Plastic and nonmetallic article shaping or treating: processes – Reactive gas or vapor treatment of work
Patent
1986-09-08
1988-11-22
Silbaugh, Jan H.
Plastic and nonmetallic article shaping or treating: processes
Reactive gas or vapor treatment of work
106 93, 264 6, 264 77, 264115, 264118, 264140, 264157, 264333, C04B 4002
Patent
active
047864508
DESCRIPTION:
BRIEF SUMMARY
BACKGROUND OF THE INVENTION
The invention relates to a method for the production of building elements which are particularly suited for use as brick facings.
It is well known to make brick facings from tiles and lime sand bricks. However, tile elements are difficult to produce as their production includes shaping of the units and subsequent baking. In addition to this, the shaped units may become considerably deformed during baking. Finally, the production of brick facings from tile elements presents considerable drawbacks with respect to obtaining specific and reproducible colours as the colour development to a large extent is determined by the composition of the clay used in the production. Likewise, the production of lime-sand brick facings, which requires the use of pressure vessels, is difficult and time consuming.
The object of the invention is to provide a quick method for the production of building elements of a uniform shape and reproducible appearance, and particularly building elements for use as brick facings.
SUMMARY OF THE INVENTION
This object is obtained by the method of the invention, wherein a mixture of 40-60% by weight of cement, 60-40% by weight of aggregate, 0.5-2% by weight of thickening agent, and optionally a colouring agent or one or more additives and water in an amount of 8-17% by weight based on the dry matter of the mixture is granulated, the granules are pressed under a pressure of 50-100 kg/cm.sup.2 and at temperature over 100.degree. C. to form a single element or a string which is subsequently cut into single elements, and the element or elements is (are) stored in a humid atmosphere until a considerable setting of the cement has taken place.
Previous attempts to accelerate the production of cement building elements by pressing in moulds have faced the problem that the pressed units only can be removed from the moulds with great difficulties.
According to the invention it has surprisingly been found that by using the pressure and temperature conditions mentioned above, combined with the use of a thickening agent, a steam film is formed on the surface of the pressed unit, and this steam film acts as a release agent which makes it possible to release the element from the mould.
It has been found that the building elements made according to the invention exhibits a sufficiently large stability with respect to shape and are sufficiently weather resisting to be used as brick facings on outer walls. By proper choice of colouring agent it has proved possible to obtain elements of strongly varying colours and including colours similar to those of conventional red and yellow bricks.
The building elements may not only be produced in the form of planar units but also as angular elements for use on wall corners.
The production of granules is preferably effected by mixing the solid components, i.e., cement, aggregate (preferably in the form of sand) and a thickening agent such as carboxymethylcellulose, a separating agent such as zinc stearate, and optionally a solid colouring agent. The solid mixture thus obtained is then added to the apportioned amount of water in the vessel of a mixing apparatus, and it is mixed until a viscous mass is obtained. The viscous mass thus obtained is allowed to stand for preferably about 1/2 hr. or more. However, this period may be reduced considerably by using a moistening agent in the mixture of cement, aggregate and water. The granulation of the viscous mass is preferably effected by means of one or more horizontally placed metal nets with a mesh size ranging from 0.5 to 2 cm and by rotating impellers moving in parallel direction with the nets and at a short distance above their top surface.
When using moulds for hot pressing of the granules, the mould parts used preferably have a surface temperature of 120.degree.-160.degree. C. Temperatures above about 160.degree. C. should normally be avoided as there is a tendency at such temperature for the material to burn to the mould parts.
The pressure used is, as mentioned, 50-100 kg/cm.sup.2, and prefer
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Kutach Karen D.
L. P. Weidemann & Sonner I/S
Silbaugh Jan H.
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