Patent DE-102008035612-A1 (DE)
Title: Manufacturing wall- or floor coverings made of mineral material e.g. terracotta, by preparing masonry bricks from already used fired block bricks originating from condemned building, and cleaning the bricks from sediments and lime residues
Inventor: FISCHER TORALF
IPC: E04F13/14
Filed: 2008-07-25
Abstract: The method comprises preparing masonry bricks from already used fired block bricks originating from condemned buildings, cleaning the bricks from sediments, lime residues and mortar residues, cutting the bricks to relocatable plates with a thickness provided corresponding to its use, drying the plates, and impregnating, relocating and adhering the plates selectively in a thin-medium bed process or thick bed process. The masonry bricks are burnt at a maximum temperature of 900[deg] C. Each masonry brick is divided into multiple plates as a whole in a unique cutting process. The method comprises preparing masonry bricks from already used fired block bricks originating from condemned buildings, cleaning the bricks from sediments, lime residues and mortar residues, cutting the bricks to relocatable plates with a thickness provided corresponding to its use, drying the plates, and impregnating, relocating and adhering the plates selectively in a thin-medium bed process or thick bed process. The masonry bricks are burnt at a maximum temperature of 900[deg] C. Each masonry brick is divided into multiple plates as a whole in a unique cutting process. Before dividing, the plates are moistened at their lower surface to be embedded to relieve the lower surface from dust and other remains and for better diffusion or distribution of the adhesive within the plates. The impregnating, relocating and adhering step comprises drying off the relocated and adhered wall- or floor coverings until no dampness spots are more visible, repeatedly cleaning the plates, drying the plates until no dampness spots are present, first impregnating the plates when protecting the same against the joint mass, joining the floor coverings, acidifying or cleaning the coverings, drying the coverings and then second impregnating, drying the coverings, and finally sealing the coverings, where the first and second impregnating steps takes place with polymer and aqueous solution containing additives and with a vegetable germ oil. The sealing corresponding to the sealing step takes place with acrylate, waxes, anionic or non-ionic tenside and aqueous solution containing additive or with a wax on water basis. A section of maximum 0.5 m 2>is processed during the impregnating step, where maximum 0.5 m 2>of the surface to be covered are coated with adhesive and maximum 0.5 m 2>of the plate surface are covered with joint mortar. The sealing of the bricks takes place with the adhesive on trass basis in the thin-medium bed process or thick bed process. The joint mortar is used for sealing the wall and floor coverings and consists of Portland cement (10-30 wt.%), trass (5-15 wt.%), quartz-sand (65-80 wt.%) and pigment (5 wt.%). Additives (up to 5 wt.%) such as methyl cellulose, dispersion powder and stabilizers are admixed to the joint mortar. The adhesive used for sealing in the thin bed process consists of dispersion adhesive, powder adhesive, two-component adhesive or other adhesive with a high tensile strength. Independent claims are included for: (1) a brick cutting machine for manufacturing wall- or floor coverings; and (2) wall- or floor coverings made of mineral material such as terracotta.