GB2125089A - A method of building using settable material on a light weight permanent former - Google Patents
A method of building using settable material on a light weight permanent former Download PDFInfo
- Publication number
- GB2125089A GB2125089A GB08222072A GB8222072A GB2125089A GB 2125089 A GB2125089 A GB 2125089A GB 08222072 A GB08222072 A GB 08222072A GB 8222072 A GB8222072 A GB 8222072A GB 2125089 A GB2125089 A GB 2125089A
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- Prior art keywords
- building
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- building material
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- former
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- 239000000463 material Substances 0.000 title claims abstract description 28
- 239000004566 building material Substances 0.000 claims abstract description 91
- 238000004519 manufacturing process Methods 0.000 claims abstract description 36
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 32
- 229920005830 Polyurethane Foam Polymers 0.000 claims abstract description 13
- 239000011496 polyurethane foam Substances 0.000 claims abstract description 13
- 239000000839 emulsion Substances 0.000 claims abstract description 7
- 239000002861 polymer material Substances 0.000 claims abstract description 7
- 239000007864 aqueous solution Substances 0.000 claims abstract 4
- 238000001125 extrusion Methods 0.000 claims abstract 3
- 239000012779 reinforcing material Substances 0.000 claims abstract 3
- 239000007921 spray Substances 0.000 claims abstract 3
- 239000010410 layer Substances 0.000 claims description 77
- 238000009435 building construction Methods 0.000 claims description 32
- 239000000835 fiber Substances 0.000 claims description 29
- 229920000126 latex Polymers 0.000 claims description 25
- 239000004816 latex Substances 0.000 claims description 23
- 239000011210 fiber-reinforced concrete Substances 0.000 claims description 21
- 230000002787 reinforcement Effects 0.000 claims description 18
- 239000004568 cement Substances 0.000 claims description 17
- 238000010276 construction Methods 0.000 claims description 17
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 16
- 239000006260 foam Substances 0.000 claims description 16
- 239000010440 gypsum Substances 0.000 claims description 14
- 229910052602 gypsum Inorganic materials 0.000 claims description 14
- 239000000203 mixture Substances 0.000 claims description 14
- 229920000642 polymer Polymers 0.000 claims description 13
- 239000003365 glass fiber Substances 0.000 claims description 12
- -1 P.V.A. Substances 0.000 claims description 10
- 239000004576 sand Substances 0.000 claims description 10
- 239000004793 Polystyrene Substances 0.000 claims description 9
- 229910000831 Steel Inorganic materials 0.000 claims description 8
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- 229920001155 polypropylene Polymers 0.000 claims description 7
- 239000003513 alkali Substances 0.000 claims description 6
- 239000002937 thermal insulation foam Substances 0.000 claims description 6
- 239000004593 Epoxy Substances 0.000 claims description 5
- 239000004615 ingredient Substances 0.000 claims description 5
- 230000003014 reinforcing effect Effects 0.000 claims description 5
- 230000006835 compression Effects 0.000 claims description 4
- 238000007906 compression Methods 0.000 claims description 4
- 229920006327 polystyrene foam Polymers 0.000 claims description 4
- 239000011150 reinforced concrete Substances 0.000 claims description 4
- 238000005507 spraying Methods 0.000 claims description 4
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 claims description 3
- 239000006185 dispersion Substances 0.000 claims description 3
- 238000001035 drying Methods 0.000 claims description 3
- 238000009413 insulation Methods 0.000 claims description 3
- 239000004014 plasticizer Substances 0.000 claims description 3
- 238000003908 quality control method Methods 0.000 claims description 3
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- 239000002174 Styrene-butadiene Substances 0.000 claims description 2
- MTAZNLWOLGHBHU-UHFFFAOYSA-N butadiene-styrene rubber Chemical compound C=CC=C.C=CC1=CC=CC=C1 MTAZNLWOLGHBHU-UHFFFAOYSA-N 0.000 claims description 2
- 239000011115 styrene butadiene Substances 0.000 claims description 2
- 229920003048 styrene butadiene rubber Polymers 0.000 claims description 2
- 239000004677 Nylon Substances 0.000 claims 5
- 229920001778 nylon Polymers 0.000 claims 5
- 239000011398 Portland cement Substances 0.000 claims 2
- 238000010521 absorption reaction Methods 0.000 claims 2
- 229920005549 butyl rubber Polymers 0.000 claims 2
- 239000011344 liquid material Substances 0.000 claims 2
- 229920006174 synthetic rubber latex Polymers 0.000 claims 2
- 229920002430 Fibre-reinforced plastic Polymers 0.000 claims 1
- 230000000996 additive effect Effects 0.000 claims 1
- 239000012790 adhesive layer Substances 0.000 claims 1
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- 239000004814 polyurethane Substances 0.000 description 3
- 244000043261 Hevea brasiliensis Species 0.000 description 2
- 238000005336 cracking Methods 0.000 description 2
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- 238000011065 in-situ storage Methods 0.000 description 2
- 239000012774 insulation material Substances 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 239000003973 paint Substances 0.000 description 2
- 229920000647 polyepoxide Polymers 0.000 description 2
- 244000025254 Cannabis sativa Species 0.000 description 1
- 235000012766 Cannabis sativa ssp. sativa var. sativa Nutrition 0.000 description 1
- 235000012765 Cannabis sativa ssp. sativa var. spontanea Nutrition 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 239000004411 aluminium Substances 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- 235000009120 camo Nutrition 0.000 description 1
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- 235000005607 chanvre indien Nutrition 0.000 description 1
- 230000015271 coagulation Effects 0.000 description 1
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- 239000006261 foam material Substances 0.000 description 1
- 238000009415 formwork Methods 0.000 description 1
- 239000011211 glass fiber reinforced concrete Substances 0.000 description 1
- 230000005802 health problem Effects 0.000 description 1
- 239000011487 hemp Substances 0.000 description 1
- 230000000887 hydrating effect Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
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Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/32—Arched structures; Vaulted structures; Folded structures
- E04B1/3211—Structures with a vertical rotation axis or the like, e.g. semi-spherical structures
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/16—Structures made from masses, e.g. of concrete, cast or similarly formed in situ with or without making use of additional elements, such as permanent forms, substructures to be coated with load-bearing material
- E04B1/164—Structures made from masses, e.g. of concrete, cast or similarly formed in situ with or without making use of additional elements, such as permanent forms, substructures to be coated with load-bearing material with vertical and horizontal slabs, only the horizontal slabs being partially cast in situ
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/32—Arched structures; Vaulted structures; Folded structures
- E04B2001/3217—Auxiliary supporting devices used during erection of the arched structures
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/32—Arched structures; Vaulted structures; Folded structures
- E04B2001/3258—Arched structures; Vaulted structures; Folded structures comprised entirely of a single self-supporting panel
- E04B2001/3264—Arched structures; Vaulted structures; Folded structures comprised entirely of a single self-supporting panel hardened in situ
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Physics & Mathematics (AREA)
- Electromagnetism (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Laminated Bodies (AREA)
- Curing Cements, Concrete, And Artificial Stone (AREA)
Abstract
A method of constructing and manufacturing a lightweight cementitious building shell, panel or unit, the method comprising the steps of: establishing and controlling a lightweight per surface area relatively flexible permanent former II, e.g. of polyurethane foam for a building shell, panel or unit, which can support a thin layer of a settable modified building material 15; modifying a cementitious building material by adding thereto both an aqueous solution or emulsion of a film forming polymer material which sets to a water impervious film at room temperature and a fibrous reinforcing material, and mixing the materials to form a modified building material; applying the modified building material in a thin layer or layers by spray and/or trowel or extrusion, to at least one surface of the former and allowing the layer or layers to harden. <IMAGE>
Description
SPECIFICATION
A method of building construction
The invention relates to building construction and manufacture and more particularly to a method of changing the properties of a basic building material to overcome disadvantages which cause a restriction of use. The term basic building material as used in this specification includes reference to all settable materials that are usually mixed with water for example, cement mixture and gypsum mixtures.
Cement and gypsum mixtures are well established basic building materials and their use with a restricted number of fibre types as a reinforcement has also been well established; however most such known methods of manufacture and construction of fibre reinforced concrete and fibre reinforced gypsum suffer from various disadvantages causing a restriction of use, a restriction of fibre types and some of these disadvantages are set out below.
Ordinary cement or concrete matrix has a relatively poor bond to the fibre reinforcement and its high elastic modulus does not make it very compatible with many fibre types.
A disadvantage of fibre reinforced concrete when manufactured as a thin sheet or constructed as a thin layer is the problem of retaining a wet surface to maintain the moisture content required during the curing stage, particularly when used on site.
Other disadvantages of a fibre reinforced concrete are:
(1) the low tensile strength to compressive strength ratio:
(2) a fibre reinforced concrete has a relatively low tensile failure strain and high elastic modulus which can result in a heavily cracked matrix by the time the fibres develop a significant stress;
(3) a thin layer of fibre reinforced concrete requires a relatively high cement to sand ratio which causes considerable movement when subjected to changing temperature and moisture conditions; and
(4) a thin layer of fibre reinforced concrete when used to sandwich a foam plastic insulation foam can be highly stressed by differential temperature and moisture conditions between the internal and external sandwiching layers caused by a relatively high cement to sand ratio and the brittle nature of the concrete matrix.
Disadvantages of a fibre reinforced gypsum mixture are:
(1) the matrix has a relatively poor bond to the fibre reinforcement;
(2) a long fibre length with a wet gypsum siurry setting quickly makes the mixing of fibre reinforced gypsum followed by trowelling difficult; and
(3) a fibre reinforced gypsum has a temporary loss of strength caused by wetting and has poor resistance to water and water vapour permeability.
A disadvantage of a fibre reinforced concrete and gypsum is the relatively poor bond to a foam plastic insulation material such as polystyrene and polyurethane and especially a dense skin of sprayed polyurethane foam. The bonding of a layer of fibre reinforced concrete to a previous hardened layer of fibre reinforced concrete is relatively poor.
Another disadvantage of fibre reinforced concrete and gypsum is that long fibres, that are required to develop sufficient bond to the matrix make it difficult to hand trowel the mix especially to vertical and overhead surfaces.
Another disadvantage of applying a required thickness of concrete or gypsum in a single layer when applied to a relatively flexible former is that the weight causes movement of the former which restricts the shape to a limited variety of dome or arch shapes.
Accordingly an object of the present invention is to overcome at least in part the disadvantages stated above and provide an improved method of manufacturing a modified building material which can be applied as a very thin layer or layers to form a lightweight constructional unit, extruded unit, sandwich panel or shell in a variety of structural shapes and usable for a variety of different purposes.
It is another object of the present invention to provide a method of increasing the strength and/or reducing the elastic modulus of a cementitious building material to improve its resistance to cracking when used to sandwich and/or strengthen a lightweight relatively flexible former.
Further objects and advantages of the present invention will become apparent from the following description which are given by way of example only.
According to the present invention there is provided a simple and economical method of constructing a very thin layer or layers of modified building material both sides of a lightweight core material to form a lightweight sandwich panel of a desired shape suitable for a variety of different purposes.
According to the present invention there is provided a method of constructing a very thin layer of modified building material as a stiffening and strengthening layer to a flexible former and if required for further strength an extra layer or layers of modified building material may be applied to form a building unit or shell.
In accordance with the present invention there can be provided a method of applying a very thin layer of 1 to 9 mm in thickness of the modified building material as hereinafter defined by spraying and/or trowelling to a relatively flexible foamed plastic insulation former.
The modified building material as herein defined is modified with both a film forming water soluble dispersed polymer which sets to a water impervious film at room temperature and a fibre reinforcement to form a modified building material in which a change in the properties of the
basic building material has occurred. It is
envisaged that further additives can be included
and the numerous additives can be premixed to achieve quality control and ease of mixing the total ingredients to produce the modified building material.
The modified building material can be modified by a liquid that can be diluted with water or mixed with the water and cement matrix such as latex or synthetic latex which lowers the elastic modulus of the brittle concrete matrix. Other additives can include water soluble epoxy, water soluble adhesives such as P.V.A., polymer dispersions, expansion additives, water reducing additives and plasticizers to improve workability.
The preferred basic building material is a mixture of sand, cement and water however other mixtures are invisaged where the cement can be replaced with gypsum, the sand can be deleted or replaced with other aggregates or other mixtures with water can be combined with the water soluble dispersed polymer material and a fibre material to form the modified building material.
The modified building material matrix can be reinforced with a variety of fibres or combinations of fibres such as wire fibres, asbestos fibres, alkali resistant glass fibres, polypropylene fibres, hemp fibres, vegetable fibres or polymer fibres.
The most widely used fibre reinforced concrete is asbestos cement produced under carefully controlled factory conditions. Because of health problems with asbestos fibre, alkali resistant glass fibres and wire fibres are gaining wider use along with polypropylene fibres for impact resistance.
The applicant has discovered that a latex modified fibre reinforced concrete is self curing has a lower elastic modulus and a higher bonding property which improves the mechanical compatibility and impact resistance with polypropylene fibres and other fibres that have a lower elastic modulus and poorer bonding surface than asbestos or glass fibres.
The preferred latex is a synthetic latex such as styrene butadiene latex emulsion in water compared to a rubber latex emulsion in water from rubber trees which yields a natural rubber on coagulation. The synthetic latex emulsions are preferred for their improved durability and mixing properties.
Latex modified polypropylene reinforced concrete (L M P R C) is a very impact resistant material with a chemically inert fibre reinforcement in the highly alkaline environment of hydrating cements, and can be applied as a thin layer or layers to protect and/or sandwich polystyrene or polyurethane foam to form a constructional unit, extruded unit, sandwich panel or building shell.
Tests have shown that other fibres may be used with the latex modified building material and the improved bonding properties thereof reduce the tendancy of the fibres to pull out the matrix and therefore improve the properties of glass fibre reinforced concrete or steel fibre reinforced concrete.
The improved bonding properties of latex modified fibre reinforced concrete enables a shorter fibre length to be used as reinforcement without a reduction in tensile strength and hence improves the worability of fibre reinforced concrete.
The lower elastic modulus of the latex modified cement or concrete matrix enable the fibre to act as a more effective reinforcement.
Other aspects of the present invention which should be considered in all its novel aspects will become apparent from the following descriptions which are given by way of example only.
The present invention is preferably utilised for constructing a wide variety of different lightweight shell and panel shapes for a number of different purposes, however, it is particularly suitable for sandwiching a lightweight core material of any shape with a thin layer or layers of modified fibre reinforced concrete can be used as a thin protective layer over a foamed plastic insulation material such as sprayed rigid polyurethane foam. Alternatively the present invention can be used with the building method the subject of the applicants Australian Patent
Application No. 36330/78.
Examples of cross sections through building shells or panels in accordance with the present invention are shown in the accompanying drawings in which:
Figure 1 is a cross section through part of a flat lightweight building panel;
Figure 2 is a cross section through part of a flat lightweight extruded or trowelled building unit;
Figure 3 is a cross section through part of a single or double curvature lightweight building panel or shell;
Figure 4 is an example of a lightweight double curvature dome shaped building shell;
Figure 5 is a cross section through part of a lightweight double curvature building shell with flaring protruding shapes;
Figure 6 is an example of a building shell formed in accordance with the present invention showing a pattern of embedded reinforcing wires
around each flaring protruding shape incorporating an opening in the dome shaped building shell; ;
Figure 7 is an alternative example of a double
curvature building shell formed in accordance with the present invention showing a pattern of embedded reinforcing wires around each flaring
protruding shape; and
Figure 8 is another alternative example of a
building shell in accordance with the present
invention.
The present invention is preferably utilised for constructing a lightweight sandwich construction usable as an insulated outer building shell which can be used for a number of different purposes.
The outer building shell can utilise the stiffness of sandwich construction and/or the inherent properties of a double curvature shape. The invention can be used insitu or a combination of insitu and precast construction, however, it is to be appreciated that a variety of different lightweight structural shapes can be formed and are to be construed as included in the present invention.
Initially, after the shape of the building panel or shell has been decided upon a lightweight relatively flexible former material, for example, polystyrene or polyurethane foam is established and controlled so that is can support a very thin layer of modified building material.
The modified building material has been applied as a very thin layer or layers 1 to 9 mm thick and has been particularly used as two 3 mm thick layers or one 6 mm layer both sides of a relatively flexible former consisting of a polystyrene or rigid polyurethane foam. However a thin layer of 10 mm and greater is also envisaged and other lightweight relatively flexible formers such as thin galvanised steel sheeting, netting or reinforcement can be used.
The modified building material mixture consists of numerous ingredients and each solids percentage by weight of the total solids can vary considerably to achieve the desired properties.
For example the film forming water dispersed polymer which sets to a water impervious film at room temperature is usually in a water solution with the solids and water content in approximately equal proportions in its concentrated liquid form so that the dispersed polymer solids can be between 1 and 20% by weight of the total solids and more preferably between 5 and 15%. Similarly the fibre weight can be varied considerably with the fibre weight between 0.2 and 10% by weight of total solids.
Very small percentages of other ingredients can be added to the mixture such as a plasticizer and/or other ingredients to improve the performance of the modified buildling material.
A very thin layer of the modified building material is sprayed and/or trowelled onto the internal surface of the relatively flexible building shell former of a desired shape constructed of sprayed rigid polyurethane foam. Similarly a very thin layer of modified building material can be applied to more simple shapes and used to cover polystyrene foam to form numerous lightweight building panel shapes. These building shells and panels can be combined and a further layer or layers of modified building material can be applied to form a variety of building shell shapes of lightweight sandwich construction. If required selected areas of a double curvature building shell can be further reinforced with galvanised steel netting, wires, bars or sections embedded in the foam, fixed to the surface of the foam or embedded in the modified building material.
Openings in a building shell for windows and doors can be reinforced with an aluminium frame and high stress areas at the top corners can be reinforced with a higher percentage of glass fibre or woven glass fibre with epoxy bonded to the modified building material for extra strength. The building shell can be finished and protected with a light coloured water based paint. The inside surface can be a very thin sprayed or hand textured building material to give the desired internal finished surface.
In the first example of a flat lightweight buildling panel of sandwich construction shown in
Figure 1 this includes a polystyrene as a lightweight core material 1 which is sandwiched by the modified building material 2. This lightweight panel construction can be precast or the core material can be cut and fitted on site for example between prefabricated internal partitions and the double curvature building shell and a thin layer of the modified building material 2 trowelled or sprayed to both sides of the polystyrene core 1 to form a lightweight sandwich panel.
An example of a lightweight frame cross section is shown in Figure 2 and includes a thin layer of the modified building material 3 extruded or trowelled over a lightweight polystyrene core 4 or galvanised steel former.
Other lightweight polystyrene or polyurethane former shapes can be formed such as the single curvature shapes or double curvature dome shapes, for example, as shown in Figure 3 a curved lightweight core material 5 can be sandwiched with the modified building material 6 to form a lightweight single curvature shape or double curvature dome shape of lightweight sandwich construction.
The dome building shell 7 as shown in Figure 4 can consist of a sandwich construction described above and shown in Figure 3 and if desired can be additionally reinforced with small diameter high tensile galvanised wires 8 placed around arched shaped shell openings 9. These wires 8 are tensioned and fixed to the shell foundation 10,
however other forms of additional reinforcement can be galvanised steel or woven glass fibres in epoxy resin around the tops of each opening which can be arched shape to minimise stress in the shell. These arched shaped openings are weather protected by protruding construction
such as a box dormer 9A or other shape (not
shown) that can include a window or door.
The building shell shown in Figure 5 consists of an insulation core of rigid polyurethane foam 11 which was formed by spraying the foam material in thin layers onto an inflated and propped sheet material (not shown) which can be peeled off when the foam has sufficiently hardened to establish a polyurethane foam former of any desired double curvature shape which an embed opening frames 12 and be trimmed and shaped as required. This method is described in
Australian Patent Application No 36330/78.The polyurethane former 11 is relatively flexible and it can be inflated and the opening frames 12 can be propped by temporary screw adjustable props 1 3 acting in compression to tension the foam 11 to maintain the required shape while a very thin layer of high bonding, self curing, modified building material 14 is applied to the internal surface. As described above additional reinforcement such as galvanised steel or woven glass fibre in epoxy resin can be placed around the tops of each opening frame before placing the modified building material 14.When the modified building material has hardened the temporary supports can be reduced or removed or the screw adjustable props 13 can be adjusted to act in tension so that the hardened modified building material 14 is palced in compression to reduce the risk of tension cracking. If further thickness is required a second very thin layer of modified building material can be applied to the internal surface to establish the required internal thickness of modified building material 14. To sandwich and protect the polyurethane foam 11 an outer layer of modified building material 1 5 is applied.The modified building material 1 5 can incorporate white silica sand and white cement and/or can be additionally reinforced with a pattern of high tensile galvanised wires 1 6 or other additional reinforcement as described above or an extension frame 1 SA bonded around the opening frame. Depending on the thickness and additional reinforcement required the modified building material 1 5 when hardened can have a pattern of high tensile galvanised wires 1 6 tensioned over the external double curvature surface to compression stress the previous modified building material layers particularly around protruding shaped openings 1 7 as shown in Figure 6, 7 and 8.The galvanised wires are then covered with a layer of modified building material 1 5 and the complete external surface is finished to give sufficient modified building material 1 5 cover protection to the small diameter high tensile galvanised wires 1 6 and give the required thickness. The surface can be further protected by a light coloured acrylic paint.
To gain a rapid hardening of the film forming water soluble dispersed polymer material, that forms the surface seal, a drying air current can be blown over the surface of the wet modified building material.
In use the present invention provides for an inexpensive and simple building construction and manufacture which can be constructed in situ wherever required or partly premixed to simplify mixing on site or precast if required. The shape of the building shell construction is preferably of double curvature and sandwich construction to allow very thin layers of modified building material to be used and achieve a sufficiently stiff lightweight construction, however it is envisaged that other shapes particularly for building panels and units can be flat or of single curvature to construct or manufacture a lightweight building panel or unit.
In use the present invention provides other advantages such as:
(1) a simple method of reducing the curing problems associated with a thin layer of fibre reinforced concrete;
(2) providing a method of improving the watertightness of a thin layer of fibre reinforced concrete;
(3) providing a method of improving the bond between the concrete matrix and fibre reinforcement;
(4) a simple method of improving the bond between layers of fibre reinforced concrete and the bond to other materials;
(5) a simple method of applying and bonding a very thin layer of fibre reinforced concrete to complex shapes where placing of wire mesh reinforcement is difficult;
(6) a simple method of improving the mixing, watertightness and bonding properties of fibre reinforced gypsum.
Thus by this invention there is provided a method of constructing lightweight buildings by using very thin layers of modified building material which enables a building to be built in situ or precast with a minimum of formwork, materials and labour.
Particular forms of the invention have been described by way of example and it is envisaged that modifications to and variations of the invention can take place without departing from the scope of the appended claims.
Claims (14)
1. A method of building construction and manufacture the method comprising the steps of:
establishing and controlling the shape of a lightweight per surface area relatively flexible permanent former such as polystyrene or polyurethane foam or thin sheet material for a building shell, panel or unit which can support a very thin layer or layers of a settable material;
modifying a cementitious building material such as a mixture of sand, cement and water with both a film forming water soluble dispersed polymer material which sets to a water impervious film at room temperature and a fibrous reinforcing material, and mixing the materials to form a modified building material which can be applied as a very thin layer or layers with self curing and good bonding properties;;
applying the modified building material as a very thin layer or layers by trowel, spray or extrusion to at least one surface of the lightweight per surface area relatively flexible former and allowing the layer or layers to harden to establish the building shell, panel, extruded unit or unit without the need to apply a separate adhesive layer to achieve good bonding to the lightweight former or the need to maintain wet surface conditions to cure the modified building material.
2. A method of building construction and manufacture as claimed in claim 1 which additionally includes the step of:
adding other ingredients such as a plasticizer to further improve the properties of the modified building material.
3. A method of building construction and manufacture as claimed in any one of the preceding claims which additionally includes the step of:
applying a very thin layer of the modified building material to both sides of the lightweight former which an be finished smooth, textured, or with another material to form the building shell, panel or unit.
4. A method of building construction and manufacture as claimed in any one of the preceding claims which additionally includes the steps of:
shaping the relatively flexible building former from a lightweight insulation foam with good tension properties, into a double curvature shape, tension stressing the foam shell by temporary internal air pressure and by temporary internal props acting in compression to prop prefabricated shapes, window frames or door frames so that the shape of the relatively flexible building shell is maintained during the application of a very thin layer of modified building material;
after the first layer of modified building material has sufficiently hardened the temporary props are removed or can be adjusted to act in tension and the temporary air pressure can be removed;;
to protect and sandwich the insulation foam a layer of the modified building material can be applied to the external surface of the building shell embedding if required galvanised steel reinforcement or other additional reinforcement to produce a strong insulated building shell.
5. A method of building construction and manufacture as claimed in claim 4 wherein the lightweight former is a rigid polyurethane foam formed by spraying layers onto an inflated and propped elastic sheet material such as butyl rubber to form the required shape of the building shell, any surplus set foam is trimmed to the required shape before applying the modified building material.
6. A method of building construction and manufacture as claimed in any one of the preceding claims which additionally includes the step of:
applying a further very thin layer of the modified building material after a previously hardened thin layer of modified building material to form the building shell, panel or unit.
7. A method of building construction and manufacture as claimed in any one of the preceding claims wherein the film forming water soluble dispersed polymer is any one of a rubber latex material, synthetic latex material, acrylic material, P.V.A., water soluble epoxy material, or other polymer dispersions which when combined with the fibre and the building material mixture forms a polymer modified fibre reinforced building material or if the reinforcing effect of the fibre is minimal a fibre polymer modified building material that can be applied as a very thin layer with self curing and good bonding properties.
8. A method of building construction and manufacture as claimed in claim 7 wherein the building material is a sand, cement and water mixture the film forming water soluble dispersed polymer is a latex or synthetic latex and the fibrous reinforcing is any one of an alkali resistant glass fibre so that the modified building material is a latex modified glass reinforced concrete (L M G R C), is a polypropylene fibre so that the modified building material is a latex modified polypropylene reinforced concrete (L M P R C) or is a nylon fibre so that the modified building material is a latex modified nylon reinforced concrete (L N N R C) or a nylon latex modified concrete (N L M C).
9. A method of building construction and manufacture as claimed in any one of the preceding claims wherein the modified building material contains white portland cement and white silica sand particularly when applied to external surfaces to reduce the absorption of heat when exposed to sunlight.
10. A method of building construction and manufacture as claimed in any one of the preceding claims wherein the modified building material with a lower elastic modulus is used to sandwich a foam plastic insulation foam to reduce the differential temperature and moisture stresses that result in a lightweight fibre reinforced concrete sandwich construction with a foam plastic insulation core.
11. A method of building construction and manufacture as claimed in any one of the preceding claims where an additive such as a synthetic latex solution is mixed with the fibre reinforced building material to form a latex seal and bondage around the fibres to reduce the alkali attack on glass fibre and increase the durability of the glass fibre by reducing further the risk of attack on alkali resistant glass fibre.
12. A method of building construction and manufacture as claimed in any one of the preceding claims wherein the required amounts of the dry materials such as sand and cement are premixed and the required amounts of the liquid materials such as latex and water are premixed to improve the quality control and simplicity of mixing particularly for on site use.
13. A method of building construction and manufacture as claimed in any one of the preceding claims wherein the surface of the modified building material quickly hardened and sealed by drying the wet surface with a current of air.
14. A method of building construction and manufacture as claimed in any preceding claim including quickly hardening and sealing the surface of the modified building material by drying with a current of air.
1 5. A method of building construction and manufacture substantially as herein described with reference to the accompanying drawings.
1 6. A method of building as herein described incorporating the shell construction as shown in any one of Figure 4, Figure 6, Figure 7 or Figure 8 of the accompanying drawings.
14. A method of building construction and manufacture as claimed in any one of the preceding claims wherein for internal surfaces the cement is replaced with gypsum in forming the modified buidling material.
1 5. A method of building construction and manufacture substantially as herein described with reference to the accompanying drawings.
1 6. A method of building as herein described incorporating the building shell construction as shown in any one of Figure 4, Figure 6, Figure 7 or
Figure 8 of the accompanying drawings.
New claims or amendments to claims filed on 26th July 1983.
Superseded claims 1-6.
New or amended claims:- 1-16
1. A method of building construction and manufacture, the method comprising the steps of:
establishing and controlling a lightweight per surface area relatively flexible permanent former for a building shell, panel or unit, which can support a thin layer of a settable modified building material;
modifying a cementitious building material as herein defined by adding thereto both an aqueous solution or emulsion of film forming polymer material which sets to a water impervious film at room temperature and a fibrous reinforcing material, and mixing the materials to form a modified building material;
applying the modified building material in a thin layer or layers by trowel, spray or extrusion, to at least one surface of the former and allowing the layer or layers to harden which establishes the building shell, panel or unit.
2. A method of building construction and manufacture as claimed in claim 1 which additionally includes the step of:
adding further additives to improve poperties of the modified building material.
3. A method of building construction and manufacture as claimed in claim 1 or claim 2 which additionally includes the step of:
applying a thin layer of modified building material to both internal and external surfaces of the permanent former which further layers can be finished smooth, textured or with exposed aggregate.
4. A method of building construction and manufacture as claimed in claim 3 comprising sandwiching the former which is formed from a foam plastics insulation foam between thin layers of the modified building material to reduce the differential temperatures and moisture stresses in the sandwiching layers.
5. A method of building construction and manufacture as claimed in any preceding claim which additionally includes the steps of:
applying a further thin layer of the modified building material over a previously hardened thin layer of modified building material and controlling the former to avoid damage to the previously hardened layer of modified building material while the further layer is applied.
6. A method of building construction and manufacture as claimed in any preceding claim which includes the steps of:
establishing the former from a lightweight insulation foam, with good tension properties, into a double curvature shell;
controlling the foam shell by temporary internal air pressure and/or by temporary props to prop prefabricated shapes, window frames or door frames so that the shape of foam shell is maintained during the application of the first thin layer or layers of modified building material; and
applying an external layer or layers to sandwich the foam shell with the modified building material.
7. A method of building construction and manufacture as claimed in claim 6 wherein the lightweight former is a rigid polyurethane foam or epoxy foam formed by spraying layers onto an inflated and/or propped elastic sheet material such as butyl rubber or polymer sheet material such as woven nylon and trimming any surplus set foam from the former before applying the modified building material.
8. A method of building construction and manufacture as claimed in any preceding claim wherein the former and/or modified building material can have embedded therein or bonded thereto additional reinforcement such as galvanised steel or other suitable additional reinforcement such as polymer cloth or netting, fibre reinforced polymer or polymer concrete.
9. A method of building construction and manufacture as claimed in any preceding claim wherein the aqueous solution or emulsion of the film forming polymer material includes any one of a latex, synthetic rubber latex such as styrenebutadiene, acrylic material, P.V.A., water soluble epoxy material, or other polymer dispersions.
10. A method of building construction and manufacture as claimed in any preceding claim wherein the aqueous solution or emulsion of the film forming polymer material includes a latex or synthetic rubber latex. The cementitious building material is formed from a stand or fine aggregate and cement mixture and the fibrous reinforcing is any one of the alkali resistant glass fibre, a polypropylene fibre or a nylon fibre.
11. A method of building construction and manufacture as claimed in any preceding claims wherein the cementitious building material contains white portland cement and silica sand and the modified building material is applied to external surfaces of the permanent former to reduce the absorption of heat when exposed to sunlight.
12. A method of buildling construction and manufacture as claimed in any one of claims 3 to 11 when dependant on claim 3 wherein the cementitious material which is modified and applied to an internal surface of the former includes gypsum.
1 3. A method of building construction and manufacture as claimed in any preceding claim wherein the dry materials are premixed and/or the liquid materials are premixed to improve quality control and simplicity of mixing particularly for on site use.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AU8098781 | 1981-03-09 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| GB2125089A true GB2125089A (en) | 1984-02-29 |
| GB2125089B GB2125089B (en) | 1986-07-02 |
Family
ID=3759866
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB08222072A Expired GB2125089B (en) | 1981-03-09 | 1982-07-30 | A method of building using settable material on a light weight permanent former |
Country Status (2)
| Country | Link |
|---|---|
| AU (1) | AU551323B2 (en) |
| GB (1) | GB2125089B (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| AU2007100985B4 (en) * | 2007-07-31 | 2008-09-04 | Domeshells Australia Pty Ltd | An improved system, method and apparatus for constructing compound curve sandwich shell structures |
Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB1541824A (en) * | 1976-04-09 | 1979-03-07 | Milburn W W | Method of forming a composite biulding structure and structure so formed |
| GB1604944A (en) * | 1977-05-23 | 1981-12-16 | Braine W G | Method of building construction |
| GB2086446A (en) * | 1980-10-21 | 1982-05-12 | Compoglass Ltd | Forming buildings by coating with glass fibre reinforced cement |
-
1982
- 1982-03-01 AU AU80987/82A patent/AU551323B2/en not_active Ceased
- 1982-07-30 GB GB08222072A patent/GB2125089B/en not_active Expired
Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB1541824A (en) * | 1976-04-09 | 1979-03-07 | Milburn W W | Method of forming a composite biulding structure and structure so formed |
| GB1604944A (en) * | 1977-05-23 | 1981-12-16 | Braine W G | Method of building construction |
| GB2086446A (en) * | 1980-10-21 | 1982-05-12 | Compoglass Ltd | Forming buildings by coating with glass fibre reinforced cement |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| AU2007100985B4 (en) * | 2007-07-31 | 2008-09-04 | Domeshells Australia Pty Ltd | An improved system, method and apparatus for constructing compound curve sandwich shell structures |
Also Published As
| Publication number | Publication date |
|---|---|
| AU8098782A (en) | 1982-09-16 |
| GB2125089B (en) | 1986-07-02 |
| AU551323B2 (en) | 1982-09-16 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PCNP | Patent ceased through non-payment of renewal fee |