U.S. patent application number 10/520463 was filed with the patent office on 2006-06-08 for building block.
Invention is credited to Agostino Di Trapani.
Application Number | 20060117699 10/520463 |
Document ID | / |
Family ID | 30005464 |
Filed Date | 2006-06-08 |
United States Patent
Application |
20060117699 |
Kind Code |
A1 |
Di Trapani; Agostino |
June 8, 2006 |
Building block
Abstract
Element and method for the construction of walls, in which the
assembly of the elements is carried out with thin joints, the
adjustment of the elements remaining easy, with elements which may
present substantial manufacturing dimensional tolerances. The
administration of the binder necessary for the assembly of the
elements is effected by the grading of the binder deposited in a
mortise of the construction element. The lifting, handling,
placement, and adjustment of the construction element during the
assembly of the wall is effected with the aid of a masonry hammer
with a handle, which is specific for the element. The height of the
elements allows for the avoidance of any cutting needed to meet the
shape of a building. The construction of masonry angles and
internal walls is carried out by the adhesive bonding of walls to
one another and without embedding.
Inventors: |
Di Trapani; Agostino; (La
Louviere, BE) |
Correspondence
Address: |
SUGHRUE MION, PLLC
2100 PENNSYLVANIA AVENUE, N.W.
SUITE 800
WASHINGTON
DC
20037
US
|
Family ID: |
30005464 |
Appl. No.: |
10/520463 |
Filed: |
July 10, 2003 |
PCT Filed: |
July 10, 2003 |
PCT NO: |
PCT/BE03/00122 |
371 Date: |
October 7, 2005 |
Current U.S.
Class: |
52/604 |
Current CPC
Class: |
E04B 2002/0228 20130101;
E04B 2002/0208 20130101; E04G 21/16 20130101; E04B 2/16 20130101;
E04B 2/18 20130101; E04G 21/162 20130101; E04B 2/20 20130101 |
Class at
Publication: |
052/604 |
International
Class: |
E04B 5/04 20060101
E04B005/04; E04C 2/04 20060101 E04C002/04 |
Foreign Application Data
Date |
Code |
Application Number |
Jul 10, 2002 |
WO |
PCT/BE02/00121 |
Claims
1-19. (canceled)
20. A construction element (1) for the construction of a wall, said
element comprising an upper face (2), a lower face (3), and lateral
faces (4), said construction element comprising at least one groove
or mortise (5), provided for the application by grading of a binder
(17), necessary for the assembly of construction elements to one
another, said mortise extending over the upper face (2) of the
construction element, said construction element likewise comprising
at least one protuberance or tenon (6), which extends over the
lower face (3) of the construction element, the mortise (5) being
arranged in such a way as to be in correspondence with the tenon
(6) of the similar construction element so as to allow for the
assembly of two similar construction elements, said mortise (5)
being associated with a load-bearing wall (24) or partition (25) of
the construction element and arranged at a distance from the outer
lateral edge (8) of the construction element, which is sufficient
to prevent the overflow of the binder (17) beyond the edge of the
element during assembly, characterised in that the mortise (5) and
the tenon (6) are dimensioned in such a way as to allow, during the
assembly of two elements, for a partial embedding such as will
allow for a strip of binder to be formed between the upper face (2)
and the lower face (3) of the elements, the sole contact between
the two superimposed elements therefore being by way of this strip
so as to allow for an adjustment of the alignment, of the height,
and of the plumb alignment of the elements which are to be
assembled.
21. The construction element (1) according to claim 20,
characterised in that the tenon (6) and the mortise (5) have a
cross-section which is approximately trapezoidal in shape, in such
a way that, when two construction elements are in the assembled
position, their lateral flanks extend approximately parallel to one
another, and the small base of the trapezoid of the tenon being
arranged opposite the small base of the trapezoid of the mortise
when they are engaged, said lateral flanks being arranged in such a
fashion as to leave a first space between them, intended to allow
for the clearance of the said binder (17), the small bases being
arranged in such a way as to leave a second space between them,
filled by said binder.
22. The construction element (1) according to claim 20,
characterised in that the depth of the mortise (5) and the height
of the tenon (6) are approximately equal and proportional to the
tolerance which is to be accommodated with the construction
element.
23. The construction element (1) according to claim 21,
characterised in that the ratio of the weight of the construction
element to the surface area of the small base of the trapezoid of
the tenon is inversely proportional to the fluidity of said binder
(17).
24. The construction element (1) according to claim 20,
characterised in that the width of the mortise (5) is less than the
thickness of the load-bearing wall or partition (7) of the
construction element on which the mortise is placed.
25. The construction element (1) according to claim 20,
characterised in that one mortise (5) straddles several walls
and/or partitions (7) of the construction element (1).
26. The construction element (1) according to claim 20,
characterised in that the height of the construction element is
dimensioned in such a way that an assembly in height of the
construction elements forms a standard height beneath interior
lintels and stretches of masonry beneath ceilings, and in that the
weight of the construction element is less than or equal to 25 kg,
and the height of the element is greater than or equal to its
length.
27. The construction element (1) according to claim 20,
characterised in that the height of the construction element is
dimensioned in such a way that an assembly in height of the
construction elements forms a standard height beneath lintels, and
that the weight of the construction element is less than 25 kg.
28. The construction element (1) according to claim 24,
characterised in that a mortise (5) is arranged above each of the
load-bearing walls (24) or partitions (25) of said construction
element.
29. The construction element (1) according to claim 20,
characterised in that the mortise (5) is designed in order to
accommodate equally a simple or straddled fitting.
30. The construction element (1) according to claim 20,
characterised in that it comprises a vertical reference alignment
shaping (9) for the assembling of opposed joints of said
construction element with other similar construction elements.
31. The construction element (1) according to claim 20,
characterised in that it is provided with at least one horizontal
false joint (10) in the form of a rounded half-shank on at least
one lateral face.
32. The construction element (1) according to claim 20,
characterised in that it is provided with at least one vertical
false joint (11) in the form of a rounded half-shank on at least
one lateral face.
33. The construction element (1) according to claim 20,
characterised in that it comprises at least one mounting (12)
provided in order to accommodate a hook for connecting the facing
wall to the load-bearing wall.
34. A combination of a construction element (1) according to claim
20, and of a tool (13) intended for lifting the said element,
characterised in that the tool is dimensioned so as to allow for
the lifting, handling, laying and adjusting the alignment, height,
and plumb alignment of the construction element (1).
35. A wall constructed with construction element (1) according to
claim 20, characterised in that it is constructed with "thin
joints" between the construction elements (1).
36. The wall according to claim 35, characterised in that it
comprises assemblies of construction elements (14, 15), each
construction assembly comprising at least two preassembled
construction elements.
37. An assembly of two walls constructed with construction elements
(1) according to claim 20, and forming between them an angle,
characterised in that the connection between the two walls is
provided by adhesive bonding and without embedding.
Description
[0001] The present invention relates to a construction element for
the construction of a wall, and to a wall constructed with such
elements, said element comprising an upper face, a lower face, and
side faces, said construction element comprising at least one
groove or mortise provided for delivering by grading a bonding
agent or binder necessary for the assembling of the construction
elements with one another, said groove or mortise extending on the
upper face of the construction element, said construction element
likewise comprising at least one protuberance or tenon, which
extends on the lower face of the construction element, the mortise
being arranged in such a way as to be in correspondence with the
protuberance or tenon of a similar construction element so as to
allow for the assembling of the construction elements.
[0002] For about 35 years the construction methods for individual
houses have used a technique referred to as the "cavity wall
technique". This type of wall is composed of two walls separated by
a space of a few centimetres. The two walls are connected to one
another by hooks.
[0003] The part of the cavity wall which is situated towards the
exterior of the building is generally made of bricks (small
elements) and is often referred to as the "facing wall".
[0004] The part of the cavity wall which is situated towards the
interior of the building is generally made of blocks (large
elements), and is often referred to as the "load-bearing wall".
[0005] The document GB 204.263 A describes a dry-stacking masonry
system which requires that the construction elements do not present
any dimensional tolerances. In addition to this, no adjustment of
the elements is possible.
[0006] The elements described in this document are of traditional
proportions (height/length <1) and comprise tenons and mortises
which serve solely to position them and lock them in place. The
elements are, in addition, in direct contact with one another.
[0007] A disadvantage of these elements is that they require a
large number of special pieces for the wall connections, which are
created in the traditional manner by crossing the masonry elements
of which they are formed.
[0008] The document FR-A-1 271 506 describes construction blocks of
traditional dimensions which present grooves or mortises of which
the cumulative width is close to the width of the block. The
cumulative width of the mortises is overall greater than the
cumulative width of the load-bearing partitions. There are no
mortises above the walls, which are therefore not load-bearing. One
disadvantage of the blocks described is that, for the assembly of
such blocks, the quantity of bonding agent used is traditional.
Another disadvantage is that, since the shape of the tenons in the
mortises on the lower part of the block is intended to allow for
easy forcing into the bonding agent (P and P' in FIG. 1), this
results in a virtually zero floating capability of the block, which
therefore means that there is practically no adjustment possible of
the height or of the plumb alignment of the blocks. The blocks
which can be used in the system described in FR-A-1 271 506 must
have very low dimensional tolerances, or be rectified in such a way
as to ensure the horizontal alignment of the elements in the
wall.
[0009] The document FR-A-2 588 900 describes construction blocks
and their assembly, in which there is no automatic delivery of the
bonding agent, and the blocks of traditional dimensions used are
necessarily without any dimensional tolerances. The mounting
described on the block serves only for the fitting armature and for
the bonding agent with which it is intended to be surrounded.
[0010] The system described in FR-A-2 588 900, as with the systems
described heretofore, requires numerous special pieces for the
connections of the walls, which are otherwise constructed in the
traditional manner.
[0011] The document EP 0 651 104 B1 describes blocks of traditional
proportions, which comprise tenon elements which are supported in
the base of mortises (cf. FIG. 4 and FIG. 2), thus preventing any
adjustment.
[0012] All the disadvantages which pertain with the systems
described above are likewise present in the document EP 0 651 104
B1.
[0013] In addition to this, none of these elements are in any case
intended for the construction of cavity walls. In effect, there is
no provision for fitting a hook which connects the walls to one
another, and the hook must therefore be placed in the joint or in
the wall itself. The joint, however, is inaccessible, and the walls
are of insufficient dimensions to allow for the placement of the
hook.
[0014] The quantity of human energy necessary in the construction
of a building is particularly substantial during the construction
of the shell, and during the construction of the walls in
particular, whether this be due to the handling of the construction
elements or their assembly with the aid of mortar.
[0015] The object of the present invention is to provide
construction elements which will allow for substantial
manufacturing tolerances to be achieved.
[0016] To this end, the invention provides for a construction
element for the construction of a wall, characterised in that it
comprises at least one mortise, which is associated with a
load-bearing wall or partition made of the construction element,
and which is arranged at a distance from the outer lateral edge of
the construction element which is sufficient to prevent the bonding
agent from extending beyond the edge of the element during
assembly, the mortise and the tenon being dimensioned in such a way
as to allow, during assembly, for a partial boxing effect which
will allow for an adjustment of the alignment, of the height, and
of the plumb alignment of the elements which are to be
assembled.
[0017] The design concept of the construction element according to
the present invention allows for a considerable amount of time to
be gained in the construction of walls and, moreover, the finish of
these walls is excellent. The assembly of the elements is made
easier, since they embed easily and partially into one another
thanks to the presence of the groove (mortise) on the upper surface
of the elements, and the protuberance (tenon) on the lower surface
of the elements. The dimensions of the mortise and the tenon are
such as will allow for the adjustment of the elements, which
facilitates the correct construction of the wall. In addition to
this, the quantity of binder to be used is substantially reduced in
relation to a traditional system of construction, because the
binder does not extend beyond the edge, and the masonry can be
erected with thin joints.
[0018] The present invention applies to the cavity wall technique
as well as to simple single interior or exterior walls,
load-bearing or non-load-bearing.
[0019] A first preferred embodiment of a construction element
according to the invention is characterised in that the height of
the construction element is of such dimensions that an assembly
upwards of construction elements forms a standard height beneath
interior lintels and beneath masonry stretches beneath ceilings,
and in that the weight of the construction element is less than or
equal to 25 kg, and the height of the element is greater than or
equal to its length.
[0020] It is recognised that the larger the masonry element is, the
more it remains relatively light and easily handled, and the more
rapid the construction of the wall will be.
[0021] It is also recognised that the number of horizontal joints
is inversely proportional to the height of the construction
element.
[0022] It is likewise recognised that the number of vertical joints
is inversely proportional to the length of the construction
element.
[0023] The horizontal joints between masonry elements will vary in
thickness and as a function of the dimensional tolerances of these
elements.
[0024] In the awareness that the vertical joint does not play an
essential part in the mechanical strength of the walls, the
construction element according to the invention is designed in such
a way as to present the best compromise between its height, its
length, and its weight in order to present the best characteristics
favouring speed of assembly.
[0025] The assembly of the elements according to the invention is
effected by adhesive bonding with the aid of a binder at thin
joints. It is known that in order for this type of assembly to be
carried out, it is necessary for elements to be used with very low
dimensional tolerances.
[0026] Thanks to the ability of the element to float on the binder
obtained by the interaction between the weight of the element, the
dimensions and shapes of the mortises and tenons, and the fluidity
of the binder, the present invention allows for the adjustment of
the alignment, the height, and the plumb alignment, and therefore
allows for the use of construction elements of which the
manufacturing tolerances are relatively great.
[0027] The technique of forming the angles and internal walls in
traditional masonry requires the masonry elements of one wall to be
crossed with those of another wall in order to create one solid
entity of the walls between one another. This technique requires
considerable know-how and a considerable amount of labour. In
addition, if masonry elements are used which comprise mortises and
tenons, the principle is known and essential for series of specific
elements to be provided in order to connect the walls between one
another.
[0028] According to a preferred embodiment of the invention, it is
possible to make use of a technique for highly simplified
realisation of angles and internal walls. In effect, the connection
between the walls is created by straightforward adhesive bonding,
with the aid of a binder, of one wall against another, no longer
requiring any crossing of masonry elements.
[0029] A mason's hammer with a handle used during the assembly of
the construction elements according to the present invention allows
for the construction element to be gripped, moved, placed, and
adjusted. In addition, when the element is suspended in this tool,
it is automatically in a vertical position ideal for placement on
the binder.
[0030] Other details and particular features of the invention can
be derived from the description given hereinafter, and by reference
to the appended drawings.
[0031] FIG. 1 shows a perspective view of a preferred embodiment of
a construction element according to the present invention.
[0032] FIG. 2 shows a perspective view of another embodiment of a
construction element according to the present invention.
[0033] FIG. 3 shows a perspective view of a third embodiment of a
construction element according to the present invention.
[0034] FIG. 4 shows a face view of a construction element used for
butt ends.
[0035] FIG. 5a shows a face view of the upper part of a
construction element according to the present invention.
[0036] FIG. 5b illustrates the assembly of two elements according
to the present invention.
[0037] FIG. 5c illustrates two elements of the present invention
after assembly.
[0038] FIG. 6a illustrates a tool according to the present
invention.
[0039] FIG. 6b illustrates a use of the tool from FIG. 5b.
[0040] FIG. 7 illustrates a full construction element according to
the invention, with an accommodation point (12) for a hook.
[0041] FIGS. 8 and 9 illustrate a part of a wall constructed with
the aid of construction elements according to the invention.
[0042] The construction element 1 represented in FIG. 1, FIG. 2,
and FIG. 3 is hollow, i.e. it is, for preference, pierced
horizontally from one side to the other, its two lateral faces
therefore presenting an aperture. In a preferred embodiment, the
construction element likewise comprises one or more internal
vertical and/or horizontal partitions.
[0043] A mortise 5 is arranged on the upper face 2, above the wall
24 or load-bearing partition 25 of the construction element 1, and
the width of the mortise is for preference less than the thickness
of the wall 24 or load-bearing partition 25. The mortise is located
sufficiently distant from the upper longitudinal edge 6 of the
construction element in such a way as to avoid, during the assembly
of the construction elements, the binder extending beyond the outer
edge of the elements. For example, with an element with a thickness
of 14 cm, the mortise is located at a distance of 1.4 cm from the
edge. This allows for exploitation in its entirety of the quantity
of binder necessary for assembly, while still carrying out clean
and careful work. In a particular embodiment, if it is intended
that the element is to be used for the construction of a
non-load-bearing wall, it can be provided with mortises and tenons
which can be offset or partially offset in relation to the walls or
partitions of the element, and therefore extend partially or wholly
above the aperture 7.
[0044] The construction element according to the invention likewise
comprises a tenon 6 intended to engage in the mortise 5 when two
construction elements are arranged one on top of the other. The
tenon is located on the lower face 3 of the construction element.
The mortise and the tenon are of such dimensions as to allow,
during assembly, partial engagement which will allow for an
adjustment of the alignment, the height, and the plumb alignment of
the elements which are to be assembled. To this end, the width of
the tenon is slightly less than the width of the mortise.
[0045] The tenon 6 and the mortise 5 have a cross-section which is
approximately trapezoidal, as illustrated in FIG. 1. Their lateral
flanks extend approximately parallel to one another and the small
base of the trapezoid of the tenon is arranged opposite the small
base of the trapezoid of the mortise when they are engaged (FIG.
5). The said lateral flanks are arranged in such a way as to allow
for a first space between them, intended for the displacement of
the binder 17 when one element is placed on another. The small
bases are arranged in such a way as to allow for a second space
between them, intended to be filled by the binder 17.
[0046] The depth of the mortise 5 and the height of the tenon 6 of
the construction element are approximately equal and proportional
to the dimensional tolerance which is to be accommodated. The ratio
of the weight of the construction element on the surface of the
small base of the trapezoid of the tenon is inversely proportional
to the fluidity of the binder 17.
[0047] According to another embodiment of a construction element
according to the invention, the mortise overlaps several walls
and/or partitions of the construction element. This mortise is
therefore associated with several walls or load-bearing partitions
distributed over the thickness of the block.
[0048] With the aim of constructing a wall, the assembling of
construction elements according to the present invention is carried
out with the aid of a binder which is first placed on a palette.
The mason supports the palette flat on the element on which he
wishes to deposit the binder, and then slides the binder with the
aid of a spatula into the mortise and spreads the binder with the
aid of this spatula, in such a way that the binder in practical
terms does not extend above the upper face 2 of the construction
element.
[0049] When the mortise of a first element is filled with binder
and a second element is placed above it, FIGS. 5a, 5b, 5c, the
tenon of the second element penetrates partially into the mortise
of the first element. The forcing of the tenon into the mortise
causes a part of the binder to go beyond the edges, via the first
space between the lateral flanks of the trapezoid shapes, outside
the mortise, so forming an adhesive strip between the upper face 2
of the first element and the lower face 3 of the second element.
The width of this adhesive strip, for a defined spacing (height of
the element plus joint) of the horizontal lines of the masonry,
will vary as a function of the inherent height of the construction
elements, but will always remain sufficient to ensure the adherence
of the elements to one another. The stability of the wall, without
ever having any overflow of binder outside the construction
element, is likewise assured due to the interaction between the
mortises, tenons, and binder. Among other things, it is thanks to
the fact that the mortise is offset in relation to the edge that
there is no overflow of the binder. The mortise therefore serves
not only to guide the tenons, but also the administration of the
binder. The width of the said adhesive strip will for preference be
close to 90% of the thickness of the load-bearing wall or partition
of the construction element. This allows for the effect to be
minimised of the impingement of the second element on the first and
vice-versa, as explained hereinafter.
[0050] The dimensions of the assembly formed by the tenon and the
mortise can be determined on the basis of the aforesaid properties
of the mortise and tenon. The width of the adhesive strips is
determined principally as a function of the cohesion of the binder
and/or the effect of the impingement. If the cohesion of the binder
is greater than that of the material, it is principally the effect
of the impingement which will dictate the width of the adhesive
strip, which for preference will be equal to 90% of the thickness
of the wall or partition. Once the width of the adhesive strip has
been fixed as determined heretofore, the minimum dimensions of the
mortise and tenon are determined in such a way that, after the
partial engagement and therefore the sufficient expulsion of a part
of the binder, the desired width of the strip is obtained, in the
awareness that a part of the binder will be absorbed by the
material. Since the construction elements have manufacturing
tolerances, their adjustment is desirable in order for walls to be
constructed correctly. The scale of this adjustment is associated
with the scale of these manufacturing tolerances. In order to
obtain a more significant degree of adjustment, it is sufficient to
increase the height of the tenon and the depth of the mortise in
proportion to one another, and, also in proportion, to reduce the
width of the tenon and of the mortise, in such a way as to retain
the same volume of binder expelled and therefore the same width of
the adhesive strip.
[0051] The significant ability of the construction element to float
on the binder contributes to the ability of the alignment to be
adjusted, as well as the height and plumb alignment, and therefore
contributes to the possible use of construction elements with
relatively large manufacturing tolerances. A substantial ability to
float results from the interaction between the fluidity of the
binder used in the invention, the weight of the element, the width
of the small base of the tenon, and the width of the large base of
the mortise which are present on the construction element according
to the invention.
[0052] The elements of a first line of masonry and the elements of
a second line of masonry superimposed on the first, do not in any
situation touch in the horizontal direction, the sole contact in
the horizontal direction between these lines being by way of the
adhesive strips formed by the binder.
[0053] In a preferred embodiment, one advantage of the construction
element according to the present invention is that it is hollow and
that it presents at least one aperture 7 on a lateral face 4a, in
such a way that the open lateral face can be adhesively bonded to a
lateral face of another similar construction element. Because the
element is hollow, its weight is reduced, so making it easier to
handle and allowing it to be lifted by means of an instrument which
for preference consists of a handle 13 which likewise serves as a
mason's hammer 16, in order to be able to adjust the alignment and
the height of the element as well as its plumb alignment. The
handle 13 is illustrated in FIG. 6a, and its use for taking up the
element is shown in FIG. 6b. This tool is profiled in such a way
that the bar located beneath the handle can be slid into the empty
part 7 of the construction element, as shown, for example in FIG.
6b.
[0054] The construction element according to the present invention
can equally be solid, if its weight or its format allow this. FIG.
7 shows an embodiment of a full construction element according to
the present invention. This comprises, for preference, a mounting
12 provided to accommodate a connecting hook which will allow the
facing wall constructed with these construction elements to be
connected to the load-bearing wall.
[0055] The construction element according to the present invention
can be manufactured from different compositions depending on the
use to which it is to be put. For example, in the case of the
construction of a rendered wall, the construction element may be
formed from concrete, allowing for relatively lightweight elements
to be obtained. This allows for elements to be proposed such that
their numbers per unit of surface area are reduced in relation to
traditional blocks.
[0056] Apart from this, a substantial increase in the height of the
construction element has been achieved. An increase in the height
of the construction element incurs a reduction in the number of
horizontal lines of masonry. In addition to this, in the awareness
that the vertical joint will not be filled, this allows for an
extremely significant advantage in the quantity of the binder and
in terms of labour to be achieved. This increase in height inverts
the traditional height/length ratio <1 of the construction
elements. Likewise, the higher the element is, the easier the
adjustment of its plumb alignment becomes. For preference, the
weight of the construction element is less than or equal to 25 kg
and its height is greater than or equal to its length. However, the
present invention also applies to elements with traditional weights
and proportions, i.e. of which the weight is less than or equal to
25 kg, and their height may be less than or equal to their
length.
[0057] The height of the construction element is for preference a
module of the standards of heights beneath interior lintels and the
stretch of walls beneath ceilings, which will avoid the elements
needing to be cut and so gaining considerable amounts of time
during the carrying out of the masonry work.
[0058] In an embodiment of the construction element according to
the invention, such as is illustrated in FIG. 3, the mortise 5 of
the construction element is provided with a void 20 to accommodate
a simple or straddled metallic fitting so as to allow for the
connection between two fittings, while minimising the quantity of
binder necessary for enrobing them. The construction element
according to the present invention can therefore likewise be used
for reinforced construction formats.
[0059] In a preferred embodiment, the construction element
according to the invention likewise comprises an alignment
reference shaping 9, which then serves to assemble opposing joints
of the said construction element with other similar construction
elements. In this way it is very easy to place the construction
element in such a way as to obtain an alternating alignment of the
vertical joints of the construction elements when a wall is
constructed with an "opposed joints" arrangement.
[0060] The construction element according to the invention can
likewise comprise at least one false horizontal joint 10 and/or
vertical joint 11 (FIG. 7) in the shape of a rounded half-shank.
This configuration of false joints allows for the joint to be
contracted at its ends, which accordingly retains the binder
serving to provide the jointing.
[0061] In a preferred embodiment, the construction element
according to the present invention is manufactured from concrete of
which the preferred composition is as follows, for one cubic metre:
TABLE-US-00001 Cement: 175 kg Crushed expanded 4/8 clay: 600 l
Crushed expanded 0/4 clay: 700 l Sand: 70 kg
[0062] This type of concrete has the following characteristics: Its
dry volumetric mass is 870 kg/m3 and its compression strength on
cubes of 5 cm per side is >4 N/mm2.
[0063] It is understood that other compositions can be used to
manufacture the construction element, with the aim being to obtain
a construction element which can easily be handled and which has
sufficient mechanical strength for it to be capable of being used
in the construction of an individual house or for other masonry
works. It is possible, for example, to add expanded polystyrene
fragments to the concrete in order to lighten it, or to add gravel
to reinforce it. Provision can likewise be made to use construction
elements according to the present invention, which may be
manufactured with materials other than baked clay, cellular
concrete, etc.
[0064] The binder used in a preferred embodiment of the present
invention is a binder which hardens very quickly once it has been
applied. At the time of the assembling of the elements, this binder
penetrates to about 30% of its volume into the material of the
construction elements. The rapid hardening of this binder is
incurred by a chemical reaction associated with a first transfer of
water from the binder towards the elements. This results in a
stability of the wall and an adherence between the elements which
are very substantial after a few minutes, which allows for walls of
considerable height to be built without ever being obliged to wait
until the binder takes, and therefore allows for work to be carried
out without stopping.
[0065] The preferred binder used for the assembling of the
construction elements according to the invention has the following
properties: [0066] Compression strength which is greater than that
of the construction element itself, for preference 15 N/mm2; [0067]
An adherence strength of at least 2 N/mm2, for preference 2.3
N/mm2; [0068] A density of 1.8 kg/l, and [0069] A ratio of water to
cement of 0.45 l/kg.
[0070] The mason prepares the binder in a bucket, mixing it
carefully with water, and he can then apply it on an entire layer
of construction elements, aligned along the length of a guidance
device, then places a layer of construction elements on top, and so
on. In addition to this, because the binder is thixotropic, it is
sufficient to remix it for a few minutes in the bucket in order to
render it fluid once again, if necessary.
[0071] In the process of construction of a wall such as is
described in the present invention, the quantity of binder
necessary is about 20 times less than the quality of mortar
habitually used in traditional construction procedures.
[0072] FIGS. 8 and 9 show a part of a wall constructed with the aid
of construction elements according to the invention. The part of
the wall can be constructed either by assembling several
construction elements beforehand, in such a way as to form only one
single construction element, or in a single operation during the
manufacture of the construction elements.
[0073] In the prior art, it was known that the internal wall is
connected by engagement in the main wall. In the same way as for
creating corners, the masonry is embedded. This is not necessary
thanks to the performance values of the binder used in the present
invention, which interact with the characteristics of the
construction element of the present invention. In effect, this
allows for walls to be adhesively bonded against one another
without embedding. In addition to this, if the elements are
provided with tenons and mortises, it is no longer essential to
have special construction elements available in order for these
masonry structures to be achieved.
[0074] The construction element represented in FIG. 4 is used
essentially for butt ends, since it presents a full lateral wall,
which allows for the header of a wall to be ended by a closed
face.
[0075] Other advantages of the construction of a wall such as
described in the present invention are, for example, the
accommodation of the manufacturing tolerances of the construction
elements. The construction elements are in fact generally
manufactured in batches in a mould. Not all the elements of the
same batch will be perfectly identical. In addition, in accordance
with the amount of use, the mould will be subjected to wear and
will produce construction elements of which the dimensions will
change. These manufacturing tolerances, which are unavoidable, do
not present a problem, because they are easily accommodated in the
process of the construction of walls according to the
invention.
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