Classifications

• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
  • E04C1/00—Building elements of block or other shape for the construction of parts of buildings
  • E04C1/40—Building elements of block or other shape for the construction of parts of buildings built-up from parts of different materials, e.g. composed of layers of different materials or stones with filling material or with insulating inserts
  • E04C1/41—Building elements of block or other shape for the construction of parts of buildings built-up from parts of different materials, e.g. composed of layers of different materials or stones with filling material or with insulating inserts composed of insulating material and load-bearing concrete, stone or stone-like material
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
  • E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
  • E04B2/04—Walls having neither cavities between, nor in, the solid elements
  • E04B2/06—Walls having neither cavities between, nor in, the solid elements using elements having specially-designed means for stabilising the position
  • E04B2/08—Walls having neither cavities between, nor in, the solid elements using elements having specially-designed means for stabilising the position by interlocking of projections or inserts with indentations, e.g. of tongues, grooves, dovetails
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
  • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
  • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
  • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
  • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
  • E04C2/288—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
  • E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
  • E04B2002/0202—Details of connections
  • E04B2002/0204—Non-undercut connections, e.g. tongue and groove connections
  • E04B2002/0206—Non-undercut connections, e.g. tongue and groove connections of rectangular shape
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
  • E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
  • E04B2002/0202—Details of connections
  • E04B2002/0204—Non-undercut connections, e.g. tongue and groove connections
  • E04B2002/0208—Non-undercut connections, e.g. tongue and groove connections of trapezoidal shape
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
  • E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
  • E04B2002/0202—Details of connections
  • E04B2002/0243—Separate connectors or inserts, e.g. pegs, pins or keys
  • E04B2002/0254—Tie rods

Definitions

• the invention relates to an insulated building element, e.g. block or panel, having interconnecting features and, particularly, a system and method of constructing a wall of such blocks/panels.
• an insulated building element e.g. block or panel
• the invention provides for simple and fast assembly by unskilled workers from a single component to erect housing or other building structures.
• geopolymer concrete is a relatively new invention that produces a sustainable and workable concrete with an exceptionally low carbon footprint in a process that avoids the use of OPC and the need for the high temperature firing of bricks.
• the present invention seeks to provide a novel insulated building element/block construction that can be implemented across the building industry.
• the invention demonstrates a way forward for geopolymer concrete and the potential for drastically reducing the carbon footprint of housing, whilst also delivering a system of manufacture and construction that the can be deployed, preferably by unskilled labour including by homeowners themselves, at rate commensurate with the need.
• the invention provides an insulated building element according to claim 1.
• the element is of sandwich construction comprised of a core insulating material (the 'core' - typically of high insulating performance) and two outer surface portions (herein called 'plates'- of geopolymer concrete), where the core material is bonded or fixed with adhesive and/or otherwise fastened to the two outer surface plates.
• the core and the plates are of the same size and shape. Whilst the plates remain parallel and in alignment with each other, the core is offset along two sides.
• the arrangement is such that blocks (i.e. elements of a size that can be handled by a single construction worker) or panels (elements of similar profile but larger than blocks) can be simply joined horizontally as well as being stacked in a brick bonding method, to form a wall.
• a surface feature e.g. in the form of a profile
• edges e.g. either two opposing edges or all four edges
• the profile/surface features may be a series of ridges and/or corresponding channels, longitudinally or laterally, on upper and lower surfaces thereof, such that stacked elements (usually in brick bonding form) interconnect with each other.
• the building elements are manufactured to high levels of accuracy (i.e. ⁇ lmm tolerances) such that the construction process is deskilled.
• the elements can be constructed 'dry', without the need to glue or cement any of them one to another, while at the same time forming exceptionally strong and stable structures.
• the elements In a tie-bar system, the elements have a number of holes vertically drilled/formed through them to enable the introduction of the tie-bars.
• a base plate is accurately mounted horizontally on a foundation to form a ring beam around the base of the building.
• Vertical tie-bars e.g. of threaded steel, fiber reinforced plastic or other material
• Multiple base plates are commonly needed for a house or structure and these are connected one to another via bolted steel side plates that ensures the continuation of the horizontal base plate. This single structure represents a base level ring beam.
• Elements are mounted on the base plates as previously described. At each floor level and/or at the roof level (the so called 'plate level') another top-plate/intermediate-plate is introduced on top of the elements and this is then screwed down to introduce a compressive force on the wall forming elements, between the base plate and subsequent levels. Accordingly, a two-story building will have three substantial ring beams made of high strength geopolymer concrete, providing exceptional strength and stability, whilst allowing the elements to be built dry.
• a particular advantage of the system is that the insulating core alone provides a locking and locating interconnection between the adjoining elements, effectively providing a zero-loss system due to bridging.
• the outcome is a wall of exceptional strength and accuracy that is highly resistive to any form of cracking or deformity due to ground movement.
• the assembled wall can be plastered over or covered by any suitable means for aesthetic and additional insulation effect.
• the building element is most likely provided in a 'block' form, i.e. typically a compact, brick-like, unit in the context of building components.
• 3 invention can alternatively be described as a 'panel' if it is in the form of a unit with a larger outward surface area compared to its width across (i.e. wall thickness).
• element, block, panel, brick, and cladding can be interchangeable in the context of the invention.
• the core material is formed from high-density expanded polystyrene (EPS) or an equivalent material that has similar insulating and strength properties.
• the outer panels are made of high compressive strength (i.e. >50MPa) geopolymer concrete to reinforce the core. Interconnection of the elements is improved by the insulating core material having a surface feature and/or a profile on a side edge thereof corresponding to a mating feature of an adjacent element in use. Mating features located on an upper side edge and lower side edge of the core material respectively enable stacked building elements to interconnect with each other.
• the insulating core material includes at least one bore therethrough, for receiving a tie bar and/or fastening rod.
• a tie bar has application in a wider system. For example a plurality of building elements can be arranged with side edges of the core material abutting to assemble a wall. Then a base beam, upon which a first row of the plurality of building elements is arranged, can be tied to a capping beam located over the assembled wall to provide tension on the building elements between the base beam and capping beam.
• the outer panels may be pinned together, through the core material, to secure the building element in a permanent shape, as an alternative or in addition to adhesive bonding with the core material. Furthermore, pinning provides structural integrity and the relative spatial relationship of the outer panels is maintained in the absence or degradation of the core material.
• An embodiment utilizes an advanced composition of geopolymer concrete of high compressive strength for the outer surface portion, together with a high density expanded polystyrene (or other suitable material) core.
• the core preferably provides high levels of insulation as well as an interconnecting and locking system.
• Overall the building element in block or panel form is a simple but high quality component for use in a walling process.
• the blocks will be provided in a full size and other smaller size (e.g. half size, quarter size etc.) formats so that a series of full size units can be laid that are each offset from adjacent upper and lower parallel rows of units.
• a half size block may be required at alternate row ends to provide a straight edge to the wall.
• a corner element may be provided to connect multiple element walls at required angles. Particularly, there may be at least two types of L-shaped corner units used to connect adjoining walls at right angles, or another required angle.
• the L-shaped blocks may have differing length extensions to be compatible with staggered/offset layers of blocks assembled into a wall.
• the construction system of the invention significantly reduces carbon emissions compared to traditional building. It allows faster, more accurate and higher quality construction at lower cost. In a very practical way, the invention can help to address the social problems of housing shortages while at the same time introducing a more sustainable system of building.
• a single block system, not twin-walled, can have exceptionally high insulation rating, e.g. R values >5 (U values ⁇ 0.19)
• an embodiment of the invention features a sandwich structured block or panel building element comprised of a high strength thin walled geopolymer concrete (GPC) outer layer for building integrity and an insulating core of high-density polystyrene providing thermal efficiency.
• the block also features a unique connecting and locking mechanism to provide simple and fast construction.
• the outer layers of geopolymer concrete (the 'plates') can be accurately manufactured (tolerances ⁇ 1mm) as well as being of a high compressive strength, which is advantageous for a thin-walled
• Geopolymer concrete can be relatively expensive compared to traditional structural building materials but, in the context of the present invention, is utilized as a relatively thin walled element in combination with a wide block of much cheaper insulating material.
• the system is also adapted for inclusion of windows.
• Capping plates can be provided for surrounding a window opening, where tie bars are then connected into the base beam and capping beam.
• Figure 1 illustrates a general view of a building element
• Figure 2 illustrates an end view of the building element according to Figure 1;
• Figure 3 illustrates a plan view of the building element according to Figures 1 and 2;
• Figure 4 illustrates a side view according to anembodiment of the invention
• Figure 5 illustrates a general view of the building element according to Figure
• Figure 6 illustrates a side elevation view of building elements according to the second embodiment being assembled into a wall
• Figure 7 illustrates a side elevation section view of an embodiment of building constructed from building elements according to the invention. Detailed description of an embodiment of the invention
• a building element is illustrated in a basic form according to Figures 1, 2 and 3.
• the element generally denoted 10, is comprised of a core material 11 and outer surface portions 12, e.g. a pair of plates, one on each side located directly against the core material.
• Figure 1 is shown as an exploded view where the core material and plate have a substantially aligned and equivalent side surface dimension.
• the core material 11 is bonded and/or otherwise fastened, e.g. by pinning, between two outer surface panels/plates in an offset configuration as shown in Figures 2 and 3.
• outer plates 12 leave an overhang 13 on at least one, but preferably two edges.
• adjacent elements can be further interconnected to form a self-supporting wall structure.
• a second like-shaped element 10 can be stacked upon the illustrated element to build a wall of the elements in a vertical direction. Said wall will be steadied in use by the interlocking nature of the overhanging lower end 13 with a protruding upper end 14, i.e. the edge of core 11 exposed from between panels 12 by virtue of the offset
• the bricks could be stacked with directly vertical alignment or, more preferably, by the traditional offset method used in brick laying where each subsequent layer is offset from the layer below by approximately half a length (as visible in Figure 7).
• Figures 4 and 5 illustrates features of an embodiment of a building element according to the invention where an offset outer surface portion/panel 22 overhangs two adjoining (lower right side as viewed) edges of a core material 21.
• the opposite (lower left as viewed) edge 23 of plate 22 is offset from a lower exposed edge of the core material, analogous to Figure 2, and an end (right side vertical as viewed) edge 25 of plate 22 is also visible as offset from the core material 21, analogous to Figure 3.
• a protruding upper edge 24 of core material 21 is visible, as is the left side end of core material 21 protruding from behind plate 22.
• the core material includes surface features 26 which take the form of a profile on the exposed upper surface 24.
• profile features 26 provide for interconnection with the underside of core material 11 of an adjacent element when stacked, i.e. as is apparent from Figure 6 where the underside of core material 21 includes mating features 27 for receiving/interconnecting with the upper profile 26.
• the features may be a series of ridges and/or corresponding channels, longitudinally or laterally, on upper and lower surfaces thereof, such that stacked elements interconnect with each other.
• a like-shaped building elements 20 can be stacked on top of each other, either in vertical alignment or, more preferably in an offset configuration as shown in Figures 6 and 7.
• the building element 20 is a sandwich construction consisting of two thin walled outer plates 22, made from geopolymer concrete, bonded to a central core 21 of insulation.
• the plates are likely to range in thickness between 10 and 20mm depending on the strength of the GPC and the specific requirement.
• the core material preferably formed of a block of polystyrene foam with impregnated graphite for improved insulation, may be bonded to the plates 22.
• a rod/fastener/pin is shown to be driven laterally through core 21, between
• Figure 4 also shows a series of through holes/bores 29 in dotted detail which represent tubular voids to receive a tie bar for wall construction as will be described further below with reference to Figure 7.
• All complete units preferably comprise exactly the same components, the only difference being that of size. While the overall size may alter, the cross width of the connecting cores 21 preferably remains consistent. This aspect allows elements of a variety of sizes to be interconnected without any loss of mechanical or thermal integrity and enables simple, flexible walling design and construction. Further, specialized components may be employed such as end and/or corner units that cooperate with a plurality of assembled building elements to aid construction of a wall/building.
• elements may be produced in large panel sizes e.g. 3m high x 2m wide x 0.180m deep, or in block-type sizes of 500mm wide x 250mm wide x 180mm deep, or smaller.
• the element by having a common width, will fit together easily and quickly to provide a highly insulated single piece wall, ideal for the construction of housing.
• the design of the exemplified panel/block system exhibits a number of highly desirable properties. For example:
• the plates have a compressive strength typically >50MPa and are manufactured to a size tolerance of ⁇ lmm. This exceptional manufacturing precision, by virtue of the chosen material, allows the panels (even down to small block sizes) to be built dry and held in place mainly by a vertical compressive force introduced by a tie bar system. Clamping the blocks between top and bottom plates provides for the wall to exhibit the properties of a single element wall rather than a multi-element one. This allows much lighter foundations to be employed.
• the insulation core is profiled which provides two benefits. Firstly, it further
• the insulation material 21 (the core of the sandwich panel) performs the function of both an interconnection between panels as well as a locating and locking component, e.g. a profile along at least the top and bottom surface of the core, to prevent movement.
• a locating and locking component e.g. a profile along at least the top and bottom surface of the core.
• each block or panel allows each block or panel to be built both horizontally and vertically depending on design or other criteria.
• design or other criteria For example, in a wall using block size elements, more complex designs of constructions such as herringbone may be employed.
• a plurality of building elements 20 can be assembled into a wall structure 30 and secured by use of a tie bar system 31.
• building elements as described above are combined with an upper capping beam 32 and a bottom base beam 33 (referred to hereinafter with reference to Figure 7 as 'top plates' and 'bottom plates') and a tie bar 31 is arranged to extend through the building elements, e.g. through bores 29 visible in Figure 3.
• the tie bars 31 e.g. a threaded rod or fiber reinforced plastic, etc.
• the tie bars 31 are mechanically fixed into the plate(s) 32, 33, typically by screwing or another suitable fixing system.
• both top 32 and bottom 33 plates are made of GPC to a variety of lengths. Most structures will require the adjacent plates to be joined together and connecting plates (of steel or other materials, not shown) can be employed to ensure the
• a building structure may have two or more ring beams; the top plate (forming one ring beam with adjacent top plates at the same level) being repeated at every floor level such that a typical two-story house with this system has three ring beams, a three story building has four and so on.
• the combined structural system will exhibit a box-like form of exceptional strength, rigidity and resistance to ground movement or failure.
• the illustrated system is adapted for inclusion of windows (not illustrated).
• a window opening can be formed by strategic layering of the building elements during construction.
• Capping plates can be arranged to surround the internal surfaces of the opening formed for receiving a window frame. Tie bars from lower and upper capping plates are then connected into the base beam and capping beam respectively so that the opening in the wall has relatively minimal effect on the overall strength.
• a Fly Ash (FA) and Ground Granulated Blast Furnace Slag (GGBFS) are used together with aggregates and either Potassium Silicate and

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• Engineering & Computer Science (AREA)
• Architecture (AREA)
• Civil Engineering (AREA)
• Structural Engineering (AREA)
• Physics & Mathematics (AREA)
• Electromagnetism (AREA)
• Building Environments (AREA)
• Laminated Bodies (AREA)

Applications Claiming Priority (2)

Publications (1)

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ID=65528365

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Family Cites Families (19)

• 2019
  • 2019-01-17 GB GB1900666.7A patent/GB2575701B/en active Active
• 2020
  • 2020-01-09 WO PCT/GB2020/050041 patent/WO2020148519A1/en unknown
  • 2020-01-09 EP EP20701095.0A patent/EP3911804A1/en active Pending
  • 2020-01-09 US US17/420,794 patent/US20220074204A1/en not_active Abandoned
• 2021
  • 2021-07-14 SA SA521422524A patent/SA521422524B1/ar unknown

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