CA2204933A1 - Method and apparatus producing lightweight concrete structure - Google Patents
Method and apparatus producing lightweight concrete structureInfo
- Publication number
- CA2204933A1 CA2204933A1 CA002204933A CA2204933A CA2204933A1 CA 2204933 A1 CA2204933 A1 CA 2204933A1 CA 002204933 A CA002204933 A CA 002204933A CA 2204933 A CA2204933 A CA 2204933A CA 2204933 A1 CA2204933 A1 CA 2204933A1
- Authority
- CA
- Canada
- Prior art keywords
- slurry
- bubbles
- cementitious
- air bubbles
- structural member
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
- E04B2/14—Walls having cavities in, but not between, the elements, i.e. each cavity being enclosed by at least four sides forming part of one single element
- E04B2/16—Walls having cavities in, but not between, the elements, i.e. each cavity being enclosed by at least four sides forming part of one single element using elements having specially-designed means for stabilising the position
- E04B2/18—Walls having cavities in, but not between, the elements, i.e. each cavity being enclosed by at least four sides forming part of one single element using elements having specially-designed means for stabilising the position by interlocking of projections or inserts with indentations, e.g. of tongues, grooves, dovetails
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
- C04B38/0051—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof characterised by the pore size, pore shape or kind of porosity
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
- C04B38/10—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by using foaming agents or by using mechanical means, e.g. adding preformed foam
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
- E04B2/14—Walls having cavities in, but not between, the elements, i.e. each cavity being enclosed by at least four sides forming part of one single element
- E04B2/26—Walls having cavities in, but not between, the elements, i.e. each cavity being enclosed by at least four sides forming part of one single element the walls being characterised by fillings in all cavities in order to form a wall construction
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2103/00—Function or property of ingredients for mortars, concrete or artificial stone
- C04B2103/40—Surface-active agents, dispersants
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2201/00—Mortars, concrete or artificial stone characterised by specific physical values
- C04B2201/10—Mortars, concrete or artificial stone characterised by specific physical values for the viscosity
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2201/00—Mortars, concrete or artificial stone characterised by specific physical values
- C04B2201/20—Mortars, concrete or artificial stone characterised by specific physical values for the density
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
- E04B2002/0202—Details of connections
- E04B2002/0204—Non-undercut connections, e.g. tongue and groove connections
- E04B2002/0206—Non-undercut connections, e.g. tongue and groove connections of rectangular shape
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
- E04B2002/0202—Details of connections
- E04B2002/0204—Non-undercut connections, e.g. tongue and groove connections
- E04B2002/0215—Non-undercut connections, e.g. tongue and groove connections with separate protrusions
- E04B2002/0217—Non-undercut connections, e.g. tongue and groove connections with separate protrusions of prismatic shape
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
- E04B2002/0202—Details of connections
- E04B2002/0204—Non-undercut connections, e.g. tongue and groove connections
- E04B2002/0226—Non-undercut connections, e.g. tongue and groove connections with tongues and grooves next to each other on the end surface
Abstract
A cementitious structural member has a high volume of encapsulated captive air and has an unusually high compressive and shear strength.
Description
-~EI~p ~A~ APPAR~TUS FOR P~ODU~IIY~ II~Iw~C~T
~ .
~r~
od for maoufact~ring d~c samc.
IlJ~LdJ~ ~Ich ha~ a high ~o~umc of .~ d cap~c ~ bct which has an ~e adv~ of P~ 6 a conc~e ~ocl~ tor ,c~ nll reduce ~hc weight ~ c bloc~, and ~e ~e qua~ty of ca~nt and ~and ~q~d to mal~e ths bloclc llo,~..,.., c~u-- '~ bloclcs ~ich haYe a high p~op~lion of pores and havc a ~y of bss tha~ about ~ lo lleven~y pouDd~ por c~bic foot haYc been ~~ ' bocause the bloc}s crumblc oq st~y a~ r~~ W~L ~e numb~:r o~ ~ ~hUe~ are p~ ' - ~ ~, thc smfiK~ ~sioo of ~e bu~bl~
nco~ tbe posi~on of ~ co,-., ~- ~nd ~6.~Eja~ smllll portions of c D~ i~
25 int~ice, i.~, an ~t~i~. L J ~kcktal C(l1~ ,~e i~ fom~d, orl if ~t is fo~ t is w~
One ~ol an ~ bloclc at1t~npts t~ solvc tbe ~J~vg~ g ~ m .3 ahlmLn3 ~wder p~ iD acbemic~l ~actiom wh~ ubb~ in ~hc and i~ p~ dh~idual bubbks ~rom ~ks~ to f~rm large ~l~l~
c sls~y dlcn ~s~ic~, ~pp~g the g~s t ' ' ~ 8as bll~cs ul thc ~ ~g S w~ gypsmn blocks sire ea~h of a ~a~ely uni~ v., cvcll ~ough - . - ~ . ~c co~e~ gspsum bloclcs ha~e a ~.. ~ stro~ u~ e of t~ c~ gypsum bloc~s is ~si ~eir ma ~1: ~, an.d ;" I n l~, ~ hbc~
1~ in~siYe and co~tly.
sli~ly, it would ~e ~igbly desirablc ~ p~id~ u.u~
a high ~ v~cb wou~d ~ co~at~ve~ i~s~vo m man~ct~ w~ish ~o~ re a d~q ~ ~hc ~e ~ fi~e ~ds p :r cubic foot ut f~ft~ po~ds pcr ~ub~ and ~h ~ould, sft~ being ~N.~d ~om 3 m~)l~ f~~.lih~ ~g ~f ~e bloc} b~ g wa~r o~ a large w~ce in~ide ~ ~locl~ ~ would ~Iso be ~ '- ~ p~o~idc a nrthod f~r manuf~
the h~ d hloc~
fd.~ t SS a ~pal objoct of shc ~o~od Cr ~ ~ 9Dl~ method f~r rna3cing ~hc sam~
;/;V1~C l~loc~: Yvhich ~9n~;n~ a high p~ f ~ir p~es but ~11 ~aIi be emplolrred i3 a w~ ~ sys~m having c~ls~r~e ~agt~ ~vhloh g~ly e~ceeds ~at ~ a co~vend~Dal *~d ~amc con~lio~
Anotba obj~ a~ o~ w ~o~idc a ligh~gh~ ot~
ce~t h~oclc w~b can be pr3du~ ~Icly aEId ~ low co~
The~e and otber, ~u~~ and more ~pecific ~jec~ a~d ~dvan~s of the ih-llG~ will be ~en~ tv tl~ose sl~od in th~, art ~om thc ~ull~ i..g de~ed .iescri~ptior ~ereof~ sakeD in c~j~liO~ wi~ ha~b~ iII wbich:
the U1~C~ ~ lightwdght c~ ;~s biodt of t~ ill.~ ~
~3~ ~cti~c of ~e ~c~od o~
Fig. 3 ~ a bop ~ J~ ~ of a bl~clc moldod io ~ordu~ ~Ith ;'~'!i Pig~ 4 is a bo~om ~,~ e view ~~ the ~oc~ ~ Pig. 3.
Sr~ ;arly ~11 of the bu~bles each ha~re ~ h in thc ~nge of a~out Ul~ so 114 of a2l ~h Ihe ~l-mrsr h8~ a ~ .y Afl~ T't ge~ ao ~alt the C~
0 of ~ s ~ fo~Tn lar~~ b~
., l~e ~lurry ~cl~xl~ wa~; a ceme~dJios8 bi~; a plu~li~ of ;malll air b-tt~
fo~n l~lrg~ tJ~ ~; a~ ~I ~mu~ co~o~on ~ a~gy wmc~ for ~8 t~oclc ~ dil~S ~zed p~es ~omc of which are ~bh.;,r, ~nc~ a~ cach h~ a ~ih m thc rang~ of ~x ~Jl~ to ~ of ~
i~h l~e , -n~al u~ ha8 a ~dt~ in ~e Iange o~ fi~fC poc~8 per cub~c f~t porcs ~ith a wid~ ~o greqOcr ~ of ao i~
ngidli~ hta~ tio~s~L~In~. Thc3Lu~,~'~t~co~
~d pom bà~g in~ d ~d a~ch having a ~id~h ~ ~c ran~e of abou~ 8 proccss for ~ " a ~ lg}~t c~ s~ n~...... Tbe proc~
'F--~5 t~e ste~ of n~L~i~g Soge~ a c~ ~der utd watcr u~d supplyir~g ,'"~h ~ aiJ ltO form a 51~ h~--~1 wi~ s~all ~r bubblc3 a~d han~g a ~.~ ~
-- r p~ b thc m~ema~t o~ ~e bubUes through ~ u~ing t~ ~u~ into a i ~ . - . ~
r b ~9,.
. . . ;, . ., . i, process inrl~~s thc st~ of ~g ~g~lher a suy~ dr oo for~ a ~ ' pvunng ~hc ~lm~
a mold ~ ~es up ~d f~ a ~. ~ghl ~gid s~l ~, a~ b~ ~he ~ hJrd~ ~g the ~ L ~ ~ f~ 9 ~J ~zc alr~ubbks and ~en~ y prev~t ~o '-s - ~ he i~ d ~ ur bubb~eg.
- ~ 8 fi~ t a~ the i~YC~ pro~dc ~ ~
pr~cess for p~d~l~ g a li~t.. ~ ~ n~ Thc process il~7~ 5~p8 of mixin~ toget~ ~I c~ ~s ~ and ~ g 2~ al~ to f~m; a S1S~ C~ , heatillg a ~)sd ~ a ~tJlre s.-ll~- i~ -; to b~ a~ krubbh~ ~n said s1wT~ ~r - ~ ~ m~ld to ftxm s ~noof~ 3]urry of tbe u~,u~ ide an i~ru.
pro~s for p~ i~ a l~ghtweigh~ ~s st~ ud tn~h~
25 ;.~,1~e~t~p of mL~i~,eto~e~a~--.~ bi~ ndw~lEr~d~ ~g to form a ~ r'-~A Wittl small air b~ ]es, p~ d~!e slurly i~l~ ~aid hea~ mokl, a~. ~i" ~e ~rfa~e tensioll of shc bubble~ to *~
~aalescing of t~e bu~es to fo~ i~.~l 3i~e ~ir bubbles.
.~2 proce~ it~ ~U~g a lightw~ight ~_~~al n~. l~ne p~oce~
' . , , _ tho vis~osiq Of ~aid 81~ 8~d to c ~ es ~ fo~ e d s~e air b--Sbt- . ~6 dle v~ of the slm~ ~ c~re the ~ ~ze air b~le~ g tbe ~h~Ty to ~ to form a light~eightporou~ sl~u~e l~ g .. a ~.. ~1~ of pores which d~aw l~uid illtO wd 8~,~ by c~illa~
-r~ appl~ g w~ r to the ~ och that the nctwo~ o' porcs ~al1vs wat~ ~to ~e purpose of c~ g Ihc u~e th~eof ~d not by way of ~mi~atio~ of the icope of - tke i"~c~lion, ~ ~ch lil~e ~' I ~ r~ k~ ~-Y C~.~ lg ~ ~
10 lL~ g' lu' the ;cvual ~ g. 1 is a blocJc d~am illuslrati~g t~e process far ufac~ing a ceme~ti~ous b~oclc or o~ nen8tious sl~
~ ~ u ' ~ e ~v~ the ~k s of t~e ~.. ~ ~ ~ hl Pig. l, c0~ l1~ ~nd wa~ 10l are c~ er lOO ~or a s~ort puiod, presently typic~ about threc t~ ve lS resulti~g mi~ ~s ~ d far about t~ s~or~ 7he foam lO3 s, p'~ air fa~
thc S~Ty. Poam 103 i~ ~d by blo~g o~ ~g air illtO a ~o~ning ag~t.
l'ne bubbles ~ fo~m lO3 pr~y p~erably ~Irc quit~ I ancl the ~oam has an ap~ua~e s~ to ~hat of sbavi~g <~ l~le foun b~bbles typi~y h~e a wi~th ~f less thall abo~ one ~ty-~ourth of inch l~e bu~bl~ l~tly are of slu~ry l11. Limc lO9 an bc addod to increase tke visc~ r cf dle rcsul~g slurry 1 1. S~-- r, ~.~IQ can, ~ dc~. be ~ed ~ foam 103 ~Of to ~fir ~ 3 to lOQ.
~S Walcr lOl is p~ently ~.cf~ cated to a ~ hc r~nge of aghty ~o ~. hu~ dg~ty cle~ees P. ~e foam 103 i5 ~ ~Ltl~ p-~f ~a~
hcatod to ~ e of eipty to one hund~ed ei~hty degr~e~ F. I~e mo~d 112 a~dlor rm~er 1l)0 p~ r ~ly ~e beated to a t~ e in tbe ra~ge of dgh~ to ~out ~nc h~d cigh~ dcgr~ . p~ q~ heat ca 30 sdded ~ mibccr 100 ~y blowing htated air i~to the mixer ~ by any other de~
~by those of skill ~n tbc a~t, the s~nd, foasning i r Ln n~er 100 noed not bc ~d.
Lon of ceme~t ~ saDd by w~gh~ ~D be in thc r~ge of 10:1 ~ 10~ the ratio of cen~t So i~d by welght l;rplC~
. 5 Af~r the ~ 101, 8and 1~ m 103, -- ~ 104, c~nt 1~
' '~ j,,, p~ J~ f~ly ~ff, Le., has ~ ~ty grea~r thall tbc ~ dtica~ ~sco~ty.
10 at sm~i~t ~JI~i~lUl~; ~a sca l~eZ ~the slu~r having a ~ A~C a~d a selc~d co.~3~1ion and c~ ,c which ~ bubbles i3~ ~lurry 100 c~ not . .
~ b '~t' -'ly dl ~ which ~e i~ a sele~ted w~d~h ~ ~ tke: b~bble~ can no~
mol~ thr~gh ~he sl~y. ooal~ of bubb~es i5 ;i.~ When b~bb~
5 d~ ~ nd unit~ A pa~ ~f bub~ can to~ch wiebwt c: ~ ~ ~ ~ For e~b, a ~ of I ,?~ -~nl b~;bblcs towb and cach re~ t~cir oIiginsl ~llcri~l sl~
- ~ey ha~fe not co~ J If a pair of bub~la b~mp ~nd causc ~ach ot~ to chao~eshape wi~out b~ B ~c ~r wall of ~ither bubbie, tbey haw ~t ~x~'~
If a ~ of b~bles bun~ Lr to u~h o~ 8~d a p~o~ 1'~'' D--l wall of e~h lc co~ses a~ the bubbl~s join ~ a fi~c ci~ht ~e c~fi~c t~ - ~with dlc a~iginal s~ ~all of a~h ~ pt at ~ cirallar li~e along wh~h the :~1 w~lls moct and join). tbeD ~he bub~bs hmre ~ah~ a pur - of n~ balls a~ prcssed gen~y agunst one aD~, Ihey ss~e o~ a figu~ dght type ~nfi~ ti~n As u~ed h~ein, tbC ~,c~ - y ~ cal ~ds~
2S of ~ f r.t;~ sllL~Ty at am~t ~n~ ~t sca lc~el (~e sltmy ha~g a ~le~
~mpaume a~ a sebc~ com~ on anc c~ - ) above which ~ir bc~bles can Dot m~ve through tbe S}UIly~ T~e ~cnn~ory c~itical ~q iS gread:r tha~ ~he cFi~l ~ , ie., a slu~ry with tbe ~ n~llr cr~ riscosi~ iS SdffCI
tt~ a ~lurry with the ~ cri~ viscosity. Heat 113 is ~,fc ~, but not wld 112 to heat ~he mold to a se~~a~e of ~om e~8h~
degrecs P to ~fo hund~ d ~ dcgroes ~ en mold 112 is beated, d2c hc~t iD
elle mold brca~ bubbles w~ich src in she slurry adjacent ~e inner ~ ~r . ~ of dlc a ~ iv~lJ ~oth, d~se, 'L- ' _ cutet blodc ~f~;e ,~ which ~s Pdj~ f the moltl llZ a~ h~s ~~II pa~s tht ~ ~r~ p~ e t,vpically o~ ~ r~ of a~ inch wide~ or ~nall~r. He~ ~om ,, . _ ..
. .~ mo~d 112 ha3~s ~ g of d~ ~~urry. Molds far produang bloc}s a~d odler r'-~ ,~, S C~ ue wc~ Owl~ 3111 thc ~ aIl~i ~i~l not be d~
t~c cemc~t 106 or od~ ~8~- 3~h u~ calaum cblorid~ c~n prodwe bea~
hea~, ~ G ' ' - ~0~1 with ~c hcu p~v . iJ~l by ~e hea~od ~ld 112t fuse3 ~llm~r 111 1~ 111 to a point below ~c ~ c~ri~ca! v2~00si~ so d~at an bllb~l~s in t~c s~ry 111 caIl ml3YCt 'L_ P~ d fo~l l~ge~ l)ub~ lbt alr ll)ubble8 m ~lC slulry hsvca ai~ ace t~OD. l~e hcat al50 fnnr1i~ 5 ill CO~IJ~ with sllrfac~ IX~
r ~ t of l~e ~.~ ~e bubbl~ he ~am 103 ~ill ~t ~r co~ c ~ co~csoc unless the slurIy i5 beatod So a t~
d~ ly to a qme ~ l~e ~ge of ~c~y dcgree~ to one h~d and dghl3r dc~. It is ~i~ipated. h~ .w, ~t bub~le8 in fo~m 103 co~ be cQllDrs~d without usin~ heat and ~ a a~c.r.i~l~ s~ong sucf~tant, ;~Q As u~ n, ~e su~&e ~ ion of a bubble in a cemellddous slurry a~ ent ~essure at ~ea level (th~ ~ a sdec~d t~:mperat4re, r'A ~d C~ ~ a c~tain ~i~cos~ty bd~w ~he ~ J~ is t~e ~ilit~ of thc ~ubble to ~t ;~
I~ce of ~ ar s~qnt(S~ or otl~s ch -~;r~ ill the ~Y-~ of ott~ s far caus~g a bu~;bk to col7apsc o~ el~ lcno~m, t~
are foam~ng a~ whi~:h produce bubbles whioh al~e mo~ sist~t to coll~pse a~d coqIrscin~ a~ în tbe: p~l~e of a cc~in s~ts or ~ heat, v~
ul~o; - } or o;h~ means a~ applied tt~ thc ~ us slurIy to c~se bubblc to colla~se or cc~ e wi~h atlO~lel bu~blc 00 fo~m ~ ncw larga bubbl~ ~ ~ g ~e~t can produce bubb~ m~e rcsistant to 2 p~r wrfact~nt ~8~ anotl~
f~-Ti~ agcn~ A~ a foan~i~g ag~t ~ s~ect~, os a~ ~e mcans for in~rodu~
b~bbles ~n a cemen~oL~ sl~y is ~ d7 the~ O~ tlC OI' ot C~ CA 02204933 1997-05-09 -~ _9_ width ran~ ~ bubblc~ L~ ob~ dm~n~ Ihc diesir~d ~ paiod when lhe ~t~
e cn~ surface ~ioD of ~ bubblc ~ ~ surf~cc t~~ be~ which ~ ba~
S ~rill oo~.e ~ with o~e~ lcs ~a c ~ X ~ mbialtp~ e ~ sca ror~ , and haYing a ca~in visco~ below the p~imu~ critical vi~co~) to - ~ 5 ~~ ngth) of ~me whel~ tbc Yisco~i~ O~ io~ be low d~
When slu~ 111 fi~s alld it~ WOWLt~ is ~educed bdow tbe prim~
.: ), . ~
c~ . a~ t~ y d~ Ig, tbe ~ of ~c ~lulry be~ns ~
- ~ 15 ~d~ 3~u~y contin~s oo inc~c ~1 thc sh~r scl s an~ f~m~ a wb~ntial}y dgid - blocL In ~ p~e~tly ~.~d L ~c~ of the ~n~ oo, ~c ~r of the ~x~nrlc About fou~ inutes aft~ dle slu~y ~ pou~ed into the mo~ it ~a5 12a~od :: a~l fo~d a ' ~" bl~ wh~h is ~ - - ~ ng;~ to be s~ ~om dle mold ~hc n~eeDn blocl~ i~ pushed ~ out of ~ ~Id by a pl~n ~bich ~ ;~ s part of Ihe bo~m of the mold Once this platfOEm clea~ ~e ~op c ~cJo~oro~bloclc, -~ t ~ ' -~ Asthebl~cl~114is~ y ~oqn ~}e mold, it is fur~a hyd~d 115 by spsz~ the ~olo~ with ~va~cr o~
~ bloc~ in a waO~ bath ~he po~e ne~o~ in the bloclc 11L4 abs~
s,.pplc~.~l wa~ ~nto the blocic by ca~i~ ~on Thi~ - -, r ~ t ~
f~ ' the slo~ ~g of the ~ .V1~ ad~ wat~ to co~ylt~ thc haJi~ W~r 10 t}lC ori~ k sh~r ~3 to evapo~a~c into an in ~ ;es and into tbe amb~ent aLr, can~b~ll~g wa~ f~om ~he O~t aDd P~ J
~ .
~r~
od for maoufact~ring d~c samc.
IlJ~LdJ~ ~Ich ha~ a high ~o~umc of .~ d cap~c ~ bct which has an ~e adv~ of P~ 6 a conc~e ~ocl~ tor ,c~ nll reduce ~hc weight ~ c bloc~, and ~e ~e qua~ty of ca~nt and ~and ~q~d to mal~e ths bloclc llo,~..,.., c~u-- '~ bloclcs ~ich haYe a high p~op~lion of pores and havc a ~y of bss tha~ about ~ lo lleven~y pouDd~ por c~bic foot haYc been ~~ ' bocause the bloc}s crumblc oq st~y a~ r~~ W~L ~e numb~:r o~ ~ ~hUe~ are p~ ' - ~ ~, thc smfiK~ ~sioo of ~e bu~bl~
nco~ tbe posi~on of ~ co,-., ~- ~nd ~6.~Eja~ smllll portions of c D~ i~
25 int~ice, i.~, an ~t~i~. L J ~kcktal C(l1~ ,~e i~ fom~d, orl if ~t is fo~ t is w~
One ~ol an ~ bloclc at1t~npts t~ solvc tbe ~J~vg~ g ~ m .3 ahlmLn3 ~wder p~ iD acbemic~l ~actiom wh~ ubb~ in ~hc and i~ p~ dh~idual bubbks ~rom ~ks~ to f~rm large ~l~l~
c sls~y dlcn ~s~ic~, ~pp~g the g~s t ' ' ~ 8as bll~cs ul thc ~ ~g S w~ gypsmn blocks sire ea~h of a ~a~ely uni~ v., cvcll ~ough - . - ~ . ~c co~e~ gspsum bloclcs ha~e a ~.. ~ stro~ u~ e of t~ c~ gypsum bloc~s is ~si ~eir ma ~1: ~, an.d ;" I n l~, ~ hbc~
1~ in~siYe and co~tly.
sli~ly, it would ~e ~igbly desirablc ~ p~id~ u.u~
a high ~ v~cb wou~d ~ co~at~ve~ i~s~vo m man~ct~ w~ish ~o~ re a d~q ~ ~hc ~e ~ fi~e ~ds p :r cubic foot ut f~ft~ po~ds pcr ~ub~ and ~h ~ould, sft~ being ~N.~d ~om 3 m~)l~ f~~.lih~ ~g ~f ~e bloc} b~ g wa~r o~ a large w~ce in~ide ~ ~locl~ ~ would ~Iso be ~ '- ~ p~o~idc a nrthod f~r manuf~
the h~ d hloc~
fd.~ t SS a ~pal objoct of shc ~o~od Cr ~ ~ 9Dl~ method f~r rna3cing ~hc sam~
;/;V1~C l~loc~: Yvhich ~9n~;n~ a high p~ f ~ir p~es but ~11 ~aIi be emplolrred i3 a w~ ~ sys~m having c~ls~r~e ~agt~ ~vhloh g~ly e~ceeds ~at ~ a co~vend~Dal *~d ~amc con~lio~
Anotba obj~ a~ o~ w ~o~idc a ligh~gh~ ot~
ce~t h~oclc w~b can be pr3du~ ~Icly aEId ~ low co~
The~e and otber, ~u~~ and more ~pecific ~jec~ a~d ~dvan~s of the ih-llG~ will be ~en~ tv tl~ose sl~od in th~, art ~om thc ~ull~ i..g de~ed .iescri~ptior ~ereof~ sakeD in c~j~liO~ wi~ ha~b~ iII wbich:
the U1~C~ ~ lightwdght c~ ;~s biodt of t~ ill.~ ~
~3~ ~cti~c of ~e ~c~od o~
Fig. 3 ~ a bop ~ J~ ~ of a bl~clc moldod io ~ordu~ ~Ith ;'~'!i Pig~ 4 is a bo~om ~,~ e view ~~ the ~oc~ ~ Pig. 3.
Sr~ ;arly ~11 of the bu~bles each ha~re ~ h in thc ~nge of a~out Ul~ so 114 of a2l ~h Ihe ~l-mrsr h8~ a ~ .y Afl~ T't ge~ ao ~alt the C~
0 of ~ s ~ fo~Tn lar~~ b~
., l~e ~lurry ~cl~xl~ wa~; a ceme~dJios8 bi~; a plu~li~ of ;malll air b-tt~
fo~n l~lrg~ tJ~ ~; a~ ~I ~mu~ co~o~on ~ a~gy wmc~ for ~8 t~oclc ~ dil~S ~zed p~es ~omc of which are ~bh.;,r, ~nc~ a~ cach h~ a ~ih m thc rang~ of ~x ~Jl~ to ~ of ~
i~h l~e , -n~al u~ ha8 a ~dt~ in ~e Iange o~ fi~fC poc~8 per cub~c f~t porcs ~ith a wid~ ~o greqOcr ~ of ao i~
ngidli~ hta~ tio~s~L~In~. Thc3Lu~,~'~t~co~
~d pom bà~g in~ d ~d a~ch having a ~id~h ~ ~c ran~e of abou~ 8 proccss for ~ " a ~ lg}~t c~ s~ n~...... Tbe proc~
'F--~5 t~e ste~ of n~L~i~g Soge~ a c~ ~der utd watcr u~d supplyir~g ,'"~h ~ aiJ ltO form a 51~ h~--~1 wi~ s~all ~r bubblc3 a~d han~g a ~.~ ~
-- r p~ b thc m~ema~t o~ ~e bubUes through ~ u~ing t~ ~u~ into a i ~ . - . ~
r b ~9,.
. . . ;, . ., . i, process inrl~~s thc st~ of ~g ~g~lher a suy~ dr oo for~ a ~ ' pvunng ~hc ~lm~
a mold ~ ~es up ~d f~ a ~. ~ghl ~gid s~l ~, a~ b~ ~he ~ hJrd~ ~g the ~ L ~ ~ f~ 9 ~J ~zc alr~ubbks and ~en~ y prev~t ~o '-s - ~ he i~ d ~ ur bubb~eg.
- ~ 8 fi~ t a~ the i~YC~ pro~dc ~ ~
pr~cess for p~d~l~ g a li~t.. ~ ~ n~ Thc process il~7~ 5~p8 of mixin~ toget~ ~I c~ ~s ~ and ~ g 2~ al~ to f~m; a S1S~ C~ , heatillg a ~)sd ~ a ~tJlre s.-ll~- i~ -; to b~ a~ krubbh~ ~n said s1wT~ ~r - ~ ~ m~ld to ftxm s ~noof~ 3]urry of tbe u~,u~ ide an i~ru.
pro~s for p~ i~ a l~ghtweigh~ ~s st~ ud tn~h~
25 ;.~,1~e~t~p of mL~i~,eto~e~a~--.~ bi~ ndw~lEr~d~ ~g to form a ~ r'-~A Wittl small air b~ ]es, p~ d~!e slurly i~l~ ~aid hea~ mokl, a~. ~i" ~e ~rfa~e tensioll of shc bubble~ to *~
~aalescing of t~e bu~es to fo~ i~.~l 3i~e ~ir bubbles.
.~2 proce~ it~ ~U~g a lightw~ight ~_~~al n~. l~ne p~oce~
' . , , _ tho vis~osiq Of ~aid 81~ 8~d to c ~ es ~ fo~ e d s~e air b--Sbt- . ~6 dle v~ of the slm~ ~ c~re the ~ ~ze air b~le~ g tbe ~h~Ty to ~ to form a light~eightporou~ sl~u~e l~ g .. a ~.. ~1~ of pores which d~aw l~uid illtO wd 8~,~ by c~illa~
-r~ appl~ g w~ r to the ~ och that the nctwo~ o' porcs ~al1vs wat~ ~to ~e purpose of c~ g Ihc u~e th~eof ~d not by way of ~mi~atio~ of the icope of - tke i"~c~lion, ~ ~ch lil~e ~' I ~ r~ k~ ~-Y C~.~ lg ~ ~
10 lL~ g' lu' the ;cvual ~ g. 1 is a blocJc d~am illuslrati~g t~e process far ufac~ing a ceme~ti~ous b~oclc or o~ nen8tious sl~
~ ~ u ' ~ e ~v~ the ~k s of t~e ~.. ~ ~ ~ hl Pig. l, c0~ l1~ ~nd wa~ 10l are c~ er lOO ~or a s~ort puiod, presently typic~ about threc t~ ve lS resulti~g mi~ ~s ~ d far about t~ s~or~ 7he foam lO3 s, p'~ air fa~
thc S~Ty. Poam 103 i~ ~d by blo~g o~ ~g air illtO a ~o~ning ag~t.
l'ne bubbles ~ fo~m lO3 pr~y p~erably ~Irc quit~ I ancl the ~oam has an ap~ua~e s~ to ~hat of sbavi~g <~ l~le foun b~bbles typi~y h~e a wi~th ~f less thall abo~ one ~ty-~ourth of inch l~e bu~bl~ l~tly are of slu~ry l11. Limc lO9 an bc addod to increase tke visc~ r cf dle rcsul~g slurry 1 1. S~-- r, ~.~IQ can, ~ dc~. be ~ed ~ foam 103 ~Of to ~fir ~ 3 to lOQ.
~S Walcr lOl is p~ently ~.cf~ cated to a ~ hc r~nge of aghty ~o ~. hu~ dg~ty cle~ees P. ~e foam 103 i5 ~ ~Ltl~ p-~f ~a~
hcatod to ~ e of eipty to one hund~ed ei~hty degr~e~ F. I~e mo~d 112 a~dlor rm~er 1l)0 p~ r ~ly ~e beated to a t~ e in tbe ra~ge of dgh~ to ~out ~nc h~d cigh~ dcgr~ . p~ q~ heat ca 30 sdded ~ mibccr 100 ~y blowing htated air i~to the mixer ~ by any other de~
~by those of skill ~n tbc a~t, the s~nd, foasning i r Ln n~er 100 noed not bc ~d.
Lon of ceme~t ~ saDd by w~gh~ ~D be in thc r~ge of 10:1 ~ 10~ the ratio of cen~t So i~d by welght l;rplC~
. 5 Af~r the ~ 101, 8and 1~ m 103, -- ~ 104, c~nt 1~
' '~ j,,, p~ J~ f~ly ~ff, Le., has ~ ~ty grea~r thall tbc ~ dtica~ ~sco~ty.
10 at sm~i~t ~JI~i~lUl~; ~a sca l~eZ ~the slu~r having a ~ A~C a~d a selc~d co.~3~1ion and c~ ,c which ~ bubbles i3~ ~lurry 100 c~ not . .
~ b '~t' -'ly dl ~ which ~e i~ a sele~ted w~d~h ~ ~ tke: b~bble~ can no~
mol~ thr~gh ~he sl~y. ooal~ of bubb~es i5 ;i.~ When b~bb~
5 d~ ~ nd unit~ A pa~ ~f bub~ can to~ch wiebwt c: ~ ~ ~ ~ For e~b, a ~ of I ,?~ -~nl b~;bblcs towb and cach re~ t~cir oIiginsl ~llcri~l sl~
- ~ey ha~fe not co~ J If a pair of bub~la b~mp ~nd causc ~ach ot~ to chao~eshape wi~out b~ B ~c ~r wall of ~ither bubbie, tbey haw ~t ~x~'~
If a ~ of b~bles bun~ Lr to u~h o~ 8~d a p~o~ 1'~'' D--l wall of e~h lc co~ses a~ the bubbl~s join ~ a fi~c ci~ht ~e c~fi~c t~ - ~with dlc a~iginal s~ ~all of a~h ~ pt at ~ cirallar li~e along wh~h the :~1 w~lls moct and join). tbeD ~he bub~bs hmre ~ah~ a pur - of n~ balls a~ prcssed gen~y agunst one aD~, Ihey ss~e o~ a figu~ dght type ~nfi~ ti~n As u~ed h~ein, tbC ~,c~ - y ~ cal ~ds~
2S of ~ f r.t;~ sllL~Ty at am~t ~n~ ~t sca lc~el (~e sltmy ha~g a ~le~
~mpaume a~ a sebc~ com~ on anc c~ - ) above which ~ir bc~bles can Dot m~ve through tbe S}UIly~ T~e ~cnn~ory c~itical ~q iS gread:r tha~ ~he cFi~l ~ , ie., a slu~ry with tbe ~ n~llr cr~ riscosi~ iS SdffCI
tt~ a ~lurry with the ~ cri~ viscosity. Heat 113 is ~,fc ~, but not wld 112 to heat ~he mold to a se~~a~e of ~om e~8h~
degrecs P to ~fo hund~ d ~ dcgroes ~ en mold 112 is beated, d2c hc~t iD
elle mold brca~ bubbles w~ich src in she slurry adjacent ~e inner ~ ~r . ~ of dlc a ~ iv~lJ ~oth, d~se, 'L- ' _ cutet blodc ~f~;e ,~ which ~s Pdj~ f the moltl llZ a~ h~s ~~II pa~s tht ~ ~r~ p~ e t,vpically o~ ~ r~ of a~ inch wide~ or ~nall~r. He~ ~om ,, . _ ..
. .~ mo~d 112 ha3~s ~ g of d~ ~~urry. Molds far produang bloc}s a~d odler r'-~ ,~, S C~ ue wc~ Owl~ 3111 thc ~ aIl~i ~i~l not be d~
t~c cemc~t 106 or od~ ~8~- 3~h u~ calaum cblorid~ c~n prodwe bea~
hea~, ~ G ' ' - ~0~1 with ~c hcu p~v . iJ~l by ~e hea~od ~ld 112t fuse3 ~llm~r 111 1~ 111 to a point below ~c ~ c~ri~ca! v2~00si~ so d~at an bllb~l~s in t~c s~ry 111 caIl ml3YCt 'L_ P~ d fo~l l~ge~ l)ub~ lbt alr ll)ubble8 m ~lC slulry hsvca ai~ ace t~OD. l~e hcat al50 fnnr1i~ 5 ill CO~IJ~ with sllrfac~ IX~
r ~ t of l~e ~.~ ~e bubbl~ he ~am 103 ~ill ~t ~r co~ c ~ co~csoc unless the slurIy i5 beatod So a t~
d~ ly to a qme ~ l~e ~ge of ~c~y dcgree~ to one h~d and dghl3r dc~. It is ~i~ipated. h~ .w, ~t bub~le8 in fo~m 103 co~ be cQllDrs~d without usin~ heat and ~ a a~c.r.i~l~ s~ong sucf~tant, ;~Q As u~ n, ~e su~&e ~ ion of a bubble in a cemellddous slurry a~ ent ~essure at ~ea level (th~ ~ a sdec~d t~:mperat4re, r'A ~d C~ ~ a c~tain ~i~cos~ty bd~w ~he ~ J~ is t~e ~ilit~ of thc ~ubble to ~t ;~
I~ce of ~ ar s~qnt(S~ or otl~s ch -~;r~ ill the ~Y-~ of ott~ s far caus~g a bu~;bk to col7apsc o~ el~ lcno~m, t~
are foam~ng a~ whi~:h produce bubbles whioh al~e mo~ sist~t to coll~pse a~d coqIrscin~ a~ în tbe: p~l~e of a cc~in s~ts or ~ heat, v~
ul~o; - } or o;h~ means a~ applied tt~ thc ~ us slurIy to c~se bubblc to colla~se or cc~ e wi~h atlO~lel bu~blc 00 fo~m ~ ncw larga bubbl~ ~ ~ g ~e~t can produce bubb~ m~e rcsistant to 2 p~r wrfact~nt ~8~ anotl~
f~-Ti~ agcn~ A~ a foan~i~g ag~t ~ s~ect~, os a~ ~e mcans for in~rodu~
b~bbles ~n a cemen~oL~ sl~y is ~ d7 the~ O~ tlC OI' ot C~ CA 02204933 1997-05-09 -~ _9_ width ran~ ~ bubblc~ L~ ob~ dm~n~ Ihc diesir~d ~ paiod when lhe ~t~
e cn~ surface ~ioD of ~ bubblc ~ ~ surf~cc t~~ be~ which ~ ba~
S ~rill oo~.e ~ with o~e~ lcs ~a c ~ X ~ mbialtp~ e ~ sca ror~ , and haYing a ca~in visco~ below the p~imu~ critical vi~co~) to - ~ 5 ~~ ngth) of ~me whel~ tbc Yisco~i~ O~ io~ be low d~
When slu~ 111 fi~s alld it~ WOWLt~ is ~educed bdow tbe prim~
.: ), . ~
c~ . a~ t~ y d~ Ig, tbe ~ of ~c ~lulry be~ns ~
- ~ 15 ~d~ 3~u~y contin~s oo inc~c ~1 thc sh~r scl s an~ f~m~ a wb~ntial}y dgid - blocL In ~ p~e~tly ~.~d L ~c~ of the ~n~ oo, ~c ~r of the ~x~nrlc About fou~ inutes aft~ dle slu~y ~ pou~ed into the mo~ it ~a5 12a~od :: a~l fo~d a ' ~" bl~ wh~h is ~ - - ~ ng;~ to be s~ ~om dle mold ~hc n~eeDn blocl~ i~ pushed ~ out of ~ ~Id by a pl~n ~bich ~ ;~ s part of Ihe bo~m of the mold Once this platfOEm clea~ ~e ~op c ~cJo~oro~bloclc, -~ t ~ ' -~ Asthebl~cl~114is~ y ~oqn ~}e mold, it is fur~a hyd~d 115 by spsz~ the ~olo~ with ~va~cr o~
~ bloc~ in a waO~ bath ~he po~e ne~o~ in the bloclc 11L4 abs~
s,.pplc~.~l wa~ ~nto the blocic by ca~i~ ~on Thi~ - -, r ~ t ~
f~ ' the slo~ ~g of the ~ .V1~ ad~ wat~ to co~ylt~ thc haJi~ W~r 10 t}lC ori~ k sh~r ~3 to evapo~a~c into an in ~ ;es and into tbe amb~ent aLr, can~b~ll~g wa~ f~om ~he O~t aDd P~ J
3(~ p~e~g tbc cement ~om co~le~ly h~dls~g. Ihe ~}~ i~to the bloc~c by cap~y acQon of s~F~n~ wa~ bclp~ tO C~et thC los~ of ~a~r by eva~on m~ ~ i~ bl~ck pa~w.
~ ,-.
-~_ - 10-1~K hJd~ 116 ~ cd on ~ p~lkt, ~hrinl~ wr~ or 17 with oth~ hrdralod blo~ on ~c pal~cts ~d is 2~ct out ~ ~hc ~ ~D
~e 118. T~e ~loc~ 116 can also be phc~ in a~ ove~, auloc~re, o~ od~a dcs~d . :,,~,;.~
r~ o~ (~ed or ~ot~ to be cur~ The ~ c. ~- ~'h ~ P ~ apor ~ t!~ a~
~;~ S Hea~ a~d wa;cr s;an be ~lized eo ~ thc ~peod at ~hich The g~ of ~ig. 2 illw~:s thc ~p ~.i the c~8cal ~it~ X 13 i~ e gr~h of Pig. 4 by ~ ne 121. Af~
1~ b~t ~om thc mold ~d d~ he heat con~ined ~r bdng g~d i~ ~lucr~ 111 -~ . r 1 ~ps 1~3 bc~o~ ~c ~ c;it~ X f~ ~ J) t~rty - VLsoo~ r, a~ bubbles m tlle ~Imr~ 111 coalc~o~ ~ fa~m ~Ic~ ~b8~ant~all~ ~11 of , .,, " - , . ~ ~ lS wbi~b ~ave ~ wi~th ;~ lhe ~gc ~ lJ128 ~}f Im iDch ~o about o~b~ n in~
f~ably lJ64 ~ onc qaar~ of an ~h Om7e t~e ~osLt~lr of dmry 111 i~ no long~ below linc 121, ~e bu~ D ~e ~lu~y 111 call ~o hr~r co~lcscG lhe ~iscosity Or s~u~ 111 oan not bc bebw l~e 121 ~or tl~o lo~g, oth~
- : ~ e.. ; ~y l~ge bu~les fonn i~ ~c ~lu~ 111~
- pour~ into ms~ld 112, it i~ ble tha~ ~ ~pidly sett~g ~lu~gr c~ bc ~d ~ich, wben pou~ed ~ m~d 1~2, hasa ~t~ 122 whic~ ~sl~s t~n the cn~l ~ty g ~ t~ nslnnc~ ~ho~n in hg. ~. In s~h ~ cax, it i8 1!1 adv~ble ~ ~ze a fa~r ~g agent which is mo~ ;csislant ~ s~lrfs~nts or 0~5 ~o~ty of sl~r ll 1 ~ch~ t~ ~osit3r 121. OIle ~ nt~
t~s app.~ is *~t t~e hea~ F~u~hs in Ihe slmry ten~
tcward ti~e bott~m of tl~e mvld, ~I~_~g a bloc~c ~hich i~ slrong~r at th~ bo~m 3~;) than at d~e top. When ~e sl~ 111 po~d i~to a mold is ~ a~3d pre~ the n~gra~ion ~f l~ubb2es, it also ~ to }~rcvc:nt s~md ~d o~:r c~t~ ~m bei~g pull~d toward ~e ~ of tke mold m~:r grxvi~. S~nihdy, if ~c sl}~ 111 _ .
s ~i~d by mLser lOQ is ~rly ~ff and ~ 1'7. C~ S}Wt , *, C~ ard ~ bo~m of ~ esul~g ;in a bloc~ hav ng a v~cL~ f tbe ~1~ 111 is 1~ ~ lhe ~ cn~ ~;~ aln be adJw~
, f~.r ~s ~ ~, it i8 de~cd ~ bl~e eighl minute~ (s~ aQ hour. l~ tay, e~
~stead of fo~ ~ r the bloc~c bO Sd, t~ th~ ~no~t of ~ a~ldeds ~ dmry 10 111, mi~cer 1~ ~ m~ 113 ~ bloclc 114 c~ be d~s~ to slow tbe fa~
f ~bblcs ~ to ~lo~ the ~ aod h~de~îng of ~c sh~ 111. Ibe qu~os of , ." -. ~.
- r~- J.S 0~ r ba-bbks i~s a c~ - bl~c ~ ~~ ~roc~ ~ which is m--l)f~ T6d m acr~c With thc ~le~ of the il~
nsc~si~ 123 is belos~ cal Y~i~ ubs~dally a~l of ~e re~Ll~ng larg~:r 20 pl~s~a~l)t 1164 of a~ inch ~p to t~c~Sua~ of s~ m~h The rcwl~g lar~cr bubbks dîff~t ~ of ~ ~ ~s YVi~ ~spcct ~ bQb~1es Q~ p~ i~
of ~bc aO~ bu~ie Ot pl~ volon2e in a bloc~c ~ o~Gr ~ Ol~ ~1 25 ~- or in ~e ,~y m a mo~ T~e larg~r bubblcs fafmed i~s tbe du~y ~re of ai~t~r~ y, it a~ e 1~ ~e bubWe, dlc morc lilcely it wil~
S~e a~ ~ et~v~lc Of ~ 4 ;r~l ~s D,~ ;rsl C~
ccment m d~c slu~y c~ fonn a~ i~2ercoD~ec~d ri~d netw~ f~ ad rS~ r bQb~les ~d tkrou~s the blocl~ and v~b h~, w~ the dc~it~t of' the bloclc is a~out twen~-five pounds p~ cu~ic foot. a com~S ~ ~ of a~out 2SO pSL
lI)e den2n~ e blodc o~ the ~.~ Lly ill the ~8e cf abo-~t fivc -poo4ds pcr a~ic foot oQ ~ c pound~ p~ ccbic f~ ~d~ D pOWl ~mt of oe~nt or sa~olume af waler, dlc Yolu~e o~ ai~, c~;. in ~he ;J ~ e prop~- of b~der, s~nd, w~, dc. ~ h ale i~ ~0 fQlm a ~lu~r i~ ~ x .~~ Y~ ~ desi~ dy, cen ~;ti~n~ mated81) ~ in t~e rlUlgC af 10~ tD 75~, of fiLbr (suld ~ ~tba 0 ~ular ¢~al ~na~i~l~ is in t~e rang~ of zcro ~ 5~%, of gypsum ~ otl~cr c-~c.. I71" wbich ~od~ces Jetup tis~ i~ ~ ~ t~ 10%~ of ~mc ~ anoth~
- ~ COI~lpCmGBt w~ich; ~ ~r~'~ ~ the ~iscoatlr o~ l~C dur~ u ~m zx~ lS%, of an 5 a~ent (~h~h ~ay ~w~de wa~) ~ Og6 to SO*, o~ ~ hy~pe ~uwa~ ~d ~h ~ ~on~iomc surfa~t) is ~om 0% ~ 21~*, of wat~r is ~m ~% to S09~
fib~s is ~1)% bo 20%~ 1~ fibers a~ ddsd to s~ and redu~ thc cif ~e ~ lh~ blcclc or otha c~
p~ ~ ~, ~on fibcr~ fibcr c~ any olher d h~ a h~rdrol~~d pro~dn c~r blood. ~y ~ foaming a~cQt caD b~ ueil~zoh A~ au~mplc of ~ 8mQO~ s~t L~ mclamin~
f~ekyde pol~~ Me~as~ne fuoc~ to 2S ~wunt of wat~ is ~ Ibe durry s~ up fi~ SodilL~n 2 cthy~y~
anionic surf~c~e ~hich ca~ be u~lized. l~iton X100, a oon-ionic ~c~t mau~ y U~o~ ~de, can al~o be ut~ ADj~ and non-io~
su~ts ~uoe surf~ce ta~ion and facili~t~ d~e ~~les~g of lur b~b~les into~
larg~ ~zc bub~s.
A h~h~C, f~r ~an~le a phosph~ e8t~, c~ bc ~tilizod ~1) }~ep a noll-ionic ~ in sob~on in a~alinc ~ - . b{any ~n~onic and non-ionic --~ -131-5ulfi~h 01C lcr50 '' ' ~go~i~m bcnzo~. 9~1t, or dn~ rod ~va~ ca~l lx o~lized t~
'5i~4~ ig ~ G~ g tl!~ic ~Y~ of such S B~ wsy of a~ t t~ , m o~e par~l~ ~~bod of ~c mYen~o~ a ~ Q i8 8ddo;~ Oo ~Id tll3m~ i iD mil~~ 100 aod rr~ced w~ ~hc c~ ow compo~i~on fo~ ahGut tkirty ~are ~8 ~e ~ ~,.r . the l~ 5tin~ ~m~y i~5; ~ed llltO OOC aG~ lI~C m~S~ ~ '~ -~-' - 1~ C_ -- 5~
~ 'lode~ cn~ (15 ~ b)~ 0.1~ i&8% b~ ~wight~, g~p~m (0.1 to S.O~o b~ Ql to 16% by wci~ht), ~ aDiol~ic surf~t~t ~0.1 ~ 2.0*
. ~1 b~ ~/G~'l), fibcrs fO.l Io IS~ by ~raght), aDd ~a~:r (15 co 50~ l~r *~t).
~ " . 5-: .
,'?i'',~ prlt (0.1 ~ 29E~ t)y ~ight), Im ~IOIIlC ~lll~t (O.l to 2.0~ bg ~igbt~t a phosph~ ~r (~.1 ~ 2.0~ ~y weight), 30diuDl l~te ~0.1 t~ 2.096 5~ ~~ght), . . ;
-' '' ~d ~a~ 18~ to ~% b~
By w~ of ~ ~ ,1~ ~d ~ot by ~va~ o~ lin~on, i~
a~j~ ~g5~~ ~h~ ~m ~ hy~l~l ~lood p~wda, five ~8~~~ ~ wa~
heated ~ ~ety d~j~es F, r~ ~~ on-ionic Tr~ X~ u dlei p~ of Ihc ~e i~5 ~e range ~ 7 ~ 12 50 t~ blood will ~m~ ~ 5blo~
in~o tlle f~e ~geot mixnn~ t~ p~duce a ~ r D5~i~ ~uving m~ty m~
an 1t32 of ~ i~b s~ide) s~ 5bblc~ ~he f~ -_ing &g~t i~ hca~d 2S ~ ~inety degrea F. A ~ h~&~ by ~ togetb~r ~ about fiYc lo teD
se~ds ~c hul~drod poonds of cem~nt, one h~od po~ds of ~nd, ~y ~
~f Ma~ GI1 ~o~ic ~ : - (caotaining I -'- -~ d by W. R Grace ~ C~., ~any grams of poIy~ylene fiber, ~ -cl~c ~d a ~f gallon~ of wata he~lted ~ ~iDe~ dcgrees F. l~e ~i~ ~m cr-, o ~ ed togcth~ wi~ t~e hun~d and ~cn~f de~ F. ~c mo~s a~ ~r ~ X
-eigbt~ &grees F. ~ ~&out ~our minute~, ~ ?~y b~ ~ up and formod g~
~,A~ o~3a~c Po~ t libe b~ood or h~ lJ~ in p~erably s a pH of ~n 7 ~ 14 b~ it helps d~ a~t ~onn foam ~hcn ~
~ ~IC pO1~8 a~ J . t~ ~y 4~ s~ ~g1~ the W~ Qf' :~ ~t ~ir~ly ~ widdy f~: Vl~~ a~ h to ~out V2 of 911 s~De tota~ ~olume ~f pale spaee, e~ccept nc~ ~c o~ ~:o of tbe blo~, ~i~
~ a ~wch hYver ~1~ ol' p<~e ~paoc be~o~c of the ~
lS of ~e .u.,~on it is de~r~c ~ p~doce blw~ m ~hich a lsgc majont~ of ~c As no~d, ~I surfas:t~nt ~ l~ y~f 'ly ~li~d ~D
redwe d~e su~ce te~sion o~ ~r bubbIcs in t~e d~y to Scilit~ ~e c 1~ of 20 dlc bu~les to farm la~ger bubble~ U~aRou~ Irib~ a smf ~~n~ O~y. heat As used ha~ the width of ~ bubblc LS dc~cd ~ calsu~g tht 25 ~am~er of a sphcrc ~a~ ~c ~olmne of t~ e di~ of the ~ the wid~ ~f ~he buWl~ Mo~ ~ubble~ i~ the ~od ~-,,- I-~;r~
ur ~to ~ ~y; ~ a~ ~ 8~3 ~ ~ ~ F~ o~ygen, ni~ogcr~, ~ CA 02204933 1997-05-09 _, -~or anod~ ~; ~, by ~y o~ d~d p~s. ~s u~d b~~. ~e ~rm :' ~Bloc}s pl~l~J ill ~ce with the inve~ n ha~e ~y sh~e ,~d ~ bot tbe b~ y pA,f~ ".y hav~ hollow~ P~n-lil~ d~ugh S ~e bloc~s ~uch d~ when d~ ed in r~ c on ~p of the ot~er, ver~c~lly ~ted ~eb~ c~ be ~ '~ ~ ~ough tb~ holbws lo foo~s ~d tbc hollows f~ with ~ ~ m a ~c~Ily ~d conclete ~r s . ~~s~ ~gth of d~o stacl~ed bloclQ~. E7~ser, ttle bloc}~ p~ e a t~gue c qpc c~ w ~uch ~t ~t Icsst o~e ~ongue at one a~ f a bloc~ ca~
be fi~ uld seated sn a g~~ve uq the emi of ~ jc' q~, block~ F~er ~11, Ihe grooves on the bo~om of a socond bloc~ ~d Qo Ihe fi~st bloc~ Such a lDngoe lS and groavc bloc~ ~..r~ .. dgnific~ ~ made wilh dle , . ~
O~e to~gue and groo~e ~locl~ de~ is illus~d in Pigs 3 and 4 whe~ b10cic iO tnr~ Y ~e I4 a~d grooY~ 17 w~ich confo~ d in~fit with ~0 eDd ~ilh bl~ lQ. S~ F, bloclc lO i~ s a lip 18 ~rhich is g~.,ll~ e ~;ess 19 ~<Jrmod i~q ~e bottom 23 ~ bloc3c pll~ced o~ ~p of bl~clc 10. !310c~ 10 ..-- 1~5 p~ 2; ' sides 11, 24; paralleli Ic~F..a~ - ~ 12, 13; ~nd, o~ing~ or ho~ow~ ~0 a}sd Zl c- ~ ~ .g ~ou~h bloc~ 10 frQm top to 25 bo~L ~ach hoLow 20 ~ 1 has a ~c~ngQl~ cr~ s ~ ' uea Ha~rm~ d~lil~d my ~ ch t~s as to enabk tbose sl~illed in the art to ~d ~d pra~ce it, s~d haYe d~ the pl~uil~r
~ ,-.
-~_ - 10-1~K hJd~ 116 ~ cd on ~ p~lkt, ~hrinl~ wr~ or 17 with oth~ hrdralod blo~ on ~c pal~cts ~d is 2~ct out ~ ~hc ~ ~D
~e 118. T~e ~loc~ 116 can also be phc~ in a~ ove~, auloc~re, o~ od~a dcs~d . :,,~,;.~
r~ o~ (~ed or ~ot~ to be cur~ The ~ c. ~- ~'h ~ P ~ apor ~ t!~ a~
~;~ S Hea~ a~d wa;cr s;an be ~lized eo ~ thc ~peod at ~hich The g~ of ~ig. 2 illw~:s thc ~p ~.i the c~8cal ~it~ X 13 i~ e gr~h of Pig. 4 by ~ ne 121. Af~
1~ b~t ~om thc mold ~d d~ he heat con~ined ~r bdng g~d i~ ~lucr~ 111 -~ . r 1 ~ps 1~3 bc~o~ ~c ~ c;it~ X f~ ~ J) t~rty - VLsoo~ r, a~ bubbles m tlle ~Imr~ 111 coalc~o~ ~ fa~m ~Ic~ ~b8~ant~all~ ~11 of , .,, " - , . ~ ~ lS wbi~b ~ave ~ wi~th ;~ lhe ~gc ~ lJ128 ~}f Im iDch ~o about o~b~ n in~
f~ably lJ64 ~ onc qaar~ of an ~h Om7e t~e ~osLt~lr of dmry 111 i~ no long~ below linc 121, ~e bu~ D ~e ~lu~y 111 call ~o hr~r co~lcscG lhe ~iscosity Or s~u~ 111 oan not bc bebw l~e 121 ~or tl~o lo~g, oth~
- : ~ e.. ; ~y l~ge bu~les fonn i~ ~c ~lu~ 111~
- pour~ into ms~ld 112, it i~ ble tha~ ~ ~pidly sett~g ~lu~gr c~ bc ~d ~ich, wben pou~ed ~ m~d 1~2, hasa ~t~ 122 whic~ ~sl~s t~n the cn~l ~ty g ~ t~ nslnnc~ ~ho~n in hg. ~. In s~h ~ cax, it i8 1!1 adv~ble ~ ~ze a fa~r ~g agent which is mo~ ;csislant ~ s~lrfs~nts or 0~5 ~o~ty of sl~r ll 1 ~ch~ t~ ~osit3r 121. OIle ~ nt~
t~s app.~ is *~t t~e hea~ F~u~hs in Ihe slmry ten~
tcward ti~e bott~m of tl~e mvld, ~I~_~g a bloc~c ~hich i~ slrong~r at th~ bo~m 3~;) than at d~e top. When ~e sl~ 111 po~d i~to a mold is ~ a~3d pre~ the n~gra~ion ~f l~ubb2es, it also ~ to }~rcvc:nt s~md ~d o~:r c~t~ ~m bei~g pull~d toward ~e ~ of tke mold m~:r grxvi~. S~nihdy, if ~c sl}~ 111 _ .
s ~i~d by mLser lOQ is ~rly ~ff and ~ 1'7. C~ S}Wt , *, C~ ard ~ bo~m of ~ esul~g ;in a bloc~ hav ng a v~cL~ f tbe ~1~ 111 is 1~ ~ lhe ~ cn~ ~;~ aln be adJw~
, f~.r ~s ~ ~, it i8 de~cd ~ bl~e eighl minute~ (s~ aQ hour. l~ tay, e~
~stead of fo~ ~ r the bloc~c bO Sd, t~ th~ ~no~t of ~ a~ldeds ~ dmry 10 111, mi~cer 1~ ~ m~ 113 ~ bloclc 114 c~ be d~s~ to slow tbe fa~
f ~bblcs ~ to ~lo~ the ~ aod h~de~îng of ~c sh~ 111. Ibe qu~os of , ." -. ~.
- r~- J.S 0~ r ba-bbks i~s a c~ - bl~c ~ ~~ ~roc~ ~ which is m--l)f~ T6d m acr~c With thc ~le~ of the il~
nsc~si~ 123 is belos~ cal Y~i~ ubs~dally a~l of ~e re~Ll~ng larg~:r 20 pl~s~a~l)t 1164 of a~ inch ~p to t~c~Sua~ of s~ m~h The rcwl~g lar~cr bubbks dîff~t ~ of ~ ~ ~s YVi~ ~spcct ~ bQb~1es Q~ p~ i~
of ~bc aO~ bu~ie Ot pl~ volon2e in a bloc~c ~ o~Gr ~ Ol~ ~1 25 ~- or in ~e ,~y m a mo~ T~e larg~r bubblcs fafmed i~s tbe du~y ~re of ai~t~r~ y, it a~ e 1~ ~e bubWe, dlc morc lilcely it wil~
S~e a~ ~ et~v~lc Of ~ 4 ;r~l ~s D,~ ;rsl C~
ccment m d~c slu~y c~ fonn a~ i~2ercoD~ec~d ri~d netw~ f~ ad rS~ r bQb~les ~d tkrou~s the blocl~ and v~b h~, w~ the dc~it~t of' the bloclc is a~out twen~-five pounds p~ cu~ic foot. a com~S ~ ~ of a~out 2SO pSL
lI)e den2n~ e blodc o~ the ~.~ Lly ill the ~8e cf abo-~t fivc -poo4ds pcr a~ic foot oQ ~ c pound~ p~ ccbic f~ ~d~ D pOWl ~mt of oe~nt or sa~olume af waler, dlc Yolu~e o~ ai~, c~;. in ~he ;J ~ e prop~- of b~der, s~nd, w~, dc. ~ h ale i~ ~0 fQlm a ~lu~r i~ ~ x .~~ Y~ ~ desi~ dy, cen ~;ti~n~ mated81) ~ in t~e rlUlgC af 10~ tD 75~, of fiLbr (suld ~ ~tba 0 ~ular ¢~al ~na~i~l~ is in t~e rang~ of zcro ~ 5~%, of gypsum ~ otl~cr c-~c.. I71" wbich ~od~ces Jetup tis~ i~ ~ ~ t~ 10%~ of ~mc ~ anoth~
- ~ COI~lpCmGBt w~ich; ~ ~r~'~ ~ the ~iscoatlr o~ l~C dur~ u ~m zx~ lS%, of an 5 a~ent (~h~h ~ay ~w~de wa~) ~ Og6 to SO*, o~ ~ hy~pe ~uwa~ ~d ~h ~ ~on~iomc surfa~t) is ~om 0% ~ 21~*, of wat~r is ~m ~% to S09~
fib~s is ~1)% bo 20%~ 1~ fibers a~ ddsd to s~ and redu~ thc cif ~e ~ lh~ blcclc or otha c~
p~ ~ ~, ~on fibcr~ fibcr c~ any olher d h~ a h~rdrol~~d pro~dn c~r blood. ~y ~ foaming a~cQt caD b~ ueil~zoh A~ au~mplc of ~ 8mQO~ s~t L~ mclamin~
f~ekyde pol~~ Me~as~ne fuoc~ to 2S ~wunt of wat~ is ~ Ibe durry s~ up fi~ SodilL~n 2 cthy~y~
anionic surf~c~e ~hich ca~ be u~lized. l~iton X100, a oon-ionic ~c~t mau~ y U~o~ ~de, can al~o be ut~ ADj~ and non-io~
su~ts ~uoe surf~ce ta~ion and facili~t~ d~e ~~les~g of lur b~b~les into~
larg~ ~zc bub~s.
A h~h~C, f~r ~an~le a phosph~ e8t~, c~ bc ~tilizod ~1) }~ep a noll-ionic ~ in sob~on in a~alinc ~ - . b{any ~n~onic and non-ionic --~ -131-5ulfi~h 01C lcr50 '' ' ~go~i~m bcnzo~. 9~1t, or dn~ rod ~va~ ca~l lx o~lized t~
'5i~4~ ig ~ G~ g tl!~ic ~Y~ of such S B~ wsy of a~ t t~ , m o~e par~l~ ~~bod of ~c mYen~o~ a ~ Q i8 8ddo;~ Oo ~Id tll3m~ i iD mil~~ 100 aod rr~ced w~ ~hc c~ ow compo~i~on fo~ ahGut tkirty ~are ~8 ~e ~ ~,.r . the l~ 5tin~ ~m~y i~5; ~ed llltO OOC aG~ lI~C m~S~ ~ '~ -~-' - 1~ C_ -- 5~
~ 'lode~ cn~ (15 ~ b)~ 0.1~ i&8% b~ ~wight~, g~p~m (0.1 to S.O~o b~ Ql to 16% by wci~ht), ~ aDiol~ic surf~t~t ~0.1 ~ 2.0*
. ~1 b~ ~/G~'l), fibcrs fO.l Io IS~ by ~raght), aDd ~a~:r (15 co 50~ l~r *~t).
~ " . 5-: .
,'?i'',~ prlt (0.1 ~ 29E~ t)y ~ight), Im ~IOIIlC ~lll~t (O.l to 2.0~ bg ~igbt~t a phosph~ ~r (~.1 ~ 2.0~ ~y weight), 30diuDl l~te ~0.1 t~ 2.096 5~ ~~ght), . . ;
-' '' ~d ~a~ 18~ to ~% b~
By w~ of ~ ~ ,1~ ~d ~ot by ~va~ o~ lin~on, i~
a~j~ ~g5~~ ~h~ ~m ~ hy~l~l ~lood p~wda, five ~8~~~ ~ wa~
heated ~ ~ety d~j~es F, r~ ~~ on-ionic Tr~ X~ u dlei p~ of Ihc ~e i~5 ~e range ~ 7 ~ 12 50 t~ blood will ~m~ ~ 5blo~
in~o tlle f~e ~geot mixnn~ t~ p~duce a ~ r D5~i~ ~uving m~ty m~
an 1t32 of ~ i~b s~ide) s~ 5bblc~ ~he f~ -_ing &g~t i~ hca~d 2S ~ ~inety degrea F. A ~ h~&~ by ~ togetb~r ~ about fiYc lo teD
se~ds ~c hul~drod poonds of cem~nt, one h~od po~ds of ~nd, ~y ~
~f Ma~ GI1 ~o~ic ~ : - (caotaining I -'- -~ d by W. R Grace ~ C~., ~any grams of poIy~ylene fiber, ~ -cl~c ~d a ~f gallon~ of wata he~lted ~ ~iDe~ dcgrees F. l~e ~i~ ~m cr-, o ~ ed togcth~ wi~ t~e hun~d and ~cn~f de~ F. ~c mo~s a~ ~r ~ X
-eigbt~ &grees F. ~ ~&out ~our minute~, ~ ?~y b~ ~ up and formod g~
~,A~ o~3a~c Po~ t libe b~ood or h~ lJ~ in p~erably s a pH of ~n 7 ~ 14 b~ it helps d~ a~t ~onn foam ~hcn ~
~ ~IC pO1~8 a~ J . t~ ~y 4~ s~ ~g1~ the W~ Qf' :~ ~t ~ir~ly ~ widdy f~: Vl~~ a~ h to ~out V2 of 911 s~De tota~ ~olume ~f pale spaee, e~ccept nc~ ~c o~ ~:o of tbe blo~, ~i~
~ a ~wch hYver ~1~ ol' p<~e ~paoc be~o~c of the ~
lS of ~e .u.,~on it is de~r~c ~ p~doce blw~ m ~hich a lsgc majont~ of ~c As no~d, ~I surfas:t~nt ~ l~ y~f 'ly ~li~d ~D
redwe d~e su~ce te~sion o~ ~r bubbIcs in t~e d~y to Scilit~ ~e c 1~ of 20 dlc bu~les to farm la~ger bubble~ U~aRou~ Irib~ a smf ~~n~ O~y. heat As used ha~ the width of ~ bubblc LS dc~cd ~ calsu~g tht 25 ~am~er of a sphcrc ~a~ ~c ~olmne of t~ e di~ of the ~ the wid~ ~f ~he buWl~ Mo~ ~ubble~ i~ the ~od ~-,,- I-~;r~
ur ~to ~ ~y; ~ a~ ~ 8~3 ~ ~ ~ F~ o~ygen, ni~ogcr~, ~ CA 02204933 1997-05-09 _, -~or anod~ ~; ~, by ~y o~ d~d p~s. ~s u~d b~~. ~e ~rm :' ~Bloc}s pl~l~J ill ~ce with the inve~ n ha~e ~y sh~e ,~d ~ bot tbe b~ y pA,f~ ".y hav~ hollow~ P~n-lil~ d~ugh S ~e bloc~s ~uch d~ when d~ ed in r~ c on ~p of the ot~er, ver~c~lly ~ted ~eb~ c~ be ~ '~ ~ ~ough tb~ holbws lo foo~s ~d tbc hollows f~ with ~ ~ m a ~c~Ily ~d conclete ~r s . ~~s~ ~gth of d~o stacl~ed bloclQ~. E7~ser, ttle bloc}~ p~ e a t~gue c qpc c~ w ~uch ~t ~t Icsst o~e ~ongue at one a~ f a bloc~ ca~
be fi~ uld seated sn a g~~ve uq the emi of ~ jc' q~, block~ F~er ~11, Ihe grooves on the bo~om of a socond bloc~ ~d Qo Ihe fi~st bloc~ Such a lDngoe lS and groavc bloc~ ~..r~ .. dgnific~ ~ made wilh dle , . ~
O~e to~gue and groo~e ~locl~ de~ is illus~d in Pigs 3 and 4 whe~ b10cic iO tnr~ Y ~e I4 a~d grooY~ 17 w~ich confo~ d in~fit with ~0 eDd ~ilh bl~ lQ. S~ F, bloclc lO i~ s a lip 18 ~rhich is g~.,ll~ e ~;ess 19 ~<Jrmod i~q ~e bottom 23 ~ bloc3c pll~ced o~ ~p of bl~clc 10. !310c~ 10 ..-- 1~5 p~ 2; ' sides 11, 24; paralleli Ic~F..a~ - ~ 12, 13; ~nd, o~ing~ or ho~ow~ ~0 a}sd Zl c- ~ ~ .g ~ou~h bloc~ 10 frQm top to 25 bo~L ~ach hoLow 20 ~ 1 has a ~c~ngQl~ cr~ s ~ ' uea Ha~rm~ d~lil~d my ~ ch t~s as to enabk tbose sl~illed in the art to ~d ~d pra~ce it, s~d haYe d~ the pl~uil~r
Claims (10)
1. A viscous moldable cementitious slurry for forming a cementitious structural member, said slurry including (a) water (b) a cementitious binder; and, (c) a plurality of bubbles, substantially all of said bubbles each having a width in the range of about 1/128 to 1/4 of an inch;
said slurry having a viscosity sufficient generally to prevent the coalescing of said bubbles to form larger bubbles.
said slurry having a viscosity sufficient generally to prevent the coalescing of said bubbles to form larger bubbles.
2. A viscous moldable cementitious slurry for forming a cementitious structuralmember, said slurry including (a) water;
(b) a cementitious binder;
(c) a plurality of small air bubbles, said slurry having a viscosity sufficient generally to prevent the coalescing of said bubbles to form larger bubbles; and, (d) means for reducing surface tension to facilitate the coalescing of said bubbles to form larger bubbles when the viscosity of said slurry is reduced to a selected level.
(b) a cementitious binder;
(c) a plurality of small air bubbles, said slurry having a viscosity sufficient generally to prevent the coalescing of said bubbles to form larger bubbles; and, (d) means for reducing surface tension to facilitate the coalescing of said bubbles to form larger bubbles when the viscosity of said slurry is reduced to a selected level.
3. A rigid lightweight cementitious structural member comprising (a) a rigid cementitious structure; and, (b) a network of different sized pores in said structure some of which are interconnected and each having a width in the range of about 1/128 to 1/4 of an inch;
said structural member having a density in the range of five pounds per cubic foot to fifty pounds per cubic foot.
said structural member having a density in the range of five pounds per cubic foot to fifty pounds per cubic foot.
4. The cementitious structural member of Claim 3 including a smooth surface with small pores each having a width no greater than about 1/32 of an inch.
5. A rigid lightweight cementitious structural member comprising (a) a rigid cementitious structure;
(b) a network of pores in said structure some of which are interconnected and each having a width in the range of about 1/128 to 1/4 inch and sharped and dimensioned to draw water into the structure by capillary action; and, (c) water in said pores.
(b) a network of pores in said structure some of which are interconnected and each having a width in the range of about 1/128 to 1/4 inch and sharped and dimensioned to draw water into the structure by capillary action; and, (c) water in said pores.
6. A process for producing a lightweight cementitious structural member, comprising the steps of (a) mixing together a cementitious binder and water and supplying air to form a slurry entrained with small air bubbles and having a viscosity which generally prevents the movement of said bubbles through said slurry;
(b) pouring said slurry into a mold to set up and form a lightweight rigid structural member, and, before said slurry hardens.
(i) decreasing the viscosity of said slurry to permit said bubbles to coalesce to form increased size air bubbles, and (ii) increasing the viscosity of said slurry to capture said increased size air bubbles and generally prevent coalescing of said increased size air bubbles.
(b) pouring said slurry into a mold to set up and form a lightweight rigid structural member, and, before said slurry hardens.
(i) decreasing the viscosity of said slurry to permit said bubbles to coalesce to form increased size air bubbles, and (ii) increasing the viscosity of said slurry to capture said increased size air bubbles and generally prevent coalescing of said increased size air bubbles.
7. A process for producing a lightweight cementitious structural member, comprising the steps of (a) mixing together a cementitious binder and water and supplying air to form a slurry entrained with small air bubbles;
(b) pouring said slurry into a mold to set up and form a lightweight rigid structural member, and, before said slurry hardens, (i) permitting said bubbles to coalesce to form increased size air bubbles, and (ii) increasing the viscosity of said slurry to capture said increased size air bubbles and generally prevent coalescing of said increased size air bubbles.
(b) pouring said slurry into a mold to set up and form a lightweight rigid structural member, and, before said slurry hardens, (i) permitting said bubbles to coalesce to form increased size air bubbles, and (ii) increasing the viscosity of said slurry to capture said increased size air bubbles and generally prevent coalescing of said increased size air bubbles.
8. A process for producing a lightweight cementitious structural member, comprising the steps of (a) mixing together a cementitious binder and water and supplying air to form a slurry entrained with small air bubbles;
(b) heating a mold to a temperature sufficient to break air bubbles in said slurry adjacent said mold to form a smooth slurry surface; and, (c) pouring said slurry into said heated mold.
(b) heating a mold to a temperature sufficient to break air bubbles in said slurry adjacent said mold to form a smooth slurry surface; and, (c) pouring said slurry into said heated mold.
9. A process for producing a lightweight cementitious structural member, comprising the steps of (a) mixing together a cementitious binder and water and supplying air to form a slurry entrained with small air bubbles;
(b) pouring said slurry into said heated mold; and, (c) decreasing the surface tension of said bubbles to facilitate the coalescing of said bubbles to form increased size air bubbles.
(b) pouring said slurry into said heated mold; and, (c) decreasing the surface tension of said bubbles to facilitate the coalescing of said bubbles to form increased size air bubbles.
10. A process for producing a lightweight cementitious structural member, comprising the steps of (a) mixing together a cementitious binder and water and supplying air to form a slurry entrained with small air bubbles;
(b) fusing said slurry to (i) decrease the viscosity of said slurry, (ii) coalesce said air bubbles to form increased size air bubbles;
(c) increasing the viscosity of said slurry to capture said increased size air bubbles;
(d) permitting said slurry to set to form a lightweight porous structure including a network of pores which draw liquid into said structure by capillary action; and, (e) applying water to said structure such that said network of pores draws water into said structure by capillary action.
(b) fusing said slurry to (i) decrease the viscosity of said slurry, (ii) coalesce said air bubbles to form increased size air bubbles;
(c) increasing the viscosity of said slurry to capture said increased size air bubbles;
(d) permitting said slurry to set to form a lightweight porous structure including a network of pores which draw liquid into said structure by capillary action; and, (e) applying water to said structure such that said network of pores draws water into said structure by capillary action.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US08/641,524 US5775047A (en) | 1996-05-10 | 1996-05-10 | Method and apparatus for producing lightweight concrete structure |
| US08/641,524 | 1996-05-10 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2204933A1 true CA2204933A1 (en) | 1997-11-10 |
Family
ID=24572748
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002204933A Abandoned CA2204933A1 (en) | 1996-05-10 | 1997-05-09 | Method and apparatus producing lightweight concrete structure |
Country Status (2)
| Country | Link |
|---|---|
| US (1) | US5775047A (en) |
| CA (1) | CA2204933A1 (en) |
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| US6467229B2 (en) * | 1998-12-24 | 2002-10-22 | Tony J. Azar | Mortarless brick |
| US6302675B1 (en) * | 1999-03-24 | 2001-10-16 | Foxfire, Llc | Pressed earth block machine |
| WO2001019579A1 (en) * | 1999-09-15 | 2001-03-22 | Air Crete Block, Inc. | Method and apparatus for forming lightweight concrete block |
| US6676862B2 (en) | 1999-09-15 | 2004-01-13 | Advanced Building Systems, Inc. | Method for forming lightweight concrete block |
| AUPQ285499A0 (en) * | 1999-09-15 | 1999-10-07 | Henderik Corporaal | Building block or panel |
| US6416260B1 (en) * | 2000-05-18 | 2002-07-09 | Permawall Systems, Inc. | Self-connecting, reinforced retaining wall and masonry units therefor |
| US6530772B1 (en) * | 2000-06-30 | 2003-03-11 | Consolidated Minerals, Inc. | System for making aerated concrete blocks having at least one passageway drilled therein |
| US6533970B1 (en) * | 2000-06-30 | 2003-03-18 | Consolidated Minerals, Inc. | Method for making aerated concrete blocks having at least one passageway drilled therein |
| AU2004205065B2 (en) * | 2003-01-15 | 2009-05-14 | Commonwealth Scientific And Industrial Research Organisation | Cementitious products |
| AU2003900156A0 (en) * | 2003-01-15 | 2003-01-30 | Commonwealth Scientific And Industrial Research Organisation | Cementitious products |
| US7461490B2 (en) * | 2003-01-23 | 2008-12-09 | Omar Toledo | Construction block system |
| ES2221811B1 (en) * | 2003-06-27 | 2005-12-16 | Apc Europe S.A. | CONSTRUCTION AND PROCEDURE PLASTER AND CORRESPONDING USES. |
| KR100505836B1 (en) * | 2003-08-28 | 2005-08-02 | 주식회사 제이지비 | Architectural brick |
| US20080028988A1 (en) * | 2006-02-21 | 2008-02-07 | Welker Charles D | Method and apparatus for making air-entrained or cellular high-strengthconcrete |
| US8408781B2 (en) | 2006-02-21 | 2013-04-02 | Charles D. Welker | System, method and apparatus for entraining air in concrete |
| JP2009536276A (en) * | 2006-05-10 | 2009-10-08 | ベネックス テクノロジーズ プロプライエタリー リミテッド | Improvements on concrete masonry hollow blocks |
| WO2008089250A2 (en) * | 2007-01-17 | 2008-07-24 | Carpentercrete, Llc | Lightweight cementitious material and method of making |
| ITUD20070130A1 (en) * | 2007-07-23 | 2009-01-24 | C M E Spa Sa | MACHINE AND PROCEDURE FOR THE PRODUCTION OF STRUCTURAL ELEMENTS FOR BUILDING IN CEMENTITIAL MATERIALS WITH ONE OR MORE INSERTS IN POLYMERIC MATERIAL |
| GB2466653B (en) * | 2008-12-31 | 2013-08-07 | Genesis Global Ltd | Use of a Blood Hydrolysate as a Cement Material |
| US20120222586A1 (en) * | 2009-10-27 | 2012-09-06 | Asahi Kasei Construction Materials Corporation | Humidity-controlling building material and method for producing same |
| US8443563B2 (en) * | 2010-04-09 | 2013-05-21 | Malcolm Schmidt | Building block having the appearance of wood shake |
| US20120041087A1 (en) | 2010-08-12 | 2012-02-16 | Evgeniy Nikolaevich Yastremskiy | Dry mixture for manufacturing cellular fibro concrete and method thereof |
| US10941567B2 (en) * | 2014-05-28 | 2021-03-09 | E. Dillon & Company | Wall construction system |
| PT2952248T (en) * | 2014-06-05 | 2019-10-25 | Saint Gobain Placo Sas | Apparatus and method for the production of foam |
| FR3075234B1 (en) * | 2017-12-20 | 2020-01-17 | Haidar Ben Raffion | BUILDING BLOCK |
| US11408173B2 (en) * | 2019-11-22 | 2022-08-09 | Lazarian World Homes | Foam as modular support |
| US11686063B2 (en) * | 2019-12-12 | 2023-06-27 | Robert Daggett | Interlocking blocking system for retaining walls and other uses |
Family Cites Families (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US786884A (en) * | 1904-05-28 | 1905-05-11 | Robert P Faulkner | Building-block. |
| US800385A (en) * | 1905-03-02 | 1905-09-26 | John Henry Miller | Building-block. |
| US4069809A (en) * | 1976-07-19 | 1978-01-24 | Strand Lyle L | Solar heat collecting porous building blocks |
| US5024035A (en) * | 1979-10-18 | 1991-06-18 | Insulock Corporation | Building block and structures formed therefrom |
| US4587279A (en) * | 1984-08-31 | 1986-05-06 | University Of Dayton | Cementitious building material incorporating end-capped polyethylene glycol as a phase change material |
| US5457926A (en) * | 1993-11-03 | 1995-10-17 | Templeton Trust | Interlocking block |
-
1996
- 1996-05-10 US US08/641,524 patent/US5775047A/en not_active Expired - Fee Related
-
1997
- 1997-05-09 CA CA002204933A patent/CA2204933A1/en not_active Abandoned
Also Published As
| Publication number | Publication date |
|---|---|
| US5775047A (en) | 1998-07-07 |
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| Date | Code | Title | Description |
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| FZDE | Discontinued |