RU2166037C1 - Construction unit and machining attachments for its manufacture - Google Patents

Abstract

FIELD: construction engineering; hollow, masonry, and concrete units possessing bulging and decorative characteristics. SUBSTANCE: masonry concrete unit has main (building) part and finishing (protective and decorative) layer; the latter is 10-30 mm thick depending on type of surface finish and availability of facet; in addition to face finish of unit provided in parallel with hole axes, finishing layer may be made both on one and on two ends of this unit, if necessary; portland cement, brand 400, is used as binding material, ratio of materials for main part of unit is as follows, mas. %: volcanic ashes, 33-78; haydite, 0-44; fuel (boiler) slag, 0-44; portland cement, brand 400, 11-12; water, the balance; finishing layer is made of mix, ratio of ingredients is as follows, mas.%: granite, 0-33; marble, 0-33; tufa, 0-33; portland cement of cement brand 400, 33-34; water, the balance. Machining attachments for manufacturing construction unit (see Clause 1) has collapsible form and device for making voids and for positioning this device relative to form; the latter has plastic cell for producing finishing layer; form shell is made with cylindrical and conical openings and guiding webs; void-making device is made in the form of metal punches with plastic cone tightly fitted therein and facility for placing the latter between webs in the course of production. Machining attachments are provided with changeable inserts for producing finishing layers on ends of construction unit. Masonry concrete units are manufactured using various basic materials and combining main (building) part and finishing (protective and decorative) layer in masonry to produce monolithic article. EFFECT: improved precision of manufacture; reduced cost for building external walls and their in-service repairs. 4 cl, 3 dwg

Description

 The invention relates to the construction, in particular to hollow front wall concrete stones with both construction and decorative properties.

 Widely known are various building materials for erecting walls of buildings and structures, as well as plaster compositions and facing materials to protect the exterior walls of buildings from atmospheric phenomena and to give these walls decorative properties (Nanazashvili I.Kh. Building materials, products and structures. Reference book. M .: Higher school, 1990, L. Popov. General technology of building materials. M: Higher school, 1989).

However, these materials have several disadvantages:
- the outer (front) surfaces of wall building materials in the form of ceramic or silicate bricks, ceramic stones or panels made from them in the factory, as well as concrete wall stones do not have finishing (protective and decorative) surfaces, are susceptible to the effects of temperature fluctuations, rains and fogs in combination with gusts of wind, due to which the outer walls of buildings are prone to smudges, delamination and chipping. In order to avoid these defects, expensive finishing work in the form of plastering or lining with artificial ceramic and natural stone tiles is used. However, even with such a finish, even minor defects made under the influence of atmospheric phenomena, cause the destruction of the facing coatings;
- wide permissible size deviations (from 1 to 4.5%) of both wall and facing materials, which entails an increased consumption of cement-sand mortars and labor costs during construction work and their cost increases;
- the use of a relatively narrow formulation of raw materials used both in the manufacture of wall concrete stones and for their decoration.

 The closest analogue to the proposed building element is a building element in the form of a hollow concrete stone having a rectangular shape, with a finishing layer located on the front side and at the end. The building element is made of concrete mixture, and the finishing layer is made of a mixture containing sand, cement and coloring pigments (see UK application N 2238807, publ. 12.06.91).

 The closest analogue in terms of the device is tooling for the manufacture of a building element, consisting of a collapsible form, a device for forming voids and fixing the latter relative to the form (see UK application N 1645776, publ. 18.10.27).

 The objective of the invention is the provision of the manufacture of wall concrete stones using various options for raw materials and combining in these stones the main (construction) part and the finishing (protective and decorative) layer in a monolithic product with high accuracy in obtaining specified sizes and shapes, which reduce the cost of building from them external walls of buildings, and their repair during operation.

The problem is solved in that in a building element in the form of a wall, hollow concrete stone, having the shape of a rectangular parallelepiped, with a finishing layer located at least on the front surface, the finishing layer has a thickness of 10-30 mm, depending on the type of texture and availability facet, while the concrete stone is made of a mixture containing in wt.%:
Volcanic Ash - 33-78
Expanded clay - 0-44
Fuel (boiler) slag - 0-44
Portland cement brand M 400 - 11 -12
Water - Else
and the finishing layer is made of a mixture containing in wt.%:
Granite - 0-33
Marble - 0-33
Tuff - 0-33
Portland cement brand 400 - 33-34
Water - Else
At the same time, in the building element, the finishing layer is made of a mixture containing Portland cement grade M 400 white or colored.

 Also, the problem is solved in that in the technological equipment for the manufacture of the building element according to claim 1, consisting of a collapsible mold and a device for molding voids and fixing the latter relative to the mold, the mold has a plastic cuvette for molding the finishing layer, and the shell of the mold is made with cylindrical and conical holes and guide cheeks, while the device for forming the voids is made in the form of metal punches with a tightly inserted plastic cone, and the installation for displacements of the last between the cheeks in the molding process.

 At the same time, the technical equipment is equipped with interchangeable inserts for the manufacture of finishing layers at the ends of the building element.

 In FIG. 1 schematically shows a mold for the manufacture of a building element with a facing layer of one of its front sides.

 In FIG. 2 shows a device for forming the voids of a building element.

 In FIG. 3 schematically illustrates interchangeable mold inserts.

 Technological equipment for the manufacture of a building element consists of a collapsible form (Fig. 1) with a plastic cuvette for molding a facing layer, the inner bottom of which is made smooth or with various reliefs that imitate the textured finish of the front surface of this layer obtained from products made of natural stone percussion abrasive or sandblasted. The metal shell 2, providing the molding of the main part of the stone, has a handle 3, guide cheeks 4, conical 5 and cylindrical 6 holes.

 The device for forming voids (Fig. 2) consists of a plate 1, the lower long end of which is rigidly attached to the surface of the vibrating table (not shown in the figure), to which, in turn, hollow metal punches (which are made conical in the manufacturing example of the element) are attached inserted plastic cones 3. In the upper part of the plate, a unit 4 is made, which during molding is placed between the guiding cheeks of the mold.

 Replaceable inserts (Fig. 3) are made in the form of rigid metal bar frames with one smooth metal wall 1 (a), used when it is necessary to manufacture one end facing layer and with two smooth walls 1 (b), if necessary, to make two end facing layers.

The diagonally arranged rods 2 and 3 on the upper parts of the liners serve as handles for installing and removing these liners during operation, where
L is the liner length equal to the length of the building element minus the thickness of the finishing layer;
L - o.s. the length of the liner when arranging the finishing layers at both ends of this element.

 In the manufacture of the proposed building element, the following work is performed.

 First, solutions of the main part of the element and its finishing layer are prepared according to the above formulations using the known technology, then a cuvette 1 (Fig. 1) of the form is placed on a vibrating table of known design and filled with a solution selected for the finishing layer and vibrated, adding the solution with a spatula aligned with it with the edges of the cuvette 1 (Fig. 1) until the exit of air bubbles stops on the surface of the solution, after which the cuvette with the vibrated solution is placed on a fixed shelf and give the necessary exposure, airborne from the ambient temperature, and after that the cuvette with the vibrated and aged solution is again placed on the inoperative vibrating table, put on the casing of form 2 (Fig. 1), and push the form (Fig. 1) onto the device for forming voids in stone ( Fig. 2). The guiding cheeks, installation and holes provide reliable fixation and precise location of prefabricated punches forming voids in the manufactured products. The clamps that provide the process of assembly and operation of the mold, the exact mating of the inner surfaces of the walls of the cell and the shell, are not shown in the figures.

 Then fill the form (Fig. 1) with a solution of the main part of the stone and, including a vibrating table, compact this solution with the addition of it and aligning it with a spatula with the edges of the shell 2 (Fig. 1) until water appears on the surface of the vibrated solution. After that, the vibrating table is turned off, the shape is shifted (Fig. 1) from the device for forming voids (Fig. 2) and set for natural drying until the building element is completely ready.

 If it is necessary to obtain a building element with a finishing layer on the front and one of the end surfaces, insert the insert (Fig. 3a) in such a way that between the wall 1 (Fig. 3) of this the liner and the end wall of the cuvette (Fig. 1), a space is formed, filled with a finishing solution, which is supplemented by vibration and leveled with a spatula, as described above, until air bubbles are released, after which the vibration is stopped, the resulting layer is given the necessary exposure The mold and the mold are reinstalled on a vibrating table, a device for forming voids is inserted into it, filled with a solution of the main part of the product, and then they work as described above, but only with removal of the insert at the end of the solution compaction operation.

 If it is necessary to obtain two ends with a finishing layer from a building element, an insert (Fig. 3, 6) is used and all work is carried out as with the insert shown in FIG. 3a.

 The manufacture of a pilot industrial building element fully confirmed the achievement of the goal set in the invention.

Claims (3)

1. A building element in the form of a wall, hollow concrete stone, having the shape of a rectangular parallelepiped, with a finishing layer located at least on the front surface, characterized in that the finishing layer has a thickness of 10-30 mm, depending on the type of texture and the presence of facet , while the concrete stone is made of a mixture containing, wt.%:
Volcanic ash - 33 - 78
Expanded clay - 0 - 44
Fuel (boiler) slag - 0 - 44
Portland cement grade M 400 - 11 - 12
Water - Else
and the finishing layer is made of a mixture containing, wt.%:
Granite - 0 - 33
Marble - 0 - 33
Tuff - 0 - 33
Portland cement grades 400 - 33 - 34
Water - Else
2. The building element according to claim 1, characterized in that the finishing layer is made of a mixture containing Portland cement grade M 400 white or color.  3. Tooling for the manufacture of a building element according to claim 1, consisting of a collapsible mold and a device for forming voids and fixing the latter relative to the mold, characterized in that the mold has a plastic cuvette for molding the finishing layer, and the shell of the mold is made with cylindrical and conical holes and guide cheeks, while the device for forming voids is made in the form of metal punches with a tightly inserted plastic cone and a device for placing the last waiting cheeks in the molding process.  4. Technical equipment according to claim 3, characterized in that it is equipped with interchangeable inserts for the manufacture of finishing layers at the ends of the building element.

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