CONCRETE PAVING BLOCK
The present invention relates to a paving. More particularly, the invention relates to a concrete paving block for use on a substructure, the paving block having a top surface, a bottom surface and side portions extending between the top surface and the bottom surface. The paving block comprises a first layer and a second layer. In position of use, the second layer is on top of the first layer.
The superstructure may typically be a flat roof of a building, a pavement, a parking area, a driveway etc. where paving block is a desired surface.
Prior art concrete paving blocks or paving stones typically comprise a single layer of concrete. Such paving blocks has been produced for decades. However, since the 1980s, there has been commercially available concrete paving blocks comprising a double layer type of stone being made from two layers of different types of concrete. A bottom layer, a so-called base mix, is made of high strength concrete combined with a high concentration of stone, such as for example granite, in order to achieve high strength and durability. On top of such a base mix, a so-called face mix is added. A face mix is typically made from fine aggregate and a high concentration of cement to achieve a solid surface with substantially no visible signs of stone. The face mix may also comprise colour pigments to achieve a desired visible appearance.
Concrete paving blocks are manufactured in many different forms and sizes, typically with a surface area ranging from about 50 cm<2>to about 1600 cm<2>, or even larger, and a thickness of the block typically ranging from 4-5 cm to 10-15 cm. Having a density of about 2400 kg/m<3>, prior art concrete paving blocks have a weight ranging from about 100 kg/m<2>to about 350 kg/m<2>for said thickness range.
Such weight represents challenges both with respect to transportation, and with respect to deadload on a roof of a building structure. However, a particular concern is related to personnel handling the paving blocks. Thus, prior art paving blocks represents drawbacks with respect to economical aspects and HES (Health, Environment and Safety) aspects.
A person skilled in the art will appreciate that concrete paving blocks will not absorb any significant amount of water. This is normally not a problem if a surface provided with concrete paving blocks is
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drained via a storm water piping system dimensioned for torrential rain. However, World Meteorological Organization already reports a more than 10% increase in precipitation, and predictions are even worse for the upcoming decades.
Due to the facts that a majority of storm water piping systems are old and not dimensioned for the increased precipitation, and a run-off coefficient in urban areas tending to increase due to an increase in surface areas having substantial impermeable surfaces, flooding tends to increase. To remedy such an increase in flooding due to torrential rain, some local authorities demands that a surface shall be self-draining, i.e. that at least some of the water from a torrential rain shall be infiltrated into the ground. When the ground which carries the concrete paving block is suitable for infiltration, the otherwise “impermeable” concrete paving block may typically be made permeable by arranging at least some of the concrete blocks of the paving mutually distant, and fill the joint with a permeable material such as for example suitable sand.
However, in some cases a substructure that carries the concrete paving block may not be suitable for infiltration. A typically example is when the substructure is a roof of a building. Another example is a substructure consisting substantially of solid rock. To reduce the risk of flooding in such instances, local authorities may demand systems for attenuation of water resulting from torrential rain, i.e. systems that temporarily store and slowly release surface water run-off to a drainage system. An attenuation system is one of the key features of sustainable drainage systems, so-called SuDS.
An attenuation system may comprise large volume tanks or basins for temporarily storing water from torrential rain. Arranging such tanks or basins are relatively straight forward when the substructure is the ground in “virgin” areas with sufficient slope. However, in urban areas, it may be difficult and even impossible to provide tanks or basins in the ground. In such urban areas, a relatively large proportion of the surface area receiving precipitation may be flat-roof buildings wherein attenuation systems of the above-mentioned type are not practical for obvious reasons.
The invention has for its object to remedy or to reduce at least one of the drawbacks of the prior art, or at least provide a useful alternative to prior art.
The object is achieved through features, which are specified in the description below and in the claims that follow.
The invention is defined by the independent patent claim. The dependent claims define advantageous embodiments of the invention.
In a first aspect of the present invention, there is provided a concrete paving block for use on a substructure, the paving block having a top surface, a bottom surface and side portions extending between the top surface and the bottom surface, the paving block comprising a first layer and a second layer, the second layer in a position of use, is on top of the first layer, wherein a density of
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the first layer is lower than a density of the second layer, wherein the second layer is impermeable to water, and wherein the paving block further comprises spacing means extending from at least one of the side portions for keeping side portions of two adjacent paving blocks mutually distant.
In this document, the term “impermeable to water” is meant a water absorption of maximum 6% by weight tested in accordance with the standard NS-EN 1338:2003.
Providing an impermeable second layer, i.e. the top layer, in combination with the spacing means has the effect that water from for example a torrential rain virtually will be drained only through apertures or grooves provided by the spacing means, and not through the second layer. Further, an impermeable top layer may also provide a surface that are less vulnerable for dirt and organic growth that may affect a technical and visual appearance of the paving block.
If the paving blocks are arranged on a permeable substructure, the water drained through the apertures will penetrate through the substructure. However, if the substructure is impermeable, such as for example a roof of a building, or if the amount of water passing the apertures exceeds the draining capacity of the substructure, the first layer will absorb at least some of the water passing through the apertures.
Thus, the first layer of concrete paving block may be utilized as an attenuation system for temporarily storing torrential rain.
The top layer, i.e. the second layer, may be made from fine aggregate and a high concentration of cement to achieve a solid surface with substantially no visible signs of stone. Thus, the top layer may be similar to a so-called face mix. The face mix may also comprise colour pigments to achieve a desired visible appearance.
Preferably, the second layer fulfils the requirements of NS-EN 1338:2003.
Providing a first layer with a density being lower than the density of the second layer has the effect of reducing the overall weight of the concrete paving block. The overall weight reduction of the concrete paving block depends on the reduction in density of the first layer as compared with the second layer, and on the thickness ratio of the first layer as compared with the overall thickness of the concrete paving block.
The first layer may comprise any known lightweight aggregates suitable for use with cement. The lightweight aggregates may be natural or artificial. Natural lightweight aggregates may be such as pumice (which probably is a commonly used natural lightweight aggregate), scoria, volcanic cinders, tuff and diatomite. Artificial aggregates may typically be rotary kiln produced lightweight aggregates such as for example expanded clays, slates, slag or perlite. So-called cenospheres, which are hollow spheres, comprised largely of silica and alumina with cavities filled of inert gases such as nitrogen and carbon dioxide, and recycled glass beads are additional multi-functional fillers that
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may be used as lightweight aggregates in said first layer of the present invention.
Due to their technical features, price and availability, lightweight expanded clay aggregate interconnected by means of cement, has proven very suitable concrete for the first layer of the paving block according to the present invention. In one embodiment, the first layer may comprise a mixture of expanded clay aggregate and other aggregates such as for example, but not limited to, stones and/or sand interconnected by means of cement. Depending on the mixture of clay aggregate and other aggregates, the ratio of density of the first layer may be less than half the density of the second layer.
Alternatively to, or addition to the expanded clay aggregate and any stones and/or sand, the second layer may comprise particulate EPS (expanded polystyrene) or particulate XPS (extruded polystyrene) interconnected by cement and an organic material. A concrete made of particulate EPS or XPS interconnected by means of cement, is known as poly concrete.
With respect to weight, a poly concrete may be advantageous over a concrete made from for example expanded clay aggregate, simply because the density of for example EPS is less than the density of expanded clay aggregate. However, a poly concrete does not have the same water absorbing capability as a concrete made from expanded clay aggregate. Further, a poly concrete has a lower compressive strength than concrete made from expanded clay aggregate. Therefore, a concrete paving block wherein said first layer is made from or comprising expanded clay aggregate, has a wider range of use as compared with a concrete paving block wherein said first layer is made from or comprising poly concrete.
Thus, the first layer may comprise a natural or artificial lightweight aggregate interconnected by means of a cement. In one embodiment, the aggregate is selected from the group consisting of: expanded clay; a particulate plastic material such as expanded or extruded polystyrene; or a combination thereof. However, other lightweight aggregates of the aforementioned types are also conceivable.
A concrete substantially consisting of expanded clay aggregate and cement has a density of about 800 kg/m<3>. Therefore, a first layer made from such a concrete may have a density being about one third of the density of the second layer made from for example a so-called face mix concrete having a density of about 2400 kg/m<3>. If the first layer comprises a mixture of expanded clay aggregate and for example, XPS, the density of the first layer may be less than one third of the density of the second layer.
In addition to the weight reducing effect, a first layer comprising expanded clay aggregate is, as discussed above, also capable of absorbing water received for example from torrential rain. Thus, the first layer of concrete paving block may be utilized as an attenuation system for temporarily storing torrential rain.
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In order to achieve as high weight reducing effect as possible and an attenuation system capable of temporarily storing as much water as possible, the concrete paving block should ideally comprise the first layer only. However, a first layer comprising expanded clay aggregate will have a relatively rough surface, even if it in the manufacturing process is vibrated and compressed while in the formwork. Such a rough surface has proven to be visually less attractive than a face-mix made from fine aggregate and a high concentration of cement to achieve a solid surface with substantially no visible signs of stones (or expanded clay aggregate). Further, a rough surface will also be prone to hold dirt and provide good environmental conditions for undesired organic growth.
In order to achieve as high weight reducing effect as possible and an attenuation system capable of temporarily storing as much water as possible, the thickness of the first layer is preferably larger than the thickness of the second layer.
The concrete paving block may comprise a third layer made from a similar, but not necessarily an identical, concrete mix or composition as the second layer. Such a third layer is arranged on the first layer, but on an opposite side of the second layer.
In one embodiment, the third layer may form a bottom surface of the paving block. The purpose of such a third layer may be to provide an even surface capable of resisting local high stress from for example an uneven substructure. The third layer may comprise reinforcement, for example in the form of suitable fibers made from steel, plastic, glass or natural minerals.
In one embodiment, the third layer is provided solely to manufacture a concrete paving block providing two alternative “top surfaces”. The alternatives provided by the second and third layers may be of technical character, for example permeability and/or hardness, or they may have a different visual appearance, for example different colour. In one embodiment, the third layer may have both a different visual appearance and a different technical character from the second layer. Thus, the desired top surface of the concrete paving block may be selected from the second layer or the third layer, i.e. the third layer constitutes a bottom portion of the concrete paving block when the second layer constitutes the top surface, and the second layer constitutes a bottom portion of the concrete paving block when the third layer constitutes the top surface.
The spacing means extending from at least one of the side portions may have more than one purpose. One purpose of such a spacing means is to keep side portions of two adjacent paving blocks mutually distant so that a clearance or gap is provided. Such a clearance may typically be filled with a permeable material, such as for example a suitable sand or even gravel, to facilitate drainage of water from the surface. This type of drainage is of particular interest when surface water is infiltrated into the superstructure. Another purpose of said spacing may be to provide an interlocking effect between two adjoining side portions, as will be discussed below.
The spacing means may have a vertical extent in the position of use that is less than a thickness of
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the concrete paving block. Thus, it is possible to “hide” a top portion of the spacing means by a filler material that may be provided in the gaps or grooves between the concrete paving blocks.
In the following is described examples of preferred embodiments illustrated in the accompanying drawings, wherein:
Fig.1 shows a perspective view of a first embodiment of a concrete paving block according to the invention;
Fig.2 shows a perspective view of a second embodiment of a concrete paving block according to the invention;
Fig.3 shows an alternative embodiment of the concrete paving block shown in fig.1; and
Figs.4 to 6 show top view of various configurations of spacing means according to the invention.
Positional specifications, such as top, bottom, side, upper, lower, right and left, refer to the positions that are shown in the figures.
Like or corresponding elements are indicated by the same reference numeral in the figures.
In the figures, the reference numeral 1 indicates a concrete paving block according to the present invention. The concrete paving block 1 is defined by a top surface 3, a bottom surface 5 and side portions 7 (four side portions shown in the figures) extending between the top surface 3 and the bottom surface 5. The paving block 1 comprises a first layer 10 and a second layer 12 arranged on top of the first layer 10.
The first layer 10 is made from a lightweight concrete, such as for example expanded clay particles interconnected by a cement to form a block. Leca<®>or Liapor<®>are examples of expanded clay particles that are suitable for use in providing a lightweight concrete for the first layer 10.
In a prototype of the invention, a first layer of the concrete paving block was made from 13% (by weight) cement, 46% Leca<®>and 41% sand. The prototype fulfilled all desired results.
Alternatively, or additionally, the first layer 10 may comprise aggregate made from for example particulate plastic material such as for example EPS or XPS, or other types of aggregates mentioned above.
The second layer 12 arranged on top of the first layer 10 may typically be made from fine aggregate and a high concentration of cement to achieve a solid surface with substantially no visible signs of stone. The second layer 12 is typically a so-called face mix being impermeable to water as discussed above.
Thus, the density of the first layer 10 is lower than the density of the second layer 12.
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In the figures, a thickness of the first layer 10 is about seven times that of the second layer 12.
In fig.1, the concrete paving block 1 has a quadratic form with three substantially plane side portions 7 and one side portion 7 provided with spacing means in the form of lips 9’ extending in a position of use in a vertical direction. A surface provided by means of a plurality of concrete paving blocks according to the embodiment shown in fig.1, will be “continuous”, i.e. substantially without gaps between the individual paving blocks when plane side portions 7 abut each other, while there will be a gap or an aperture between two concrete paving blocks 1 on the side portion 7 provided with the lips 9’.
In the embodiment shown in fig.1, a variety of spacing patterns may be provided in a surface covered by means of concrete paving blocks 1 according to the present invention. If two side portions 7 without any lips 9’ faces each other, no spacing is provided. If one side portion 7 without lips 9’ faces a side portion 7 of a neighbouring block 1provided with lips 9’, a “single” spacing is provided. If two side portions 7 of neighbouring blocks 1 provided lips 9’ are arranged face to face, a “double” spacing is provided.
In fig.2, the two side portions 7 shown are provided with spacing means here shown as lips 9, 9’ extending vertically along the first layer 10 of the side portions 7.
In the embodiment shown, the two lips 9 on the left side portion 7 are different from the four lips 9’ shown on the right side portion 7. Each pair of the four lips 9’ are configured for receiving a lip 9 of a not shown neighbouring concrete paving block 1. Thus, the lips 9, 9’ both serves as a spacing between side portions 7 of two neighbouring paving blocks 1, and an interlocking means for preventing two adjacent paving blocks from relative movement sideways. However, such an interlocking means is provided only if the two side portions not visible in fig.2 are provided with lips identical to the lips 9, 9’ being visible, configured so that two opposing side portions 7 have different types of lips 9, 9’, as shown in fig.5.
The lips 9, 9’ shown in fig.2 are integrated with and made from the same material as the material of the first layer 10, i.e. expanded clay aggregate in the embodiment shown.
In fig.3, the concrete paving block 1 is provided with a third layer 14. The third layer 14 is arranged on opposite side of the second layer 12 so that the first layer 10 is arranged between the second layer 12 and the third layer 14. The purpose of the third layer 14 may be to provide a bottom layer capable of withstanding high local stresses. Alternatively, the purpose of the third layer 14 may be to provide a concrete paving block having two alternative visual appearances and/or technical characters as discussed above.
In the embodiment shown in fig.3, two opposite side portions 7 are provided with lips 9’. If two concrete paving blocks shown in fig.3 are arranged side by side in the orientation shown, the lower right lip 9’ of a first paving block will be inserted between the two lowermost lips 9’ on the left of a
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second paving block (not shown). A side face of the right lip 9’ of a first concrete paving block 1 is configured to abut a side face of a “single” lip 9’ (corresponding to the uppermost shown in fig.3) of second paving block (not shown). Thus, the lips 9’ both provides an interlocking means and a spacing means.
Figures 4-6 show examples of various configurations of spacing means in the form of lips 9, 9’ arranged on all four side portions 7 of the concrete paving block 1. The lips 9, 9’ comprises two types; major lips 9, and minor lips 9’. In figures 4-6 each of the concrete paving block comprises four major lips 9 and eight minor lips 9’. In figures 4 and 5, a major lip 9 of the concrete paving block 1, may be arranged between two minor lips 9’ of a neighbouring concrete paving block (not shown). The lips 9, 9’ will in such an arrangement provide both a spacing means and an interlocking means. Alternatively, a major lip 9 of the concrete paving block 1, may abut a major lip 9 of a neighbouring concrete paving block (not shown). In such an embodiment, spacing means only is provided.
Thus, in the embodiment shown in figures 1 to 5 the spacing or annulus between adjacent concrete paving blocks 1 may be varied. In the embodiment shown in fig.6, the spacing should be constant.
The size of the major lips 9 and minor lips 9’ may be adapted to the size of the gaps desired in a surface provided by means of the concrete paving blocks according to the invention.
In a prototype of the concrete paving block according to the present invention, the thickness of the first layer is about 76 mm, and the thickness of the second layer is about 11 mm, i.e. the thickness of the first layer is about seven times that of the second layer. A footprint of the concrete block was 198 mm x 198 mm. A dry weight of such a paving block wherein the first layer was made from expanded clay aggregate is about 3,6 kg, while a prior art concrete block of same dimensions has a weight of about 8,4 kg.
In a laboratory test of a prototype paving block 1 of the aforementioned type wherein the first layer 10 was made from expanded clay aggregate, proved to have a water storing capacity for simulated torrential rain of about 20 % by volume. Thus, the concrete paving block 1 according to the prototype represents a water storage capacity of about 15 litres/m<2>. Due to the impermeable second or top layer 12, the paving block 1 absorbed water substantially in an upward direction from the lowermost portion of the first layer 10. However, some of the water flowing along the side portions 7 of the paving block 1, i.e. the water flowing off the top surface 3 and downwards along the side portions 7, may be absorbed from the side portions 7 of the first layer 10.
From the above, it should be clear that the concrete paving block according to the present invention provides a paving block which is substantial lighter than prior art paving block, while at the same time may be capable of providing attenuation of torrential rain. Further, in a position of use the concrete paving block may have a visual appearance as known from prior art paving blocks.
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The paving block according to the present invention is manufactured by pouring the concrete in a formwork or casting frame and then vibrating and/or compressing each of the layers before the framework are removed relatively few seconds after the second layer (top layer) has been compressed/vibrated. The layers are poured “wet-in-wet” which secures a very good adherence or interconnection between the two or three layers of concrete in the paving block.
It should be noted that the above-mentioned embodiments illustrate rather than limit the invention, and that those skilled in the art will be able to design many alternative embodiments without departing from the scope of the appended claims. In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim. Use of the verb "comprise" and its conjugations does not exclude the presence of elements or steps other than those stated in a claim. The article "a" or "an" preceding an element does not exclude the presence of a plurality of such elements.
The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage.
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