US3442991A - Method for producing aeroconcrete building blocks - Google Patents

Method for producing aeroconcrete building blocks Download PDF

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Publication number
US3442991A
US3442991A US641054A US3442991DA US3442991A US 3442991 A US3442991 A US 3442991A US 641054 A US641054 A US 641054A US 3442991D A US3442991D A US 3442991DA US 3442991 A US3442991 A US 3442991A
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Prior art keywords
mixture
stone
core
stones
die
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US641054A
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Walter Lanz
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/50—Producing shaped prefabricated articles from the material specially adapted for producing articles of expanded material, e.g. cellular concrete
    • B28B1/503—Moulds therefor
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
    • E04B2/28—Walls having cavities between, but not in, the elements; Walls of elements each consisting of two or more parts kept in distance by means of spacers, all parts being solid
    • E04B2/30—Walls having cavities between, but not in, the elements; Walls of elements each consisting of two or more parts kept in distance by means of spacers, all parts being solid using elements having specially designed means for stabilising the position; Spacers for cavity walls

Definitions

  • This invention relates to a method for manufacturing an inorganic profilated brick or stone having high sound and heat isolating properties and adapted for making monolithic walls.
  • Hollow profilated bricks or stones have been used for making monolithic walls, whereby a number of stones have been assembled with their hollow spaces in vertical alignment, whereafter reinforcing irons have bene inserted into the vertical canals formed by the hollow spaces of the stones and such canals have been filled with cast concrete in order to anchor the reinforcement in the stones.
  • the brick or stone according to this invention is made of aeroconcrete and comprises a longitudinal hollow space open at one bearing or contact side and at least at one end face of the stone, and hollow spaces extending from said longitudinal hollow space to the other bearing or contact side of the stone.
  • this die comprising a fiat bottom structure, a rectangular frame having side walls and end walls disengageably assembled and positioned on said bottom structure, the depth of theframe corresponding to the desired thickness of the stones to be formed, and core means adapted for insertion into the said frame, said core means comprising at least one unity for forming the hollow spaces of at least one stone, said core unity including a longitudinal core member and core members extending laterally from said longitudinal core member, the effective height of the core unity being equal to the depth of the frame so that the end surfaces of said laterally etxending core members contact said bottom structure and the end surface of said longitudinal core member is in a common plane with the upper edge of the frame when the core unity is inserted into the frame.
  • the attached drawing illustrates, by way of example, three embodiments of the profilated stone such as an embodiment of the die according to this invention, the above method being explained with reference to the illustration of the die.
  • FIG. 1 is a perspective view of the first embodiment of the hollow profilated stone
  • FIG. 2 is a top view of the first embodiment
  • FIG. 3 is a top view of the second embodiment
  • FIG. 4 is a top view of the third embodiment
  • FIG. 5 is an end view of the stone illustrated in FIGS. 1 and 2 and
  • FIG. 6 is a perspective view of a die or mould for producing the stones illustrated in FIGS. 1, 2 and 5.
  • the large-size profilated stones shown in the drawing are suitable for making monolithic walls and are made of aeroconcrete.
  • For domestic building stones of the type shown in FIGS. 2 and 4 are preferably used.
  • the stone of type A shown in FIGS. 1, 2 and 5 has a size in the order of 25 x 25 x cm. It has two vertical side walls 1 and 2 with four webs 3 at right angles to and between walls 1 and 2. The dimensions and distance between webs 3 is such that three vertical canals or hollow spaces 4 of square cross section are formed between the webs, the cross section of such canals or apertures being in the order of 12 x 12 cm. for the above dimensions of the stone.
  • the canals 4 are open at both bearing or contact surfaces formed by the upper and lower end surfaces of walls 1 and 2.
  • a recess 5 of rectangular cross section and having a size in the order of 12 x 6 cm. for the above overall dimensions of the stone is provided at each end of the stone, recesses 5 being substantially parallel to the spaces 4.
  • the recesses 5 are open at both bearing or contact sides and also at the end faces of the stone.
  • the upper surfaces of the webs 3 are at a distance from the upper edge surfaces of walls 1 and 2 so that a longitudinal horizontal recess or hollow space 40 (best seen in FIG. 5) is formed extending throughout the length of the stone and open at the upper bearing side and at the ends of the stone.
  • the canals 4 and recesses 5 communicate with the longitudinal recess or hollow space 40.
  • the upper surface of webs 3 is V-shaped, this particular form being due to a corresponding shape of the mould or die wherein the stones are cast.
  • the depth of the said longitudinal recess or hollow space 40 measured from one upper inner edge of wall 1 or 2 to the intersecting line of the inner wall surface with the V-shaped upper surface of a web 3 is in the order of half the width of this space, that is the distance between the inner surfaces of walls 1 and 2.
  • This stone or brick shown in FIGS. 1, 2 and 5 is the standard type.
  • the modified form B shown in FIG. 3 is a nxing stone allowing attachment of door or window frames and the like
  • the modified form C shown in FIG. 4 is a corner stone, both made of aeroconcrete.
  • These stones B and C have side walls 1 and 2, webs 3 and hollow spaces or recesses 4 and 5.
  • one end surface of stones B and C is closed so that the upper longitudinal hollow space of these stones is only open at one end where it communicates with the one recess 5.
  • Stone B which has preferably the same length as stone A has a recess 7 of square cross section in its closed end wall 6, recess 7 serving for receiving a door frame or window frame not shown in the drawing. It has only three webs 3 and two hollow spaces 4, but another hollow space 8 adjacent end wall 6 open at both bearing sides of the stone and having a cross section substantially corresponding to the cross section of recess 5.
  • the stone of type C is somewhat shorter than the stones of type A and B, for instance in the order of 60 cm. It has a straightend wall 6 and a narrow hollow space 8 between the outer hollow spaces 4.
  • continuous vertical canals will be formed in a wall made of stones piled upon each other, such canals taking up the vertical reinforcement and the cast concrete.
  • continuous horizontal canals are formed in the upper portion of stones arranged horizontally side by side, such horizontal canals ending only at an end, a corner or at an opening of the wall where stones of type B or C are used.
  • the continuous horizontal canals serve for accommodation of the horizontal reinforcements and they will be filled with cast concrete so that a monolithic wall structure is obtained.
  • the stones may be made of any suitable aeroconcrete without organic fillers, having sufficient heat and sound isolating properties for domestic buildings and having an expanding or gas-developing time sufficiently long for the manufacturing method described below.
  • the aeroconcrete mixture disclosed in Swiss Patent 360,332 is particularly suiable for this purpose.
  • Other suitable mixtures well known in the art may also be used, the composition of the mixture being not an object of this invention.
  • the die or mould shown in FIG. 6 is suitable for simultaneously forming six profilated stones of type A shown in FIGS. 1, 2 and 5.
  • the die has a bottom structure 9 preferably made of boards glued together by means of a water-resistent glue and having a plane top surface.
  • a frame of rectangular form having two vertical side walls 10 and two end walls 11 inserted between side walls 10 is supported on the bottom structure 9.
  • the side and end walls 10 and 11 are removably assembled by means of tie rods 12 passing through bores of the outer reinforcing blocks of end walls 11 and through bores of the side walls 10 and having wing nuts 13 at their outer ends.
  • the depth of the frame corresponds to the thickness or height of the stone to be produced in the die.
  • each core unit 15 For forming the upper longitudinal hollow space 40 and the hollow spaces 4 of the stone, six similar core units 15 are provided having each a longitudinal core member or carrier 15a and three core members 15b extending at right angles from carrier 15a, of square cross section and a distance from each other corresponding to the thickness of the webs 3 of the stone to be formed.
  • the total height of the core units 15 is equal to the depth of the frame so that the end faces of core members 1512 will contact the bottom structure 9 and the upper horizontal surface of the carrier 15a will be in a common plane with the upper edge surface of frame walls 10 and 11 when the core portion is inserted into the frame.
  • a strip 16 is fixed at the upper horizontal surface of each core member 15a, said strip 16 having a width inferior to the width of the core member 15a and extending from the ends of the core unit beyond the outer surface of the frame walls 10.
  • the side walls 10 For forming the hollow spaces or recesses 5 at the ends of each stone A the side walls 10 have core portions 17 fixed to their inner surface between adjacent separating walls 14 and between the outer separating walls and the end Walls 11 respectively, such core portions serving equally for preventing displacement of the core units inserted into the die in longitudinal direction that is, parallel to the side walls 10.
  • the upper end surfaces of core portions 17 have a V-shaped profile wherein the corresponding V-shaped profile of the core member 15a will closely engage when the core unit is inserted into the die frame.
  • the dies or moulds for producing stone types B (FIG. 3) and C (FIG. 4) are not shown in the drawing, because the modifications of the die illustrated in FIG. 6 for obtaining these stone types will be obvious.
  • Core members 17 will be omitted at one sidewal of the frame and the core member 15a of each core unit will be shortened to the desired length of the longitudinal hollow space to be formed at the top side of the stone.
  • the cross section and arrangement of the core members 15b is adapted to the cross section and arrangement of the hollow spaces 4 and 8 to be formed.
  • core members of a shape corresponding to the recess 7 are provided instead of core members 17 in one corner of each die compartment.
  • the die may be of a size allowing simultaneous production of more or less than six stones.
  • the components of the concrete such as water, cement sand, a gas-developing agent and a stabilizer if desired are mixed in a mixing device to a mixture which may b cast into the die frame.
  • a mixing device to a mixture which may b cast into the die frame.
  • the mixture is cast into the die frame to a level required by the proportion of the volume of the stones to be formed from the expanded mixture and the unexpanded mixture cast into the frame.
  • the frame is filled to the half of its full height. In order to properly fill all the corners of the die it is necessary to thoroughly distribute the mixture in the die by means of a trowel or the like and the level or surface of the mixture should be flat and parallel to the top surface of the bottom structure 9.
  • the separating walls 14 are inserted into the frame and are pressed downwards thereby displacing the mixture until the lower edge surfaces of the separating walls contact the top surface of the bottom structure 9.
  • the separating walls are anchored in the grooves a and their upper edge surface is in a common plane with the upper edge surfaces of walls 10 and 11.
  • the core units 15 are now inserted into the compartments of the die.
  • the core members 15b are pressed into the mixture until their lower end face contacts the top surface of the bottom structure, whereby the level of the mixture slightly rises due to the displacement of mixture by the core members 15b.
  • the roof-shaped lower surface of the carrier 15a engages the V-shaped recesses of he core members 17 without yet contacting the mixture, whereby the core units are secured against longitudinal displacement in the die.
  • the upper surface of core members 1511 are in the said common plane comprising the the upper edge surfaces of the frame.
  • the core units 15 are removed whereafter the die remains unchanged for a period in order of three days for fully setting the aeroconcrete.
  • the frame is then disassembled after removal of the wing nuts 13, and the stones and separating Walls are lifted off from the bottom structure. The times indicated relate to a minimum temperature of the mixture and of the treating room of 180 C.
  • a method for producing aeroconcrete building blocks which comprises,
  • said confining space is of a width to accommodate a plurality of building blocks, and including the step of subdividing said confining space into a series of rectangular subspaces each open at the top but isolated from each other, said subdividing being performed substantially immediately after the distributing step.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Moulds, Cores, Or Mandrels (AREA)
US641054A 1962-12-31 1967-05-24 Method for producing aeroconcrete building blocks Expired - Lifetime US3442991A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CH1530562A CH397198A (de) 1962-12-31 1962-12-31 Anorganischer, thermisch und akustisch isolierender Formhohlstein zur Bildung von monolithischem Mauerwerk, Verfahren zu dessen Herstellung und Giessform zur Ausführung des Verfahrens

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US (1) US3442991A (de)
AT (1) AT253405B (de)
CH (1) CH397198A (de)
DE (1) DE1459309A1 (de)
GB (1) GB1064070A (de)

Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3607605A (en) * 1966-06-23 1971-09-21 Toray Eng Co Ltd Composite building material
US3954924A (en) * 1972-06-08 1976-05-04 Imperial Chemical Industries Limited Method for simultaneously casting sheets on blocks of cellular polymeric material
US4357289A (en) * 1980-01-31 1982-11-02 Jakobsson Per A H Method for the production of building elements of the lightweight concrete type
US4393018A (en) * 1981-09-08 1983-07-12 Burrell Construction & Supply Co. Method for making a concrete block
US4670204A (en) * 1982-07-07 1987-06-02 Cruise Thomas E Process of producing an insulated concrete masonry unit with low density heat bridges
US4793587A (en) * 1987-09-03 1988-12-27 Leon Berger Core for molding hollow concrete blocks
US4819396A (en) * 1982-07-07 1989-04-11 Cruise Thomas E Insulated concrete masonry unit with low density heat bridges
US20040218985A1 (en) * 2003-04-30 2004-11-04 Klettenberg Charles N. Method of making a composite masonry block
US20070193181A1 (en) * 2006-01-30 2007-08-23 Klettenberg Charles N Dry-cast concrete block
US20080160126A1 (en) * 2006-12-29 2008-07-03 Apex Construction Systems, Inc. Compactable mold for forming building blocks
US20080258340A1 (en) * 2007-04-19 2008-10-23 Klettenberg Charles N System and method for manufacturing concrete blocks
US20110101200A1 (en) * 2009-04-20 2011-05-05 Container Design Services Corporation Fence Form Post & Insert Assembly
US20180044915A1 (en) * 2007-02-02 2018-02-15 Les Materiaux De Construction Oldcastle Canada, Inc. Wall with decorative facing
US10619348B2 (en) 2013-02-25 2020-04-14 Les Materiaux De Construction Oldcastle Canada Inc. Wall assembly
CN111705956A (zh) * 2020-06-24 2020-09-25 宝业湖北建工集团有限公司 多功能墙体及其建筑施工方法

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2000469B (en) * 1977-07-04 1982-04-07 British Steel Corp Moulding shaped articles
CN104563328B (zh) * 2014-12-26 2017-05-03 甘肃天鸿金运置业有限公司 一种复合组砌抗震空斗砖墙

Citations (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE78867C (de) * A. BRUCKNER, Aachen, Ludwigsallee 101 Hohltafeln aus Gyps und Rahmen zur Herstellung derselben
US676620A (en) * 1900-08-04 1901-06-18 American Plaster Ventilated Tile Company Mold for building-tiles.
US786370A (en) * 1904-08-27 1905-04-04 William L Marchand Wall construction.
FR376787A (fr) * 1907-04-15 1907-08-20 Jean Marie Mounic Fabrication de pierres moulées à aération continue
US2100479A (en) * 1934-10-23 1937-11-30 William P Witherow Apparatus and method of making expanded cement articles
US2119860A (en) * 1936-03-04 1938-06-07 William P Witherow Expanded cement process
US2270541A (en) * 1939-02-02 1942-01-20 Charles A Martin Apparatus for forming aerated concrete slabs
US2476653A (en) * 1945-02-24 1949-07-19 Jr Robert S Elberty Press for molding building blocks
US2522116A (en) * 1945-12-18 1950-09-12 Hayes Econocrete Corp Of Ameri Method of molding lightweight concrete panels
GB702992A (en) * 1950-09-19 1954-01-27 Horace Keeble Improvements in or relating to a method of moulding hollow articles of self-setting materials
FR1060135A (fr) * 1952-07-02 1954-03-30 Perfectionnements apportés aux procédés et appareils pour le moulage d'éléments préfabriqués, notamment en béton
FR1088187A (fr) * 1953-05-15 1955-03-03 Appareil pour le moulage des blocs de matière agglomérée ou analogues
FR1135584A (fr) * 1955-11-08 1957-04-30 Procédé et dispositif pour la fabrication d'agglomérés
US3217069A (en) * 1961-03-08 1965-11-09 Brixite Ltd Method of moulding cement articles

Patent Citations (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE78867C (de) * A. BRUCKNER, Aachen, Ludwigsallee 101 Hohltafeln aus Gyps und Rahmen zur Herstellung derselben
US676620A (en) * 1900-08-04 1901-06-18 American Plaster Ventilated Tile Company Mold for building-tiles.
US786370A (en) * 1904-08-27 1905-04-04 William L Marchand Wall construction.
FR376787A (fr) * 1907-04-15 1907-08-20 Jean Marie Mounic Fabrication de pierres moulées à aération continue
US2100479A (en) * 1934-10-23 1937-11-30 William P Witherow Apparatus and method of making expanded cement articles
US2119860A (en) * 1936-03-04 1938-06-07 William P Witherow Expanded cement process
US2270541A (en) * 1939-02-02 1942-01-20 Charles A Martin Apparatus for forming aerated concrete slabs
US2476653A (en) * 1945-02-24 1949-07-19 Jr Robert S Elberty Press for molding building blocks
US2522116A (en) * 1945-12-18 1950-09-12 Hayes Econocrete Corp Of Ameri Method of molding lightweight concrete panels
GB702992A (en) * 1950-09-19 1954-01-27 Horace Keeble Improvements in or relating to a method of moulding hollow articles of self-setting materials
FR1060135A (fr) * 1952-07-02 1954-03-30 Perfectionnements apportés aux procédés et appareils pour le moulage d'éléments préfabriqués, notamment en béton
FR1088187A (fr) * 1953-05-15 1955-03-03 Appareil pour le moulage des blocs de matière agglomérée ou analogues
FR1135584A (fr) * 1955-11-08 1957-04-30 Procédé et dispositif pour la fabrication d'agglomérés
US3217069A (en) * 1961-03-08 1965-11-09 Brixite Ltd Method of moulding cement articles

Cited By (23)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3607605A (en) * 1966-06-23 1971-09-21 Toray Eng Co Ltd Composite building material
US3954924A (en) * 1972-06-08 1976-05-04 Imperial Chemical Industries Limited Method for simultaneously casting sheets on blocks of cellular polymeric material
US4357289A (en) * 1980-01-31 1982-11-02 Jakobsson Per A H Method for the production of building elements of the lightweight concrete type
US4393018A (en) * 1981-09-08 1983-07-12 Burrell Construction & Supply Co. Method for making a concrete block
US4670204A (en) * 1982-07-07 1987-06-02 Cruise Thomas E Process of producing an insulated concrete masonry unit with low density heat bridges
US4819396A (en) * 1982-07-07 1989-04-11 Cruise Thomas E Insulated concrete masonry unit with low density heat bridges
US4793587A (en) * 1987-09-03 1988-12-27 Leon Berger Core for molding hollow concrete blocks
US20040218985A1 (en) * 2003-04-30 2004-11-04 Klettenberg Charles N. Method of making a composite masonry block
US20070193181A1 (en) * 2006-01-30 2007-08-23 Klettenberg Charles N Dry-cast concrete block
US20080157430A1 (en) * 2006-12-29 2008-07-03 Apex Construction Systems, Inc. Compacting techniques for forming lightweight concrete building blocks
US7992837B2 (en) * 2006-12-29 2011-08-09 Lacuna Inc. Techniques and tools for assembling and disassembling compactable molds and forming building blocks
US20080156963A1 (en) * 2006-12-29 2008-07-03 Apex Construction Systems, Inc. Techniques and tools for assembling and disassembling compactable molds and forming building blocks
US20080160126A1 (en) * 2006-12-29 2008-07-03 Apex Construction Systems, Inc. Compactable mold for forming building blocks
US8282871B2 (en) 2006-12-29 2012-10-09 Lacuna Inc. Techniques and tools for assembling and disassembling compactable molds and forming building blocks
US8252221B2 (en) 2006-12-29 2012-08-28 Lacuna Inc. Compacting techniques for forming lightweight concrete building blocks
US7988123B2 (en) * 2006-12-29 2011-08-02 Lacuna Inc. Compactable mold for forming building blocks
US20180044915A1 (en) * 2007-02-02 2018-02-15 Les Materiaux De Construction Oldcastle Canada, Inc. Wall with decorative facing
US10472821B2 (en) * 2007-02-02 2019-11-12 Les Materiaux De Construction Oldcastle Canada, Inc Wall with decorative facing
US7695268B2 (en) 2007-04-19 2010-04-13 Marshall Concrete System and method for manufacturing concrete blocks
US20080258340A1 (en) * 2007-04-19 2008-10-23 Klettenberg Charles N System and method for manufacturing concrete blocks
US20110101200A1 (en) * 2009-04-20 2011-05-05 Container Design Services Corporation Fence Form Post & Insert Assembly
US10619348B2 (en) 2013-02-25 2020-04-14 Les Materiaux De Construction Oldcastle Canada Inc. Wall assembly
CN111705956A (zh) * 2020-06-24 2020-09-25 宝业湖北建工集团有限公司 多功能墙体及其建筑施工方法

Also Published As

Publication number Publication date
CH397198A (de) 1965-08-15
AT253405B (de) 1967-04-10
GB1064070A (en) 1967-04-05
DE1459309A1 (de) 1969-01-23

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