RU2658923C1 - Method of making facade blocks - Google Patents

Abstract

FIELD: construction.

SUBSTANCE: invention relates to the field of construction, namely to the methods of manufacturing inhomogeneous building blocks and can be used as a bearing and finishing element in the construction of buildings and structures for various purposes with a facade cladding of natural or artificial stone. Method of manufacturing facade blocks includes the preparation of load-bearing building blocks, sawing out the facing slabs of natural or artificial stone and fixing them on the front side of the blocks. To carry out this fixation, the following operations are carried out in sequence: on the horizontal base, formwork is assembled from vertical plates forming collapsible cells in the form of facing plates. These plates are placed on the bottom of the cells with a facing side down. Steel fiber concrete mixture is poured into the cells. Load-bearing building blocks are laid on top of the mixture and the formed structures inside the cells are maintained to a set with a mixture of at least 50 % strength. After that, formwork is performed.

EFFECT: technical result is a simplification of the production of facade blocks with an increase in the strength of finished products.

1 cl, 3 dwg

Description

The invention relates to the field of construction, and in particular, to methods for manufacturing heterogeneous building blocks and can be used as a supporting and finishing element in the construction of buildings and structures for various purposes with facade cladding made of natural or artificial stone.

The use of stone cladding for facades significantly improves the aesthetic characteristics of any building. The installation of hinged facades with cladding from ceramic granite slabs or slabs made of natural stone is a rather laborious and expensive process, requiring careful monitoring of the installation of hidden fastening systems. And if mistakes are made, the fall of large slabs of stone can lead to material damage as well as to human victims. In accordance with GOST 23342-2012, the thickness of the plates should be at least 40 mm, as a result of which the dead load on the supporting structures increases significantly and the cost of the material increases. At the same time, an expensive fixing system is required (see Building materials. A training manual. Edited by GA Airapetov, GV Nesvetaeva - Rostov n / A: Phoenix Publishing House, 2004).

The practice of modern technology for finishing facades of buildings and structures has a tendency to use tiles made of artificial materials as part of facade panels imitating natural stone (see, for example, patent RU 2132916, class E04F 13/00, publ. 10.07.1999; RU 2183236, CL E04F 13/14, published on June 10, 2002). All of them are distinguished by the need to carry out work after the erection of a building structure, which increases the overall delivery time of the facility. Also, the work takes place under construction conditions, often at a height - as a result, the quality of the products decreases. The proof of this is the small warranty period for the operation of such facades. It is also known that ordinary facing materials - analogues of natural stone, when used for more than a year as a result of aggressive environmental influences, fade, reducing the decorative qualities of the building.

Closest to the technical nature of the claimed invention is a method of manufacturing facade blocks, including the preparation of load-bearing building blocks, sawing tiles from natural or artificial stone and their fixation on the front side of the blocks (see patent RU 44589, class E04C 1/40, publ. March 27, 2005). The document does not disclose details of the method, but it is indicated that fixing occurs by gluing, which imposes severe restrictions on the operating conditions and the service life of the resulting facade block.

The technical problem is the creation of a method that allows to establish a cost-effective automated production of reliable and durable facade blocks. The technical result consists in simplifying the manufacture of facade blocks while increasing the strength of the finished product. The problem is solved, and the technical result is achieved by the fact that according to the method of manufacturing facade blocks, including the preparation of load-bearing building blocks, sawing tiles from natural or artificial stone and their fixation on the front side of the blocks, to perform this fixation, the following operations are performed sequentially: on horizontal the base is mounted formwork from vertical plates forming collapsible cells in the form of facing plates, placed at the bottom of the cells of the decree facing slabs, pour the steel-fiber-concrete mixture inside the cells, load-bearing building blocks are laid on top of the mixture and maintain the formed structures inside the cells until the mixture reaches at least 50% strength, and then formwork is carried out. It is advisable to use bricks as supporting building blocks.

In FIG. 1 shows a General view of the finished facade blocks;

in FIG. 2, 3 - assembly diagram of the formwork in the form of a grilyato lattice.

A method of manufacturing facade blocks consists in preparing load-bearing building blocks 1 (for example, standard bricks or cinder blocks, foam blocks, etc.), cutting out the facing plates 2 and fixing them on the facade side of the blocks using layer 3 of fiber-reinforced concrete. Plates 2 with a thickness of 5-10 mm, depending on the type and purpose of the element, are cut from an array of natural or artificial stone on a waterjet machine, which automatically cuts out plates 2 of the necessary shape with high accuracy and polishes the facing surface. On the back, cuts can be made to improve traction.

To carry out this fixation, a formwork is mounted on a horizontal base, for example, in the form of a reconfigurable grill lattice of vertical metal plates 4, forming collapsible cells 5 in the form of facing plates 2 (length-width). At the bottom of the cells place plates 2 facing side down. Inside cells 5, a steel fiber-reinforced concrete mixture is poured with a batcher with an electronic mass control system, the volume of which is calculated based on the thickness of the required adhesive layer 3 (5 mm) and the area of the contact surface (block size 1). Layer 3 is formed from a high-strength self-compacting steel-fiber concrete mixture with a minimum strength of B80, frost resistance of F1000, water resistance of W20, and the workability grade is P5. The mixture preferably has the following composition per 1 m ³ : cement M600 - 750 kg, sand - 1250 kg, silica fume - 60 kg, superplasticizer - 10 kg, water - 200 l, wavy steel fiber measuring 0.3 * 15 mm - 250 kg. High-density matrix provides adhesion, and the introduction of steel fiber increases endurance during prolonged exposure to power and temperature. The steel-fiber-concrete mixture is mobile and self-compacting, after pouring it does not require vibration - it itself is evenly distributed over the entire working area.

Bearing building blocks 1 are manually or automatically placed on top of the mixture. After this, a special machine with guides checks the horizontalness of their upper faces. After reconciliation, the formed structures are kept inside cells 5 and transferred to the set strength zone, where they are maintained until at least 50% strength is obtained by the mixture (under favorable conditions, about 8 hours steaming). After this, the stripping is carried out.

After stripping, the finished facade blocks are folded onto a pallet, packaged (wrapped with waterproofing film) and transferred to a warehouse.

Quality control is carried out in each shift in the following parameters:

- mobility control of steel-fiber concrete mix (cone spread);

- the strength of steel fiber concrete (the manufacture of cubes with subsequent testing);

- Ultrasonic integrity control of the contact seam for 5% of the product;

- direct determination of the strength of the adhesive layer by the separation method (at least three arbitrary elements).

Thus, through the use of a strong and durable contact seam made of steel fiber concrete, which has not only high adhesion properties to the surface of stone, brick and concrete, but also provides reliable joints due to its own high strength, frost resistance and waterproofness, the proposed invention allows to produce facade blocks with high degree of reliability and durability. The proposed method for the manufacture of facade blocks with finished cladding by transferring the bulk of the work to factory conditions allows to reduce the cost and improve the quality of products, as well as reduce the consumption of stone material.

The use of manufactured facade blocks provides the ability to clad buildings and structures with natural or artificial stone without additional work on the installation of the curtain wall and with a minimum consumption of cladding material. Masonry from the resulting products can be performed both seam and seamless, depending on the requirements of the architect. Combinations of arrangement of elements of various colors and shades will allow to obtain various aesthetic parameters.

Claims (8)

1. A method of manufacturing facade blocks, including the preparation of load-bearing building blocks, sawing of facing slabs from natural or artificial stone and their fixation on the front side of the blocks, characterized in that the following operations are performed sequentially to carry out the specified fixation: on a horizontal base, a formwork is mounted from vertical plates forming collapsible cells in the form of facing plates, place the indicated plates with the facing side down at the bottom of the cells, steel fiber-reinforced concrete mixture is poured inside the cells, load-bearing building blocks are laid on top of the mixture and maintain the formed structures inside the cells until a mixture of at least 50% strength is set, then carry out the stripping. 2. The method according to p. 1, characterized in that the bricks are used as load-bearing building blocks.

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