RU2423230C2 - Solid wall element of woodwool stabilised with cement - Google Patents

Abstract

FIELD: construction. ^ SUBSTANCE: construction elements for walls, containing cement-based woodwool and having slots arranged at the upper end and along the sides. Construction elements are made of a mixture of woodwool, cement and water with the weight ratio between woodwool and cement equal to 1:1.88 and 1:1.92, which is poured into steel moulds. Finished elements have density of 200-300 kg/m3. The system of low-rise buildings construction includes above-specified construction elements, which are connected at the sides with vertical concrete columns poured in situ, and also with a horizontal framing beam, which is poured in situ in the upper end of the element. The elements are placed on a foundation with the help of a guide made of a perforated plate and are fixed to it with the help of plaster. Roof timbers are fixed in the framing beam with the help of steel angle elements. ^ EFFECT: production of items with proper heat-insulating properties, high heat capacity, moisture resistance, resistance to rot, fire resistance. ^ 8 cl, 14 dwg, 1 ex

Description

The scope of the invention

The present invention relates, on the one hand, to a method of manufacturing wall blocks one floor high, which are cast from a mixture of cement-stabilized wood wool, and, on the other hand, to a building system for connecting these blocks to each other to erect load-bearing exterior walls.

BACKGROUND OF THE INVENTION

Cement-stabilized wood wool today exists only in the form of so-called wood-fiber insulation boards. This material, which is made from wood wool, cement and water, has existed in Europe since the 1920s. Plates typically have a width of 500 or 600 mm and a length of 2000 or 2400 mm. Their thickness is from 20 to 150 mm. A wood-fiber insulation board is primarily used as insulation for plastered load-bearing walls, sound-absorbing ceiling and self-supporting ceiling insulation.

This building material is characterized by good heat-insulating properties and high heat capacity. It has a good ability to accumulate moisture, and due to its open pore structure, it can also quickly absorb and release moisture. The wood-fiber insulation board is not susceptible to decay and has been tested to be highly resistant to mold. Plastered wood-fiber insulation boards located on the facades of buildings under the influence of rain for more than 50 years of operation, as well as buried in the ground for 30 years, did not reveal any signs of decay. In addition, the material has high fire resistance. Wood-fiber insulation boards do not emit formaldehyde and at least any noticeable amount of volatile organic compounds (VOCs).

The existing method of manufacturing wood fiber insulation boards is limited to a maximum plate thickness of 150 mm and a maximum width of 600 mm. This eliminates the production of wall blocks in the form of solid elements. Assembling wood-fiber insulation boards into solid wall blocks, from the point of view of industrial construction, is a relatively expensive operation.

SUMMARY OF THE INVENTION

The present invention relates to a method for manufacturing building blocks using wood wool, cement and water, including:

- preparation of molds for casting these blocks;

- obtaining wood wool and its moisture;

- stabilization of the water content in wood wool at 25%;

- mixing stabilized wood wool with dry cement in a weight ratio of from 1: 1.88 to 1: 1.92;

- pouring the mixture into a mold;

- ensuring the solidification of the mixture.

The invention also relates to a building block for walls containing cement-bonded wood wool and characterized in that it is made in accordance with the above method.

The present invention also relates to a method for building buildings, including:

- joining the above building block to the foundation using plaster;

- connection of these blocks with side ends to each other by pouring concrete columns into vertical cavities formed by grooves made on the side ends of the blocks;

- pouring into the grooves on the upper ends of the blocks of the concrete strapping beam, which can be used to attach the rafters.

Brief Description of the Drawings

Figure 1 depicts an example section of a steel mold (1.1) for pouring a solid wall block of cement-stabilized wood wool. On the side walls of the mold there are strips (1.2) of triangular section for forming a V-shaped groove at the ends of the block, according to FIG. 3.

Figure 2 illustrates a sectional view of an example of pouring a solid wall block. Two lifting slings (2.1) attached to a round beam (2.2) are poured into the block. On the upper side of the mold is a channel-shaped strip (2.3) of sheet steel, designed to create a rectangular groove, according to Fig.4.

Figure 3 illustrates how the V-shaped grooves (3.1) at the lateral ends of the block form a rectangular cavity (3.2), intended for filling in place of a column of concrete that connects the blocks to each other.

Figure 4 depicts a rectangular groove (4.1) in the upper ends of the wall blocks, and also illustrates the temporary connection of wall blocks with U-shaped brackets (4.2) made of sheet steel.

Figure 5 shows in a perspective view a sample of a completed one-piece wall block with window openings, and also illustrates the installation of blocks on a foundation.

6 shows a guide from a perforated plate (6.1) attached to a concrete slab.

7 illustrates an example of how a block (7.1) of wood wool is attached to a foundation using cement plaster (7.2).

Fig. 8 illustrates the connection of wood wool blocks using concrete columns cast in situ (8.1). A nagle made of a reinforcing bar is fixed in the foundation at the junction (8.2) of the blocks.

Figure 9 illustrates the filling of the strapping beam (9.1) in the upper end of the block, as well as its reinforcement with steel reinforcement (9.2).

10 shows an example of fasteners (10.1) for fastening windows and doors.

11 illustrates an example of attaching rafters to the strapping beam using corner elements (11.1), attached to both the strapping beam and the rafters. The lower part of the rafters is covered with a waterproofing layer (11.2).

12 shows conduits and boxes (12.1) that are installed in hollow holes in a block and are smeared with plaster (12.2) before applying the finishing layer.

13 shows a section of a wall of blocks of wood wool, the surface of which is covered with an external (13.1) and internal (13.2) reinforced plaster, as well as a sealant layer on the top of the wall (13.3).

Fig. 14 shows a U-beam (14.1) located between two wall blocks. In the upper corners of the blocks, recesses (14.2) are made to accommodate the beam.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The invention relates, on the one hand, to a method of manufacturing exterior wall blocks of cement-stabilized wood wool, that is, solid wall blocks, and, on the other hand, to a building system for assembling these elements into load-bearing exterior walls. The thickness of the blocks is selected based on the required thermal insulation and bearing capacity. This technology relates primarily to walls that are not exposed to large vertical loads, for example, to the outer walls of individual houses.

Preparation method

Blocks of wood wool are made by pouring a mass of wood wool (a mixture of wood wool, cement and water) into steel molds. The manufacture of this mass is carried out so that the mass of wood wool obtained from coniferous wood in a special planing machine is moistened and mixed with cement. At the same time, the ratio of the components of the mixture between cement and moistened wood wool is essential for the elasticity of the mass during casting: if too much cement is used, the mass of wood wool and cement is not sufficiently elastic, thus increasing the density. On the other hand, if too little cement is used, the strength of the block may decrease. The mixing of the specified mass, as well as the filling of the forms, differs from the manufacture of wood-fiber insulation boards, which have a maximum thickness of 150 mm. Solid wall blocks, according to one embodiment of the present invention, are produced using a weight ratio of 1: 1.9 between wet wood wool and dry cement (for conventional building fiber boards, the ratio of the components of the mixture is 1: 2.0). In practice, it was proved that the composition of the mixture with a weight ratio of 1: 1.90 is suitable for a casting height of 400 mm without loss of strength and an excessive increase in block density; the density may be in the range from 200 to 300 kg / m ³ . Tests have shown that the composition of the mixture with a weight ratio of less than 1: 1.88 can lead to problems with the surface strength of the material. When mixing components in a ratio of more than 1: 1.92, some blocks become too dense and shrink. Tests have also shown that problems may occur with a lower mix ratio when trying to coat all wood wool with cement. It is important to cover all wood wool with cement, since cement provides the final product with resistance to fire and microbial growth. According to one embodiment of the invention, molds are used with a length of 6 m, a height of 2.4 m and a depth of 400 mm (internal dimensions), however, the dimensions can be changed in accordance with the required dimensions of the wall blocks. Adjacent to the upper edge of the molds, an adjustable steel sheet strip having a cross section of 100 × 160 mm is placed to create a groove at the upper end of the blocks. Likewise, trims with a triangular cross section are placed on both side walls of the mold to create V-shaped grooves on the side ends of the blocks. Lifting slings are poured on each side of the block to enable subsequent gripping and holding of the blocks after the cement has hardened and during assembly. To achieve the desired density, the mass of wood wool is constantly weighed during the filling process. Then this mass is distributed evenly on the surface of a horizontally lying shape to achieve uniform density. When the entire mass of wood wool is distributed, the forms are slightly overwhelmed. The mass is compacted by placing the molds in a stack on top of each other, while the bottom of the upper mold forms a cover for the underlying mold. A lid is placed on the uppermost form, over which concrete loads weighing approximately 1000 kg / m ² are placed. The removal of the block from the mold is possible after 24 hours. Blocks are lifted from the mold and set to dry. Window openings, if any, are usually cut out after the blocks solidify, however, the window openings can also be molded when filling the blocks. Doorways and large windows are placed between two wall blocks. In the upper edges of the wall blocks, recesses are made to accommodate the U-shaped beams according to FIG. Mounting plates are installed on both sides of the window and door openings to support mounting. Windows and doors can be attached to these plates with screws. Solid wall blocks can be delivered to the construction site immediately after they harden to sufficient strength and are dried to obtain the desired density. Blocks ready for delivery have a density of 200-300 kg / m ³ (the exact density may vary for different buildings, primarily depending on the required thermal insulation).

Building system

For individual houses, walls made of wood wool blocks are erected by installing manufactured wall blocks directly on a foundation, usually a rand beam. Blocks are attached to the base by installing them on a strip of cement plaster mortar on the inside of the wall. Then, when the blocks are docked with the side ends to each other, a vertical square cavity with a side of 70 mm is formed, formed by V-shaped grooves, as shown in Fig.3. The blocks are temporarily fixed in place by punching the holes and interlocking the blocks with U-shaped brackets made of sheet steel in the upper end. Blocks are connected to each other by side faces by pouring concrete columns into vertical cavities. Concrete columns, in addition to connecting the blocks to each other, serve to give the wall sufficient vertical load bearing capacity for blocks with low density and for blocks having a thickness of up to 150 mm. Then, a concrete beam (serving as a strapping / ring beam) with a height of 160 mm and a width of 100 mm is poured into a groove at the upper end of the blocks. This beam is reinforced with concrete columns. The strapping beam can also be made higher if it is necessary to distribute the load over large window openings. The rafters are attached to the strapping beam using steel corner elements, which can either be poured into the strapping beam or screwed to it. Windows and doors are attached to the mounting plates using ordinary screws with dowels, according to figure 10.

For the treatment of internal surfaces, plaster or plasterboard sheets are used. The plaster layer is preferably reinforced with a welded reinforcing mesh with a galvanic coating or a stainless steel mesh. Reinforcing reinforcement is placed in the outer layer of the plaster. The reinforcing mesh is also placed on top of the joints of the wall blocks, in the lower layer of the stucco mortar. Thus, at the junction of the blocks produce double reinforcement. In the case of using gypsum plasterboards, they are glued to the wall with gypsum plaster mortar. The joints between the sheets are filled by laying a layer of gypsum plaster between blocks made of wood wool and drywall sheets along the entire joint.

On the outside, surface treatment includes plaster, which is reinforced in the same way as the inner layer of plaster, or any other type of facade material. The top of the wall and window openings are covered with plaster mortar from the effects of wind. If breathable facade material such as wood panels or facade bricks is used, the outside of the brickwork should also be coated with a mortar of plaster.

Electrical wires are inserted into the masonry in the hollowed channels (as for, for example, lightweight concrete walls). Fasteners for fastening to the wall objects of small weight, for example, paintings, are performed in a layer of plaster (or in a gypsum board) using plastic plugs, metal dowels or rubber dowels. In the case of heavier items, such as kitchen cabinets for dishes or wall-mounted bookshelves, sheet metal profiles are used that are placed in grooves cut into / grooved into the wall. Alternatively, threaded plugs or injection alabaster can be used.

Additional details of the building system are apparent from the description of the drawings, as well as from the claims.

In a further embodiment of the invention, the proposed manufacturing method and molds shown in FIG. 1 are used for casting solid wall blocks from cemented cement bonded wood wool according to FIG. 2. The blocks are cast with grooves at the side ends, according to FIG. 3, to provide lateral connection of the blocks to each other. The blocks are cast with a groove on the upper ends in accordance with figure 4 to ensure the filling of the strapping / ring beam. Window openings are cut out in already cast blocks, see FIG. 5.

In the proposed construction system, blocks of wood wool are placed on the foundation in accordance with Fig.6, along a guide made of perforated steel sheet according to Fig.7, on a strip of plaster. The blocks are connected in accordance with Fig. 8 by pouring concrete columns in the joints between the blocks. The strapping beam is poured from concrete at the top of the block according to Fig. 9 in such a way that this beam reinforces the wall together with concrete columns. Windows and doors are fixed in the mounting guide plates with ordinary screws according to Fig.10. The rafters are attached to the strapping beam according to Fig.11.

The wiring is inserted into the wall blocks according to Fig. 12. The inner and outer layers of the plaster are applied in accordance with Fig. 13. The plaster layer must be reinforced with a welded reinforcing mesh with galvanic coating or stainless steel mesh.

Example

In a further embodiment of the invention, a method for manufacturing solid wall building blocks includes the following.

- Preparation of wood wool; preferably wood wool should have the following characteristics: each strip of coniferous material has an approximate thickness of 0.3 mm, a width of 2.5 mm and a length of 300 mm.

- Putting wood wool in a bath with water to moisturize it.

- Rolling wet wood wool between rubberized rollers, which ensures uniform water content in wood wool. Preferably, the water content in wood wool when mixed with cement is 24-26%, and more preferably 25% (by weight).

- Weighing wood wool before loading it into the water bath and after this operation.

- Putting a weighted amount of wood wool after rolling through rubberized rollers into a container for mixing with dry cement. The specified amount of wood wool can be measured, for example, using measuring load modules (company Siemens, Germany).

- Adding dry cement to the mixing tank. The amount of dry cement is preferably 1.88-1.92 times in a weight ratio greater than the amount of wood wool with a uniform water content. It is preferable to use any metering device, for example, Thomal, to obtain the appropriate dose of cement. As cement, it is preferable to use standard Portland cement. The mass ratios of wood wool and cement 1: 1,90 or in the range of 1: 1,895-1: 1,905 provide good properties of the resulting blocks.

- Mixing a mixture of components. During the tests, the Van Elten device (Holland) was used. Stirring continued for 40-60 seconds.

- Pouring the mixture into molds. The process can be carried out at positive temperatures. Tests were performed indoors.

Claims (8)

1. A method of manufacturing building wall blocks one floor high of wood wool, cement and water, including:
- preparation of molds for casting blocks;
- obtaining wood wool and its moisture;
- stabilization of the water content in wood wool at the level of 24-26%;
- mixing stabilized wood wool with dry cement in a weight ratio of from 1: 1.88 to 1: 1.92;
- uniform distribution of the mass of wood wool on the surface of the lying form;
- ensuring the solidification of the mixture. 2. The method according to claim 1, in which:
- fill out the form when it is in a lying position;
- overfill the form to some extent;
- stack several forms on top of each other;
- place the lid on top of the uppermost form;
- place concrete loads with a specific gravity of approximately 1000 kg / m ³ on said lid. 3. The method according to claim 1, in which the weight ratio of wood wool and cement is in the range from 1: 1,895 to 1: 1,905. 4. The method according to claim 3, in which the weight ratio of wood wool and cement is 1: 1.90. 5. A building wall block one floor high containing cement-bonded wood wool, characterized in that it is made in accordance with the method according to any one of claims 1 to 4. 6. A method of building a building, including:
- joining a building block, made in accordance with paragraph 5, to the foundation using plaster;
- connection of these blocks with side ends to each other by pouring concrete columns into vertical cavities formed by grooves made on the side ends of the blocks;
- pouring into the grooves on the upper ends of the blocks of the concrete strapping beam, which can be used to attach the rafters. 7. The method according to claim 6, in which the specified block is sealed with plaster. 8. The method according to claim 6, in which create double layers of reinforcing mesh in the surface layer of plaster on top of the junction of the two blocks.

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