WO2022243532A1 - A building element comprising a foam glass kernel coated with fiber cement and a method thereof - Google Patents

A building element comprising a foam glass kernel coated with fiber cement and a method thereof Download PDF

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Publication number
WO2022243532A1
WO2022243532A1 PCT/EP2022/063765 EP2022063765W WO2022243532A1 WO 2022243532 A1 WO2022243532 A1 WO 2022243532A1 EP 2022063765 W EP2022063765 W EP 2022063765W WO 2022243532 A1 WO2022243532 A1 WO 2022243532A1
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WO
WIPO (PCT)
Prior art keywords
foam glass
building element
cement
fiber cement
building
Prior art date
Application number
PCT/EP2022/063765
Other languages
French (fr)
Inventor
Guomin JI
Baktash SADAT
Yaser RAFFEA
Abdiaziz Saeed ABUKAR
Original Assignee
Foamrox As
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
Application filed by Foamrox As filed Critical Foamrox As
Publication of WO2022243532A1 publication Critical patent/WO2022243532A1/en

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C17/00—Surface treatment of glass, not in the form of fibres or filaments, by coating
    • C03C17/006—Surface treatment of glass, not in the form of fibres or filaments, by coating with materials of composite character
    • C03C17/007—Surface treatment of glass, not in the form of fibres or filaments, by coating with materials of composite character containing a dispersed phase, e.g. particles, fibres or flakes, in a continuous phase
    • 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
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E04C2/288—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E04C2/296—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and non-metallic or unspecified sheet-material
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C2218/00—Methods for coating glass
    • C03C2218/30—Aspects of methods for coating glass not covered above
    • C03C2218/365—Coating different sides of a glass substrate
    • 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
    • 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
    • C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure

Definitions

  • a Building element comprising a foam glass kernel coated with fiber cement and a method thereof.
  • the present invention relates to building elements comprising a foam glass kernel coated with a high-strength fiber cement wherein the fiber cement is applied in a method comprising et least two steps.
  • Cement is known to be a sort of "living" material since the material has a feature of shrinking over time.
  • An effect that appears when coating for example a kernel of a foam glass block with a layer of cement is that the cement will withdraw from respective foam glass surfaces being coated. At the same time cracks in the cement surface may appear for example.
  • a building element comprising a foam glass kernel coated with a cement mixture of a certain dimension should have the ability to withstand bending to some extent without cracking of a surface coated with the cement mixture. Further, withstanding a mechanical pressure on a surface of the building element should be possible within a certain limit of pressure. Further, when several building elements are placed side by side for example, then a cement mixture covering respective joints between building elements should be stable over time and not crack. Building elements comprising foam glass elements is known. And it is also known to apply fiber cement onto building elements. For example, fiber cement plates are used as a replacement for asbestos in different types of building plates. There exists for example fiber cement plates for covering roofs of buildings, also as fiber cement siding plates used on facades of buildings.
  • US 10844716 B2 disclose for example the use of a foam glass kernel covered with polyurea on all sides of the kernel.
  • This example of a building element is intended for use as a lining element in a tunnel.
  • EP 3685015 A1 disclose a tunnel profile element constituted of several assembled foam glass kernels, wherein the assembled foam glass kernels are covered with an unbroken polyurea layer on all sides of the tunnel profile element.
  • the polyurea is strong enough to hold the assembled foam glass kernels together.
  • the present invention is related to a lightweight construction element for different applications in building industry which can replace the use of concrete building blocks for example.
  • the lightweight construction element comprises foam glass kernels coated with a fiber cement of a specific fiber cement formulation, which when cured comprises "dead" materials.
  • the coating needs to have sufficient crack resistance and the fiber cement coating is known to be shrinking during curing, etc.
  • coating all six sides of a foam glass block may leave openings or have reduced coverage thickness of fiber cement for example along edges connecting the respective six surfaces of a foam glass block due to shrinking during curing.
  • at least one uncoated block shaped foam glass kernel is combined side by side with another block shaped uncoated foam glass kernel, and then is covered with fiber cement to create a larger piece of a construction element, the fiber cement coverage of the tiny crack in between two joined surfaces of the respective two uncovered foam glass kernels may be reduced due to shrinking of the cement coating on outer surfaces of the respective surfaces of the foam class blocks facing each other, which are divided by the tiny crack between the two joined foam glass blocks. Therefore, a weekend mechanical strength of an assembled and fiber cement coated building element may be the result.
  • a building element comprising a foam glass kernel coated with an improved fiber cement.
  • the invention is particularly, but not exclusively, advantageous for obtaining a building element comprising a defined shaped foam glass element covered at least on one surface with fiber cement, wherein the cement formula comprises at least a
  • Figure 1 illustrates an example of embodiment of the present invention.
  • Figure 2 Illustrates further details of the example of embodiment depicted un Figure 1.
  • Figure 3 depicts further details of the illustration of details in Figure 2.
  • Figure 4 illustrates an example of a finished outer surface of the example of embodiment illustrated in Figure 1.
  • Figure 5 illustrates an example of assembling at least two foam glass blocks into one building element.
  • FIG. 1 illustrates a perspective view of an example of embodiment of a building element 10 according to the present invention.
  • the building element 10 comprises a foam glass kernel or block 11.
  • the respective edge surfaces 13, 13a, 13b and 13c of the building element 10 are in this example of embodiment embodied with raw foam glass surfaces. In other examples of embodiment can some or all the edge surfaces 13, 13a, 13b and 13c be covered with fiber cement.
  • FIG. 2 illustrates a view of the building element 10 as seen straight towards the edge surface 13a.
  • the illustration clearly indicates the sandwich construction of the building element 10. Further detail of the sandwich construction is illustrated in Figure 3, wherein details of the marked section 14 is illustrated
  • Figure 3 illustrates further details of the sandwich construction illustrated in Figure 2.
  • the illustration is a cross section of the foam glass kernel 11 and the surface 12 running perpendicular to the surface 12. Inside the fiber cement covering the surface 12 fibers 15 are illustrated.
  • the illustration is only an illustration of how fibers may be oriented inside a fiber cement section. The number, volume and orientation of fibers may be arranged differently.
  • Figure 4 illustrates that a finished building element 10 may have a smooth surface covering respective fibers inside the building element surfaces.
  • a known problem with fiber cement is that fibers may protrude outside a surface of the fiber cement after application of the fiber cement. This may be a problem related to the length of the respective fibers. Shorter fibers seem to have less tendency to protrude out of a surface of fiber cement. However, it is possible to apply a plaster cement layer on top of the fiber cement covering protruding fibers.
  • Figure 5 illustrates an example of joining at least two building elements 10a and 10b forming a larger building element. When combined there will be a small opening or crack 18 in between the respective side surfaces of the respective building elements 10, 10b that are facing each other when joined.
  • the fiber cement may then be applied onto the respective surfaces of the foam glass kernels of element 10a and respectively the foam glass kernel of the element 10b. Fibers 17 inside the fiber cement may bridge the crack 18 as illustrated.
  • the fibers 17 may be sticking out of the surface of the applied fiber cement. Then, if the fiber cement is subject to shrinking when curing the bonding of the two respective building elements 10 and 10b is probably weakened.
  • a first thin layer (for example 5mm) of fiber cement may be applied first across the crack 18. Then the fibers 17 are applied across the crack 18 and pushed inside the first fiber cement layer. Then a further second layer of fiber cement (for example 5mm) is then applied over the combined surfaces of the first element 10a and the second element 10b.
  • a building element may be shaped as a rectangular shaped foam glass plate wherein a front side surface and a backside surface of the rectangular shaped foam glass element is covered with fiber cement.
  • a building element may be shaped as a curved foam glass element wherein an outer surface and an inner surface of the curved foam glass element is covered with fiber cement.
  • at least one edge surface of a rectangular shaped building element may have an angel different from ninety degrees relative to a front side of a rectangular shaped foam glass plate.
  • a building element may be shaped as a cylinder-shaped foam glass element, wherein an outer surface of the cylinder and an inner surface of the cylinder is coated with fiber cement.
  • At least one surface of the building element is covered with fiber cement while another surface is covered with another type of material, for example an ornamentation or interior decorations like a painted surface or tapestry.
  • At least one surface of the building element is covered with fiber cement while another surface is covered with polyurea.
  • a cement formulation comprising at least 16,5% weight percentage of silica dust of of the weight of cement that is used when making the fiber cement as well as 1,7% of SRA-N of weight percent of the weight of cement and an additional 1,5% weight percentage of the weight of cement used.
  • the volume, number of fibers, length of fibers and orientation of fibers used in the fiber cement is a design choice dependent on an application of a coated foam glass kernel.
  • Foam glass can be made in different shapes, for example as a curved element which can be used to form a curved roof element used in a hallway for example.
  • a composite building element for example comprising walls of the hallway being joined with curved and fiber cement covered foam glass elements.
  • the assembly of more complex building element is possible by using an assembly frame wherein respective foam glass elements are positioned and then coated with fiber cement and thereby constitutes a prefabricated section of for example a hallway.
  • a building element may comprise a defined shaped foam glass element covered at least on one surface with fiber cement, wherein the cement formula comprises at least a
  • At least one surface of a shaped foam glass element may be covered with fiber cement and at least one other surface of the shaped foam glass element may be covered with polyurea.
  • a further step may comprise applying longer fibers across a crack in between adjacent foam glass elements before applying the fiber cement.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Civil Engineering (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Dispersion Chemistry (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • General Chemical & Material Sciences (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Composite Materials (AREA)
  • Inorganic Chemistry (AREA)
  • Laminated Bodies (AREA)
  • Panels For Use In Building Construction (AREA)

Abstract

The resent invention is related to building elements comprising foam glass elements of a defined shape and size wherein at least one surface is covered with fiber cement made from a cement formula providing increased crack resistance and minimal shrinking during curing of the fiber cement.

Description

A Building element comprising a foam glass kernel coated with fiber cement and a method thereof.
FIELD OF THE INVENTION The present invention relates to building elements comprising a foam glass kernel coated with a high-strength fiber cement wherein the fiber cement is applied in a method comprising et least two steps.
BACKGROUND OF THE INVENTION
Cement is known to be a sort of "living" material since the material has a feature of shrinking over time. An effect that appears when coating for example a kernel of a foam glass block with a layer of cement is that the cement will withdraw from respective foam glass surfaces being coated. At the same time cracks in the cement surface may appear for example.
However, when a cement-based building element is cured the cement is a "dead" material. A foam glass kernel is also a dead material. Therefore, combining two "dead" materials in a building element is preferable.
It is known in prior art that different cement compositions or mixtures may have different degrees of shrinkage for example.
However, when making a building element like a foam glass kernel coated with a cement layer there are several parameters of the building element that needs to be fulfilled to serve as a useful building element in construction industry.
For example, a building element comprising a foam glass kernel coated with a cement mixture of a certain dimension should have the ability to withstand bending to some extent without cracking of a surface coated with the cement mixture. Further, withstanding a mechanical pressure on a surface of the building element should be possible within a certain limit of pressure. Further, when several building elements are placed side by side for example, then a cement mixture covering respective joints between building elements should be stable over time and not crack. Building elements comprising foam glass elements is known. And it is also known to apply fiber cement onto building elements. For example, fiber cement plates are used as a replacement for asbestos in different types of building plates. There exists for example fiber cement plates for covering roofs of buildings, also as fiber cement siding plates used on facades of buildings.
US 10844716 B2 disclose for example the use of a foam glass kernel covered with polyurea on all sides of the kernel. This example of a building element is intended for use as a lining element in a tunnel.
EP 3685015 A1 disclose a tunnel profile element constituted of several assembled foam glass kernels, wherein the assembled foam glass kernels are covered with an unbroken polyurea layer on all sides of the tunnel profile element. The polyurea is strong enough to hold the assembled foam glass kernels together.
In general building industry, the use of polyurea coated foam glass kernels is to some extent an overkill when used in for example buildings. The cost is higher and there are some environmental issues when working with polyurea.
The present invention is related to a lightweight construction element for different applications in building industry which can replace the use of concrete building blocks for example. The lightweight construction element comprises foam glass kernels coated with a fiber cement of a specific fiber cement formulation, which when cured comprises "dead" materials.
The article "The Effect of Fiber Length and Volume on Material Properties and Crack resistance on Basalt Fiber Reinforced Concrete" Research Article Open Access, Volume 2018, Article ID 7520549 disclose some of the issues regarding fiber cement properties, which indicate that not all fiber cement formulations can be used as a coating material on a foam glass kernel when considering specific properties of a specific use of a fiber cement covered foam glass kernel.
For example, the coating needs to have sufficient crack resistance and the fiber cement coating is known to be shrinking during curing, etc.
For example, coating all six sides of a foam glass block may leave openings or have reduced coverage thickness of fiber cement for example along edges connecting the respective six surfaces of a foam glass block due to shrinking during curing. Further, if at least one uncoated block shaped foam glass kernel is combined side by side with another block shaped uncoated foam glass kernel, and then is covered with fiber cement to create a larger piece of a construction element, the fiber cement coverage of the tiny crack in between two joined surfaces of the respective two uncovered foam glass kernels may be reduced due to shrinking of the cement coating on outer surfaces of the respective surfaces of the foam class blocks facing each other, which are divided by the tiny crack between the two joined foam glass blocks. Therefore, a weekend mechanical strength of an assembled and fiber cement coated building element may be the result.
It is therefore a need of an improved fiber cement that can be applied onto foam glass kernels and an improved method of joining uncovered foam glass blocks to create larger covered construction elements.
OBJECT OF THE INVENTION
It is an object of the present invention to provide an alternative to the prior art.
In particular, it may be seen as an object of the present invention to provide a building element comprising a foam glass kernel coated with an improved fiber cement.
SUMMARY OF THE INVENTION
Thus, the above-described object and several other objects are intended to be obtained in a first aspect of the invention by providing a building element comprising foam glass elements covered with fiber cement.
The invention is particularly, but not exclusively, advantageous for obtaining a building element comprising a defined shaped foam glass element covered at least on one surface with fiber cement, wherein the cement formula comprises at least a
- a defined weight of cement,
- at least 16,5 weight percentage silica dust of the defined weight of cement,
- at least 1,7 weight percentage of shrinkage-reducing additive (SRA-N) of the defined weight of cement, - at least 1,5 weight percentage superplasticizers (SIKA) of the defined weight of cement.
The present invention is further advantageous for obtaining a method of assembling a plurality of building elements into one larger building element comprising:
- assembling respective foam glass elements adjacent to each other in a pattern representing a defined shape of the larger building element, - covering at least one surface of the assembled foam glass elements with fiber cement.
Respective aspects of the present invention may each be combined with any of the other aspects. These and other aspects of the invention will be disclosed and elucidated with reference to the embodiments described herein. DESCRIPTION OF THE FIGURES
Figure 1 illustrates an example of embodiment of the present invention.
Figure 2 Illustrates further details of the example of embodiment depicted un Figure 1.
Figure 3 depicts further details of the illustration of details in Figure 2. Figure 4 illustrates an example of a finished outer surface of the example of embodiment illustrated in Figure 1.
Figure 5 illustrates an example of assembling at least two foam glass blocks into one building element.
Figure 6 illustrates a problem with curing of cement in prior art. DETAILED DESCRIPTION OF AN EMBODIMENT
Although the present invention is disclosed in connection with specific examples of embodiments, it should not be construed as being in any way limited to the presented examples. The accompanying claim set defines the scope of protection of the present invention. In the context of the claims, the terms "comprising" or "comprises" do not exclude other possible elements or steps. Further, the mentioning of references such as "a" or "an" etc. should not be construed as excluding a plurality. The use of reference signs in the claims with respect to elements indicated in the figures shall also not be construed as limiting the scope of the invention.
Furthermore, combining individual features mentioned in different claims may possibly be advantageously, and the mentioning of these features in different claims does not exclude that a combination of features is not possible and advantageous.
Figure 1 illustrates a perspective view of an example of embodiment of a building element 10 according to the present invention. The building element 10 comprises a foam glass kernel or block 11. There are two opposite located surfaces 12, 12a that are covered with fiber cement. The respective edge surfaces 13, 13a, 13b and 13c of the building element 10 are in this example of embodiment embodied with raw foam glass surfaces. In other examples of embodiment can some or all the edge surfaces 13, 13a, 13b and 13c be covered with fiber cement.
Figure 2 illustrates a view of the building element 10 as seen straight towards the edge surface 13a. The illustration clearly indicates the sandwich construction of the building element 10. Further detail of the sandwich construction is illustrated in Figure 3, wherein details of the marked section 14 is illustrated
Figure 3 illustrates further details of the sandwich construction illustrated in Figure 2. The illustration is a cross section of the foam glass kernel 11 and the surface 12 running perpendicular to the surface 12. Inside the fiber cement covering the surface 12 fibers 15 are illustrated. The illustration is only an illustration of how fibers may be oriented inside a fiber cement section. The number, volume and orientation of fibers may be arranged differently.
Figure 4 illustrates that a finished building element 10 may have a smooth surface covering respective fibers inside the building element surfaces. A known problem with fiber cement is that fibers may protrude outside a surface of the fiber cement after application of the fiber cement. This may be a problem related to the length of the respective fibers. Shorter fibers seem to have less tendency to protrude out of a surface of fiber cement. However, it is possible to apply a plaster cement layer on top of the fiber cement covering protruding fibers.
Figure 5 illustrates an example of joining at least two building elements 10a and 10b forming a larger building element. When combined there will be a small opening or crack 18 in between the respective side surfaces of the respective building elements 10, 10b that are facing each other when joined.
The fiber cement may then be applied onto the respective surfaces of the foam glass kernels of element 10a and respectively the foam glass kernel of the element 10b. Fibers 17 inside the fiber cement may bridge the crack 18 as illustrated.
However, as discussed above, the fibers 17 may be sticking out of the surface of the applied fiber cement. Then, if the fiber cement is subject to shrinking when curing the bonding of the two respective building elements 10 and 10b is probably weakened.
It is also possible to apply extra fibers 17 across the crack 18. According to a method of the present invention, a first thin layer (for example 5mm) of fiber cement may be applied first across the crack 18. Then the fibers 17 are applied across the crack 18 and pushed inside the first fiber cement layer. Then a further second layer of fiber cement (for example 5mm) is then applied over the combined surfaces of the first element 10a and the second element 10b.
Regardless of how the weaking of the assembled elements are mitigated, it is necessary to have a fiber cement that does not shrink considerably curing.
In an example of embodiment of the present invention, a building element may be shaped as a rectangular shaped foam glass plate wherein a front side surface and a backside surface of the rectangular shaped foam glass element is covered with fiber cement.
In an example of embodiment of the present invention, a building element may be shaped as a curved foam glass element wherein an outer surface and an inner surface of the curved foam glass element is covered with fiber cement. In an example of embodiment of the present invention, at least one edge surface of a rectangular shaped building element may have an angel different from ninety degrees relative to a front side of a rectangular shaped foam glass plate.
In an example of embodiment of the present invention, a building element may be shaped as a cylinder-shaped foam glass element, wherein an outer surface of the cylinder and an inner surface of the cylinder is coated with fiber cement.
In an example of embodiment of the present invention, at least one surface of the building element is covered with fiber cement while another surface is covered with another type of material, for example an ornamentation or interior decorations like a painted surface or tapestry.
In an example of embodiment of the present invention, at least one surface of the building element is covered with fiber cement while another surface is covered with polyurea.
According to an aspect of the present invention a cement formulation comprising at least 16,5% weight percentage of silica dust of of the weight of cement that is used when making the fiber cement as well as 1,7% of SRA-N of weight percent of the weight of cement and an additional 1,5% weight percentage of the weight of cement used. The volume, number of fibers, length of fibers and orientation of fibers used in the fiber cement is a design choice dependent on an application of a coated foam glass kernel.
Using this formulation when coating at least one foam glass kernel on at least one surface of the foam glass kernel provides a lightweight building element with sufficient qualities to be applied in different types of different construction element applications.
Foam glass can be made in different shapes, for example as a curved element which can be used to form a curved roof element used in a hallway for example.
It is also within the scope of the present invention to form a composite building element, for example comprising walls of the hallway being joined with curved and fiber cement covered foam glass elements. The assembly of more complex building element is possible by using an assembly frame wherein respective foam glass elements are positioned and then coated with fiber cement and thereby constitutes a prefabricated section of for example a hallway.
According to an example of embodiment of the present invention a building element may comprise a defined shaped foam glass element covered at least on one surface with fiber cement, wherein the cement formula comprises at least a
- a defined weight of cement,
- at least 16,5 weight percentage silica dust of the defined weight of cement,
- at least 1,7 weight percentage SRA-N material of the defined weight of cement,
- at least 1,5 weight percentage SIKA material of the defined weight of cement.
For example, at least one surface of a shaped foam glass element may be covered with fiber cement and at least one other surface of the shaped foam glass element may be covered with polyurea.
According to an example of embodiment of the present invention a method of assembling a plurality of foam glass elements into one larger building element may comprise:
- assembling respective foam glass elements adjacent to each other in a pattern representing a defined shape of the larger building element,
- covering at least one surface of the assembled foam glass elements with fiber cement.
For example, a further step may comprise applying longer fibers across a crack in between adjacent foam glass elements before applying the fiber cement.

Claims

1. Building element comprising a defined shaped foam glass element covered at least on one surface with fiber cement, wherein the cement formula comprises at least a
- a defined weight of cement,
- at least 16,5 weight percentage silica dust of the defined weight of cement,
- at least 1,7 weight percentage of shrinkage-reducing additive (SRA-N) of the defined weight of cement,
- at least 1,5 weight percentage superplasticizers (SIKA) of the defined weight of cement.
2. Building element of claim 1, wherein the is
3. Building element of claim 1, wherein respective volume, amount of fibers, length of fibers and orientation of fibers is adapted according to the use of the building element.
4. Building element of claim 1, wherein a building element is shaped as a rectangular shaped foam glass plate wherein a front side surface and a backside surface of the rectangular shaped foam glass element is covered with fiber cement.
5. Building element of claim 1, wherein a building element is shaped as a curved foam glass element wherein an outer surface and an inner surface of the curved foam glass element is covered with fiber cement.
6. Building element of claim 3, wherein at least one edge surface of the rectangular shaped building element has an angel different from ninety degrees relative to the front side of the rectangular shaped foam glass plate.
7. Building element of claim 1, wherein a building element is shaped as a cylinder-shaped foam glass element, wherein an outer surface of the cylinder and an inner surface of the cylinder is coated with fiber cement.
8. Building element of claim 1, wherein at least one surface of the shaped foam glass element is covered with fiber cement and at least one other surface of the shaped foam glass element is covered with polyurea.
9. Building element of claiml, wherein an additional thinner layer of
10. Method of assembling a plurality of building elements according to claim 1 into one larger building element comprising:
- assembling respective foam glass elements adjacent to each other in a pattern representing a defined shape of the larger building element,
- covering at least one surface of the assembled foam glass elements with fiber cement.
11. Method of claim 1, wherein a further step comprises applying longer fibers across a crack in between adjacent foam glass elements before applying the fiber cement.
PCT/EP2022/063765 2021-05-21 2022-05-20 A building element comprising a foam glass kernel coated with fiber cement and a method thereof WO2022243532A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
NO20210633 2021-05-21
NO20210633 2021-05-21

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