GB2557171A - Construction system - Google Patents
Construction system Download PDFInfo
- Publication number
- GB2557171A GB2557171A GB1617836.0A GB201617836A GB2557171A GB 2557171 A GB2557171 A GB 2557171A GB 201617836 A GB201617836 A GB 201617836A GB 2557171 A GB2557171 A GB 2557171A
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- GB
- United Kingdom
- Prior art keywords
- construction
- breathable
- mould
- block
- blocks
- 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
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Classifications
-
- 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
-
- 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
- E04C1/00—Building elements of block or other shape for the construction of parts of buildings
-
- 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
- E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
- E04C2/041—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres composed of a number of smaller elements, e.g. bricks, also combined with a slab of hardenable material
-
- 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
- E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
- E04C2/041—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres composed of a number of smaller elements, e.g. bricks, also combined with a slab of hardenable material
- E04C2/042—Apparatus for handling the smaller elements or the hardenable material; bricklaying machines for prefabricated panels
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
- E04G21/00—Preparing, conveying, or working-up building materials or building elements in situ; Other devices or measures for constructional work
- E04G21/14—Conveying or assembling building elements
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
- E04G21/00—Preparing, conveying, or working-up building materials or building elements in situ; Other devices or measures for constructional work
- E04G21/14—Conveying or assembling building elements
- E04G21/16—Tools or apparatus
-
- 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
- E04B2002/0215—Non-undercut connections, e.g. tongue and groove connections with separate protrusions
-
- 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
- E04B2002/0215—Non-undercut connections, e.g. tongue and groove connections with separate protrusions
- E04B2002/0219—Non-undercut connections, e.g. tongue and groove connections with separate protrusions of pyramidal 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
- E04B2002/0256—Special features of building elements
- E04B2002/0258—Gripping or handling aids
-
- 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
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Mechanical Engineering (AREA)
- Physics & Mathematics (AREA)
- Electromagnetism (AREA)
- Building Environments (AREA)
Abstract
A method of constructing a wall 20, the method comprising providing a lifting device 30 and a plurality of breathable construction blocks 10, each having upper and lower surfaces which together define interengageable profiles to enable the blocks to be stacked. The wall is formed using the lifting device to lift and position the construction blocks in the predetermined orientation so that the interengageable profiles interengage. The outer surface of the wall is then rendered with a breathable render 40. The block may be formed from a mixture of binder, such as straw or flax, sand, chalk and clay. The render may be lime based and may be sprayed on the walls. A fixing connector, such as a timber insert, may be embedded in the blocks during manufacture to allow for the mounting of a joist or eaves hanger. Also claimed is a method of forming a breathable construction block, including the step of using a mould to define the upper and lower interengageable surfaces. The method may include the use of a stackable stillage and a moisture removal element comprising a wicking surface.
Description
(54) Title of the Invention: Construction system
Abstract Title: Method of constructing a wall using blocks having interengageable surfaces (57) A method of constructing a wall 20, the method comprising providing a lifting device 30 and a plurality of breathable construction blocks 10, each having upper and lower surfaces which together define interengageable profiles to enable the blocks to be stacked. The wall is formed using the lifting device to lift and position the construction blocks in the predetermined orientation so that the interengageable profiles interengage. The outer surface of the wall is then rendered with a breathable render 40. The block may be formed from a mixture of binder, such as straw or flax, sand, chalk and clay. The render may be lime based and may be sprayed on the walls. A fixing connector, such as a timber insert, may be embedded in the blocks during manufacture to allow for the mounting of a joist or eaves hanger. Also claimed is a method of forming a breathable construction block, including the step of using a mould to define the upper and lower interengageable surfaces. The method may include the use of a stackable stillage and a moisture removal element comprising a wicking surface.
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Application No. GB1617836.0
RTM
Date :27 March 2018
Intellectual
Property
Office
The following terms are registered trade marks and should be read as such wherever they occur in this document:
DIATHONITE
Intellectual Property Office is an operating name of the Patent Office www.gov.uk/ipo
TITLE: CONSTRUCTION SYSTEM
DESCRIPTION
The present invention relates to a construction system for use in constructing walls and to associated methods.
It is known in the art to construct buildings from cast or extruded earth blocks formed from earth mixed with a binder, typically straw or the like. These concrete-free blocks are environmentally friendly and may be laid by hand like a conventional masonry brick using a breathable (typically lime) mortar. However, despite undoubted benefits (low carbon, good thermal properties, breathability and recyclability) typically the use of this type of earth block is currently limited to the restoration of historical buildings/specialist new-build projects with a historical or ecological aim.
The present applicant has identified the need for an improved construction system intended to encourage the use of earth block techniques in more mainstream construction.
In accordance with a first aspect of the present invention, there is provided a method of constructing a walled structure (e.g. building), the method comprising: providing: a lifting device; and a plurality of breathable (modular) construction blocks each construction block having an upper surface and a lower surface, wherein the upper and lower surfaces together define interengageable profiles to enable the lower surface of a first construction block to interengage with an upper surface of a second construction block when the second construction block is stacked upon the first construction block in a predetermined orientation; forming a wall using the lifting device to lift and position the construction blocks, whereby vertically neighbouring blocks are stacked in the predetermined orientation so that the interengageable profiles interengage; and rendering an outer surface of the wall with a breathable render.
In this way, a high speed mechanised method of constructing a walled structure (typically load-bearing walled structure) is provided which provides a strong and stable structure which is breathable and capable of being erected by a single human operator. The combination of the high block mass, interengageable profiles (which act to resist unwanted lateral movement) and outer render obviate the need for labour intensive mortar application whilst still providing a breathable structure.
In the context of the present invention, the term breathable is defined as permeable to water vapour. The choice of a breathable block material is considered important since it allows natural control of moisture content within the wall structure and, in the case of a walled building, inside the building itself.
In one embodiment, the breathable block material comprises a mixture of a binder (typically a naturally available product such as straw or flax) and one or more of sand; chalk; clay; and hydraulic lime (typically a combination of sand, chalk and clay with an option to include hydraulic lime). The precise combination and quantity of constituents will greatly depend upon the size of the blockwork and properties of the natural products available in the location of manufacture.
Typically the construction blocks will be high mass blocks (e.g. each greater than 100 kg, for example each greater than 200 kg).
Typically each construction block will present a facing area of greater than 0.2 m2 (e.g. greater than 0.3 m2 or even greater than 0.4 m2).
Typically the interengageable profiles comprise a plurality of (e.g. longitudinally-spaced) projections and corresponding (e.g. longitudinally-spaced) recesses. Typically each projection is a snug fit in its corresponding recess. In this way relative lateral movement may be kept to a minimum.
In one embodiment, the step of rendering comprises applying a sprayable render with a spray device.
In one embodiment, the render comprises a lime-based render (e.g. lime and cork render).
Typically the wall is formed on a footing (e.g. formed in a conventional manner).
In one embodiment, the method further comprises providing a further plurality of breathable construction blocks each with a structural fixing connector (e.g. for use in mounting a joist or eaves hanger). In one embodiment, the structural fixing connector comprises a timber insert embedded in each of the further plurality of construction blocks during manufacture of the construction blocks.
In one embodiment, the structural fixing connector comprises one or more anchoring bolts embedded in the construction blocks during manufacture.
In one embodiment, each of the further plurality of construction blocks includes a lower surface with a profile configured to interengage with an upper surface profile of the first-defined plurality of construction blocks. In one embodiment, each of the further plurality of construction blocks an upper surface with a profile configured to interengage with a lower surface profile of the first-defined plurality of construction blocks.
In accordance with a second aspect of the present invention, there is provided a method of forming a construction block configured for use in a mechanised lifting construction technique, the method comprising: providing a mould (e.g. two-part mould) defining a block profile with upper and lower interengaging profiles; filling the mould with a breathable block material provided in a pourable form; and allowing the breathable block material in the mould to dry.
In one embodiment, the breathable block material comprises a mixture of a binder (typically straw or flax) and one or more of sand; chalk; clay; and hydraulic lime (typically a combination of sand, chalk and clay with an option to include hydraulic lime).
Typically the construction block formed in the mould is a high mass block (e.g. greater than 100 kg, for example each greater than 200 kg).
Typically the block profile defined by the mould has a facing area of greater than 0.2 m2 (e.g. greater than 0.3 m2 or even greater than 0.4 m2).
In the context of the present invention, the term breathable is defined as permeable to water vapour.
Typically the interengageable profiles comprise a plurality of (e.g. longitudinallyspaced) projections and corresponding (e.g. longitudinally-spaced) recesses. Typically each projection is a snug fit in its corresponding recess (e.g. when first and second construction blocks formed in the mould are stacked in a predetermined orientation).
In one embodiment, the step of allowing the breathable block material in the mould to dry comprises allowing the breathable block material to be air-dried (typically by contact with an available airflow).
In one embodiment, the mould is provided on a stillage (e.g. frame providing a raised shelf for supporting the mould).
In one embodiment, the stillage comprises a support shelf defining at least one airflow passage therethrough. In one embodiment, the support shelf comprises a mesh or grill defining an array of airflow passages.
In one embodiment, the stillage is configured to be stackable (e.g. with one or more other stillages of the same design).
In one embodiment, the stillage is configured to be lifted and manoeuvred by a lifting device (e.g. forklift truck).
In one embodiment, the stillage comprises one or more lifting points (e.g. a pair of forklift sockets for receiving the forks of a forklift truck).
In one embodiment, the step of allowing the breathable block material in the mould to dry comprises stacking a plurality of stillages (each with a corresponding mould filled with the breathable block material) in a drying house.
In one embodiment, the drying house is an external structure (e.g. roofed structure). In one embodiment, the drying house is formed by adding a roof to an uppermost one of the stacked plurality of stillages.
In one embodiment, the drying house is configured to allow exposure of the stacked stillages to the wind.
In one embodiment, the drying house is configured to receive low grade heat (e.g. during cold or excessively wet periods of the year).
In one embodiment, the method further comprises loading the stillages (e.g. stacked stillages) into a delivery vehicle and transporting the construction blocks in their respective stillage. In this way, the stillage used both to support the blocks during drying and to safely transport the blocks to site.
In one embodiment, the method comprises removing the mould prior to loading the stillage into the delivery vehicle. In another embodiment, the method comprises removing the mould upon delivery of the stillages to a delivery location.
In one embodiment, the method further comprises agitating the breathable block material whilst the breathable block material is in the mould.
In one embodiment, the method further comprises removing water which collects on an upper surface of the mould (e.g. during the agitating step).
In one embodiment, the agitating step comprises applying a vertical agitation action to the mould to encourage water to collect on an upper surface of the breathable block material.
In one embodiment, the breathable block material is poured into the mould with the mould positioned on the stillage. In one embodiment, the stillage is placed (either before or after pouring of the breathable block material) on an agitating platform. In this way, there is no need to disturb the mould after the agitation step is completed - the stillage may simply be picked up with the mould in situ and both elements are moved together to a drying stage.
In one embodiment, the contents of the mould are placed in proximity to a moisture removal element configured to draw moisture from the block (i.e. with an exposed surface of the block being in contact with the moisture removal element). In this way, the rate of moisture removal may be increased during drying.
In one embodiment, the moisture removal element comprises an absorbent material. For example, the moisture removal element comprises a wicking surface (e.g. formed form fibrous material such as a layer of hessian fabric).
In one embodiment, wherein the moisture removal element (e.g. wicking surface) is configured to form a high surface area profile in the side of the block in contact with the wicking surface. This high surface area profile will assist with the bonding of a subsequently applied render layer.
In one embodiment, the mould is positioned on top of the moisture removal element (e.g. wicking surface). In this way, the weight of the block being formed in the mould will bare against the moisture removal element. In the case of a system with one or more stillage, the moisture removal element may be positioned on the support shelf immediately beneath the mould.
In one embodiment, the method further comprises embedding a structural fixing connector (e.g. for use in mounting a joist or eaves hanger) in the breathable block material.
In one embodiment, the structural fixing connector comprises a timber insert.
In one embodiment, the structural fixing connector comprises one or more anchoring bolts which become embedded in the construction block as the block sets.
In accordance with a third aspect of the present invention, there is provided a construction system comprising: a plurality of breathable construction blocks each with upper and lower surfaces together defining interengaging profiles; and a lifting device for lifting and orientating the construction blocks.
In one embodiment, the breathable block material comprises a mixture of a binder (typically straw or flax) and one or more of: sand; chalk; clay; and hydraulic lime (typically a combination of sand, chalk and clay with an option to include hydraulic lime).
Typically each construction block is a high mass block (e.g. with a mass greater than 100 kg, for example each greater than 200 kg).
Typically each construction block has a facing area of greater than 0.2 m2 (e.g. greater than 0.3 m2 or even greater than 0.4 m2).
Typically the interengageable profiles comprise a plurality of (e.g. longitudinallyspaced) projections and corresponding (e.g. longitudinally-spaced) recesses.
In one embodiment, the construction system further comprising a spray device for spraying a breathable render.
In one embodiment, the system further comprises a further plurality of breathable construction blocks each with a structural fixing connector (e.g. for use in mounting a joist or eaves hanger).
In one embodiment, the structural fixing connector comprises a timber insert embedded in each of the further plurality of construction blocks during manufacture of the construction blocks.
In one embodiment, the structural fixing connector comprises one or more anchoring bolts which are embedded in the construction block during manufacture.
In one embodiment, each of the further plurality of construction blocks includes a lower surface with a profile configured to interengage with an upper surface profile of the first-defined plurality of construction blocks. In one embodiment, each of the further plurality of construction blocks an upper surface with a profile configured to interengage with a lower surface profile of the first-defined plurality of construction blocks.
An embodiment of the present invention will now be described by way of example with reference to the accompanying drawings in which:
Figure 1 is a schematic perspective view of a breathable construction block in accordance with an embodiment of the present invention;
Figure 2 is a schematic view illustrating a first stage of a building technique in accordance with the present invention using the breathable construction block of Figure 1;
Figure 3 is a schematic perspective view of a further breathable construction block in accordance with the present invention;
Figure 4 is a schematic view illustrating a second stage of a building technique in accordance with the present invention using the breathable construction blocks of Figures 1 and 3;
Figures 5A-5F are schematic views illustrating stages in the manufacture and delivery of the breathable construction block of Figure 1.
Figure 1 shows a high mass moulded modular breathable construction block 10 comprising an elongate body 12 defining a pair of parallel square end faces 12A, a pair of longitudinally extending parallel rectangular side faces 12B, an upper face 12C and a lower face 12D. Upper and lower faces 12C, 12D together define defining interengageable profiles 14A, 14B which enable the breathable construction block 10 be stacked in an interengaged configuration with further modular blocks 10 made to the same design to form a load-bearing wall 20 as illustrated in Figure 2 using a crane 30 with a precise rotator positioning mechanism.
As described in more detail in relation to Figures 5A-5F, breathable construction block 10 is formed from a mixture of sand, chalk, clay and straw. In this example elongate body has dimensions of 1,5m x 0.3 m x 0.3m producing a facing area of 0.45 m2. Typically this will result in a block with a mass of around 230 kg.
Interengageable profiles 14A, 14B respectively comprise a series of longitudinally spaced projections each with a profile corresponding to a square pyramid frustum and a series of longitudinally spaced recesses each with a profile corresponding to the projections and intended to provide a snug fit when interengageable profiles 14A, 14B interengage.
Figure 2 illustrates a first stage of construction in which a load-bearing wall 20 is formed by positioning a series of modular breathable construction blocks 10 in a stacked configuration upon a footing or foundation 22 using crane 30. Modular breathable construction blocks in shorter lengths (e.g. the two projection and three projection blocks illustrated in Figure 2) may be formed by placing a dividing plate in the mould during manufacture.
Figure 3 shows a second variety of breathable modular construction block 10’ produced in the same mould as modular breathable construction block 10 but with a structural fixing connector 16 for use in mounting a joist or eaves hanger. In this example structural fixing connector 16 comprises a timber insert 16A embedded along an upper edge of one longitudinal side of the breathable block material. A plurality of longitudinally spaced anchoring bolts 16B (e.g. rag bolts) inserted through the timber insert 16A are embedded in the modular breathable construction block as the block sets during manufacture.
Figure 4 illustrates a second stage of construction in which load-bearing wall 20 (which now includes a layer of modular breathable construction blocks 10’ for connecting a floor or roof component) is rendered with a sprayable breathable render 40 using a spray device 42. In one embodiment, the sprayable breathable render is a lime cork render such as Diathonite lime cork render sold by Diasen® s.r.l., Italy. This outer layer of breathable render acts to bind modular breathable construction blocks 10, 10’ together whilst providing insulation and protection for the blocks.
Figures 5 A-5F illustrate a method of manufacturing and delivering modular breathable construction blocks 10.
In Figure 5 A a stackable steel stillage 100 comprising front and rear pairs of legs 102A, 102B and a raised wire-mesh support shelf 104 is positioned on a vertical agitating platform 110. Support shelf 104 includes a pair of forklift sockets 106 to assist lifting and positioning of the stillage 100. A hessian sheet 120 is placed on support shelf 104 to act as a wicking surface during a subsequent drying stage.
A two-part block mould 130 (shown before the two parts are bolted together) is positioned on top of hessian fabric sheet. Two-part block mould 130 when connected forms an open base and open top.
In Figure 5B two-part block mould 130 is bolted together and a breathable block material 140 in a pourable form has been poured into the mould 130 via the open top after application of a lubricant spray to prevent the material sticking to the mould. The constitute parts of the breathable block material may vary depending upon the size of block and the properties of the natural materials available. In this example, the breathable block material comprises 3 parts sharp sand; 2 parts chalk; 1 part clay; 60 litres of barley straw; and sufficient water to create a pourable consistency. Optionally, the breathable block material may further comprise 1 part hydraulic lime (NHL5).
As illustrated in Figure 5B, vertical agitating platform 110 is activated (either during or after pouring of the breathable block material 140) and this causes air bubbles and water to rise to the top of the mould. Water collecting at the top of the mould is removed at this stage.
As shown in figure 5C, after a period of agitation stillage 100 is removed using a forklift device from vertical agitating platform 110 with the mould 130 undisturbed.
As show in in Figure 5D, stillage 100 is stacked in a tower form with other stillages for air-drying. A roof 155 is added to the uppermost stillage in each to stack to form in an outdoor drying house 150. Drying house 150 has an open-wall structure positioned outdoors to take advantage of the wind. However, during periods of extreme cold or rain it may be necessary to use low grade heat (e.g. a by-product of some other process or burning waste timber) in which case the open-wall structure of drying house 150 will typically be temporarily covered (e.g.
using a scaffold curtain or the like) to retain the heat and heat will be supplied from the bottom of the tower and allowed to percolate upwards.
Figure 5E shows the modular breathable construction block 10 formed after drying is complete and mould 130 is removed. Hessian sheet 120 has been removed to show more clearly the raised wire-mesh support shelf 104.
As illustrated in Figure 5F, modular breathable construction blocks 10 may be transported in a delivery vehicle 160 whilst mounted on stackable stillages 100. The blocks may be transported either in the mould 130 or after removal from the mould 130.
Advantageously, the mechanical building technique of the present invention provides a 10 faster build rate than a conventional earth block or brick technique and requires a different set of building skills. Potentially, structures of a significant size could be erected by a single crane operator. Potentially no scaffold is required and safety risk reduced by virtue of the mechanisation. From an environmental point of view, the breathable blocks used in the technique may be low carbon product (heat is generally not required in the production of the 15 blocks and there is no concrete used in the formation of the blocks). Furthermore, the block material is re-mixable and therefore re-usable. In addition, the breathability of the blocks and outer render provide for enhanced moisture control.
Claims (31)
1. A method of constructing a walled structure, the method comprising: providing:
a lifting device; and a plurality of breathable construction blocks each construction block having an upper surface and a lower surface, wherein the upper and lower surfaces together define interengageable profiles to enable the lower surface of a first construction block to interengage with an upper surface of a second construction block when the second construction block is stacked upon the first construction block in a predetermined orientation;
forming a wall using the lifting device to lift and position the construction blocks, whereby vertically neighbouring blocks are stacked in the predetermined orientation so that the interengageable profiles interengage; and rendering an outer surface of the wall with a breathable render.
2. A method according to claim 1, wherein the breathable block material comprises a mixture of a binder, sand, chalk and clay.
3. A method according to claim 1 or claim 2, wherein the construction blocks each have a mass greater than 100 kg.
4. A method according to any of the preceding claims, wherein the step of rendering comprises applying a sprayable render with a spray device.
5. A method according to any of the preceding claims, wherein the render is a lime-based render.
6. A method according to any of the preceding claims, wherein the method further comprises providing a further plurality of breathable construction blocks each with a structural fixing connector.
7. A method according to claim 6, wherein the structural fixing connector comprises a timber insert embedded in each of the further plurality of construction blocks during manufacture of the construction blocks.
8. A method of forming a construction block configured for use in a mechanised lifting construction technique, the method comprising:
providing a mould defining a block profile with upper and lower interengaging profiles; filling the mould with a breathable block material provided in a pourable form; and allowing the breathable block material in the mould to dry.
9. A method according to claim 8, wherein the breathable block material comprises a mixture of a binder, sand, chalk and clay.
10. A method according to claim 8 or claim 9, wherein the step of allowing the breathable block material in the mould to dry comprises allowing the breathable block material to be airdried.
11. A method according to any of claims 8-10, wherein the mould is provided on a stillage.
12. A method according to claim 11, wherein the stillage comprises a support shelf defining at least one airflow passage therethrough.
13. A method according to claim 11 or claim 12, wherein the stillage is configured to be stackable.
14. A method according to any of claims 11-13, wherein the step of allowing the breathable block material in the mould to dry comprises stacking a plurality of stillages in a drying house.
15. A method according to any of claims 11-14, wherein the method further comprises loading the stillages into a delivery vehicle and transporting the construction blocks in their respective stillage.
16. A method according to any of claims 8-15, wherein the method further comprises agitating the breathable block material whilst the breathable block material is in the mould.
17. A method according to claim 16, wherein the method further comprises removing water which collects on an upper surface of the mould.
18. A method according to claim 17, wherein the agitating step compri ses applying a vertical agitation action to the mould to encourage water to collect on an upper surface of the breathable block material.
19. A method according to any of claims 16-18 when dependent upon claim 11, wherein the breathable block material is poured into the mould with the mould positioned on the stillage and the stillage is placed on an agitating platform.
20. A method according to any of claims 8-19, wherein the contents of the mould are placed in proximity to a moisture removal element configured to draw moisture from the block.
21. A method according to claim 20, wherein the moisture removal element comprises a wieking surface.
22. A method according to claim 20 or claim 21, wherein the moisture removal element is configured to form a high surface area profile in the side of the block in contact with the wicking surface.
23. A method according to any of claims 20-22, wherein the mould is positioned on top of the moisture removal element.
24. A method according to any of claims 8-23, wherein the method further comprises embedding a structural fixing connector in the breathable block material.
25. A method according to claim 24, wherein the structural fixing connector comprises a timber insert.
26. A construction system comprising:
a plurality of breathable construction blocks each with upper and lower surfaces together defining interengaging profiles; and a lifting device for lifting and orientating the construction blocks.
27. A construction system according to claim 26, wherein the breathable block material comprises a mixture of a binder, sand, chalk and clay.
28. A construction system according to claim 26 or claim 27, wherein each construction block has a mass greater than 100 kg.
29. A construction system according to any of claims 26-28, wherein the construction 10 system further comprising a spray device for spraying a breathable render.
30. A construction system according to any of claims 26-29, wherein the system further comprises a further plurality of breathable construction blocks each with a structural fixing connector.
31. A construction system according to claim 30, wherein the structural fixing connector comprises a timber insert embedded in each of the further plurality of construction blocks during manufacture of the construction blocks.
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Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB1617836.0A GB2557171B (en) | 2016-10-21 | 2016-10-21 | Construction system |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB1617836.0A GB2557171B (en) | 2016-10-21 | 2016-10-21 | Construction system |
Publications (3)
| Publication Number | Publication Date |
|---|---|
| GB201617836D0 GB201617836D0 (en) | 2016-12-07 |
| GB2557171A true GB2557171A (en) | 2018-06-20 |
| GB2557171B GB2557171B (en) | 2021-10-27 |
Family
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Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB1617836.0A Active GB2557171B (en) | 2016-10-21 | 2016-10-21 | Construction system |
Country Status (1)
| Country | Link |
|---|---|
| GB (1) | GB2557171B (en) |
Citations (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB575638A (en) * | 1943-10-16 | 1946-02-27 | Leslie Smyth | Improvements in or relating to building blocks, bricks, or the like |
| GB1167760A (en) * | 1967-12-28 | 1969-10-22 | Intercon Res Inc | Improvements in and relating to Masonry Walls and Partitions and Method of Fabricating Same |
| DE3810934A1 (en) * | 1988-03-31 | 1989-10-12 | Rudolf Peter Gmbh & Co Kg Kies | Process for using returned residual concrete from ready-mixed concrete |
| WO1997043499A1 (en) * | 1996-05-09 | 1997-11-20 | Waldemar Szczepina | Interlocking building block |
| US20030046884A1 (en) * | 2001-09-12 | 2003-03-13 | Haynes Scott D. | Multi-unit concrete block tongs |
| GB2441763A (en) * | 2006-09-16 | 2008-03-19 | Jack Moody Ltd | Building block with connection formation and engaging formations |
| WO2009039440A2 (en) * | 2007-09-21 | 2009-03-26 | Oryzatech, Inc. | Improved building block, building block mold, and method for forming building block |
| DE202008017553U1 (en) * | 2008-09-05 | 2009-12-31 | Rekers Betonwerk Gmbh & Co. Kg | Heavy duty wall system |
| WO2016015139A1 (en) * | 2014-08-01 | 2016-02-04 | Just Biofiber Corp. | Load bearing interlocking structural blocks and modular building system |
-
2016
- 2016-10-21 GB GB1617836.0A patent/GB2557171B/en active Active
Patent Citations (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB575638A (en) * | 1943-10-16 | 1946-02-27 | Leslie Smyth | Improvements in or relating to building blocks, bricks, or the like |
| GB1167760A (en) * | 1967-12-28 | 1969-10-22 | Intercon Res Inc | Improvements in and relating to Masonry Walls and Partitions and Method of Fabricating Same |
| DE3810934A1 (en) * | 1988-03-31 | 1989-10-12 | Rudolf Peter Gmbh & Co Kg Kies | Process for using returned residual concrete from ready-mixed concrete |
| WO1997043499A1 (en) * | 1996-05-09 | 1997-11-20 | Waldemar Szczepina | Interlocking building block |
| US20030046884A1 (en) * | 2001-09-12 | 2003-03-13 | Haynes Scott D. | Multi-unit concrete block tongs |
| GB2441763A (en) * | 2006-09-16 | 2008-03-19 | Jack Moody Ltd | Building block with connection formation and engaging formations |
| WO2009039440A2 (en) * | 2007-09-21 | 2009-03-26 | Oryzatech, Inc. | Improved building block, building block mold, and method for forming building block |
| DE202008017553U1 (en) * | 2008-09-05 | 2009-12-31 | Rekers Betonwerk Gmbh & Co. Kg | Heavy duty wall system |
| WO2016015139A1 (en) * | 2014-08-01 | 2016-02-04 | Just Biofiber Corp. | Load bearing interlocking structural blocks and modular building system |
Also Published As
| Publication number | Publication date |
|---|---|
| GB2557171B (en) | 2021-10-27 |
| GB201617836D0 (en) | 2016-12-07 |
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