EP1183431A1 - Method and apparatus for distributing mortar - Google Patents

Abstract

The present invention relates to a method and an apparatus for distributing mortar or the like binding material mix in connection with masonry work. Said binding material mix is held in a hopper (1) suspended above the workplace. From the hopper said mix is first induced by forced action conveyor means (2, 3) to move in a controlled manner essentially horizontally to above a distribution point. The mix is thereafter induced to flow, via distribution means comprising a flexible free fall portion (10, 10a) and material mix spreading means (11) arranged at said distribution means, down to the final destination (17) of the work.

Description

Method and apparatus for distributing mortar

The present invention relates to a method for distributing mortar or the like binding material in connection with masonry, as well as to a distributing apparatus for such a material .

For ages bricks and the like masonry pieces have been attached one upon and adjacent to the other using a layer of binding material arranged between the pieces, i.e. most usually a mortar based on sand, lime and nowadays also cement . Today different kinds of additives are also usually mixed into the mortar in order to make the material mix more plastic, for accelerating or decelerating the chemical reaction or in order to achieve other desired properties. While mortar earlier always was produced on site, the production can nowadays also been transferred to more or less industrial premises where a uniform quality and desired properties can easily be achieved and controlled.

In brick masonry work performed on a building site the labour methods, however, still follow the ancient principle, i.e. a mortar layer is spread on an underlying brick layer using hand tools, usually a trowel. In order to fill the vertical seam between adjacent bricks the outermost brick is either pushed in a horizontal direction so that mortar builds up against the previous brick, or mortar is dashed with the trowel against the end face of the brick. In this manner masonry work has been done for thousands of years, and until now no more effective method for on site masonry work has been found. The partial transferal of the production of mortar from the work site to another location has not, as such, changed the working methods with respect to the actual masonry work. This is true also for such working sites where the mortar is delivered e.g. from a truck by pumping directly up to the upper floors. Especially for laying blocks of lightweight aggregate concrete or the like relatively big masonry pieces having good thermal insulation properties the custom practice is such that mortar for binding the pieces is spread as two parallel strips between which there should remain an air cavity which functions as a heat insulation in the mortar. This structure causes new problems since the spreading of mortar as two strips is considerably more difficult than covering with mortar the whole upper surface of the wall . For this purpose a mortar sledge has earlier been developed, said sledge comprising a mortar tray which is pulled along the uppermost brick layer, said tray having two parallel outlet openings. Such a tray draws about ten liters of mortar after which it must always be refilled. This refilling is usually done with manual means also in such cases, where the mortar is supplied to the site by pumping, since employing a pump for pumping the small mortar quantities used at a time is clearly uneconomical .

A mortar sledge full of mortar is a rather heavy structure and thus positioning guides are arranged to extend from the sides of the sledge downwards at both sides of the wall. These guides, however, prevent the sledge from proceeding when it reaches crossings or corners of the wall. At such locations the sledge is normally lifted over the obstruction, in which cases mortar will flow freely also to such places where it either will be wasted or will constitute an undesirable cold bridge between said mortar strips. Thus, especially for complicated structures like cellars or structures with a wide variety of shapes, which structures are favored today, the utility of such a sledge is very limited. Also for straight wall portions the use of a traditional mortar sledge will sometime quite seriously mess up the alignment wires arranged for the alignment of the wall .

Thus, in most cases the brick laying work in practice will be performed at each work site in exactly the same manner as it has been done since long ago, i.e. it includes a considerable amount of manual work, which slows down the brick laying work and increases the costs . In order to eliminate these problems the method and the arrangement according to the present application for distributing mortar or the like has been invented. The characteristics of the invention are evident from the appended claims. Thus, the method according to the present invention is characterized in that the binding material mix is held in a container which is suspended above the object of labour, from which container the material mix is induced first by forced action conveying means to move in a controlled manner in an essentially horizontal direction to a location above a distribution point and thereafter to flow, via distributing means comprising a portion of flexible free fall, down to the final destination for use. The inventive apparatus, on the other hand, is characterized in that the apparatus comprises a container for material mix positioned generally above the object of labour, the outlet end of said container having power-operated essentially horizontal primary screw conveyor means arranged for conveying the mix, the opposite end of said conveyor means being provided with distribution means comprising a flexible portion of essentially free fall.

The invention will hereafter be described with reference to some favorable embodiments thereof as well as to the appended drawings, wherein

Figure 1 discloses a general arrangement in accordance with the present invention,

Figure la in a partial blow-up discloses the general arrangement of Figure 1 in accordance with a special embodiment,

Figure 2 discloses a partial blow-up of Figure 1 at the location of said distributing means, Figure 3 discloses the positioning of a distributing head in accordance with the inventive arrangement at a corner of a wall structure, and

Figure 4 discloses a press means developed especially for filling the vertical seam between blocks, the end of said press means further being disclosed i Figure 4a seen from the end thereof.

A central portion of the arrangement according to Figure 1 comprises a mortar hopper 1 of suitably 200 to 500 liters, said hopper favorably being relatively high in relation to the base area. The adhesion of mortar to the vertical hopper walls will be insignificant and, thus, the cleaning easy. At the suitably open outlet, i.e. the lower end la of the hopper or vessel a favorably essentially closed conveyor tube 3 is arranged, said tube containing a worm conveyor 2 (shown in phantom) . A motor 5 known per se rotates said worm conveyor 2 suitably via a transmission 4. In the embodiment disclosed said motor 5 is an electrical motor which favorably obtains its power from a combustion engine driven electrical generator 6 which, as such, can be commercially obtained and adapted in a favorably fixed manner in connection with the arrangement. For the control of the speed of the worm conveyor 2 and, thus, its output, into exact conformity with that required the arrangement favorably comprises a speed control apparatus 7 known per se for controlling the rotational speed of said motor 5 favorably steplessly in a manner which will be closer described below.

As such, the exact rotation of the worm conveyor can be effected also in other ways, but the described combustion motor driven arrangement defines a separate functional entity which is independent of external power. The inventive apparatus will mainly be used outdoors and thus the use of a combustion engine will constitute no essential inconvenience in relation to the advantage obtained. For indoors use this arrangement can be replaced with, e.g., a hydraulic power feed using vegetable oil, which arrangement, however, requires separate feeding lines (not shown) . In outdoor premises also combustion engine driven hydraulics may be appropriate.

In accordance with the present invention the arrangement disclosed above is suspended above the object of labour so that sufficient working space will be provided under the arrangement. In practice this suspension can be effected as disclosed in Figure 1 so that lifting wires 9 or the like extend from the lifting eye 8 of a crane (not shown) to different portions of the arrangement so that the arrangement will remain essentially in balance. Since said mortar hopper 1 represents the heaviest weight of the arrangement it will be located fairly close to the vertical equilibrium axis, and thus the emptying of the hopper will not have any considerable influence on the balance of the apparatus. When the hopper is full the total weight of the apparatus will favorably be in the order of 1200 to 1500 kilograms and thus the work site crane or a lighter lifting arrangement adapted for this special purpose can be used for the suspension of the arrangement. Such a lighter arrangement may even include a lifting fork or the like of a forklift truck.

According to the present invention the opposite end of the worm conveyor, with respect to the mortar hopper 1, is connected to mortar distribution means generally referred to as 11, said distribution means including flexible portions 10, 10a. Said flexible portions 10, 10a are formed of hose like portions whose lower ends are connected, favorably via fast coupling means 12, to mortar spreading or distribution means 11. According to the preferred embodiment disclosed in Figure 1 said distribution means 11 comprise distribution tubes 14, which tubes suitably comprise closing devices 13. Said tubes are favorably adjustably interconnected in a favorably mutually parallel disposition. The lower ends, respectively, of said distribution tubes 14 are suitably open at least backwards in relation to said distribution mean's 11 direction of movement, leading into an open spreading slide means or spreading shoe 15. During use this spreading shoe 15 rests upon the uppermost layer of blocks already laid so that said shoe behind itself can form a strip 18 of mortar which extends in the mortar groove 17 of the uppermost block 16 and up to a suitable level above said groove, which strip 18 suitably extends continuously in the longitudinal direction. Between parallel mortar strips 18 remains a mortar-free zone 19, which in accordance with Figure 3 will be located at the insulation portion 20 found at least in blocks of larger width. Said spreading shoe 15 itself constitutes, in the embodiments disclosed in the drawings, an essentially straight flute- like piece, but in another embodiment of the present invention said spreading shoe 15 comprises a swing-like lower portion (not shown) so that, by tilting the spreading head 11, mortar strips 18 with different exactly controlled thicknesses can be achieved to suit the conditions of the object of the work.

The parallel spreading means disclosed in Figures 1, 2 and 3 are interconnected by a suitably adjustable intermediate piece 21, at which a control lever for said closing means 13 and/or actuating means (not shown) for controlling the stepless speed regulator 7 for the driving machinery 5 for said worm conveyor 2 is arranged so that the user can use them during the progress of the work.

Functionally the startup of the arrangement is commenced by filling the hopper 1 with mortar favorably industrially made using concrete transport equipment . After this the apparatus suitably operates so that a person who performs the actual bricklaying, at a suitable starting point, brings said spreading shoes 15 of said parallel spreading means 11 upon the mortar grooves 17 of the uppermost layer of blocks 16. The driving motor for said worm conveyor 2 is started at a speed which transports, from said hopper 1, so much mortar per time unit as one assumes will be spread in the form of mortar strips 18 on the upper surface of said blocks 16. In practice the rotational speed is adjusted to suite the progress of the masonry work, typically about 20 to 100 liters per minute.

Said worm conveyor 2 presses mortar mix to the end 3a of said conveyor tube 3, which is opposite to said hopper 1. At said end 3a the outlet drop portion 22 is open downwards. At said outlet drop portion 22 the material ' s direction of travel changes to be essentially vertical, i.e. the mix will flow downwards by its own weight simultaneously leaving the conveyor tube 3. In order to make this possible, the mix must meet certain plasticity conditions which can easily be achieved in the industrial production of mortar. According to Figure 1 the first outlet drop portion 22 suitably extends downwards in the shape of a drop tube 24 which favorably is attached using fast coupling means 23 for facilitating detachment and thus the cleaning of the apparatus. The drop portion 22 ends in a choking chamber 26 which also is attached using fast coupling means 25. A dividing knife 27 is favorably located in said choking chamber 26 shown in phantom in the drawing. Said dividing knife distributes the downwards sinking mix in a desired way, i.e. usually in equal amounts to the parallel hoses 10, 10a acting as said flexible portions. In some cases a secondary power driven worm conveyor (not shown) is arranged in said drop tube 24 for forcing the mix downwards, but in most case such an arrangement is unnecessary. In practice it has turned out that expressly the free dropping portion constituted by said drop tube 24 when having a length of 0.2 to 1.0 meters, favorably about 0.5 meters, provides an especially suitable feeding pressure equalization with respect to the smooth function of said spreading shoes 15.

According to one embodiment of the present invention said drop tube 24 is arranged so that it comprises a portion made of, e.g., rubber or the like material, which portion slightly expands under the impact of the pressure. A pressure sensor or a dynamic proximity switch (not shown) is arranged at said portion for controlling the rotational speed of said motor 5. By using such a structure a nearly fully automatic feeding arrangement can achieved, wherein the mix feed via said worm conveyor 2 automatically is adjusted .to the mix distributing rate. According to another inventive embodiment disclosed in more detail in Figure la said drop tube 24 comprises a substantially expanded portion 24a, in which case the mix fed by said conveyor 2 at least to some extent will totally detach from the walls of said drop tube 24 and by its own weight in an essentially frictionless manner freely drop down to said dividing knife 27.

In practice it has been observed that said worm- or screw conveyor 2, as such, by its own action improves the quality of the mortar and prevents an internal separation of its different components . For the same reason the transport of the mortar using, e.g., a vibrator known per se in the profession is rather inappropriate since a vibration expressly causes such a separation, whereas the use of a vibrator in connection with the mix hopper itself might be appropriate especially in such embodiments which do not comprise a combustion motor driven electrical generator which, as such, in a way functions as a discreet vibrator.

By the use of an arrangement in a accordance with the present invention the masonry work will becom considerably faster. By feeding the mortar down from above and directly to the object of the bricklaying and distributing the mix there, any kind of unnecessary handling of mortar is avoided, which reduces the requirement of labour. Thus a typical working team comprises three persons, of which one essentially continuously will spread mortar while the two other persons lay blocks upon the spread mortar. The conventional three week bricklaying time needed for erecting a typical cellar in a building can be effected in three days. In practice it has turned out that one restricting factor in masonry work actually will be the time needed for raising scaffolding on the worksite so that the masonry team is able to work standing on said scaffolds.

In addition to the actual timesaving, the faster work performance reduces the weather dependence, and generally no mason's tents are needed even in the winter, since mortar can be ordered, also in large quantities, from the factory in a better weatherproof quality without the risk of premature hardening. Simultaneously, the mortar ordered from the factory will be more uniform to its other qualities. No external electric power nor pressurized water for mortar mixers will be required on the work site. Also for washing the arrangement's own inherent electrical generator will provide electrical power for a pressure washer and the washer produces its own pressure. The fact that the invention, in practice, will require the use of a hoisting means will lower the barrier for obtaining a crane to the working site, which in most cases will bring about also other savings. Thus, the hoisting equipment necessary for the present invention will improve other functions at the work site in an indirect manner.

One further advantage provided by the present invention is the fact that there is no special need to handle or breath mortar or any of its constituents, which clearly reduces any allergic or other harmful impacts . The work is also in other ways lighter and thus less exhausting. Simultaneously, the mortar waste rate is considerably lower compared to traditional masonry work. For understanding this one should study Figure 3 disclosing a corner portion of a wall. At such a location a traditional mortar sledge must be lifted up from the wall, after which the sledge must be turned onto the next wall. At the actual corner spot there will then remain an area without mortar spread on the correct spots, while, on the other hand, waste mortar usually will spill during the whole lifting procedure. From Figure 3, on the other hand, it will be evident that the distribution of mortar with the inventive apparatus can be continued the whole way round without any waste of mortar. If necessary, the output of mortar can momentarily be slowed down by changing the control of the worm conveyor, or, alternatively, entirely stopped if closing means 13 are arranged in the spreading apparatus 11 in accordance with the disclosed embodiment. Figure 3 discloses a spreading arrangement adapted for a right-handed person, in which case the brick- laying work will proceed in a clockwise direction.

Finally, Figure 4 discloses a special adaptation of the general concept in accordance with the present invention, which arrangement is intended especially for filling the vertical seams between the blocks 16. This arrangement comprises a distribution means which differs from the ones described earlier, i.e. a nozzle end 29 including an actively working press device. Due to a fast connecting means 13 this arrangement can be attached to the end of one of said flexible hoses 10, 10a, (the other hose comprising a similar device at the opposite side of the wall, or, alternatively, a cap plug during this stage of operation.) Said active nozzle end comprises a worm conveyor 31 which is rotated by a accumulator powered drill gun 30. In a feeder tube 32 said worm conveyor feeds mortar mix emerging from said hose 10 directly into the vertical slit 28 between the blocks or other masonry pieces 16 via a nozzle having, at one end thereof, a flat nozzle opening 33 which is arranged favorably turnably at the end of said tube 32.

One considerable advantage with the arrangement according to the present invention is the independence of any external factors, which is an appreciated quality especially at small building worksites. This, however, does not imply that the general arrangement according to the present invention cannot be adapted also at such destinations where mortar, concrete and other material is supplied in a manner which is comparable to industrial production, i.e. by pumps and other conveyors and, at least momentarily, essentially continuously. Thus, the general arrangement according to the present invention can also be utilized, with certain modifications, in connection with pumping trucks or the like heavy equipment known per se .

Although the present invention has been disclosed above mainly with reference to bricklaying procedures using larger blocks, it should be understood that it can be utilized, as such or with minor modifications, also for other kinds of masonry. Thus, a traditional facade masonry has, until now, presented problems, since one functional provision for a facade brick wall is an open and well functioning air slit between the facade wall and the structure therebehind. A traditionally implemented facade brick laying easily brings about excess mortar which will fall down to the bottom of the air slit and thus ruins the ventilation. Contrary to this, the arrangement according to the present invention and a special adaptation thereof can achieve an extremely exact and, in practice, completely controlled use of mortar which prevents waste mortar from filling the air slit.

Above some favorable embodiments of the present invention have been disclosed. It should, however, be clear that the present invention can be implemented also in many other ways within the scope of the appended claims.

Claims

Claims

1. A method for distributing mortar or the like binding material mix in connection with bricklaying work, c h a r a c - t e r i z e d in that said binding material mix is held in a hopper (1) suspended over the place of work, from which hopper said mix is induced first to be transferred in a controlled manner by forced action conveyor means (2, 3) essentially horizontally to a position over a distribution point and, thereafter, to flow down to the final destination (17) of the work in a second operation, via distribution means comprising a flexible portion (10, 10a) of free fall and spreading means

(11) arranged at said distribution means.

2. A method as defined in claim 1, c h a r a c t e r i z e d in that a worm conveyor (2) is used as said conveyor means, said worm conveyor being induced to feed said mix to the upper end (22) of an essentially vertical drop tube (24) functioning as a first tube- like dropping portion, from which said mix is induced to fall by its own weight down, via a choking portion (26) suitably comprising a distributing knife (27) , to said spreading means (11) and further to said destination (17) of the work .

3. A method as defined in claim 1 or 2 , c h a r a c t e r i z e d in that the transferal of said mix in said drop portion (10, 10a) and/or in said spreading means (11) is facilitated by separate secondary conveyor means .

4. A distribution apparatus for mortar or the like binding material mix (18) to be used in connection with attaching masonry pieces (16), c h a r a c t e r i z e d in that the apparatus comprises a material mix hopper (1) located generally over the place of work, power driven (4, 5) essentially horizontal primary worm conveyor means (2, 3) arranged at an outlet end (la) of said hopper (1) for transferring said mix, and material mix spreading means (11) connected to distri- bution means comprising a flexible portion (10, 10a) of essentially free fall arranged at the opposite end (3a) of said conveyor means (2, 3) .

5. An apparatus as defined in claim 4, c h a r a c t e r i z e d in that a secondary worm conveyor is arranged in connection with an essentially vertical first dropping portion

(24) for moving therein in a forced manner and/or that said essentially vertical dropping portion (24) comprises a portion

(24a) of an essentially enlarged cross-section.

6. An apparatus as defined in claim 4 or 5, c h a r a c t e r i z e d in that a choking portion (26) comprising a distributing knife (27) is arranged at the lower end of a favorably to its cross-section enlarged vertical dropping portion (24, 24a) , from which choking portion (26) distribution means comprising said flexible portion (10, 10a) lead to said spreading means (11) which suitably are provided with fast connector means (12) and favorably with control means (13) .

7. An apparatus as defined in claim 6, c h a r a c t e r i z e d in that said spreading means (11) comprise parallel spreading slide means (15) , the intermediate distance between said means forming parallel binding material strips (18) on the upper surface of said masonry pieces (16) , an insulating air slot (19) of predefined width remaining between said strips (18) .

8. An apparatus as defined in claim 6 or 7, c h a r a c t e r i z e d in that said spreading means (11) comprise pressing means (29, 32) comprising a worm conveyor (31) to be rotated by an accumulator powered drill gun (30) or the like, turnably mounted nozzle means (33) favorably being arranged at the outer end of said pressing means.

9. An apparatus as defined in any one of claims 4 to 8, c h a r a c t e r i z e d in that an electrical generator (6) and/or a hydraulic motor or the like power apparatus is arranged favorably in connection with said material mix hopper (1) , for producing a favorably steplessly controllable machine power for said primary worm conveyor means (2) , where said power equipment favorably functions simultaneously as a vibrator for improving the fluidity of the material mix.

10. An apparatus as defined in any one of claims 4 to 9, c h a r a c t e r i z e d in that said distribution apparatus is arranged as an essentially balanced entity which is to be suspended freely from a crane or the like device above a workplace .