-04-06 1979-11-02 Lambert Ind Embout de projection pour materiau pateux
GB2145353A (en) * 1983-08-25 1985-03-27 Corrosion Systems Limited Spraying fibre reinforced cement
FR2577844A1 (fr) * 1985-02-26 1986-08-29 Gorget Jacques Procede de fabrication de pierres de taille reconstituees ayant l'aspect de pierres de recuperation et pierres ainsi obtenues
EP0200026A2 (de) * 1985-04-17 1986-11-05 Walter Dkfm Ing. Neumüller Pumpe
US4668451A (en) * 1985-05-09 1987-05-26 Langson Bruce K Process of making a full life size artificial rock formation from a natural rock formation surface

Patent Citations (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2004465A (en) * 1930-02-26 1935-06-11 Walker Cement Products Inc Cement shingle
US3708124A (en) * 1968-06-07 1973-01-02 P Kellert Cement spray gun
GB1306793A (en) * 1971-02-05 1973-02-14 British Ceramic Res Ass Apparatus for blasting material such as a column of extruded material
FR2228364A5 (de) * 1973-05-04 1974-11-29 Ippolito Marceau
GB1489604A (en) * 1974-12-02 1977-10-26 Wilce B Moulding of channel sections
GB2011518A (en) * 1977-11-23 1979-07-11 Ibstock Building Products Ltd Cement guns
FR2421679A1 (fr) * 1978-04-06 1979-11-02 Lambert Ind Embout de projection pour materiau pateux
GB2145353A (en) * 1983-08-25 1985-03-27 Corrosion Systems Limited Spraying fibre reinforced cement
FR2577844A1 (fr) * 1985-02-26 1986-08-29 Gorget Jacques Procede de fabrication de pierres de taille reconstituees ayant l'aspect de pierres de recuperation et pierres ainsi obtenues
EP0200026A2 (de) * 1985-04-17 1986-11-05 Walter Dkfm Ing. Neumüller Pumpe
US4668451A (en) * 1985-05-09 1987-05-26 Langson Bruce K Process of making a full life size artificial rock formation from a natural rock formation surface

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2676020A1 (fr) * 1991-05-02 1992-11-06 Sogea Procede de fabrication d'un materiau de parement a base de mortier renforce par des fibres de verre.
US5467923A (en) * 1992-02-17 1995-11-21 Burian Gesellschaft M.B.H. & Co. Kg Method and device for the monolithic application of a thermal-insulation and/or fire-protection compound to a surface
EP0847808A1 (de) * 1996-12-10 1998-06-17 Deitermann Chemiewerk GmbH & Co. KG Spritzpistole zum Verteilen und Aufbringen von Massen mit einem hohen Anteil an Bitumen-Wasser-Emulsion
WO2017001734A1 (fr) * 2015-06-30 2017-01-05 Eurl Baumer Damien Système et procédé de projection de béton léger d'isolation
FR3038331A1 (fr) * 2015-06-30 2017-01-06 Eurl Baumer Damien Systeme et procede de projection de beton leger d'isolation
US11040463B2 (en) 2015-06-30 2021-06-22 Eurl Baumer Damien System and method for spraying lightweight insulating concrete
CN107724651A (zh) * 2017-10-10 2018-02-23 火星盛世机械制造有限公司 墙面砂浆打印多喷头装置及建筑墙面砂浆打印一体机器人

Also Published As

Publication number Publication date
DE69008873T2 (de) 1995-01-05
EP0378437B1 (de) 1994-05-18
ATE105904T1 (de) 1994-06-15
EP0378437A3 (de) 1991-01-16
GB8900736D0 (en) 1989-03-08
DE69008873D1 (de) 1994-06-23

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