RU2311514C2 - Two-layer facing building member (variants) - Google Patents

Abstract

FIELD: construction, particularly two-layer facing panels used for decorative civil and industrial building facing.

SUBSTANCE: facing building member comprises concrete monolithic body having facing layer of regular or irregular shape. Both layers are formed of semi-dry materials. Fine filler used for constructional layer is quartz sand and keramzite sand with gradation factor of 1.1-2.8. Coarse filler is milled keramzite gravel having particle dimensions of 5-10 mm. Facing layer includes Portland cement M500. said components are taken in the following amounts (% by weight): constructional layer in semidry state: Portland cement 20-35, keramzite sand 5-37, quartz sand - 0-37, milled keramzite gravel - 5-45, remainder is water; facing layer in semidry state: Portland cement 15-30, sand 60-75, remainder is water. The second building member variant is also disclosed.

EFFECT: improved constructional and decorative properties, extended range of building members application due to creation of two building member variants, increased quality and service characteristics.

4 cl, 11 ex

Description

The invention relates to construction, in particular to the production of two-layer facing building elements with both building and multivariate decorative properties that meet modern requirements of architectural solutions for decorative exterior cladding of civil and industrial construction objects.

From the technical level, the “Decorative facing building stone” is known, consisting of building and decorative facing layers. The decorative-facing layer is made of a mixture of a hydraulic binder, filler and pigment, and silicate or ceramic bricks are used as the building layer, and the specified ratio of the thickness of the finishing and building layers is maintained [П No. 2131006].

The disadvantage of this facing building stone is that it does not have sufficient heat-insulating properties, and the finishing layer does not allow to obtain a diverse texture of finish.

From the technical level, a two-layer concrete building stone is also known, including a facing layer made of a mixture of cement, expanded clay, sand and water in the following ratio of 2.4: 2.2: 5.4: 1.0 with the addition of 10% plasticizer and the necessary amount of coloring pigment. The construction layer is made of foam concrete or expanded clay concrete containing a mixture of cement, expanded clay, sand and water in a ratio of 3.1: 3.4: 1.9: 0.15 with the addition of a foaming agent. The thickness ratio between the building layer and the finishing layer is 2.3: 0.7 [P RU No. 2208102, 2003.07.10]. The use of expanded clay in the composition of the building and facing layers can improve the heat-insulating properties of building stone, but increases the thickness of the finishing layer.

It is also known that in order to improve the quality of the building layer, fine-grained (sand) concrete is injected with relatively rigid quartz expanded clay sand, which promotes branching of cracks, inhibits their growth, reduces the stress concentration in the contact zone of concrete components, which leads to an increase in the impact strength of concrete [AC SU 887518, BI No. 45 07.12.81].

Known wall concrete facing building element, composed of the main (construction) layer and facing (protective and decorative) layer. The decorative facing layer is 10-30 mm thick, and the following ingredients are used as a mixture for its manufacture in the ratio, wt. %: granite 0-33, marble 0-33, tuff 0-33, Portland cement grade M400 33-34, the rest is water. The main building layer is also prepared on the basis of a binder, which is used Portland cement grade 400 in the following ratio of ingredients, wt. %: volcanic ash 33-78, expanded clay 0-44, fuel (boiler slag 0-44), Portland cement grade M 400 11-12, water - the rest. Moreover, in the building element, the finishing layer is made of a mixture containing Portland cement grade M 400 - white or colored [P RU 2166037, publ. 2001.09.10].

The closest in technical essence and the number of matching essential features for the claimed two-layer facing building element is a building element according to item No. 2173374. The building element of the prototype has a regular or irregular geometric shape in the form of a spatial polyhedron, and the composition of its building layer in wt. % includes a filler in the form of volcanic ash 5-32, perlite sand 0-32, expanded clay 45-75, as well as Portland cement M 400 - 10 and water. The facing layer also consists, wt. % of Portland cement M 400 of any color 30, water and filler in the form of chips of marble, and / or granite, and / or tuff, and / or crushed stone, and / or basalt, and / or limestone, and / or diabase, and / or syenite, and / or diorite, and / or labrodorite, and / or sandstone, and / or quartzite, and / or glass breakage, and / or ceramic or silicate brick, and / or metlakh or glazed tiles, and / or porcelain products 0 -50 and has a thickness of the order of 5-45 mm.

The building element of the prototype allows for the production of wall concrete stones using various options for raw materials and the combination of the finishing and building layers in these stones in a monolithic product with high accuracy of obtaining the specified sizes and shapes.

The objective of the invention is to expand the arsenal of two-layer facing building elements by creating two variants of these products, characterized by high operational and quality characteristics.

Technical results that can be obtained by implementing the claimed variants of the invention are:

- the possibility of realizing the appointment of a new monolithic two-layer facing building element,

- increasing the strength of a two-layer facing building element.

The solution of this problem and the achievement of the above technical results for the product according to the first embodiment became possible due to the fact that in a two-layer facing building element in the form of a concrete wall monolithic body with a finishing layer having the right or wrong geometric shape, in which the material for the building layer is a mixture, including small and large aggregate, Portland cement not lower than M 400 and water, and the material for the facing layer is a mixture comprising Portland cement colored sand, aggregate in the form of sand and water, mixtures for materials of both layers were used in a dry phase state, quartz sand and / or expanded clay sand with a particle size of 1.1 to 2.8 were used as fine aggregate for the material of the building layer crushed expanded clay gravel of a fraction of 5-10 mm is used as a large aggregate, and Portland cement M 500 is present in the composition of the facing layer in the following ratio of components, wt. %:

The composition of the mixture of the building layer in a dry phase state:

Portland cement 20-35 Expanded clay sand 5-37 Quartz sand 0-37 Crushed expanded clay gravel 5-45 Water Rest

The composition of the mixture of the facing layer in a dry phase state:

Portland cement M 500 15-30 Sand 60-75 Water Rest.

The solution of this problem and the achievement of the above technical results for the product according to the second embodiment became possible due to the fact that in a two-layer facing building element in the form of a concrete wall monolithic body with a facing layer having the right or wrong geometric shape, in which the material for the building layer is a mixture, including small and large aggregate, Portland cement not lower than M 400 and water, and the material for the facing layer is a mixture comprising Portland cement l The color of sand, aggregate in the form of sand and water, mixtures for materials of both layers were applied in a dry phase state, quartz sand and / or expanded clay sand with particle size from 1.1 to 2.8 were used as fine aggregate for the material of the building layer. as a large aggregate - gravel and / or crushed stone of dense rocks, and Portland cement M 500 is present in the composition of the facing layer during the following sorting of components, wt. %:

The composition of the mixture of the building layer in a dry phase state:

Portland cement 10-20 Expanded clay sand 5-20 Quartz sand 0-36 Gravel and / or crushed stone of dense rocks 10-26 Water rest

The composition of the mixture of the facing layer in a dry phase state:

Portland cement M 500 15-30 Sand 60-75 Water Rest

In an example of a particular embodiment of a building facing element, at least one pigment in an amount of 0.5-10% by weight of Portland cement is additionally included in the mixture of the facing layer in a semi-dry phase state.

The use of 5-10 mm fractions in combination with quartz and expanded clay sand with a particle size modulus of 1.1 to 2.8 provides a uniform pseudo-porous structure with a density of up to 1350 kg / m in the inventive material according to the first embodiment for a building layer of crushed expanded clay gravel fraction .

The use of mixtures in a semi-rigid phase state allows to accelerate the production process due to the possibility of immediate stripping, which reduces the metal consumption of the tooling and increases productivity, and is also aimed at achieving such high operational and technical characteristics as frost resistance of at least 50 cycles, compressive strength from M 75 to M 150 according to the first embodiment and from M 75 to M 300 according to the second embodiment.

The thickness of the facing layer correlates with the size of the aggregate and is in the range from 2 to 10 mm.

In the manufacture of the facing layer, gray, white or colored Portland cement grade 500 can be added to the composition of the mixture, as well as pigments, the percentage of introduction of which is from 0.5 to 10% by weight of Portland cement. In the manufacture of the building layer, gray Portland cement grade not lower than M 400 is used.

The inventive two-layer facing building element is made as follows. At the same time, the composition of the mixture of the building layer in the dry phase state and the composition of the mixture of the facing layer in the dry phase in forced mixers are prepared and fed to separate bins of the molding machine. First, fill the mixture of the main building layer in one or more stages with compaction and vibration. Then immediately fill the mixture of the facing layer and produce the final vibration sealing of both layers. Next, an immediate stripping of the product is made and its endurance with or without heating until the product has a tempering strength.

In particular embodiments, pigment is added to the mixture for the facing layer at the rate of 0.5-10% by weight of Portland cement in this mixture.

The practical applicability of the inventive two-layer facing building element is shown in the following specific examples.

Example 1 (first option)

At the same time, the composition of the mixture of the building layer in the semi-dry phase state and the composition of the mixture of the finishing layer in the semi-dry phase state in forced-action concrete mixers are prepared and fed to separate bins of the molding machine. First, the mixture of the building layer is backfilled in several stages with compaction and vibration. Then immediately fill the mixture of the facing layer and produce the final vibration sealing of both layers. Next, an immediate stripping of the products and their exposure with heating to achieve the tempering strength of the product are carried out.

The material used is a mixture in a semi-dry phase state of the following composition, wt. %:

For the construction layer:

Portland cement twenty Expanded clay sand 5 Quartz sand twenty Crushed expanded clay gravel 45 Water 10

For the facing layer:

Portland cement M 500 fifteen Sand 75 Water 10

which corresponds to the minimum values of the components within the claimed limits for Portland cement and expanded clay sand and the maximum value of crushed expanded clay gravel in the mixture of the building layer, as well as the minimum value of Portland cement and the maximum - sand in the mixture of the facing layer.

Received a two-layer facing building element with the following indicators:

The thickness of the facing layer, mm 9 Covering color Gray The density in the dry state, kg / m ³ 1320 Compressive strength, kg / cm ² 75 Frost resistance, cycles fifty

Example 2 (first option)

According to example 1, a red pigment is added to the mixture for the front layer in the amount of 5% by weight of portladcement in this mixture.

The material used is a mixture in a semi-dry phase state of the following composition, wt. %:

For the construction layer:

Portland cement  24 Expanded clay sand 21 Quartz sand 0 Crushed expanded clay gravel 45 Water 10

For the facing layer:

Portland cement M 500 23 Sand 67 Water 10

which corresponds to the average value for expanded clay sand and the maximum for crushed expanded clay gravel within the claimed limits in the mixture of the building layer and the average values for Portland cement and sand in the mixture of the facing layer. Quartz sand is absent in the mixture of the building layer. The amount of red pigment corresponds to a value close to the average within the claimed limits.

Received a two-layer facing building element with the following indicators:

The thickness of the facing layer, mm 10 Covering color red The density in the dry state, kg / m ³ 1350 Compressive strength, kg / cm ² 120 Frost resistance, cycles fifty

Example 3 (first option)

According to example 1, a yellow pigment is added to the mixture for the front layer in an amount of 0.5% by weight of portladcement in this mixture. Exposure with heating until the product reaches the ductile strength.

The material used is a mixture in a semi-dry phase state of the following composition, wt. %:

For the construction layer:

Portland cement 27 Expanded clay sand 21 Quartz sand 37 Crushed expanded clay gravel 5 Water 10

For the facing layer:

Portland cement M 500 twenty Sand 70 Water 10

which corresponds to the maximum value for quartz sand, the average values for Portland cement and expanded clay sand and the minimum value of crushed expanded clay gravel within the claimed limits in the mixture of the building layer. The amount of yellow pigment corresponds to the minimum value within the claimed limits.

Received a two-layer facing building element with the following indicators:

The thickness of the facing layer, mm 8 Covering color yellowish The density in the dry state, kg / m ³ 1750 Compressive strength, kg / cm ² one hundred Frost resistance, cycles fifty

Example 4 (first option)

According to example 1, in the mixture for the front layer is additionally introduced a pigment of red in the amount of 5% by weight of portladcement in this mixture.

The material used is a mixture in a semi-dry phase state of the following composition, wt. %:

For the construction layer:

Portland cement fifteen Expanded clay sand 37 Quartz sand 0 Crushed expanded clay gravel 38 Water 10

For the facing layer:

Portland cement M 500 10 Sand 80 Water 10

which corresponds to a value for Portland cement less than the minimum within the claimed limits, the maximum value for expanded clay sand and is characterized by the absence of quartz sand. The amount of red pigment corresponds to a value close to the average within the claimed limits.

Received a two-layer facing building element with the following indicators:

The thickness of the facing layer, mm 9 Covering color light red The density in the dry state, kg / m ³ 1250 Compressive strength, kg / cm ² 68 Frost resistance, cycles 40

Example 5 (first option).

According to example 1, in the mixture for the front layer is additionally introduced a red pigment in an amount of 10% by weight of portladcement in this mixture.

The material used is a mixture in a semi-dry phase state of the following composition, wt. %:

For the construction layer:

Portland cement 35 Expanded clay sand 5 Quartz sand 2 Crushed expanded clay gravel 48 Water 10

For the facing layer:

Portland cement M 500 35 Sand 55 Water 10

which corresponds to the values of the components above the maximum for crushed expanded clay gravel, the maximum for Portland cement and the minimum for expanded clay sand in the building layer mixture and above the maximum for Portland cement and below the minimum for sand in the facing layer mixture. The amount of red pigment corresponds to the maximum value in the claimed range.

Received a two-layer facing building element with the following indicators:

The thickness of the facing layer, mm 9 Covering color red The density in the dry state, kg / m ³ 1280 Compressive strength, kg / cm ² 150 Frost resistance, cycles thirty

At the same time, a significant cost overrun of cement was obtained, an increase in cost and a decrease in quality in frost resistance.

Example 6 (option 1)

According to example 1, a red pigment is added to the mixture for the front layer in an amount of 0.3% by weight of portladcement in this mixture.

Exposure until the product reaches the ductile strength without heating.

The material used is a mixture in a semi-dry phase state of the following composition, wt. %:

For building layer

Portland cement twenty Expanded clay sand 45 Quartz sand twenty Crushed expanded clay gravel 5 Water 10

For the facing layer:

Portland cement M 500 25 Sand 65 Water 10

which corresponds to values above the maximum for expanded clay sand and the minimum for Portland cement and crushed expanded clay gravel within the claimed limits for the building layer. The amount of red pigment corresponds to a value less than the minimum relative to the claimed limits.

Received a two-layer facing building element with the following indicators:

The thickness of the facing layer, mm 5 Covering color Gray The density in the dry state, kg / m ³ 1400 Compressive strength, kg / cm ² 75 Frost resistance, cycles fifty

Example 7 (second option)

Separately, the composition of the mixture of the building layer in the semi-dry phase state and the composition of the mixture of the finishing layer in the semi-dry phase state in forced-action mixers are prepared and simultaneously fed to separate bins of the molding machine. First, the main building layer is backfilled in several stages with compaction and vibration. Then immediately cover the facing layer and produce the final vibration sealing of both layers. Next, an immediate stripping of the products and their exposure with heating to achieve the tempering strength of the product are carried out.

The material used is a mixture in a semi-dry phase state of the following composition, wt. %:

For building layer

Portland cement 10 Expanded clay sand 24 Quartz sand thirty Dense gravel and gravel 26 Water 10 For facing layer Portland cement M 500 fifteen Sand 75 Water 10

which corresponds to the minimum value for Portland cement, the maximum - for gravel and crushed stone of dense rocks, close to average - for expanded clay sand and quartz sand within the claimed limits for a mixture of the building layer, as well as the minimum value for the Portland cement cladding layer.

Received a two-layer facing building element with the following indicators:

The thickness of the facing layer, mm 2 Covering color Gray The density in the dry state, kg / m ³ 2000 Compressive strength, kg / cm ² 200 Frost resistance, cycles fifty

Example 8 (second option)

According to example 7, a yellow pigment in the amount of 14% of the amount of Portland cement in this mixture is additionally introduced into the mixture of the facing layer.

The material used is a mixture in a semi-dry phase state of the following composition, wt. %:

For the construction layer:

Portland cement fifteen Expanded clay sand twenty Quartz sand 29th Dense gravel 26 Water 10

For the facing layer:

Portland cement M 500 23 Sand 67 Water 10

which corresponds to the maximum value for gravel of dense rocks, the average value for Portland cement, close to the average for expanded clay sand within the claimed limits of the mixture of the building layer, as well as the average values for Portland cement and sand in the facing layer. The amount of yellow pigment corresponds to a value above the maximum within the claimed limits.

Received a two-layer facing building element with the following indicators:

The thickness of the facing layer, mm 7 Covering color intense yellow The density in the dry state, kg / m ³ 2200 Compressive strength, kg / cm ² one hundred Frost resistance, cycles fifty

Example 9 (second option)

According to example 7.

Exposure without heating until the product reaches the ductile strength.

The material used is a mixture in a semi-dry phase state of the following composition, wt. %:

For the construction layer:

Portland cement twenty Expanded clay sand 22 Quartz sand 22 Crushed stone of dense rocks 26 Water 10

For the facing layer:

Portland cement M 500 thirty Sand 60 Water 10

which corresponds to the maximum values for Portland cement and crushed stone of dense rocks, the average value for expanded clay sand within the claimed limits for the mixture of the building layer, as well as the maximum value for Portland cement and the minimum for sand in the mixture of the front layer.

Received a two-layer facing building element with the following indicators:

The thickness of the facing layer, mm 8 Covering color Gray The density in the dry state, kg / m ³ 2200 Compressive strength, kg / cm ² 300 Frost resistance, cycles fifty

Example 10 (second option)

According to example 7, a yellow pigment in an amount of 0.3 of the amount of Portland cement in this mixture is additionally introduced into the mixture of the facing layer.

Exposure until the product reaches the ductile strength without heating.

The material used is a mixture in a semi-dry phase state of the following composition, wt. %:

For the construction layer:

Portland cement 8 Expanded clay sand 36 Quartz sand 16 Dense gravel and gravel thirty Water 10

For the finishing layer:

Portland cement M 500 thirty Sand 60 Water 10

which corresponds to the value of Portland cement less than the minimum, expanded clay sand - the maximum value for the mixture of the building layer, as well as the maximum value of Portland cement and the minimum sand for the mixture of the facing layer. The amount of yellow pigment corresponds to a value less than the minimum relative to the claimed limits on the mass of Portland cement. Received a two-layer facing building element with the following indicators:

The thickness of the facing layer, mm 10 Covering color Gray The density in the dry state, kg / m ³ 2500 Compressive strength, kg / cm ² 60 Frost resistance, cycles 40

Example 11 (second option)

According to example 7.

Exposure to achieve the tempering strength of the product with heating.

The material used is a mixture in a semi-dry phase state of the following composition, wt. %:

For the construction layer:

Portland cement 25 Expanded clay sand 38 Quartz sand 0 Dense gravel and gravel 27 Water 10

For the facing layer:

Portland cement M 500 35 Sand 55 Water 10

which corresponds to the values for Portland cement, expanded clay sand and gravel and crushed stone of dense rocks above the maximum components in the declared limits in the mixture of the building layer, as well as the values for Portland cement above the maximum and sand below the minimum in the mixture of the facing layer.

Received a two-layer facing building element with the following indicators:

The thickness of the facing layer, mm 2 Covering color Gray The density in the dry state, kg / m ³ 2200 Compressive strength, kg / cm ² 300 Frost resistance, cycles fifty

As can be seen from examples 1-3 in the first embodiment and 7-9 in the second embodiment, the claimed combination of essential features in the form of preparation of material compositions for the building and facing layers in a dry phase state and the components that make up the material, allows the claimed variants of a two-layer facing building element to fulfill the task - the expansion of the arsenal of two-layer facing building elements by creating two versions of these products, characterized by high operational onnymi and quality characteristics, and their purpose to realize high quality characteristics of the compressive strength of M75 to M150 for a first embodiment and from M300 to M75 of the second embodiment. The use of crushed claydite gravel of 5-10 mm in the composition of the building layer in combination with expanded clay sand with a particle size modulus of 1.1 to 2.8 allows you to create a pseudo-porous structure that provides, on the one hand, a high density of the building layer, on the other hand, high heat insulating properties. The correlation of the percentage of pigment with the weight of Portland cement in the facing layer in the range from 0.5 to 10% provides the possibility of obtaining for both variants the desired color of the facing layer (examples 2, 3, 4, 5). Reducing the amount of pigment below the claimed limit does not provide staining of the facing layer, the excess leads to overuse of the pigment (examples 6 and 8).

The increase in Portland cement in both cases increases the compressive strength of the two-layer building element (examples 3, 5, 8). A decrease in the amount of Portland cement below the claimed limits leads to a significant decrease in strength (examples 4, 9). Exceeding the claimed limits leads to cost overrun of Portland cement (examples 5, 11).

The increase in the content of gravel and / or crushed stone of dense rocks in the building mixture for the second option increases the density and compressive strength (examples 9, 10).

The use of Portland cement M 500 as part of the facing layer in both cases increases the strength of the product and its quality.

Claims (4)

1. A two-layer facing building element in the form of a concrete wall monolithic body with a facing layer having a regular or irregular geometric shape, in which the material for the building layer is a mixture comprising fine and coarse aggregate, Portland cement grade not lower than 400 and water, and the material for the facing layer is a mixture including Portland cement of any color, aggregate and water, characterized in that the mixture for the materials of both layers are applied in a semi-dry phase state, as fine for the material of the building layer, quartz sand and expanded clay sand with a particle size modulus of 1.1 to 2.8 were used, crushed expanded clay gravel of a fraction of 5-10 mm was used as a large aggregate, and Portland cement M 500 was present in the composition of the facing layer in the following ratio of components , wt.%: the composition of the mixture of the building layer in a dry phase state: Portland cement 20-35 expanded clay sand 5-37 quartz sand 0-37 crushed expanded clay gravel 5-45 water rest the composition of the mixture of the facing layer in a dry phase state: Portland cement M 500 15-30; sand 60-75 water rest 2. The two-layer facing building element according to claim 1, characterized in that the composition of the mixture of the facing layer in a dry phase state further includes at least one pigment in an amount of 0.5-10% by weight of Portland cement. 3. A two-layer facing building element in the form of a concrete wall monolithic body with a facing layer having a regular or irregular geometric shape, in which the material for the building layer is a mixture comprising small and large aggregate, Portland cement not lower than M 400 and water, and the material for the facing layer is a mixture comprising Portland cement of any color, aggregate and water, characterized in that the mixture for the materials of both layers are applied in a semi-dry phase state, as a fine The carrier for the material of the building layer is quartz sand and / or expanded clay sand with a particle size modulus of 1.1 to 2.8, gravel and / or crushed stone of dense rocks are used as a coarse aggregate, and Portland cement M 500 is present in the composition of the facing layer in the following ratio components, wt.%: the composition of the mixture of the building layer in a dry phase state: Portland cement 10-20 expanded clay sand 5-36 quartz sand 0-36 gravel 10-26 water rest the composition of the mixture of the facing layer in a dry phase state: Portland cement M 500 15-30 sand 60-75 water rest 4. The two-layer facing building element according to claim 2, characterized in that at least one pigment in an amount of 0.5-10% by weight of Portland cement is additionally included in the mixture of the facing layer in a semi-dry phase state.