BLOCKS, BEAMS, PIPES AND BUILDING ELEMENTS THAT CAN BE SAWN AND NAILED

Abstract: Blocks, beams, pipes etc. and building elements of different types, which can be sawn and nailed. The aggregate employed in this manufacture consists of lightweight aggregate with a particle size fraction varying between 2 and 20 mm. The particle size fraction of the aggregate is first bonded with cement or other binder, whereupon polyurethane is injected into the product to fill out the external porosity.

Description: Blocks, beams, pipes and building elements that can be sawn and nailed The present invention relates to a composite building material suitable for lightweight building structures and satisfying the demands for improved rationalisation in the building industry. Combining lightweight aggregate and cellular plastic for building structures is previously known.. The lightweight aggregate is bonded with cellular plastic instead of cement, use being made of a coarser particle size fraction, from 10 to 30 mm. However, these materials have been unable to pro¬ vide the requisite fire resistance. In the event of a fire, the cellular plastic burns away and the lightweight aggre- gate is exposed and gradually falls apart, whereupon the fire can penetrate deeper into the structure. Furthermore, these building materials are subjected to heavy deformation under compressive loads before rupture occurs, and their useful¬ ness therefore is limited. The present invention obviates these shortcomings in that the aggregate particles are first bonded with cement, gypsum or a combination of these binders. It is possible to use particle size fractions having a diameter from as small as 2 mm to highter values in different particle size combi- nations. The wide range of useful particle size fractions makes it possible to broaden the production program. By first bonding the particles so that an external porosity is obtained therebetween, and then supplying poly¬ urethane or other cellular plastic, a material is obtained which does not have the negative properties of a product consisting solely of lightweight aggregate and cellular plastic. A particle size" fraction of from 2 to 4 mm or from 2 to 8 mm makes it possible to produce panelling elements having a thickness of about 12 mm and in the same dimensions as gypsum panels. The surface layers of the panels may consist of paper, glass fibres, thin sheet metal, mortar etc., and the panels may have a volumetric weight of about 400 kg/m3, i.e. at 12 mm thickness a weight of about 5 kg/m2. The space between two panelling elements may be inject¬ ed with an insulating polyurethane layer, or a different cellular plastic having a higher insulation resistance than the panelling elements may be glued in position within said space, whereby a highly insulated structure is obtained. It is, of course, also possible to produce larger rein¬ forced structures for outer walls, floors and ceilings. Lightweight aggregate blocks can be produced with a re¬ duced amount of binder in block-making machines, and after setting and drying, for instance polyurethane is injected into these blocks. The blocks are then provided with a suit¬ able number* of holes which do not extend all the way through the block. The polyurethane is injected into these holes. By suitable positioning of these holes, the entire block can be thoroughly injected with polyurethane. The invention has been described above with reference to the production of building materials. It is, however, also possible to produce doors, window frames, reinforced boat hulls etc. ' OMPI

Claims: What I claim and desire to secure by Letters Patent is: 1. Blocks, beams, pipes, and building elements of diffe- ) rent types, in which the aggregate material in the finished product consists of particle size-graded lightweight aggre¬ gate, such as fired, expanded clay or shale, as well as eruptively formed aggregates, pumice and the like, a binder, and an expanding material, it being possible to manufacture the products in such a manner that they can be sawn and nailed, c h a r a c t e r i z e in that the grading be¬ tween the minimum and maximum particle size diameters in the aggregate is from 2 mm up to 20 mm, for instance from 2 to 4 mm, from 2 to 5 mm, from 2 to 8 mm, from 3 to 8 mm, from 4 to 10 mm, from 10 to 16 mm, from 12 to 20 mm etc.; and that the aggregate particles are first bonded with cement or a quick-setting binder, such as a cement-gypsum mixture, and with an amount of binder which is so small that a free external porosity is obtained between the particles, where¬ upon an expanding material, such as polyurethane, is inject¬ ed into the product to fill out completely the free external porosity.

Inventors: HOLM HARRY, HOLM, HARRY
Applicants: HOLM HARRY, HOLM, HARRY
Application year: 1984
Main classification: C04B15
IPC codes: C04B28