WO2019211654A1

WO2019211654A1 - Brick made from recycled garbage, with armed and light weapons and green and acoustic

Info

Publication number: WO2019211654A1
Application number: PCT/IB2018/053129
Authority: WO
Inventors: Reza FOROUMANDI
Original assignee: Foroumandi Reza
Priority date: 2018-05-04
Filing date: 2018-05-04
Publication date: 2019-11-07

Abstract

The embodiments herein provides The bricks are made from garbage recycling, armed and lightweight, green and acoustic classified in the field of environment, new technologies of roads, construction and recycling, which are used in the construction industry, manufacturing as much as desired, for production Prefabricated parts, etc., the recycling of unrecovered and non-degradable polymeric waste, recycling of polystyrene products, etc., are used.

Description

Brick made from recycled garbage, with armed and light weapons and green and acoustic

The bricks are made from garbage recycling, armed and lightweight, green and acoustic classified in the field of environment, new technologies of roads, construction and recycling, which are used in the construction industry, manufacturing as much as desired, for production Prefabricated parts, etc., the recycling of unrecovered and non-degradable polymeric waste, recycling of polystyrene products, etc., are used.

The innovation refers to an advantageous technology in C04B LIME; MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS (devitrified glass-ceramics C03C 10/00); REFRACTORIES (alloys based on refractory metals C22C); TREATMENT OF NATURAL STONE

E01D 101/22 E21D 11/06 C04B 18/02 Agglomerated materials C04B 16/08 expanded polystyrene beads C04B 20/00 Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups

C04B 14/00-C04B 18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B 14/00-

C04B 18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials -

Considering the spread and development of science and the emergence of many technologies in the last century, the recognition of newly created bricks has also been remarkably developed, so that today we use different kinds of bricks made by different materials, each of which has its own use. At present, various types of bricks are produced in light and ultra-light bricks. One of the most important materials used in building walls that directly affect mechanical weight and durability of concrete is bricks that form about 2.3 of walls in terms of weight and volume. In the past, natural aggregates such as mineral and river sand were used to produce most bricks, mortars, and infrastructure of roads, etc. These aggregates have disadvantages in terms of weight, use and environmental performance, which caused many problems for the road construction industry and other related industries. By increasing the technology of producing bricks and new human needs for lighter bricks and subsequently reducing the dead load of building and other road and construction projects, and providing new needs to overcome the disadvantages of old bricks and replacement with new bricks, new ways were developed.

According to the policies for the use of green and environmental materials and the recycling of indissoluble waste and the technical problems and industrialization of buildings and the Development Document 1404 and the use of modern materials of road and building construction for the production of housing approved by the Law on the Organizing and Protection of the production and Supply of Housing in 2008 and increasing the technical, mechanical, environmental and economic factors, the recycled bricks of recycled polymer materials account for about 85% of the total volume of these bricks, aggregates and 13% of cement and mineral materials and 1% of adhesive and protective polymers such as acrylic or polyester resin and 1% of polymer and metal fibers, were designed and manufactured as sample which not only have the advantages of the previous aggregates, but also have new features such as much lighter weight, high insulation, lower cost, environmental performance, high compressive strength and high elasticity, very low water absorption, resistance to high humidity and acidity conditions, armed, colored, various forms and so on.

Finally, new bricks entered the market, which not only have the advantages of previous materials, but also have some new advantages such as environmental protection, lighter weight, higher technical resistance, longer durability, and lower costs in various designs and sizes.

The worst disadvantages of these bricks is that they are imported and the high cost of this system is due to customs fees and other political and economic problems of the country and environmental problems due to insufficient raw and insulation materials and high cost and high delivery time and quality loss due to transportation, the use of heavy raw materials and asbestos; these problems had led to a recession in the market and construction industry. All these disadvantages will be solved by the production of bricks recycled from waste.

Bricks are said to adobes on which government sentences were written (carved), and by burning these adobes, they kept the writings on it. It is not known when the bricks were used for the first time. It is believed that the early humans, after observing the cooking of the mud adjacent to their ovens and seeing that the cooked mud was harder than the clods beside it, they found out its properties and method of making the bricks. Brick has also been used as a building material for a long time. The use of bricks as building materials in Iran has an ancient history. Famous ancient buildings that were made by brick include Taq Kasra. Another example is the floor of the corridor of Jameh Mosque of Isfahan, which was built by the bricks that during the Sassanid period were used to build a fire temple. In general, the use of bricks throughout Iran's history has been widespread, and lots of buildings, such as fire temples, mosques, residential buildings and the like have been built by brick. Currently, due to the increasing population density and the construction of multi-storey buildings, bricks cannot be used on the skeleton of this type of buildings, and metal or concrete skeletons are used; however, bricks are used for facades, or bricks are used in parts of the hall and other spaces. The hand-made (pressed) brick has been made for seven thousand years with the hands, and has made palaces, temples, schools, mosques and buildings solid and beautiful, but nowadays this handicrafts industry that has been used for thousands of years is not used any more. In the urban development of Tehran, there is no effect of hand-made bricks near the Shush Square, Rey Old Road and Hashemabad, but in Mahmoudabad, there are still 30 brick chimney bars of hand-made brick furnaces, some of which are up to 300 meters long and have been shut off forever since 1977. In the early years of the Iran-Iraq war, Iraqi aircrafts targeted the chimneys several times instead of the Tehran Refinery. Before the furnaces were electrical, the high brick bars did the ventilation as chimneys. Tehran has a traditional and very modern identity with its old buildings and historical monuments; the beauty and identity of Shamsol Emareh and Dar-al-Fonoun, Palace of museums, historical mosques, brick buildings of Hassanabad area, transom of National Garden, Communication and Post Museum, Saderat Bank Building, Sassanid / Achaemenid style brick buildings of National Museum of Iran, Ministry of Foreign Affairs, Doduments and Registration Building, old school, dome of the Charsough and the Big Market, marketplaces, caravansaries and the building of many houses and shops in the old parts of Tehran are due to these bricks.

Brick made of clay is used for at least 5000 years. It seems the first time it was used to build cities in Mesopotamia and Darsand in Pakistan. First, to make the brick, people mixed clay and straw by kicking them. Then, the prepared mixture was poured into rectangular molds and cooked under the sun. The brick that was cooked under the sun could not be kept solid without straw. Eventually, the people of Babylonia, Assyria and Ancient Egypt found that by melting clay, the bricks would be more durable and more resistant to air.

In the valuable period of the Seljuk architecture, bricks were used as the main building materials for all buildings such as caravansaries, water cisterns, royal buildings, public buildings, mosques, tomb bars, tomb towers, long bars of mosques and the like, which led to their systematic skeletal arrangement. The bricks were also used for facades in different ways such as skeleton-free cover with high creativity. In lots of works of the country during this period, there are a lot of types of brickwork arts, so that in the Kharraqan towers in Qazvin there are more than thirty types of brickwork, with beautiful arches of facades and Kofi brick lines, and in Jameh Mosque of Isfahan, there are up to 375 arches in various types, most of which are from the Seljuk period.

In this valuable period of architecture, there are the most beautiful designs in the types of brick chimneys, brick k nodes, brick Kofi lines on mosques such as the bar of Damghan Mosque with a height of 26 m, the multifaceted minaret bar of Naien Mosque with a height of about 30 m and the bar of Sareban minaret with a height of 48 m, and also the unparalleled bar of the Ali Mosque, which had previously been the bar of Sanjariya Mosque, that had been about 52 meters high, which later part of its head fell due to an earthquake, and is now about 42 meters high.

Bricks are divided into two categories based on their material:
Pressed bricks
Machine bricks

Given the technical, environmental, and economic problems of existing briks in domestic and international market, which are mostly inorganic and non-armed and with thermal and expansion production technology, we explain the existing problems from 2 environmental and technical and executive viewpoints.

The extra use and accumulated sponge polymer waste and biodegradable recycling technology (hot recycling) and not economical polymers in the present era

The presence of soot and dust in the silica alloy and ferrosilicon industry

The extra use of minerals as the main raw material causing environmental problems.

Thermal production technology and the use of fossil fuels in large rotary biodegradable and contaminated kilns of Light Expanded Clay Aggregate

Excessive pollution of extraction, production by clay with the heat above 1200 degrees

Spatial heavy density

Extremely high price

Lack of necessary, sufficient and affordable supplies in all regions of the country due to limitation of mines and imposing very high transportation costs (about 3 times the price of the product)

Lack of technical quality for use in wet and humid areas and chemical environments

Incompatibility with most adhesive materials and mortars

It is not safe to be used as aggregates in structural and special concrete independently

Lack of variety and colorability for specific uses

Very high water absorption

Problems with the addition of chemical additives

Lack of shape variety (with rounded and sharp corner)

Not being armed

Considering the ever-increasing advances in the building industry and the emergence of new materials that have advantages such as light weight, earthquake resistance, atmospheric resistant, long service life and high speed performance, this has resulted in many uses of these materials in this field. And in line with these materials, bricks with unique features have been produced for building industry.

According to the explanations provided in the previous section of this Code on the disadvantages and problems of previous materials, and the national requirements and regulations of the country, and solving the problems of existing and old materials approved by the National Standard and the Road, Housing and Urban Development Research Center and avoiding the problem of accumulation of plastic waste and disposable containers without recycling and without returning to nature and inflicting various diseases on humans and other living organisms, a product has been designed as a construction brick in sizes approved by the standard and Road, Housing and Urban Development Research Center, which collects all these waste, and after the washing and milling stages, combine them with a liquid mortar, and creates a panel with a good resistance and light weight and no pollution and low cost for uses in the construction industry and other industries. All or most of the problems and disadvantages of the past according to domestic and foreign standards will be resolved by the production of these bricks made of recycled waste materials.

The Invention Objectives :

1. To resolve previous material defects such as:

High cost- non-recyclable -heavy weight - causing environmental problems

2. Recycling of non-recoverable and destructive waste such as plastic and manual bags, expanded polystyrene disposable containers, plastophones, ionolites, waste plastics fibers and other materials and plastic and polymer derivatives; bulky and lightweight EPS

3. Employment

Recycling and utilization of non-degradable sponge polymeric waste in a dry and cool form, about 85% and replacing valuable and vital minerals

Reducing drinking water consumption by about 50% in production and care as environmentally-friendly materials

Eco-friendly production technology without heat, fossil fuels and large thermal furnaces and preventing the production of greenhouse gas and the destruction of valuable meadows and mines

Reducing mineral raw materials consumption as national wealth by about 80%

Changing people's attitudes towards rubbish and their value for all people

Spatial and volume density lighter than similar ones (due to the use of polymeric recycling materials)

Reduced cost of industrial aggregates with advanced and special non-heat generation technology, the use of recycled raw materials and existing and cheap polymeric materials in all parts of the world

Removing the color constraints of industrial lightweight aggregates by producing color lightweight aggregates with a very large variety of colors

Very light weight

Good compressive and tensile strength: Due to the availability of cement and plastic fibers and homogeneous adhesives

Very good sound and thermal insulation: Plastic recycled chips and aggregates, and EPS derivatives instead of air.

Armed and Armored for surface and tensile strength and breaking: Due to the availability of plastic fibers

Very good thermal conductivity: due to porosity

Very low throw: because of the ability to recycle smaller materials easily and without cost

Very low price: Due to the availability of cheap recycled materials to 65% of the total volume and production in the country without the need for imported materials

Easy and low cost shipping: Due to the very little weight and the convenient geometric volume, it can be packed

Paintability: Due to the availability of cement and other materials homogeneous with polyester

Not using of disposable containers and plastic and hand bags and EPS products expanded from waste and nature

Not using of garbage of textile and packaging factories

Optimization of energy consumption of natural resources of the country due to insulation of residential and industrial buildings

Not using of harmful and toxic chemical raw materials in the production

Continuous and useful employment

Not using of clay and other environmentally valuable minerals in bricks production

Reduction of air pollutants of baking raw material in the production of industrial lightweight aggregates

Reduction of spongy polymer materials in nature and waste collection centers

Reducing drinking water consumption in about 50% of the cycle of concrete and lightweight aggregates due to water absorption of less than 3%

Not using of harmful and biodegradable chemicals in the production process

Changing waste into a valuable and usable product

The other objects, features and advantages will occur to those skilled in the art from the following description of the preferred embodiment and the accompanying drawings in which:

Fig.1

illustrates the Mixing material and water to produce recycled bricks, according to an embodiment herein .

Fig.2

illustrates a sole of the The produced brick (the bricks may be produced in all sizes according to customer's request) , according to an embodiment herein.

Fig.3

illustrates the Wall made of recycled bricks, according to an embodiment herein.

Fig.4

illustrates a Recycled bricks made with coloring , according to an embodiment herein.

Item	Spatial weight	Crushing strength	Water absorption	Thermal resistance	Thermal conductivity coefficient	Porosity rate
Nonstructural bricks	500-400	48	4>	A	0.1	75
Semi-structural brick	750-500	55	2>	A	0.1	75
Structural brick	900-750	64	2>	A	0.05	75
Special bricks	1200-900	78	1>	A	0.05	75
Item	Special Weight	Compressive strength	Water absorption	Bending strength	Thermal conductivity coefficient	Thermal resistance
Nonstructural concrete c250	780	3.2	12>	2.8	0.1	A
Structural concrete c350	1400	32	10>	22	0.1	A

[table 1] Technical and mechanical specifications of bricks made of recycled waste

Fig.5

the diagram block map.

In the following detailed description, a reference is made to the accompanying drawings that form a part hereof, and in which the specific embodiments that may be practiced is shown by way of illustration. The embodiments are described in sufficient detail to enable those skilled in the art to practice the embodiments and it is to be understood that the logical, mechanical and other changes may be made without departing from the scope of the embodiments. The following detailed description is therefore not to be taken in a limiting sense.

The bricks can be used for: Construction of all walls without other coatings and external facing coatings- covering of the walls exposed to water and humidity (toilets, baths and swimming pools, etc.)-Gable roof coverings-LSF and wooden prefabricated floor coverings -various types of original and dropped ceilings-production of various types of cover and special security doors .

Brick ingredients :

Portland cement: Usual Portland cement is used according to ASTM C150 standard.

Protective and Adhesive Polymer (Resin): acrylic resin and polyester resin according to ASTM C881 standard

Water: It is used according to the rules of the ABA and ASTM C1602 as drinking water.

Expletive: It is expanded and ultra-light polymeric sponge waste in chip and micronized form in cubic dimensions up to a maximum of 2 mm.

Polymer Fibers: It is of Polypropylene, Glass, Carbon and Composite based on standard

Steel Fibers: It is of galvanized, iron, carbon and composite fibers

The bricks made of recycled waste are armed and lightweight, green and acoustic classified in the field of environment, new technologies of road and construction and recycling, and are used in the road construction and building industries, the production of bricks in the desired size, the production of pre-pieces and the like by the recycling of recyclable and non-degradable polymer waste, polystyrene products waste, etc.

Production steps :

The method of producing these bricks without thermal energy and by grinding recycled polymer materials as chip and the combination of these chips with cement materials, resins and polymer and metal fibers in semi-dried way in special mixers according to the instructions is as following:

First, recycled sponge polymers are collected, rinsed and dried, then by special milling machine they are micronized at a maximum of 3 ml and are stored in bag warehouses. Then cemented and dry materials such as cement, microsilica, paint and polymer fibers are mixed in dry mixers and stored as armed cemented materials in metal silos. Then the cement and adhesive materials (acrylic resin) and water are combined together and a good transparent mortar is stored in the steel silos with a low second rotation. The recycled materials are then poured into a special mixer (centrifuge) and then slowly rotated and then the cement mortar that is designed with pre-designed proportions according to the type and use, is sprayed into the mixer and is mixed with fast round. Finally, the mixture inside the mixer and the recycled material are completely covered with adhesive materials and mortar. Subsequently, the dry and powdered cement material is sprayed and mixed with water according to pre-designed proportions and is poured into brick molds. It will be in the furnace for 8 hours. Then, the bricks are taken to the special warehouses, and they should be kept in humidity 75% or in water for 16 hours.

It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the claims.

The main use of these bricks is in the road and building industry and are used to cover the walls-ceilings-facades and floors. As it seems, due to the high volume of building construction in any country, we can save billions by establishing the production line of these bricks .

Claims

The invention of a brick made of recycled waste, with armed and lightweight, green and acoustic features comprising :
Portland cement: Usual Portland cement is used according to ASTM C150 standard.
Protective and Adhesive Polymer (Resin): acrylic resin and polyester resin according to ASTM C881 standard
Water: It is used according to the rules of the ABA and ASTM C1602 as drinking water.
Expletive: It is expanded and ultra-light polymeric sponge waste in chip and micronized form in cubic dimensions up to a maximum of 2 mm.
Polymer Fibers: It is of Polypropylene, Glass, Carbon and Composite based on standard
Steel Fibers: It is of galvanized, iron, carbon and composite fibers
In accordance with claim 1 , Claimed bricks can be designed and manufactured in different sizes.
In accordance with claim 1 , The claimed bricks can be designed and manufactured in different colors.
In accordance with claim 1 ,The produced bricks are made of recycled waste and are completely biodegradable and have no contamination for nature.
In accordance with claim 1 , The price of bricks is about 60 percent lower than the price of bricks made of clay.
Bricks are armed with polymer fibers, such as: polypropylene fibers, glass fibers, carbon fibers, nano-carbon fibers, polyethylene fibers, and composites and these features will increase the quality of the technical and mechanical reaction of bricks and walls.
The bricks are cooked for 8 hours at 300°C, and then are immersed in water for 16 hours.
The use of bricks in walls and ceilings will make the walls light and they also act like a sound insulation.Independent claim 6: The technique of producing bricks made of waste recycling, with armed and light and green and acoustic features
Manufacturing technique of Brick made from recycled garbage, with armed and light weapons and green and acoustic : First, recycled sponge polymers are collected, rinsed and dried, then by special milling machine they are micronized at a maximum of 3 ml and are stored in bag warehouses. Then cemented and dry materials such as cement, microsilica, paint and polymer fibers are mixed in dry mixers and stored as armed cemented materials in metal silos. Then the cement and adhesive materials (acrylic resin) and water are combined together and a good transparent mortar is stored in the steel silos with a low second rotation. The recycled materials are then poured into a special mixer (centrifuge) and then slowly rotated and then the cement mortar that is designed with pre-designed proportions according to the type and use, is sprayed into the mixer and is mixed with fast round. Finally, the mixture inside the mixer and the recycled material are completely covered with adhesive materials and mortar. Subsequently, the dry and powdered cement material is sprayed and mixed with water according to pre-designed proportions and is poured into brick molds. It will be in the furnace for 8 hours. Then, the bricks are taken to the special warehouses, and they should be kept in humidity 75% or in water for 16 hours.
We have no claim on the software section.