RU2325491C2 - Method of making construction blocks with natural rock or wood finishes - Google Patents

Abstract

FIELD: construction, superstructures.

SUBSTANCE: principle applies to construction, in particular to production of face tiles and blocks and can be used in the preparation of wall blocks with face tiles from natural rock, or wood panels and also ceramic tiles. The technical result is to ensure the functional capability of blocks during cost reduction of its preparation. Firstly, flat decorative elements (FDE) are prepared, which can be done in the form of one or more tiles of natural rock or in the form of one or more wood panels, and also a combination of these. FDE may consists of number of fragments of each, and side surfaces of FDE are preliminary polished and are fitted one to the other and then placed in the frame, tightly tuck together and inundated with a liquid building mixture. One or more ready FDE is placed in a shaped tray and concrete is poured and the tray is put on a vibration press and vibrated to complete compaction of the concrete and then the ready block is dried under natural conditions. A formwork for a ready construction block is then prepared. Construction blocks can also be prepared from foam concrete, in which the foam concrete layer is placed in a vertical plane from the internal side of the block. In this case the foam concrete layers are made in the form of separate inserts or layer of foam concrete is made by pouring foam concrete into a tray frame using parting metallic plate, which is removed after the tray has been filled up by concrete and foam concrete. For the preparation of flat decorative elements, a moulding box with clamps is used. For the strengthening of the attachment of flat decorative elements to the surface of the construction block, a number of ways are used to preliminary work on rear surfaces of the flat decorative elements. To widen the nomenclature of construction blocks, blocks can be made in form of half-blocks, corner blocks or double sided polished blocks. For work convenience, blocks are prepared with an opening at the top with an undercut for proper handling and hand grip.

EFFECT: ensuring functional capability of a block and reduction of its production cost.

14 cl, 6 dwg

Description

The invention relates to the construction, namely the production of facing plates and blocks, and can be used in the manufacture of wall blocks with tiles made of natural stone or wooden panels, as well as with ceramic tiles.

The well-known "Method of mosaic coating" (AS USSR No. 896216, IPC 3 E04F 15/02, BI No. 1, 1982), including laying on a bearing base of a mosaic carpet on a mortar mixture and keeping the latter until it hardens, while before laying the mosaic carpet on its back surface, a lattice made of water-soluble material is fixed, then the cavity of the lattice is filled with a dry building mixture, after which the carrier base is moistened.

The disadvantage of this method is the inability to obtain a durable finish of the outdoor building block using heterogeneous materials - natural stone, wood panels or ceramic tiles.

The well-known "Method for the manufacture of decorative heat and sound insulating facing panels" (AS USSR No. 1783092, MPK-5 E04F 13/02, BI No. 47, 1992). Before laying the ceramic tile is heated to 250-280 ° C. The connection of the tile with a layer of sheet foamed thermoplastic is carried out by pressing under a pressure of 0.15-0.5 kG / cm ² . Then stand the tile under pressure until it cools to a temperature of 40-50 ° C.

The disadvantage of this method is the inability to obtain a durable finish of the outdoor building block due to the low strength properties of building products using sheet foamed thermoplastic for products used for the exterior decoration of buildings and structures.

The well-known "Method of volume-profile cladding of building products with tiled materials on the principle of" self-anchoring "(Passport of scientific and technological achievement No. 29, VNIINTPI Gosstroy of the USSR, UDC 693.69, GASNTI 67.13.41, 1991). The method involves the use of a relief matrix made with parallel repeating persistent and inclined faces, the inclined position of which is ensured by a steel profile of the corner type. Cladding tiles are laid on the inclined faces of the matrix with an inlet relative to its resistant faces, the matrix with tile They are installed in a pallet for molding building products, and a relief three-dimensional structure is imparted to the lined surface, thereby achieving a significant improvement in plasticity and a variety of building facades, and pinching ("self-anchoring") of the upper ends of the tiles increases the strength of their fastening to the panel.

The disadvantage of this method is the inability to obtain a durable finish of the outdoor building block using heterogeneous materials - natural stone, wood panels or ceramic tiles.

The well-known "Method for the manufacture of concrete products with a facing layer" (A.S. USSR No. 1783092, MPK-5 VB 13/02, BI No. 32, 1991). The method is as follows. First, the forming surfaces of the sides and matrices of the pallet are treated with emulsion lubricant. Then, water is sprayed onto the surface of the pallet matrices until a film is formed and ceramic tiles are laid. The tiles moisturize, lay the mortar layer and the concrete mixture of the structural layer. They produce vibration compaction and subsequent heat treatment of products. Then make formwork and surface cleaning.

The disadvantage of this method is the inability to obtain a durable finish of the outdoor building block using heterogeneous materials - natural stone, wood panels or ceramic tiles.

The closest in technical essence and the achieved technical result and selected as a prototype is the "Method for manufacturing a facing plate" (AS USSR No. 1502411, MPK-4 VV 13/00, BI No. 31, 1989). Flat elements of natural stone of irregular shape in plan are laid in a pallet and their side faces and non-face surface are covered with a thin layer of methyl methacrylate with a hardener - benzoyl peroxide and incubated for a period of 80-90% of the full cure time, after which the polyester concrete mixture is poured.

The disadvantage of the prototype is the high cost of the manufactured cladding due to the high cost of materials and components. In addition, the slab made according to the prototype cannot be used as a load bearing building element.

The objective of the present invention is to develop a new method of manufacturing building blocks with a decorative coating with the achievement of a technical result - to increase the functional ability of the block with the cost of its manufacture.

The task is carried out by the fact that in the "Method for the manufacture of building blocks with natural stone or wood paneling", which includes laying flat decorative elements on the bottom of the pallet and pouring them with liquid mortar, keeping the product to solidify the building mixture, forming the product, the finished product is made in in the form of a building block, one or several surfaces of which are lined with flat decorative elements consisting of several fragments each, and the side surfaces of the pl The decorative elements are pre-ground and adjusted to each other, and then tightly installed in the mold frame and poured with a liquid mortar, after curing of which one or more finished flat decorative elements are installed in a pallet mold and filled with concrete, then the pallet mold is installed on vibropress and vibrate until the concrete is completely compacted, then the finished block is dried in natural conditions, in addition, the building block is made using foam concrete, and the foam concrete layer and they are placed in a vertical plane on the inside of the block, while the foam concrete layer is made in the form of a separate insert or is obtained by pouring foam concrete into a pallet mold using a dividing metal plate, which is removed after filling the pallet mold with concrete and foam concrete, and the building block is made in in the form of half-blocks, corner blocks, blocks with two-sided finishing, and the building block is made with a hole in the upper part of the block with undercuts for gripping the block by hand, at m flat decorative elements are made in the form of one or more tiles of natural stone or in the form of one or more wooden panels, in addition, flat decorative elements are made in the form of combinations of one or more tiles of natural stone and wooden panels, and on the back side of the flat decorative elements the building mixture is applied in the form of vertical stripes, after setting which flat decorative elements are installed in a pallet form or flat decorative elements are blow into the mold and press tightly, then apply an adhesive composition, on which a pre-made plate with grooves made of fired clay is installed, which is then coated with a moisture-proof composition, while the front surface of the wooden panels is varnished, and the reverse side with PVA glue with the addition of 10-15% of water from the volume of glue, in addition, the adhesive composition is made in the form of cement with sand with a ratio of 1: 2, diluted with water with PVA glue in a ratio of 3: 1, and the moisture barrier is made in the form of cement with sand 1: 2 ratio, diluted with water and liquid glass in a ratio of 1: 2.

The essential features of the proposed method, coinciding with the prototype, are the following features;

- laying flat decorative elements on the bottom of the pallet;

- pouring flat decorative elements with a liquid building mixture;

- keeping the product to hardening of the building mixture;

- product stripping.

Distinctive from the prototype of the essential features of the proposed method are the following features:

- the finished product is performed in the form of a building block;

- one or more surfaces of the building block are lined with flat decorative elements;

- flat decorative elements consist of several fragments each;

- the side surfaces of the flat decorative elements are pre-grinded and adjusted to each other;

- flat decorative elements are tightly installed in the frame-shape and poured with a liquid building mixture;

- after curing the liquid building mixture, one or more finished flat decorative elements are installed in a pallet form and poured with concrete;

- the pallet form is mounted on a vibrating press and vibrate until the concrete is completely compacted;

- produce drying of the finished block in vivo.

Private distinctive from the prototype of the essential features of the proposed method are the following features:

- the building block is made using foam concrete;

- a layer of foam is placed in a vertical plane from the inside of the block;

- a layer of foam concrete is performed as a separate insert;

- a foam concrete layer is obtained by pouring foam concrete into a pallet mold using a dividing metal plate, which is removed after filling the pallet mold with concrete and foam concrete;

- the building block is made in the form of half blocks, corner blocks, blocks with two-sided finish;

- the building block is made with a hole in the upper part of the block with undercuts to capture the block by hand;

- flat decorative elements made in the form of one or more tiles of natural stone;

- flat decorative elements made in the form of one or more wooden panels;

- flat decorative elements are made in the form of combinations of one or more natural stone tiles and wood panels;

- on the back side of the flat decorative elements, the building mixture is preliminarily applied in the form of vertical stripes, after which the flat decorative elements are set in a pallet form;

- flat decorative elements are laid in a form-frame and pressed tightly, then an adhesive composition is applied, onto which a prefabricated plate with grooves made of fired clay is installed, which is then coated with a moisture-proof composition;

- the front surface of wood panels is varnished, and the reverse side is with PVA glue with the addition of 10-15% of water from the glue volume;

- the adhesive composition is made in the form of cement with sand with a ratio of 1: 2, diluted with water with PVA glue in a ratio of 3: 1;

- moisture-proof composition is made in the form of cement with sand with a ratio of 1: 2, diluted with water and liquid glass in a ratio of 1: 2.

Between the essential features of the claimed invention and the achieved technical result, there is the following causal relationship.

Indeed, the new manufacturing technology of building blocks with a decorative coating allows one to obtain a variety of inexpensive high-quality products without the use of complex mechanisms and machines, as well as scarce and expensive materials, in the form of half blocks, corner blocks, blocks with two-sided finishing.

The inventive technology eliminates the use of expensive curable plastics, replacing them with common building compounds and mixtures, while the resulting finished product is more functional, because it can be used not only for cladding internal walls and erecting partitions, but also for external cladding of buildings and structures for various purposes, and the resulting finished product also serves as a building stone or block.

The use of various options for decorating the facade surface of the building block - in the form of one or more natural stone tiles, in the form of one or more wooden panels or in the form of combinations of one or more natural stone tiles and wooden panels - allows you to diversify possible options for design decisions.

The building block manufactured by the present method can be manufactured in the form of thermal protection, for which the building block is made using foam concrete, and the foam layer is placed in a vertical plane on the inside of the block. In this case, a foam concrete layer is obtained by pouring foam concrete into a pallet mold using a dividing metal plate, which is removed after filling the pallet mold with concrete and foam concrete. In addition, the foam concrete layer can be made in the form of a separate insert, which is prefabricated and used in the manufacture of building blocks.

To increase the adhesion of flat decorative elements to the surface of the building block, simple intermediate operations are performed - the building mixture is preliminarily applied in the form of vertical stripes on the back of the flat decorative elements, after setting which flat decorative elements are installed in a pallet form or flat decorative elements are laid in a frame form and tightly pressed, then apply an adhesive composition on which to install a pre-made plate with grooves made of burnt clay, which is then coated with a moisture barrier.

The achievement of the above technical result is possible only if there is a combination of all the essential features set forth in the claims, in the absence of any of them, the technical result cannot be achieved.

The remaining distinctive features of the proposed technical solution provide the operability of the method of manufacturing building blocks.

The analysis of the prior art by the applicant, including a search by patent and scientific and technical sources of information, with the identification of sources containing information about analogues of the claimed technical solution, allows us to establish that the applicant has not identified analogues that are characterized by the entire set of features identical to all the essential features of the method, specified in the claims.

Therefore, it can be argued that the invention meets the eligibility condition by the criterion of "novelty."

The invention meets the eligibility condition by the criterion of "inventive step", because it does not explicitly follow from the prior art for a specialist.

In addition, the invention is industrially applicable, since the claimed method allows its wide use in both individual construction and in small-scale production of a variety of building decorative elements and products.

The possibility of carrying out the claimed invention is confirmed by the following description of its practical implementation.

The invention is illustrated by the following drawings.

Figure 1 shows a block, a top view; figure 2 shows a frame with clamps; figure 3 shows a flat decorative element, rear view, with the applied building mixture in the form of vertical stripes; figure 4 shows a plate with grooves made of baked clay; figure 5 shows the pallet-form with two flat decorative elements installed and with the side wall folded down; figure 6 shows a wooden plate with grooves having a figured hole in which to install a decorative insert from another species of wood or natural stone.

A method of manufacturing building blocks decorated with natural stone or wood panels is implemented in this way.

First, prepare flat decorative elements, which can be made in the form of one or more tiles of natural stone, and can also be made in the form of one or more wooden panels. In addition, flat decorative elements can be made in the form of combinations of one or more natural stone tiles and wood panels. Variants using ceramic tiles and / or with mixed use of both natural stone tiles, wood panels, and ceramic tiles are also possible.

Flat decorative elements can consist of several fragments each, and the side surfaces of flat decorative elements are pre-ground and adjusted to each other, and then installed in a frame-shape, tightly pressed to each other and poured with building mortar.

When using several tiles to finish the facade side of the block, the facade surface and those side surfaces of the tiles that will be in contact with other side surfaces of the tiles during the production of the building block are carefully grinded. This is to ensure that there are no seams or gaps between the tiles used to make one building block.

Tiles are installed in a form-frame with clamps and tightly pressed against each other, which, in turn, contributes to the emergence of a diffusion phenomenon (mutual penetration of tile particles into each other). This ensures the watertightness of the facade surface, and over time, diffusion will only increase.

Then, on the back side of the flat decorative elements, a building mixture is applied in the form of vertical stripes, after setting which flat decorative elements are installed in a pallet form.

For fastening the facing surface to the block, it is possible to use building mixtures used to seal the joints between the tiles. Currently, these mixtures have the necessary properties for the implementation of their strong fixing on the surface of natural stone.

In the second embodiment, flat decorative elements are laid in a form-frame and pressed tightly, then an adhesive composition is applied, onto which a pre-made plate with grooves made of fired clay is installed, which is then coated with a moisture-proof composition.

The adhesive composition consists of cement with sand with a ratio of 1: 2, diluted with water with PVA glue in a ratio of 3: 1, and the moisture barrier consists of cement with sand with a ratio of 1: 2, diluted with water and liquid glass in a ratio of 1: 2.

Then one or more finished flat decorative elements are installed in a pallet form and poured with concrete, then the pallet form is mounted on a vibrating press and vibrated until the concrete is completely compacted, then the finished block is dried under natural conditions. Next, the formwork of the finished building block is made.

The building block can also be made using foam concrete, the foam layer being placed in a vertical plane on the inside of the block. In this case, the foam concrete layer is made in the form of a separate insert or the foam concrete layer is obtained by pouring foam concrete into the pallet mold using a dividing metal plate, which is removed after filling the pallet mold with concrete and foam concrete.

It is possible to manufacture a block with a heat and sound insulating foam layer 50 mm thick. In this case, the foam concrete layer will be located on the side opposite to the facade.

Using the inventive method, the finished product is obtained in the form of a building block, one or more surfaces of which are lined with flat decorative elements made of natural stone tiles or wooden panels.

If the front (front) side of the building block is formed from a plate or several tiles of natural stone, then several options are possible.

So, for example, when using one plate, it has dimensions of 400 × 200 × 20 mm, and the thickness of the plate may be less, if several facing tiles made of natural stone are used, then options of 2 or 8 tiles are possible. Moreover, in the variant with 2 tiles, tiles with dimensions of 400 × 150 × 10 mm and 400 × 50 × 10 mm or with dimensions of 300 × 200 × 10 mm and 100 × 200 × 10 mm are used.

When using 8 tiles, their sizes will be equal to 100 × 100 × 10 mm.

In the method of finishing from 2 or 8 tiles, decorative tiles of natural stone of different colors and shades are used, thereby achieving a color variety of finishing surfaces and the possibility of choosing color solutions. It is possible to use different types of stones.

In order to obtain equal gaps (5 mm) between the finishing surfaces during installation of walls, beacons made of glue-silicone are applied to one side and bottom side of the finishing tile (tiles) of the block. After grouting, they will not be visible. This allows you to ensure the safety of the product during transportation.

To expand the nomenclature, a building block can be made in the form of half blocks, corner blocks, blocks with two-sided finish.

For convenience, the building block is made with a hole in the upper part of the block with undercuts to capture the block by hand.

The finished building block can have dimensions of 390 × 190 × 140 mm or 390 × 190 × 190 mm.

Consider in more detail the claimed technology for the manufacture of building blocks.

The appearance of the block 1 from the top is shown in figure 1, while the block has a rectangular shape, its front surface is lined with flat decorative elements 2. In the upper part of the block 1 has an opening 3 with undercuts for gripping the block by hand.

For the manufacture of flat decorative elements using the form of the frame 4 with clamps 5, shown in figure 2.

To strengthen the fastening of the flat decorative element 2 to the surface of the building block 1, several methods of preliminary processing the back surface of the flat decorative element 2 are used.

Figure 3 shows a flat decorative element 2, rear view, with the applied building mixture in the form of vertical stripes 6. This is the first option to strengthen the fastening.

Water is added to the dry building mixture and the solution is adjusted to the required consistency. Then thoroughly washed gravel is added to the solution and mixed well. The resulting mixture is applied in vertical stripes to a flat decorative element 2 made of natural facing stone. You can use a mixture of the company "Beamix 631 flex", which is used for sealing joints, which provides protection against the possible penetration of moisture or moisture and ensures the durability of the product.

When using for finishing a block of 2 or 8 tiles, another method is used to fix the surface 2 of natural stone to the concrete of the building block 1. In this case, use a plate 7 with grooves 8 made of baked clay (see figure 4). It has dimensions of 330 × 140 × 10 mm. In this embodiment, the flat decorative element 2 is placed in the form frame 4 and pressed tightly, then an adhesive composition is applied, onto which a plate 7 with grooves is installed 8. The adhesive composition is a mixture of cement and sand (1: 2) diluted with water and glue PVA (3: 1).

Before applying the adhesive composition to the surface of a flat decorative element 2 made of natural facing stone, this surface is treated with the Betokontakt tool from Knauf. Instead of Betokontakt, you can use a mixture of gravel and grout for tile.

A clay plate 7 with grooves 8, previously moistened in water, is installed on the solution.

After setting the solution, the clay plate 7 is treated with a solution of cement and sand (1: 2), diluted with water and liquid glass (1: 2). This coating should protect the adhesive composition and the clay plate 7 from possible, in principle, the penetration of moisture or moisture.

After the adhesive solution has set, which ensures reliable bonding of the tiles to each other, a flat decorative element 2 is removed from the mold-frame 4 and installed in a pallet-mold 9 for the production of the block. The surface formed after applying the strips allows you to achieve strong adhesion of the flat decorative element 2 with concrete of the building block 1.

Figure 5 shows a variant of installation on a pallet form 9, for example, two - 10 and 11 - flat decorative elements 2. The pallet form 9 has a hinged side wall 12.

The pallet form 9 is filled with concrete and then mounted on a vibrating press (conditionally not shown). In concrete for the production of a building block, it is necessary to add 10-15% PVA glue of the volume of water.

In the production of the insulated block, the finished preform of foam concrete is installed in the pallet form 9 for the production of the building block or a thin metal plate (not shown conditionally) is inserted into the corresponding grooves of the pallet form 9, which divides the form into two parts, one of which is 50 mm wide.

One part of the pallet-mold 9 is filled with concrete for the production of the building block 1, vibrated, and the second part of the mold is filled with foam concrete, then the separating plate is removed.

For the production of building blocks 1 with wood trim, flat decorative elements 2 are made of wood panels 13 of various types of wood with a size of 400 × 200 × 15 mm. The wood panel 13 has grooves 14 of a special shape for filling them with concrete (Fig.6). The front (front) side of the wood panel 13 is pre-coated with varnish, and the reverse side is with PVA glue, with the addition of 10-15% water of the glue volume.

The wood panel 13 is installed in a pallet form 9 with rubber gaskets, ensuring the safety of the facade surface. After pouring concrete into the pallet form 9, the drying of the building block 1 is carried out in natural conditions.

In the process of mounting the wall, it is very important to obtain the same gaps between the flat decorative elements 2, for which beacons made of glue-silicone are applied to the lateral ends of the flat decorative elements 2.

In addition to the above options for manufacturing a flat decorative element 2, it is possible to produce blocks 1 with a high level of finish.

In this case, a cutout 15 corresponding to the shape of the insert 16 is made in the wooden panel 13 of the flat decorative element 2. The insert 16 is installed in the cutout of the panel 15, while the edges of the insert 16 and the cutout of the panel 15 are treated with wood glue. If necessary, make gaps, grinding, varnishing.

On the reverse side of the wood panel 13, the insert 16 is attached using a wood battens 17 5 mm thick and wood glue. The dimensions of the rail 17 may vary depending on the size of the insert 16.

The insert 16 can be made of a different wood species than the main finishing panel is a flat decorative element 2. In addition, the insert 16 can be made of natural stone. All this allows you to achieve diversity in the color scheme of the entire flat decorative element 2 and insert 16.

It is possible to produce various flat decorative elements 2, which are the constituent parts of a large image, which will be assembled during the installation of the wall from several blocks. In this case, an unlimited number of design decisions is possible.

Based on the foregoing, it can be argued that the task set in the present invention - the development of a new method of manufacturing building blocks with a decorative coating - is performed to achieve a technical result - to increase the functional ability of the block with the cost of its manufacture.

Claims (14)

1. A method of manufacturing building blocks with natural stone or wood paneling, including laying flat decorative elements on the bottom of the pallet and pouring them with liquid mortar, keeping the product to solidify the building mixture, shaping the product, characterized in that the finished product is made in the form of a building block , one or more surfaces of which are lined with flat decorative elements consisting of several fragments each, and the side surfaces of flat decorative elements the cops are pre-grinded and adjusted to each other, and then tightly installed in the mold frame and poured with a liquid mortar, after curing of which one or more finished flat decorative elements are installed in a pallet mold and filled with concrete, then the pallet mold is mounted on a vibrating press and they vibrate until the concrete is completely compacted, then the finished block is dried in natural conditions. 2. The method according to claim 1, characterized in that the building block is made using foam concrete, and the foam layer is placed in a vertical plane on the inside of the block. 3. The method according to claim 2, characterized in that the foam concrete layer is performed as a separate insert. 4. The method according to claim 2, characterized in that the foam concrete layer is obtained by pouring foam concrete into a pallet mold using a dividing metal plate, which is removed after filling the pallet mold with concrete and foam concrete. 5. The method according to claim 1, characterized in that the building block is made in the form of half blocks, corner blocks, blocks with two-sided finish. 6. The method according to claim 1, characterized in that the building block is made with a hole in the upper part of the block with undercuts to capture the block by hand. 7. The method according to claim 1, characterized in that the flat decorative elements are made in the form of one or more tiles of natural stone. 8. The method according to claim 1, characterized in that the flat decorative elements are made in the form of one or more wooden panels. 9. The method according to claim 1, characterized in that the flat decorative elements are made in the form of combinations of one or more natural stone tiles and wooden panels. 10. The method according to PP.7, 8 and 9, characterized in that the building mixture is preliminarily applied to the back side of the flat decorative elements in the form of vertical stripes, after which the flat decorative elements are set in a pallet form. 11. The method according to PP.7, 8 and 9, characterized in that the flat decorative elements are laid in the form frame and pressed tightly, then an adhesive composition is applied, onto which a prefabricated plate with grooves is made, made of fired clay, which is then coated moisture protective composition. 12. The method according to PP.8 and 9, characterized in that the facade surface of the wooden panels is varnished, and the reverse side is with PVA glue with the addition of 10-15% water from the glue volume. 13. The method according to claim 11, characterized in that the adhesive composition is made in the form of cement with sand in a ratio of 1: 2, diluted with water with PVA glue in a ratio of 3: 1. 14. The method according to claim 11, characterized in that the moisture-proofing composition is made in the form of cement with sand in a ratio of 1: 2, diluted with water and liquid glass in a ratio of 1: 2.

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