WO1999008885A1 - Elements de construction, leurs revetements et leur procedes d'application - Google Patents

Elements de construction, leurs revetements et leur procedes d'application Download PDF

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Publication number
WO1999008885A1
WO1999008885A1 PCT/GB1998/002478 GB9802478W WO9908885A1 WO 1999008885 A1 WO1999008885 A1 WO 1999008885A1 GB 9802478 W GB9802478 W GB 9802478W WO 9908885 A1 WO9908885 A1 WO 9908885A1
Authority
WO
WIPO (PCT)
Prior art keywords
building element
brick
coating
course
mortar
Prior art date
Application number
PCT/GB1998/002478
Other languages
English (en)
Inventor
Dean James Clowes
Original Assignee
Dean James Clowes
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from GBGB9717550.9A external-priority patent/GB9717550D0/en
Application filed by Dean James Clowes filed Critical Dean James Clowes
Priority to AU88151/98A priority Critical patent/AU8815198A/en
Publication of WO1999008885A1 publication Critical patent/WO1999008885A1/fr

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/02—Macromolecular compounds
    • C04B26/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44F—SPECIAL DESIGNS OR PICTURES
    • B44F9/00—Designs imitating natural patterns
    • B44F9/04—Designs imitating natural patterns of stone surfaces, e.g. marble
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • C04B28/04—Portland cements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C1/00—Building elements of block or other shape for the construction of parts of buildings
    • E04C1/40—Building elements of block or other shape for the construction of parts of buildings built-up from parts of different materials, e.g. composed of layers of different materials or stones with filling material or with insulating inserts
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/14—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements stone or stone-like materials, e.g. ceramics concrete; of glass or with an outer layer of stone or stone-like materials or glass
    • E04F13/147—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements stone or stone-like materials, e.g. ceramics concrete; of glass or with an outer layer of stone or stone-like materials or glass with an outer layer imitating natural stone, brick work or the like
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00482—Coating or impregnation materials
    • 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
    • E04B2002/0202—Details of connections
    • E04B2002/0204—Non-undercut connections, e.g. tongue and groove connections
    • E04B2002/0206—Non-undercut connections, e.g. tongue and groove connections of rectangular shape
    • 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
    • E04B2002/0256—Special features of building elements
    • E04B2002/0267—Building elements with the appearance of several bricks

Definitions

  • This invention relates to building elements, coatings for building elements, and methods of applying coatings to building elements. Particularly, but not exclusively, to elements to provide a brick-like appearance to walls and other structures.
  • a coating material to be applied to a building element said material being characterised by having as constituents:
  • the coating material includes, as a constituent, a colouring pigment — advantageously in powdered form.
  • the cementitious powder comprises ordinary Portland cement or high- fired Portland cement or a mixture thereof .
  • the cementitious powder comprises a mixture of 20% to 80% ordinary Portland Cement and 80% to 20% high-fired Portland Cement, the proportions being dependent upon the colour of the pigment.
  • constituents (a) , (b) or (c) are in substantially equal parts by volume, preferably mixed with a substantially equal part of water.
  • constituents are provided in separate receptacles within an outer packaging member.
  • a second aspect of this invention there is provided a method of applying to a building element a coating material according to the first aspect of this invention and with a colouring pigment added to the mixture of constituents (a) , (b) and (c) prior to the scattering thereon of the particulate material .
  • a method of applying to a building element a coating material according to the first aspect of this invention said material further comprising — as a constituent — a colouring pigment, characterised in that said colour pigment is mixed with the particulate material prior to scattering both the particulate material and the colouring pigment together onto the said mixture of constituents (a) , (b) and (c) applied as a coating on the building element .
  • the building element has an interrupted surface and the said mixture of constituents (a) , (b) and (c) is applied as a coating on the surfacially- interrupted face of the building element by a roller and such that there is little or no entry of said mixture into the surfacial interruptions.
  • the surfacial interruptions comprise elongate indentations extending in mutually perpendicular directions to represent mortar between adjoining bricks.
  • a building element having a brick-simulated surface provided by a method according to a said method.
  • the building element is preferably characterised in that the brick- simulated surface has the appearance of a plurality of bricks in superimposed courses with at least one brick in one course being in staggered relation to a brick in an adjoining course.
  • the building element is characterised in that at least one pair of superimposed courses has the two opposed side edges of one course staggered laterally with respect to the two opposed side edges of the other course.
  • the building element is characterised in that the said bricks and courses are bounded by simulations of mortar which, away from a perimeter of the building element, have a nominal mortar width and which, at the perimeter of the building element, have a width of half the nominal mortar width (such that two such elements placed edge-to-edge can simulate a mortar course of said nominal width) .
  • the building element comprises a formation formed from settable material, e.g. a plaster or render.
  • a casting of settable material to form a brick- like facing having a front face and a rear face in registry with one another, the front face having the appearance of a plurality of bricks in superimposed courses with at least one brick in one course being in staggered relation to a brick in an adjoining course, the bricks and courses being bounded by simulations of mortar which, away from a perimeter of the building element, have a nominal mortar width and at the perimeter of the building element have a width of half the nominal mortar width.
  • said brick-like appearance is provided by one or more coatings of an adhesive upon which sand and/or other particulate material is scattered.
  • a casting of settable material to form a brick- like facing having a front face and a rear face in registry with one another, the front face having the appearance of a plurality of bricks in superimposed courses with at least one brick in one course being in staggered relation to a brick in an adjoining course, said brick-like appearance being provided by at least one coating of an adhesive upon which sand and/or other particulate material has been scattered.
  • said coating, or the last of said coatings may include a brick-coloured pigment which, advantageously, is applied by a roller.
  • the building element comprises a set (i.e. self-supporting) casting adhered by its rear face to a support member.
  • Said support member may be a tile or like article of fired clay.
  • said support member may be a breeze block.
  • the support member has forward and rearward faces in registry with one another and with the front and rear faces of the casting.
  • the side contour of the building element is of modular form, preferably of castellated modular form to enable a plurality of such elements to interfit, preferably interdigitate, with one another.
  • a method of making a building element comprising the steps of casting or molding a plurality of support members of a uniform modular outline shape enabling them to interfit with one another, casting or molding a plurality of brick-like facings of corresponding outline shape, and adhering respective facings and support members to one another either before or after applying to the facings — on their surfaces (to be) away from the support members — one or more coatings of a material according to said first aspect of the invention.
  • Figure 1A is a perspective front view of a building element according to a first embodiment of this invention
  • Figure IB is a front elevation of the element of Fig 1A
  • Figure 2 is a perspective rear view of the building element of Figs 1A and IB
  • Figure 3 is a perspective front view of a building element according to a second embodiment of this invention
  • Figure 4 is a perspective front view of a building element according to a third embodiment of this invention
  • Figure 5 is a plan view of a building element according to a fourth embodiment of this invention
  • Figure 6 is a perspective front view of a building element according to a fifth embodiment of this invention
  • Figure 7 is a perspective front view of building elements providing a modification of the arrangement suggested in Fig 6.
  • the building element 10 shown in Figs 1 and 2 comprises a breeze block 12 and a pre-formed facing element adhered to one another .
  • the breeze block 12 is pre-formed as by casting of conventional materials (e.g. compressed ash) to have a toothed or castellated modular shape with substantially flat front and rear surfaces 16,18.
  • the block 12 has its pores sealed by submerging it in a suitable sealant .
  • the sealant may be a solution comprising a mixture of pva and styrene butadiene.
  • the pre-formed facing element 14 is separately cast or molded in a mold of similar toothed or castellated outline shape from a render material comprising, for example, sand, Portland cement and water.
  • a render material comprising, for example, sand, Portland cement and water.
  • One surface of the wet, impressionable render is embossed with a 3 -dimensional surface patterning representing three courses of staggered brickwork 20 with two simulated bricks 22 per course, the simulated bricks 22 being separated horizontally and vertically by elongate indentations 24 (e.g. of triangular or semi-circular cross-section) to represent pointing and/or mortar between the simulated bricks 22 (see Fig 1) .
  • the embossing may be provided on the lower surface of the render in the mold by the mold's bottom face.
  • the embossing may be provided on the upper face of the render in the mold by a separate, suitably shaped tool or a mold piston plate pressed onto the render mixture's upper surface .
  • the adhesive employed may comprise a mixture or blend of a styrene butadiene copolymer adhesive and a polyvinyl adhesive, together with ordinary Portland cement or high- fired Portland cement (white) or a mixture of these cements, water and, if wanted, a suitable colouring pigment (e.g. a coloured stone dust such as that known as "Jahn”) to provide a desired texture and consistency (and colour) .
  • a suitable colouring pigment e.g. a coloured stone dust such as that known as "Jahn
  • the styrene butadiene copolymer is mixed with the cement, and the polyvinyl adhesive added thereto prior to adding the water and any desired colour pigment .
  • the adhesive may comprise substantially equal parts by volume of
  • the adhesive may have the following approximate composition :
  • styrene butadiene 25 parts by volume styrene butadiene, 25 parts by volume of a cementitious powder such as ordinary Portland cement or high-fired Portland cement (white) or a mixture thereof, 25 parts by volume polyvinyl adhesive, and 25 parts by volume water.
  • a cementitious powder such as ordinary Portland cement or high-fired Portland cement (white) or a mixture thereof
  • 25 parts by volume polyvinyl adhesive 25 parts by volume water.
  • Each adhesive coating is applied by a roller to avoid or minimise the application of adhesive in the grooves 24 and, following sand being scattered thereon, a resultant brick- like effect for those grooves which are to provide a simulation or represention of inter-brick mortar.
  • at least the last coating of adhesive includes a suitable pigment to provide a suitable brick-like colouration to the front face 26 of the facing element 14
  • the pigment utilised is an organic, non-oil-based, powder colourant.
  • cementitious powder is a mixture of between
  • the two separately formed elements 12 and 14 are then bonded to one another by a suitable adhesive between the front face 16 of the breeze block 12 and the flat rear face 28 of the facing element 14.
  • the adhesive employed may be similar in composition to that used for coating the embossed surface of the element, but omitting any colour pigment and at least some of the added water.
  • the two elements 12,14 lie in registry with one another and form, when fully bonded, a single composite building element of the toothed or castellated modular shape of Figs 1 and 2.
  • This composite building element 10 may, for example, have an overall length of about 60cms (23"), a overall depth of about 24cms (9.5"), and a height of about 34cms (13.5").
  • the elements can be readily interfitted with one another
  • each composite element 10 is provided at one end with mortar representations to all its vertical edges at 25 (and, optionally, to all its horizontal edges at 35) .
  • all the mortar representations 23 at the perimeter of the building element 10 have a width of 5mm, i.e. half the nominal mortar width value of 10mm, so as to provide an overall composite width of 10mm when adjoining building elements are interfitted end to end or are superimposed one upon the other.
  • This enables that the finished structure to have a matching appearance as between the composite mortar representations 23 (provided by two adjoing elements 10) and the inward mortar representations 21 which are all of the nominal 10mm width.
  • This feature in conjunction with providing the building elements of a uniform modular outline shape enabling them to interfit with one another, also enables the building elements to be non-handed, i.e. they can be placed together either way up, and this eases and speeds up wall assembly from such building elements.
  • the building element 30 of the embodiment of Fig 3 is constructed in a substantially similar manner to that of building element 10 of Figs 1 and 2, and likewise comprises a breeze block 32 having adhesively bonded thereto a facing 32 representing a plurality of bricks in superimposed courses with at least one brick in one course being in staggered relation to a brick in an adjoining course.
  • building element 30 has the different shape of a series of steps; and a wall built from a plurality of such modular building elements 30 will have them interfit with one another sideways rather than interdigitate with one another sideways as is the case with building elements 10 of Figs 1 and 2.
  • a corner element 40 can be produced substantially as shown in Fig 4.
  • the construction is by joining a pre-cast breeze block 42 and a pre-cast render material facing 44 of similar outline to block 42, the facing 44 extending over two flat faces of the breeze block 42 that adjoin one anther to form an arris.
  • two elements 10' and 10" can be employed which are each substantially similar to the element 10 of Figs 1A and IB.
  • Element 10' (Fig 6) has its two most laterally projecting side faces 25 provided with a brick-like facing such as that on the element's front face 22.
  • Element 10" (not shown) has its one most laterally projecting side face 35 similarly provided with a brick- like facing such as that on the element's front face 22.
  • the brick facing arrangement for the two elements 110' and 110" (Fig 7) is modified to provide a "half-brick-overlap" or Flemish- brickwork appearance.
  • the two most laterally projecting side faces 25' of corner element 110' have facings which substantially represent two half -bricks
  • the one most laterally projecting side face 35" of corner element 110" has a facing which substantially represents two half-bricks.
  • the building element 50 of Fig 5 has its pre-cast facing 54 extending over all four sides of the breeze block 52.
  • the latter is centrally apertured at 55 to permit a plurality of elements 50 to be mutually superimposed to form a pillar whilst permitting a gate post, electrical conduit or other rod or pipe to be mounted and secured in the vertically aligned apertures 55.
  • Figs 1, 2, 3, 6 or 7 may be modified to provide facings such as 20 and/or 30 mounted onto different support members, e.g. shaped tiles or other structures of less depth than the breeze blocks 12 and 32. This will allow the facings to be readily applied to a wooden or metal framework to create a representation of a genuine brick wall, e.g. as a facade around a domestic hearth fire.
  • the illustrated building elements provided with coatings as described above demonstrated (in tests) surprisingly good resistance to weathering and moisture ingress. This is thought to be due to the substantial sealing of the pores of the element that result from its being coated with the mixture containing the two adhesive materials (which also serve as a binder for the cementitious powder and, in the topmost coating, for the colouring pigment) .

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Civil Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Finishing Walls (AREA)

Abstract

La présente invention concerne un élément de construction comprenant un moulage de matériau durcissable permettant de former un parement à effet brique ayant une face frontale et une face arrière alignées l'une par rapport à l'autre. La face frontale a l'apparence d'une pluralité de briques disposées en rangées superposées, au moins une brique d'une rangée étant décalée par rapport à une autre brique adjacente. Le moulage durci est collé par sa face arrière à un élément de support, tel qu'un carreau, ou tout autre article similaire en argile cuite ou en parpaing. On obtient cette fausse apparence de brique pour la face frontale en formant sur cette face des interruptions de surface en forme d'entailles allongées, s'étendant dans des directions perpendiculaires les unes aux autres, de manière à représenter un mortier entre les briques adjacentes. On applique ensuite sur cette surface interrompue un matériau de revêtement à l'aide d'un rouleau. Ce revêtement renferme: (a) un premier agent adhésif comprenant du styrène butadiène, (b) un second agent adhésif renfermant un adhésif polyvinylique, et (c) une poudre de ciment. Enfin, on disperse sur cette surface du sable et/ou un autre matériau particulaire. On peut rajouter au revêtement un pigment colorant ou incorporer ce dernier au revêtement supérieur, si on utilise une pluralité de revêtements.
PCT/GB1998/002478 1997-08-19 1998-08-19 Elements de construction, leurs revetements et leur procedes d'application WO1999008885A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU88151/98A AU8815198A (en) 1997-08-19 1998-08-19 Building elements, coatings therefor and methods of applying them

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
GB9717550.9 1997-08-19
GBGB9717550.9A GB9717550D0 (en) 1997-08-19 1997-08-19 Building elements
GB9723435.5 1997-11-05
GBGB9723435.5A GB9723435D0 (en) 1997-08-19 1997-11-05 Building elements

Publications (1)

Publication Number Publication Date
WO1999008885A1 true WO1999008885A1 (fr) 1999-02-25

Family

ID=26312089

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/GB1998/002478 WO1999008885A1 (fr) 1997-08-19 1998-08-19 Elements de construction, leurs revetements et leur procedes d'application

Country Status (2)

Country Link
AU (1) AU8815198A (fr)
WO (1) WO1999008885A1 (fr)

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2365860A (en) * 2000-08-18 2002-02-27 Frederick James Adams Cementitious surfacing composition including a polymeric additive and a method of application using a stencil
WO2002070248A1 (fr) * 2001-03-02 2002-09-12 James Hardie Research Pty Limited Revetements pour materiaux de construction
US6749897B2 (en) 2001-03-02 2004-06-15 James Hardie Research Pty Limited Coatings for building products and methods of using same
CN102797316A (zh) * 2012-08-16 2012-11-28 福建省百川建设发展有限公司 一种平屋面防火保温砖及其制备工艺与施工方法
US8993462B2 (en) 2006-04-12 2015-03-31 James Hardie Technology Limited Surface sealed reinforced building element
GB2519068A (en) * 2013-09-18 2015-04-15 Walline Ltd Precast wall segment
CN111576723A (zh) * 2020-04-10 2020-08-25 焦作市屠厨益加土特产有限公司 一种模块化复合建筑材料及方法

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1276111A (en) * 1969-06-19 1972-06-01 William John Hartnell Rapid lay building bricks
JPS4888121A (fr) * 1972-02-25 1973-11-19
GB1376895A (en) * 1970-12-10 1974-12-11 Banbury Buildings Holdings Ltd Simulated brick article of concrete or like material
US4644719A (en) * 1983-06-10 1987-02-24 Salazar Edward J Decorative wall panel
GB2262521A (en) * 1991-11-26 1993-06-23 Univ Birmingham Cementitious material

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1276111A (en) * 1969-06-19 1972-06-01 William John Hartnell Rapid lay building bricks
GB1376895A (en) * 1970-12-10 1974-12-11 Banbury Buildings Holdings Ltd Simulated brick article of concrete or like material
JPS4888121A (fr) * 1972-02-25 1973-11-19
US4644719A (en) * 1983-06-10 1987-02-24 Salazar Edward J Decorative wall panel
GB2262521A (en) * 1991-11-26 1993-06-23 Univ Birmingham Cementitious material

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
DATABASE WPI Section Ch Week 7418, Derwent World Patents Index; Class A18, AN 74-33450V, XP002084360 *

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2365860A (en) * 2000-08-18 2002-02-27 Frederick James Adams Cementitious surfacing composition including a polymeric additive and a method of application using a stencil
WO2002070248A1 (fr) * 2001-03-02 2002-09-12 James Hardie Research Pty Limited Revetements pour materiaux de construction
US6749897B2 (en) 2001-03-02 2004-06-15 James Hardie Research Pty Limited Coatings for building products and methods of using same
US6893751B2 (en) 2001-03-02 2005-05-17 James Hardie Research Pty Limited Composite product
US8993462B2 (en) 2006-04-12 2015-03-31 James Hardie Technology Limited Surface sealed reinforced building element
CN102797316A (zh) * 2012-08-16 2012-11-28 福建省百川建设发展有限公司 一种平屋面防火保温砖及其制备工艺与施工方法
CN102797316B (zh) * 2012-08-16 2014-10-29 福建省百川建设发展有限公司 一种平屋面防火保温砖
GB2519068A (en) * 2013-09-18 2015-04-15 Walline Ltd Precast wall segment
CN111576723A (zh) * 2020-04-10 2020-08-25 焦作市屠厨益加土特产有限公司 一种模块化复合建筑材料及方法

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