RU2380493C1 - Solid concrete building - Google Patents

Abstract

FIELD: construction industry.

SUBSTANCE: solid concrete low-rise building is constructed from foamed concrete with density D150-D350 (kg/m³) with spherical supports with diametres of 50-450 mcm, which are enveloped with non-porous shells of cellular shape with cell sizes of 30-70 nm and thickness of 75-100 nm. Foamed concrete is enclosed with retained formwork made of rigidly connected cement fibre plates connected to mesh and strip reinforcement which is 75% submerged in foamed concrete and the rest part of which is concreted in foundation and covering with heavy concrete. Surfaces of plates and reinforcement are enveloped with condensed layer up to 3 mm thick which appeared topotactically on the above shells in accordance with Weissenberg effect from foamed concrete with density D650-D1350 with increased adhesion strength to plates and reinforcement 0.05-0.5 MPa, providing the function of load-carrying walls to walls-covers of wafer construction, combined with enclosing and heat-insulating wall-cover at operating load of not less than 30 t/running metre.

EFFECT: improving operating reliability of the building.

8 cl, 2 tbl, 10 dwg

Description

The invention relates to the field of construction, namely to monolithic concrete buildings, and specifically to frameless buildings based on foam with load-bearing walls-shells. The most promising application of such buildings in mass low-rise housing construction in the suburbs and rural areas is due to the optimal combination of the diversity of their architectural design, structural simplicity and minimal energy and labor costs for the production of raw materials, construction and operation of these buildings. Their particularly high profitability and environmental friendliness make it possible to count on their use in targeted programs for the construction of affordable and comfortable housing by the country's population.

Concrete buildings using foam concrete are known: search engines give on the Internet more than 600 thousand links. However, toughening the search parameters gives a significant narrowing of them - up to 550-700 subject to monolithicity. The latter for non-autoclave foam concrete is very significant: this material requires a long rest period after laying or pouring into molds or formwork. Any shaking during movement gives rise to crack formation nuclei in non-autoclaved foam concrete. Therefore, monolithic buildings based on foam concrete are the most logical field of application of foam concrete as a building material.

Frame buildings with curtain walls - a field of application of non-autoclaved monolithic foam concrete, in which its low strength at average density grade according to [GOST 25485-89. Cellular concrete. Specifications] D400-D600 (kg / m ³ ) is not an obstacle [S. Ruzhinsky et al. All about foam concrete. Ed. 2nd. SPb .: Stroybeton LLC, 2006. 627 p.]. They were built from the beginning of the 60s, and with the sealant fencing, from the end of the 60s of the last century [GB 1173769, 12/10/1969]. Similarly, monolithic foam concrete is also used to fill the insulating layer in the bearing brick walls of capital buildings [CN1710223, 12/21/2005]. The advantage of the latter is multi-storey, durability and the possibility of using foam concrete of any quality, if only it is isolated from environmental access, since it is insufficiently resistant and not guaranteed from cracking that does not violate its relatively high heat-insulating ability due to low heat conductivity - not higher than λ = 0.2 W / (m · deg). The disadvantage of such buildings is the high cost of living space. The prime cost of 1 m ^{2 of} living space in them is significantly higher than declared as acceptable in the message of the President of the Russian Federation D.E. Medvedev, namely 20 thousand rubles / m ² , which is a criterion for the availability of housing in the organization of mass housing construction.

Prefabricated monolithic buildings are also known, the basis of which is a construction of two opposed slabs, rigidly interconnected and forming either a fixed formwork for a layer of foam concrete, or, on the contrary, which are themselves heat-insulating, and heavy concrete of high strength is laid in the formwork [SA 2541558, 07.05 .2007]. The advantage of the second option is the simplicity of construction, which does not require highly qualified personnel. Its disadvantage is the need to use high density foam concrete (D≥500) so that the slabs do not bend under the weight of the middle layer, which reduces the thermal resistance of the foam concrete and the heat saving of the building. The disadvantage of the first option is heavy anchors to the base on which the plates are assembled. But this drawback applies only to this constructive option, and in general the above diagram is universal and in this part is an analogue of the present invention.

The specified building design is one of the typical examples of buildings using sandwich panels. The term was introduced in Canada in the late 50s of the XX century. to indicate layered structures in which each of the layers independently performs its function, including the perception of external mechanical load. The most unexpected, based on the prior art, is the construction of the building, in which all layers are light, and the heaviest of them is foam concrete [US 2008010920, 01/17/2008]. Such a building is characterized by a low consumption of materials due to their low density and, accordingly, the relatively low cost of living space.

To overcome the separate perception of the mechanical load and other external influences by the layered structures of buildings, at least one special adhesive layer is introduced into them [JP 2000220238, 08.08.2000], which in this case is an analogue to the finish. Of course, this increases the cost of living space, the complexity of construction and the required level of qualification of technical personnel, but in order to increase the durability of the building, one has to put up with this.

More perfect from a technical point of view is a building using a supporting wall of a waffle structure [US 2002017070, 02/14/2002], in which a layer of monolithic concrete is poured between the layers of prefabricated elements, providing adhesive contact between the layers, that is, their interaction with the perception of external mechanical load and other environmental influences. The term was proposed in the United States in the late 90s and managed to enter technical dictionaries around the world. However, the insignificant adhesive strength, which is considered characteristic of foam concrete, does not allow to find any example of wafer structures using it. Nevertheless, the building under consideration is a close analogue of the present invention, since the technical solution described in the latter includes, as one of the novelty elements, the load-bearing wall of a waffle structure based on monolithic foam concrete.

The closest analogue of the present invention is a monolithic concrete building, consisting of a foundation, walls and floors, containing rigidly interconnected slabs with reinforcing elements and made of porous concrete, namely non-autoclaved foam concrete enclosed in fixed formwork [Russian patent application application laid out No. 99125744 dated 10/10/2001]. The advantage of this technical solution is the low cost of 1 m ^{2 of} living space of the building, the disadvantage is the fact that the wall, including plates with reinforcing elements and a layer of monolithic, naturally, non-autoclaved foam concrete, is not considered by the authors as a supporting structure, although it performs the functions of enclosing and heat-insulating and therefore, the considerations regarding the ratio of the elastic moduli of the layers contained in the characterizing part of the application appear to be devoid of a basis.

The objective of the invention is to significantly improve the construction and technical properties of the building structure and to ensure that the walls of the building based on foam concrete are supported by the laminated structures and further reduce its cost.

The problem is solved in that a monolithic concrete building, consisting of a foundation, walls and floors, containing rigidly interconnected slabs with reinforcing elements and made of porous concrete enclosed in a fixed formwork, is low-rise, has a free architectural form with any, including including a curved plan and facade, due to the cut of slabs and reinforcing elements, porous concrete is a monolithic foam concrete with an average density of 150-350 kg / m ³ from hardened foam concrete mixtures based on an aqueous suspension of high-strength Portland cement, including clinker, gypsum components and a dry organic component based on polymethylene polynaphthalene sulfonates with a molecular weight of 800-2000 D, with a mass ratio of the clinker part of the specified cement, the indicated polymethylene polynaphthalene sulfonates and water 100: (0.8-2): (0.28-0.35) in the specified suspension, combined with a double foam, including polyphenols in the composition of wood saponified resin in an amount of at least one third of the total weight of the foam, calculated on dry matter when wt. the ratio of foam: cement in terms of dry weight (0.015-0.02): 1, due to the chemical affinity of these aromatic compounds in which spherical vesicular pores with diameters of 50-450 μm are surrounded in foam concrete with nanostructured non-porous hydrosilicate shells of a cellular structure with a cell size of 30 -70 nm and a thickness of 75-100 nm, associated with a matrix of hydrated neoplasms of the specified foam concrete, the latter being enclosed in a fixed formwork of composite plates rigidly connected by means of a grid and strip metal reinforcement, 90-95% immersed in foam concrete, and the remaining parts connected with the main reinforcement of the floor and foundation and monolithic in the latter with heavy concrete, while the surfaces of these plates and reinforcement in foam concrete are surrounded by the specified shells on the pores thickened according to the Weissenberg effect topotactic layer with a thickness of up to 3 mm from foam concrete of increased density D650-D1350 with increased adhesive strength by an order of magnitude compared with the rest of the foam concrete to the indicated plates and reinforcement within 0.05-0, 5 MPa, providing the walls-shells of the waffle structure bearing function, combined with the enclosing and heat-insulating, with a working load of 5-50 t / linear m of the specified wall-shell.

In an embodiment of the invention, by covering these fixed-formwork plates with an accuracy of 0.1-0.5 mm, its coherence and continuity in assembly on each of its two sides are ensured when they are fastened along the sides and across the inner cavity of the formwork by means of strip reinforcing elements in the wall the shell of each floor of the building, and the welded reinforcing mesh located in the array of the specified foam concrete located in the specified cavity is provided with inlets rigidly connected to the main reinforcement of the reinforced concrete floors, and monolithic in the pockets of the upper and protrusions of the lower floors on each floor of the building are higher than the first, and on its first floor the lower slits of the specified mesh are connected with the reinforcement of the foundation and monolithic in its protrusions.

In another embodiment of the invention, the reinforced concrete slab of said interfloor floors supported on said shell walls is a monolithic or precast monolithic reinforced concrete box flooring of any given contour in plan, with boxes filled with said foam concrete, and with perimeter pockets filled with heavy concrete, in which the mentioned overlaps of the reinforcing mesh of the foam concrete layer of the wall-shell of the previous floor are monolithic, with the value of the distributed work load on the interfloor overlap in affairs 5-10 MPa depending on the said range of values of said medium density foam, with local values of concentrated workload to 45 MPa.

In a further embodiment of the invention, said fixed formwork composite slabs are slabs based on inorganic hydraulic or air binders from the group: Portland cement, magnesia binder, gypsum-cement-pozzolanic binder and fibrous aggregates from the group: chip, polymer, mineral, with a modified surface - hydrophobized or impregnated with polymers .

In an embodiment of the invention, the number of floors in a building in any climatic zone does not exceed four, excluding zones with winds with a speed equal to or more than 100 km / h, where it does not exceed two floors.

In another embodiment of the invention, the reinforcing elements of the specified wall-shell include:

- welded reinforcing mesh,

- strips of thin steel galvanized sheet, fastening between them opposed composite slabs of fixed formwork and located between them in the specified foam concrete array, said welded reinforcing mesh, and the strip includes flat sections and box-shaped sections for mounting said mesh, as well as said composite plates by screws through holes provided in the strips, forming at least three horizontal stiffeners along the height of these plates and along the width of these plates along ayney least two vertical belt stiffness on each pair of opposing plates in said permanent shuttering sides and each standing between them reinforcing mesh on each floor of this building.

In a further embodiment of the invention, plates for forming window and door openings, voids for sanitary devices and ventilation ducts are installed inside the fixed formwork.

In an embodiment of the invention, elements with stucco layers in the interior are attached to said nets and / or plates of the inner surface of said wall-shells, and elements of external waterproofing and decoration are attached to said nets and / or plates of the outer surface of said wall-shells, or waterproofing and finishing layers are applied on the indicated plates.

The invention consists in the free architectural forms of the building, due to the given forms and, accordingly, programmed by the cut of these plates, reinforcing elements and other elements of the building, and in giving the walls-shells, consisting of these plates and a foam concrete array between them, containing reinforcing mesh, bearing capacity 5 -50 t / linear meter due to the nanostructured structure of the shells of spherical pores in foam concrete, which reduces the concentration of stresses from external mechanical load in it, and is thickened topotactic layer with a thickness of up to 3 mm along the boundary of the foam concrete array with plates of fixed formwork and its contacts with the reinforcing mesh, which increases the local density of foam concrete by 500-1000 kg / m ³ against the average level in the massif of 150-350 kg / m ³ , and significantly - by an order of magnitude - adhesive strength to plates and reinforcement up to the level of 0.05-0.5 MPa, depending on the average density of foam concrete, that is, about an order of magnitude compared to foam concrete of average density in the array.

The phenomenon of thickening of foam concrete along the boundaries of the array in front of obstacles to the flow of foam concrete in the process of pouring the wall-shell of the building was discovered for the first time and represents an essential element of the novelty of the present invention. It should be considered as one of the macroeffects of the presence of nanostructured elements in the microstructure of foam concrete, namely, non-porous shells on spherical vesicular pores, that is, pores formed at the site of bubbles (vezikula - bubble, lat.) Foam. Macro effects are discussed in the description below.

The presence of these shells on the vesicular pores, which is a sub-micro and, as it turned out, even a nanostructured element of the specified hardened foam concrete, in turn, was discovered for the first time and is a consequence of the chemical affinity between cement and the outer shell of the double foam used to obtain the foam concrete mixture. It is not typical for other cements and foaming agents. The mentioned affinity is due to the aromatic compound present in the cement in the organic component - polymethylene polynaphthalene sulfonates (PNS) - the oligomer with a molecular weight of 800-2000 D and the aromatic compound present in the foaming agent - polyphenols, which are the main component of the saponified wood resin, the main product of wood chemistry, forming at least one chemical chemistry third of the outer shell of the double foam (for details on double foams, see [Sebba F. Foams and biliquid foams - aphrons. Chichester et al .: Ed. by Department of chem. eng. and chemistry, Virginia (Blacksburg) P olitechn. Inst, and State Univ., 1987, 236 pp.]) used in the foam according to the invention. PNS due to contacts with cement particles contains an admixture of calcium cations with hydrosilicate anions [Yudovich B.E. and others. On the mechanism and degree of interaction between the modifier and clinker in the process of grinding a binder of low water demand. Proceedings of the Research Institute of Cement "Binders of low water demand (chemistry, technology, production and use)", No. 104, M .: Stroyizdat, 1992, p.69-113], and polyphenols - impurities of carbohydrates that facilitate contact interactions, as well as fatty acids that contribute to hydrophobization and protection of existing contacts [Fengel D. et al. Wood: chemistry, ultrastructure. Reactions. M .: Forest industry, 1988, 360 S.]. As a result, PNS and polyphenols, binding as related substances through the π-electrons common to them, form microreactors for the synthesis of new hydrated forms, described in detail below using electron microscopy.

The formation of shells was recorded during electron microscopic studies of hardened foam concrete samples as follows. From observations of the submicrostructure of the foam concrete used in the invention, it follows that the vesicular pores generated by the stable double foam are predominantly spherical (Fig. 1) with sizes of 30-550 μm, with a smooth surface. This preservation of the shape of vesicles (vesicles), in contrast to the presence in ordinary foam concrete known from the prior art, predominantly flattened or shapeless pores with non-smooth walls, indicates the stability of the foam concrete used, its ability to pump over long distances and the possibility of laying in high layers - up to 1.7 m thick. This, along with a rapid increase in the strength of foam concrete, creates conditions for accelerating the construction of buildings and putting houses under workload. In the known cellular concrete, even with rapidly fixed porosity, namely in autoclaved aerated concrete, the pore shape is not spherical, and their surface is not smooth [A. Baranov The fundamentals of the formation of the structure of autoclaved aerated concrete. The dissertation for the degree of Doctor of Technical Sciences. M .: NIIZHB, 1981. - 386 p .; Bakhtiyarov K.I. Investigation of the influence of the quality of the porous structure and hollow material on the physicomechanical properties of cellular concrete. The dissertation for the degree of candidate of technical sciences. M .: NIIZHB, 1965 .-- 103 s, 57 s. ill.]. At the same time, the sphericity of the pores and the smoothness of their surface according to Bakhtiyarov, decree. cit., is a condition for low values of the coefficient of stress concentration from external mechanical load near the pores and, therefore, helps to increase the strength and crack resistance of cellular concrete, in particular, foam concrete used according to the invention.

Figure 2 shows the surface of the vesicular pores at high magnification. One can observe the organomineral layers that form the cellular texture. Since in these layers and in the shells of other similar spherical pores there are no small pores similar to those present on the cleaved inter-pore bridges visible in the image, it can be concluded that these shells of spherical pores are shells formed on the surfaces of all pores that arose at the sites of bubbles foam. There is nothing like this in ordinary foam concrete, the surfaces of large pores in which are almost as porous as the surfaces of the inter-pore lintels.

The cellular submicrostructure of calcium hydrosilicates arising on the surface of vesicular pores in foam concrete is shown in FIG. 3. It consists of rapidly growing Ca hydrosilicates, pushing impurities to the edges of the cells. In essence, cells arise due to faster crystallization of the main phase compared with impurity phases, which leads to the formation of intercellular boundaries composed of impurities. In this case, it is obvious that the cells are formed in self-organizing microreactors, consisting of polyphenols of the outer resin shell of the double foam ("bottoms" of the microreactors) and mineral chains of the main mineral of this cement - tricalcium silicate (alite) having the composition - O-Ca-O- Si ²⁺ -O-Ca-O- with “suspensions” of naphthalenesulfonates (“walls” of microreactors) attached to them via hydroxyls during silicon bonded to “bottoms” polyphenols via π-electrons of naphthalene groups. The absence of impurities at the growth points noted above is a condition for rapid growth, which is the main criterion sufficient for the formation of a cellular submicrostructure. The “microreactors” are open from above - through the “ceilings” flows of the mother liquor flow towards them, towards which the cells grow, turning into “columns” along the boundaries of which impurities are concentrated.

Indeed, hydrosilicate “columnar” submicrostructures growing from the cells are observed (Fig. 4) directly along the boundaries of the vesicular pores. Nearby, inside the inter-pore bridge, there is a zone of gel-like calcium hydrosilicates. There is also a zone of fibrous high-water hydrates, AFt-phases according to Taylor [Taylor X. Chemistry of cement. M.: Mir, 1996, 560 s, see pp. 215 - 218]. Together they grow together into a matrix of hydrated neoplasms of foam concrete.

The presence of a columnar shell on the shells of vesicular pores is another evidence that in the foam concrete mixture according to the invention, a submicrocellular, very dense, without large pores, structure (shell) is formed on the surface of the vesicular pores, which is not characteristic of the usual set of hydrates of cement stone. Judging by the electron microscopy data, the crystals in it are smaller than in the columnar structure known from the prior art, in particular, from the work where such a structure was first discovered in the products of hydration of cement constituents [Ciach T. Hydration of the tricalcium silicate in water paste . Journal of Cement and Concrete Research, Philadelphia, 1971, v.1, No.1, p.5-13]. The topotactic nature of the growth of the shell cleans calcium hydrosilicates of impurities, as a result of which the chains described above do not break, and when the foam concrete mixture is stationary, they continue even in the liquid phase of this mixture to unusually long distances, an order of magnitude larger than the pore size. This is set as follows.

The foam concrete mixture used in the invention is characterized by rheological behavior peculiar to Bingham’s body, which is generally considered applicable for describing the flow of cement-water systems [Ish-Shalom, M. et al. The rheology of fresh portland cement pastes. / Chemistry of Cement. Proceedings of the Fourth International Symposium. Washington, I960. US Department of Commerce. National Bureau of Standards, Monograph 43, Washington, 1962, v. 1, No.2. Part 2, sect. V]. These features of the foam concrete mixture used in the present invention are as follows:

1) it, unlike concrete, is characterized by elasticity in a fluid state and is capable of sudden compression (the rate of exposure, according to [Ish-Shalom et al., Op.cit], must be no lower than the “causing spatter”) to a slow expansion reaction ; this can be explained by the elasticity of the walls of the vesicles (bubbles) and the air contained in them; in reality, during flow (filling), the walls are completely mineralized and, therefore, can be characterized by a finite thickness that can be calculated; this is macroscopic evidence of the reality of the existence of "shells";

2) this mixture is prone to the formation of stagnant zones near the walls of the flow, if the acting body leads to an increase in its average density by more than 20% (according to [Ish-Shalom et al., Op.cit], this can be called dilatancy, but in contrast from the phenomenon observed in the cement test, when particles of relatively coarse cement with high speed mixing can precipitate, increasing the stiffness of the suspension, this phenomenon has a different nature in the foam concrete mixture and cannot be attributed to dilatancy); this should most likely be regarded as the Oldroyd effect, due to the establishment of physical adhesive bonds of the flow elements with the flow walls and a clear boundary of the flow along the wall fixed layer of material, when the flow velocity is sufficient to break these bonds; it follows that with increasing flow velocity the lumen of the pipeline expands; the effect was discovered by Oldroyd when studying the rheology of cottage cheese in cottage cheese pipelines at dairies [Reiner M., ed. Rheology. // Sat articles. M. IL, 1965, 538 pp.]; the Oldroyd effect is indeed observed during the flow of the foam concrete mixture, but more often in the mixer during the formation of the mixture; there, with increasing foam content, the adhesion of the mixture to the walls of the mixer weakens and the volume of the mixer available for mixing increases; The physical nature similar to Oldroyd’s effect is apparently the formation of “languages” of the test, “reaching” for the working body, for example, with a trowel: the slower the movement of the latter, the greater the “language” formed. However, the usual thickness of the Oldroyd layer and the length of the “tongues” of the test (2-4 cm) are much greater than that observed when pouring the foam concrete mixture into the cavity of the wall-shell;

3) the foam concrete mixture is prone to stopping the flow in front of an obstacle that sharply changes the direction and cross section of the flow (protrusion, bending, narrowing) and can change both its density and the shape of the surface of the flow; this also forms a stagnant zone, but short, with a thickness and length of up to 5 mm. This phenomenon has to be taken into account when designing the outlet pipes of mixers and pipelines. For this reason, corrugated hoses for foam concrete mixture are better than metal pipelines, as a simple form change can eliminate the stagnant zone in front of a piece of dried foam concrete accidentally caught in the pipeline. The flow stability of the foam concrete mixture and the absence of density fluctuations during the flow, despite random obstacles and random wall gaps (gaps in the formwork), but sealing with a change in the shape of the flow surface when stopped before bending the pipe or obstruction (“plug”) is usually attributed to the Weissenberg effect described in the course of rheology [Reiner, cit. cit.], as a result of building a short-range order of molecules or vesicles or other flow elements in the prevailing topotactic direction — along the flow, and when it stops — restoration of the previous short-range order, determined by the surface of an adhesion-active solid or resting flow elements during their adhesion activity. This behavior differs from the Bingham body in that, to start the flow of the latter, it is necessary to surpass the potential barrier corresponding to the shear stress limit, and to start the movement of the Weissenberg body, the potential barrier is extremely low - it corresponds to the start of motion of only one of the flow elements. But this is precisely why the flow itself, after the formation of the stagnant zone in front of the obstacle (plug), is able to self-compact the material until an equilibrium is established between the flow pressure and the back reaction of the layer of increased density, into which the flow itself has “driven” its elements up to this point. Such equilibrium can occur very late with growing bonds between the flow elements in the stagnant layer as it becomes denser (often according to the M. Polanyi power law as a result of chemisorption, in this case cohesion). This is our case of a radical increase in the density of the foam concrete mixture (thickening of the flow) before the obstacle, leading to an increase in the cohesive strength of the bonds of the foam concrete mixture, and then the adhesive bonds of the foam concrete inside this layer with the substrate - a solid surface (fixed form plates, reinforcing bars). It is this phenomenon, first recorded in the present invention, that ensures the fixation of both the fixed formwork and reinforcing meshes with a foam concrete layer and positively affects the unity of their work (determined by rigid bonds through reinforcement), that is, the joint perception of the external mechanical load by all elements of the wall-shell in moderation values of their elastic moduli and modifications of the latter due to adhesive interactions. In the case under consideration, a positive contribution is made to both the value of the shell intrinsic elasticity on the vesicles and the minimum stress concentration in the inter-pore bridges due to the spherical shape and smoothness of the pore surface, as mentioned above.

The Weissenberg effect allows one to naturally explain, as mentioned above, the absence of leakage of the foam concrete mixture through the cracks in the formwork, and also create the technological conditions ensuring this. The usual foam concrete mixture, known from the prior art, with a consistency estimated by the immersion depth of a standard cone (invented by M.E. Gensler in 1934, now regulated according to [GOST 23789-79. Cement gypsum. Test methods]), more than 4 cm even through slits 0.2 mm wide. The foam concrete mixture, which includes nanostructured shells on the outer shells of the pores, does not flow out through cracks in non-removable and any other formwork up to 3 mm wide, i.e. an order of magnitude larger. This feature can be considered as the result of at least two factors: the elasticity of the shells on the vesicles that accumulate in front of the slit and make it difficult for the mixture to flow out, as well as the presence of the valence chains mentioned above that hamper the movement of the vesicles to the gap and stop them, many of the vesicles stop long before reaching the gap. The significance of both mechanisms for the result — the formation of a thickened topotactic layer of foam concrete in front of an obstacle to the movement of the foam concrete mixture, namely, fixed formwork slabs and reinforcing bars — depends on the average density of the mixture and its consistency: the lower the density and the more fluid the mixture, the less it should manifest itself said thickening and, conversely, the higher the density and less fluid mixture, the more this thickening should occur. In practice, these dependencies are limited by the evaporation of water from the surface of the foam concrete mixture and the foam associated with it, which intensifies as the density of the foam concrete decreases, and the chemical bonding of free water by cement, which increases as the density of the foam concrete increases and the cement content in it increases, causing the same phenomena as evaporation, only at a faster pace. Therefore, it is theoretically difficult to predict the thickness of the thickened layer and the rate of its formation; practical tests are necessary, but in any case, the thickness of this layer exceeds 3 mm. Thus, the results of electron microscopy analysis fully confirm that the observed advantages of the foam concrete mass with thickened layers at the boundaries of the fixed formwork and reinforcement plates providing the indicated unexpectedly high load-bearing capacity of the wafer shell walls are due to macroeffects determined by the presence of walls in the foam concrete array shells in the building according to the invention of nanostructured shells on the surface of vesicles and pores, characterized by new properties. This is one of the most important, according to the authors of the invention, from the elements of its unexpectedness in comparison with the prior art.

In embodiments of the invention, the features of its implementation are optimized. So, despite the enhanced adhesive ability of the foam concrete array according to the invention, its connection with fixed formwork panels and mesh reinforcement are microcontacts. To ensure the indicated bearing capacity of the wall-shell, they should not be subjected to vibration and shear. This implies the need for tight ties of building elements of the building directly in contact with the foam concrete with each other and with the rest of the building structures, primarily with the main reinforcement of the foundation and floors.

Thus, in the embodiment of the invention, the stereometric stability of the entire reinforcement system of the building is established to guarantee the safety of these microcontacts in the wall-cladding, which is achieved despite the low specific metal consumption per 1 m ^{3 of} concrete in the building (less than 1 kg / m ³ ), due to the variety of reinforcing bars elements and the use of progressive strip reinforcement.

In another embodiment of the invention, as one of the constructive conditions for guaranteeing the integrity of these microcontacts in the wall-sheath, it is established that the ceiling is a reinforced concrete monolithic or precast-monolithic flooring, rigidly connected to the grid reinforcement of the wall-shells and guaranteeing the stability of its stereometric position in the spatial structure of the building and experience-tested ability to perceive the above distributed and concentrated payload.

In embodiments of the invention, guarantees are created from the shattering effect of the wind pressure on the structural basis of the building, from inaccuracies in the choice of reinforcing frame structures, and the usual requirements are provided for the placement of openings, engineering equipment in the walls, as well as for their decoration and waterproofing, which should not adversely affect stability the mentioned microcontacts in the wall-shell. It should be noted that, as you know, such microcontacts in adhesive bonds can significantly strengthen over time [P. Rebinder Surface phenomena in disperse systems. Physical and chemical mechanics. Selected Works. M .: Nauka, 1979. 381 p.]. For this reason, the precautions provided for in the embodiments of the invention may not seem so necessary. In fact, they are necessary so that the ongoing strengthening of microcontacts can increase the degree of capitalism of the building and the duration of its maintenance-free service.

For specific characteristics of the object given in the claims, it should be noted:

a) in a building in especially small quantities, such traditional, heavy, expensive, energy- and labor-intensive materials as steel and heavy concrete are used, and aluminum, brick and expanded clay are not used at all, which in the 21st century. can no longer be considered economically used in construction;

b) the values of the average density of foam concrete 150-350 kg / m ^{3 are} adopted "in anticipation of technological progress", as a number of world foreign companies currently operating in our country and representing such foam concrete at construction exhibitions do; in fact, in the example embodiment of the invention, foam concrete of the brand in average density D400 was used;

c) the given values of the molecular weight of PNS were guaranteed by the manufacturer of the additive Polyplast OJSC (Novoyoskovsk, Tula region) upon request for this indicator as optimal;

d) the given values of the mass ratio of high-strength cement, PNS and water in a cement-water suspension in the range of 100: (0.8-2) :( 0.28-0.35) and the mass ratio of dry matter of a foam based on a foaming agent, including resin saponified wood (SDO), containing less than a third of polyphenols and cement in the foam concrete mixture, was guaranteed as optimal by the manufacturer of high-strength cement for foam concrete, including PNS, and foaming agent based on SDO - Geostrom LLC (Moscow) upon requests for these indicators;

e) the remaining characteristics of foam concrete and metal reinforcement as components of a building according to the invention are established by the inventors during its implementation;

e) the bearing capacity of the specified wall-shell of the building described in the example embodiment of the invention was 30 t / linear m. The limits indicated in the formula are 5–50 t / m3 calculated by changing the initial parameters — the calculated density of foam concrete in the range of 150–350 kg / m ³ and the use of other composite slabs based on magnesia binder and wood sawdust, Portland cement and basalt fibers, gypsum cement-pozzolanic binder and staple fiberglass, Portland cement and kapron fiber. The use of asbestos-cement boards and plywood for various reasons was excluded in principle; no change in wall thickness of 300 mm was also envisaged; cement-bonded particleboards with hydrophobization and polymer impregnation are found on the building materials market;

g) the standard for maximum wind speed due to the number of storeys of frameless buildings was introduced in 2005 by the mandatory technological regulations of the EU and the USA; Designed and first introduced in Canada in 2002; Russia is expected to join this norm around 2010;

h) during the operation of the experimental building described below during 2002-2008, the effectiveness of the adopted technical solutions for reinforcement elements was proved;

i) during the construction of the experimental building, the indicated door and window openings were respectively standard and partly shaped; before filling the walls-shells with foam concrete into the formwork, insertion of the bounding plates was carried out; this practice can be replaced by pre-harvesting plates of the right size along with the rest of the building elements to speed up assembly;

j) in a similar way, it is advisable to provide for the mechanization of finishing and waterproofing works through the use of pre-prepared hinged, glued or otherwise fixed elements (panels) with finishing and waterproofing layers.

The invention becomes clearer from the description of an example of its implementation.

Example. Figure 5 presents a General view of a three-story residential building according to the invention. It is characterized by a free architectural form, in particular, includes curvilinear in terms of architectural elements. Pouring the foam concrete mixture into the fixed formwork of the supporting wall-shell of the waffle structure is shown in Fig.6.

The building is being erected, starting from concreting the foundation and foundation, walls and ceilings, and ending with the installation of floors, roofs and roofs. In this case, all these reinforcing and fixed formwork elements are pre-harvested on automated technological lines with program control for bending, welding and cutting of these nets and profiles, and cutting of these composite plates, in this case cement-bonded boards according to [GOST 26816-86. Cement bonded plates. Specifications, reprint. 1991] with the provision of any given external contours and similarity of sizes when matching between the designed opposed plates and the reinforcing nets placed between them, taking into account the mounting inlets of the latter. The resulting cutting products are packaged in an adapted container with the appropriate marking and assembly numbering, placed in a warehouse and transported to the construction site according to the network schedule. In accordance with the latter, all other construction materials are prepared, including packaged cement, as well as engineering equipment, then, on a prepared construction site with outgoing engineering communications, all workpieces are laid out according to a scheme performed using software and hardware, prepared according to the last network schedule construction of the foundation and foundation of the specified building. At the same time, in a monolithic version, reinforcement is laid and heavy concrete mixture is poured. According to a possible prefabricated-monolithic version, reinforcement and finished building elements are laid and heavy concrete mixture is poured. Use either ready-mixed concrete or prepared at the construction site. Leave free areas for mounting the main reinforcement of the bearing walls-shells. If it is necessary to strengthen the building structure for increased workload, these sections are also used, along with other possibilities, for fastening additional fittings. After the concrete has hardened, the shape or formwork of the ordered external contour of the building is assembled in the plan for pouring the floor blanks of the first floor ready-mixed or prepared on site with concrete mix, the provided floor reinforcing elements are laid in the said form or formwork, installed and bonded, rigidly fixed to the latter and to the main reinforcement of the foundation, the indicated nets for the walls-shells of the first floor around the perimeter of the building, pour the concrete mixture into the form or formwork for the floor, monopolizing the released ends and connections at grids than those indicated. The specified concrete mix is expected to solidify, meanwhile, by installing and linking to the indicated grids by means of the indicated strip reinforcement and belts from it, the opposite parts of the formwork sides of cement-bonded particle boards around the perimeter of the first floor of the building. At the same time, these plates and strip reinforcement are connected with self-tapping screws, and these grids and strip reinforcement are connected with clamps. The last connection is schematically shown in Fig.7.

Having installed the ordered fixed formwork, pour the specified foam concrete mixture into the last layers with a height of at least 1.5 m. After that, waiting for the foam concrete mass to solidify in the non-removable formwork of the first floor filled to the top, prepare the specified form or formwork and install the reinforcement elements for the specified flooring of the floor of the next floor, the main reinforcement of the pockets of which is rigidly connected by wire reinforcement to the upper nodes of the indicated meshes of the first floor, monolithic concrete the indicated bonds after the foam concrete has hardened on the first floor and repeat the described operations for the next floor, starting from the hall concrete mixes into the form or formwork of the specified flooring of the first floor.

The specified pouring of the foam concrete mixture into a fixed formwork with an installed reinforcing mesh is carried out with the consistency of the foam concrete mixture corresponding to the average cone density D300 (kg / m ³ ) for a standard cone immersion depth of at least 4 cm, at D200 - at least 6 cm, and at D150 - not less than 8 cm and lead with minimal interruptions not exceeding 30 minutes, until the completion of filling the foam concrete layer into the wall wall of each floor.

Before this pouring, it is envisaged to install at least one temperature sensor in the inner cavity of the wall-shell to fix the temperature of the foam concrete mass in the wall-shell and after its growth and subsequent decrease to 20 ° C in the winter season, the heat set is installed and connected immediately, the operation mode of which chosen according to the normative and technical documentation, and in the summer season they are not allowed through at least one heat gun or other appropriate device to cool the array below 5 ° C for e 24 hours after the fall of the exothermy of foam concrete, subject to the regime of protection of the specified array from the inclusion of vibrators at the construction site, to guarantee the smooth hardening of these thickened layers in the body of foam concrete.

The characteristics of this building are presented in table 1.

Calculation of the cost of the experimental building

The calculation was made based on the size of the building (floor plans, see Fig.8-10). The height of the walls of the basement (1st), living room (2nd) and attic (3rd) floors - respectively: 3.1; 3.4 and 3.0 m. The thickness of the walls is 300 mm, the partitions are 100 mm, and the ceilings are 320 mm.

The basement and attic windows are 0.95 × 1.6 m in size and 0.95 × 2.1 m along the basement arc. The windows on the living room floor are larger than 0.95 × 2.4 m. All doorways of standard height 2.1 m. The average width of the doorways is 0.87 m. The front door is 2.1 × 1.47 m. The bevel of the walls in the attic is 1.5 m relative to the floor of the attic floor. Pediments with a height: 3.5 and 3.0 m, respectively, from the level of the bevel of the walls. The beveled walls are made according to the scheme of filling the partition, and the thickness of the attic floor (40 m ² ) is less than the typical one and is 120 mm.

It is significant that the height of the walls and the glazing area in the building exceed the level of requirements for economy class houses. It follows that in the calculation of cost indicators made in this example according to actual data, there is a margin in relation to the cost price of economy class buildings, which may turn out to be relevant in the case of technological overlays, sharp price hikes of materials, etc.

The cost of assembling walls, partitions and ceilings takes into account the cost of the communications and installation of all engineering equipment.

The calculation results are presented in table 2 (prices in 2008, May).

From the data given in Table 2, it follows that the cost of 1 m ^{2 of the} total area of the experimental building is less than 6000 rubles / m ² (it is located in the Moscow region near the Moscow Ring Road). For comparison, we provide relevant data on the cost of 1 m ^{2 of the} total area of buildings in various areas of the Krasnodar Territory of the Russian Federation, where building materials are cheaper than in Central Russia [Emelyanova N. House, affordable for families. Stroitelnaya Gazeta, No. 50, 12.12.2008]: from 20 thousand rubles / m ² in rural settlements of Beloglinsky, Novopokrovsky and Novokubansky districts to 57 thousand rubles / m ² in Krasnodar and Novorossiysk and up to 110 thousand rubles / m ² in Sochi. Thus, with the characteristics of the building significantly exceeding the economy class level, the cost per unit of space in it is currently three times lower than in rural areas and an order of magnitude lower than in cities. This is direct evidence of the high efficiency of the technical solution according to the invention.

The building is different:

- simplicity and speed of construction: 1st floor in 1-2 days, depending on the temperature of the medium, which determines the rate of hardening of foam concrete to a level of compressive strength of 0.2 MPa, corresponding to the possibility of walking along the upper edge of the foam concrete massif with D300 without leaving traces; the work is carried out by a team of 4 people, counting in it a leader - a skilled worker with the participation of a trained worker in the preparation of foam concrete (for several buildings at once) and a logistics specialist providing the assembly procedure;

- the possibility of using low-skilled labor, including the personal participation of tenant customers;

- low cost of 1 m ^{2 the} area noted above;

- high quality and stability of materials that do not burn and do not rot; foam concrete is durable: still built in the 30s and 60s-70s of the XX century. in Ivanovo, Kostroma and the Urals, especially in Perm, houses made of foam concrete blocks of the brand in average density from D400 to D800); its advantage over crystallizing and decaying into heat and soundproof layers in the walls of Moscow reinforced concrete buildings with wooden floors of the construction of the 40s is clear - slag filling (existed for about 25 years), mineral wool in similar Moscow buildings of the 50s (existed 35 years), basalt wool in Kiev buildings built in the 60s (lasted 40 years), etc .; polystyrene boards in the building of the shopping center near Manezhnaya Square in Moscow collapsed by 50% or more only 2 years after the end of construction;

- energy saving during construction and operation; it is achieved due to the small thickness of the bearing walls and the reduced consumption of raw materials in connection with this, low energy consumption during construction without the use of handling equipment and effective thermal protection of the building due to the low thermal conductivity of the foam concrete (the thermal conductivity at D400 did not exceed 0.08 W / (m hail);

- light weight structures; the maximum weight of the used building elements did not exceed 40 kg;

- environmental protection; used materials do not emit harmful substances during the operation of the building in either liquid or gaseous form, do not emit odors, are not combustible;

- conveniences and comfort due to the free form of the premises, which can be easily verified by analyzing the floor plans of the buildings of Figs. 8-10;

- Easily standardized building design;

- suitability of design for any climatic zones;

- the suitability of the design for the effective replacement of traditional small-block construction;

- the durability of the design of the load-bearing wall-shell proposed in the invention, referred to as single-layer according to now accepted terminology; it is in connection with the compact structure that such walls are considered to be significantly more durable [AS Semchenkov Problems of technological progress. How to solve them. “Stroitelnaya gazeta”, No. 39, 28. 09. 2007] compared with multi-layer, which include load-bearing walls with curtained external heat-insulating, waterproofing, finishing layers and an internal plaster layer, characterized by short overhauls.

In conclusion, it should be noted that, according to the official review by NIIMosstroy on the project of the proposed building, it (hereinafter referred to as quotation): “may be the basis of the Affordable Housing program ... After all, building a house does not require complicated and expensive equipment and any qualifications, but simply working hands and common sense. Finally, as it was in Russia until the end of the XVII century, and then it was interrupted for three centuries, every man will be able to build his own home again (relying on the finished parts, but not only a crane, but even welding will not be required, everything will be done in advance prepared in the kit). This is a solution to a number of social problems, including personnel, and agriculture, and demographic, and migration, and the chain of others, and, of course, the construction complex; we can assume that the social significance of "this technical solution" makes it comparable to the program for the construction of five-story buildings in the 50s-70s of the last century "in the country.

Thus, this invention is prepared for widespread industrial implementation.

Table 1 Characteristics of the experimental building Indicators Units rev. Value External perimeter m 36 Building area m2 255 Effective area - "" - 207 Height at maximum m 12.65 Storeys 3 floors and attic Foundation Pile of ready-mixed concrete, depth 1550 mm, with beam grillage 200 × 300 mm 1st floor area m ² 77 2nd floor area - "" - 69 3rd floor area - "" - 61 Attic floor area - "" - 40 1st floor height m 3,1 Height 2 floors - "" - 3.4 Height 3 floors - "" - 3 Center attic height - "" - 1.8 Wall area m ² 260 Attic Wall Area - "" - 57 Area of internal partitions - "" - 146 Glazing Area (40%) m ² 80,4 Doors, interior PC 10 Roofing, metal m ² 150 Cement Boards m ² 1375, taking into account the cut (10% loss) Weight of steel reinforcement and reinforcing mesh t 3,7 Weight of strip reinforcement (tapes, profiles) - "" - 2,3 Filled concrete volume m ³ 126 Volume of heavy concrete poured - "" - 24

table 2 Calculation of the cost of the experimental building at actual costs, rub. Calculation components Units Area The cost of 1 sq.m. Building cost External walls (without doors and openings) m ² 260 1287.4 334724 Partitions (without doors) - "" - 146 863.2 126027 Ceilings (except attic) - "" - 207 1410.4 291953 Beveled Attic Walls - "" - 90 863.2 77688 Attic floor - "" - 40 863.2 34528 Window - "" - 80 3200 256,000 Roof - "" - 150 750 112500 Doors PC. 10 4000 40,000 Wallpaper m ² 450 80 36000 Pipes, cables m one hundred 250 25,000 Plumbing 125000 Carpet m ² 70 400 28,000 Laminate - "" - 117 300 35100 Tile - "" - twenty 500 10,000 TOTAL: value of a building with an area of 257 m ² 1532520 TOTAL: cost of 1 m ^{2 of the} building 5963.1

Support signature on the patent application of Klimov-Rakhovsky, 2008:

Figure 1. The predominance of spherical vesicular pores in the foam according to the invention.

Sizes from 30 to 550 microns. The sphericity and closure of vesicular pores is a feature of monolithic foam concrete used in the building according to the invention.

Figure 2. Cellular textures on the surface of the shell in the pores formed in the concrete mixture and hardening foam concrete used in the building according to the invention.

Figure 3. The cellular nanostructure of calcium hydrosilicates in the shell of a vesicular pore based on the original cell texture.

Dimensions are shown in the picture.

Figure 4. Shells on the surface of vesicular pores as part of a common matrix of hydrated neoplasms in the foam concrete used in the building according to the invention.

The boundaries of the vesicular pores are formed, counting from the pore cavity, as a shell (a light edge at the pore boundaries) and a columnar layer of low-hydrate hydrates — calcium hydrosilicates (A), “stitched” by organic nanolayers of organic matter (B) along the column boundaries that has grown over it. This texture is the nucleus of thickened layers formed in the foam concrete mixture when it is poured into the formwork cavity in the building according to the invention and then grows when the foam concrete mass is hardened in the wall-shell, making a noticeable contribution to the bearing capacity of the latter. In the inter-pore bridges these shells are part of the general matrix of hydrated neoplasms in foam concrete, which also includes gel-like accumulations of calcium hydrosilicates (B) and intergrowths of high-water fibrous hydrates (G).

Figure 5. General view of the experimental building according to the invention - a three-story building with an attic of a free-form residential building (Moscow region).

6. Pouring the foam concrete mixture into the cavity of the wall-shell during construction of the building according to the invention.

7. The connection of mesh and strip reinforcement in the box section of the latter by means of a clamp.

Designations:

1. Clamp - strip of sheet steel 0.55 mm in size 15 × 45 mm

2. The rod (rod) of the reinforcing mesh.

3. The thin-sheet profile (box section) of strip reinforcement.

4. Cement bonded particleboard.

Note. The clamp clamp is connected by punching a hole with a diameter of 4 mm through the box section of the strip reinforcement and in two tabs of the clamp in the place indicated on the sketch by an oblique cross using a special notch tool.

Fig. 8. The plan of the 1st floor of the experimental building according to the invention.

5. Here and in FIGS. 9 and 10: image scale: grid square size 1 × 1 m; bold gray dots on the floor plans - the position of the axes of the window and doorways (red dots - for color printing).

Fig.9. The plan of the 2nd floor of the experimental building according to the invention.

Figure 10. The plan of the 3rd floor of the experimental building according to the invention.

Claims (8)

1. A monolithic concrete building, consisting of a foundation, walls and floors, containing rigidly interconnected slabs with reinforcing elements and made of porous concrete enclosed in fixed formwork, characterized in that the building is low-rise, has a free architectural form with any including curved up and facade caused brim plates and reinforcement elements, aerated concrete is a monolithic foam average density of 150-350 kg / m ³ of hardened foam concrete mix n based on an aqueous suspension of high-strength Portland cement, including clinker, gypsum components and a dry organic component based on polymethylene polynaphthalene sulfonates with a molecular weight of 800-2000 D, with a mass ratio of the clinker part of the specified cement, the indicated polymethylene polynaphthalene sulfonates and water 100: (0.8-2) :( 0 , 28-0.35) in the specified suspension, combined with a double foam, including polyphenols in the composition of the wood-saponified resin in an amount of not less than one third of the total weight of the foam, calculated on dry matter when mass the ratio of foam: cement in terms of dry weight (0.015-0.02): 1, due to the chemical affinity of these aromatic compounds in which spherical vesicular pores with a diameter of 30-550 μm are surrounded in foam concrete with nanostructured non-porous hydrosilicate shells of a cellular structure with a cell size of 30 -70 nm and a thickness of 75-100 nm associated with a matrix of hydrated neoplasms of the specified foam concrete, the latter being enclosed in a fixed formwork made of composite plates rigidly connected by means of a mesh and strip metal reinforcement, 90-95% immersed in foam concrete, and the remaining parts connected with the main reinforcement of the floor and foundation and monolithic in the latter with heavy concrete, while the surfaces of these plates and reinforcement in foam concrete are surrounded by thickened shells specified in accordance with the Weissenberg effect on pores topotactic layer with a thickness of up to 3 mm from expanded concrete D650-D1350 with increased adhesive strength by an order of magnitude compared with other foam concrete to the specified plates and reinforcement within 0.05-0.5 MPa, providing the walls-shells of the waffle structure bearing function, combined with the enclosing and heat-insulating, with a working load of 5-50 t / linear m of the specified wall-shell. 2. The building according to claim 1, characterized in that the cut of these fixed-formwork slabs with an accuracy of 0.1-0.5 mm ensures its connectivity and continuity in assembly on each of its two sides when they are fastened along the sides and across the inside formwork cavities by means of strip reinforcing elements in the wall-shell of each floor of the building, and the welded reinforcing mesh located in the array of the specified foam concrete located in the specified cavity is provided with inlets rigidly connected to the main reinforcement of the reinforced concrete floors, and monolithic in the pockets of the upper and protrusions of the lower floors on each floor of the building above the first, and on its first floor the lower slots of the specified mesh are connected with the reinforcement of the foundation and monolithic in its protrusions. 3. The building according to claim 1, characterized in that the reinforced concrete slab of said interfloor floors supported on said wall-shells is a monolithic or precast-monolithic reinforced concrete box flooring of any given contour in plan, with boxes filled with said foam concrete and with pockets of perimeter filled with heavy concrete, in which the mentioned overlaps of the reinforcing mesh of the foam concrete layer of the wall-shell of the previous floor are monolithic, with the value of the distributed work load on the floor e within 5-10 MPa, depending on the specified interval of the average density values of the specified foam concrete, with local values of the concentrated working load up to 45 MPa. 4. The building according to claim 1, characterized in that the said composite slabs of fixed formwork are slabs based on inorganic hydraulic or air binders from the group:
Portland cement, magnesian binder, gypsum-cement-pozzolanic binder, and fibrous aggregates from the group: chip, polymer, mineral, with a modified surface, hydrophobized or impregnated with polymers. 5. The building according to claim 1, characterized in that the number of floors in it in any climatic zones does not exceed four, excluding zones with winds at a speed equal to or more than 100 km / h, where it does not exceed two floors. 6. The building according to claim 1, characterized in that the reinforcing elements of the specified wall-shell include:
welded reinforcing mesh,
strips of thin galvanized steel sheet fastening the opposed composite formwork opposing composite panels and the welded reinforcing meshes located between them in the specified foam concrete array, the strips including flat sections and box-shaped sections for fastening the specified meshes, as well as these composite plates by self-tapping screws through openings provided in the strips, forming at least three horizontal stiffening belts along the height of said slabs and along the edge of said slabs at least two vertical stiffening belts for each pair of opposing slabs on the indicated sides of the fixed formwork and each reinforcing mesh standing between them on each floor of the specified building. 7. A building according to any one of claims 1 and 2, characterized in that plates for forming window and door openings, voids for sanitary devices and ventilation ducts are installed inside the fixed formwork. 8. The building according to any one of claims 1 and 2, characterized in that elements with stucco layers are attached to the indicated nets and / or plates of the inner surface of the said wall-shells, and on the outside of the building to the indicated nets and / or plates the external surface of the said walls-shells are attached with elements of external waterproofing and decoration, or waterproofing and finishing layers are applied on the indicated plates.

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