FR3034117B1 - QUICK BUILDING MODULE WITH EXPANDED PERLITE CONCRETE - Google Patents

Abstract

The invention relates to a concrete-based construction module (A) having front (1) and rear (2) faces separated by a thickness forming the upper (3) and lower (4) faces of said module (A), front (1) and rear (2) faces being interconnected by side edges (5, 6) intended to be substantially vertical, the upper (3) and lower (4) faces being intended to be substantially horizontal in the mounted position of the modulus (A) in an assembly, characterized in that the modulus is made of expanded perlite concrete and that the upper (3) and lower (4) faces have shapes (3a, 3b; 4a, 4b) at different levels of height. Application in the field of construction.

Description

"Rapid building module based on expanded perlite concrete"

The present invention generally relates to a rapid construction module based on expanded perlite concrete concrete and an assembly consisting of at least two such superposed or adjacent modules, and its manufacturing process.

More particularly, the present invention relates to a rapid construction module based on expanded perlite concrete. Advantageously, such a module may comprise one or more additional materials, for example a plant material, in particular hemp, which is not limiting, as well as cement and lime.

Concrete modules of expanded perlite are thus obtained with dimensions favoring by handling. On the other hand these modules have shapes that help to secure the module with adjacent modules in a construction.

WO-A1-2005 / 035898 discloses a large-format block for supporting or permanent formwork to fill the cavities of masonry walls with carrier binder, these elements being structural elements and insulation. In this document, it is used a system comprising two breeze blocks comprising cells. This system comprises a standard block and an end block having tenon and mortise shapes for their attachment to the vertical sides of the blocks in mounted position in the construction.

This document does not cite expanded perlite concrete as a component of a cinder block. The breeze block is specified to be baked clay and the filling material of its cells is specified to be wet clay.

In addition, this document provides to make the block easier to handle to reduce the weight of the block by providing cells in its interior, which lighten its weight, these cells being filled after installation of the block in the construction. The presence of the cells increases the difficulty of manufacturing the block and its manufacturing cost.

The object of the present invention is to obtain a module based on expanded perlite concrete that is easily manipulated and can be secured even temporarily in a rapid manner with adjacent modules lying as well below or below as well as laterally at module. For this purpose, the present invention relates to a concrete-based building module having front and rear faces separated by a thickness forming the upper and lower faces of said module, the front and rear faces being interconnected by lateral edges intended for be substantially vertical, the upper and lower faces being intended to be substantially horizontal in the mounted position of the module in an assembly, characterized in that the module is expanded perlite concrete and the upper and lower faces have shapes at different levels height.

Advantageously, the shapes at different levels of height are portions respectively projecting and recessed from the upper and lower faces, the projecting parts having a section equal to the recessed parts.

Advantageously, the projecting and recessed portions of the upper face are arranged inverted with respect to the projecting or recessed portions of the lower face.

Advantageously, the section of the projecting and recessed parts is square, the protruding and recessed parts occupying the entire upper or lower face associated.

Advantageously, the module is intended to be an angle module in an assembly, the module having a recess passing through its upper face to its lower face.

Advantageously, the module is substantially rectangular parallelepiped with a height and a length of 50cm, a width of 25cm, the shapes at the outermost height levels of the module exceeding 5cm of the module.

Advantageously, the module comprises at least 75% by weight of expanded perlite.

Advantageously, the module comprises 76% expanded perlite, 9% cement, a setting accelerator, a liquid water repellent, gypsum and 13% water. The invention also relates to an assembly of modules, characterized in that it comprises at least two such modules being adjacent laterally or arranged one below the other.

Advantageously, the assembly comprises at least two series of superposed modules with offset of the modules of the superimposed series relative to the other series.

Advantageously, the assembly comprises two walls forming an angle between them formed by the superposition of angle modules, the corner module superimposed on another corner module being disposed perpendicularly to said other corner module.

Advantageously, when the module intended to be an angle module in the assembly has a recess passing through its upper face to its lower face, the recesses of the superposed corner modules are aligned and receive a vertical pole. The invention will now be described in more detail but in a nonlimiting manner with reference to the appended figure, in which: FIG. 1 is a schematic side perspective view of a first embodiment of a module according to FIG. FIG. 2 is a schematic side perspective view of a second embodiment of a module according to the present invention, such module serving as an angle module in an assembly; FIG. schematic representation of a perspective view of an assembly of modules according to the first and second embodiments according to the present invention, the modules according to the second mode serving as angle modules in the assembly.

In what will be described, the word module is to be taken in its broad sense for any element of finished or unfinished construction. For example, the module may be a component of a wall pan or an isolated element.

Such a module, which does not necessarily have a rectangular shape, can be prefabricated before mounting in an assembly or manufactured directly on its place of installation and this not necessarily in the form of a module of rectangular size. The manufacture can be carried out by pouring, spraying, adhering or molding a concrete based on expanded perlite on at least one internal drum, which will be detailed later.

Figures 1 and 2 shows two embodiments of a module A or A 'according to the present invention. The building module A or A 'is based on an expanded perlite concrete which may also contain one or more additional materials, for example an agglomerated plant material, a cement as well as building lime.

As plant material, it may be mentioned, without limitation, hemp, flax fiber, chips or sawdust or a mixture of these elements, this plant material being shaped by the addition of resin, glue or other binders, especially cemented binders. Hemp is advantageously deligned to be made more homogeneous.

In what follows, the upper edge and lower edge are respectively the edges of the module A or A 'being substantially horizontally when the module A or A is mounted in an assembly of at least two modules. The lateral edges of the module A or A 'are its edges being substantially vertical when the module A or A' is mounted in the assembly of at least two modules.

With reference to FIGS. 1 and 2, the module A or A 'has front and rear faces 2 of substantially rectangular or square configuration, these front 1 and rear 2 faces being separated by a thickness, respectively forming its upper face 3 and its lower face 4 respectively at the top and bottom of said module A or A '.

The front 1 and rear 2 faces are interconnected by side edges 5 and 6 intended to be substantially vertical while the upper 3 and lower 4 faces are intended to be substantially horizontal in the mounted position of the module A or A 'in an assembly this assembly may comprise at least two modules.

According to the present invention, the module A or A 'has on its upper face 3 and lower 4 forms, respectively 3a, 3b for the upper face 3 and 4a, 4b for the lower face 4, one of which 3b, 4b to minus protrudes outwards from the module A or A ', respectively pointing upwards for the upper face 3 and the bottom for the lower face 4 in order to at least temporarily secure such a module A or A' with at least one module lying superimposed or below said module A or A '. These forms 3a, 3b; 4a, 4b are thus forms 3a, 3b; 4a, 4b at different levels of height.

Advantageously for a module A or A 'being in the form of an intermediate module in an assembly, the shapes make it possible to secure the module A or A' with the module which is superior to it and the module which is below it.

In the preferred embodiment of the present invention, the shapes 3b and 4b are in the form of protrusions of rectangular or square section of the module A or A 'extending from a portion of the front face 1 of the module A towards the rear face of the module A or A ', these projections 3b and 4b being extended respectively over the entire surface of the upper and lower faces 3 by recessed parts 3a and 4a.

The forms 3a, 3b; 4a, 4b respectively projecting and withdrawing from the upper 3 and lower 4 faces are therefore at different levels of height. The forms 3a, 3b; 4a, 4b can advantageously cover respectively the whole of the upper face 3 and the lower face 4.

Advantageously the section of the projections 3b and 4b is equivalent to the section of the recessed parts 3a and 4a in order to have a symmetry between these parts 3a, 3b; 4a, 4b. The protruding portions 3b and recessed portions 3a of the upper face 3 are thus arranged inverted with respect to the protruding portions 4b and recessed 4a of the upper face 4.

Thus, the upper face 3 of a module A or A 'has two portions of equal section 3a, 3b, one of which 3b is projecting from the module A or A' while being raised relative to the other recessed portion 3a. . The lower face 4 of a module A or A 'has two portions of equal section 4a, 4b, one of which 3b is projecting from the module A being lower than the other recessed portion 3a. The portions of equal section 3a, 3b are advantageously square in section occupying the entire upper face 3 or lower 4 associated.

The upper 3 and lower 4 faces are therefore in stages by respectively presenting a stage 3a, 4a the innermost module A or A 'formed by the recessed parts and a stage 3b, 4b the outermost module A or A' formed by projecting parts.

When stacking two block modules, as can be seen in FIG. 3, the intermediate modules A which are not at the bottom or at the top of the assembly M nor at an angle of this assembly, only one of these modules being referenced in this figure, support two upper modules A1, A2, is supported by two lower modules A4, A3 and are adjacent to a module A5, A6 on each of their lateral sides.

The series of the modules are thus shifted compared to the series of modules which are higher or lower.

Referring to Figures 1 and 3, Figure 1 referencing the projecting portions 3b, 4b and the recessed portions 3a, 4b of the upper 3 and lower 4 faces, it is the upper projecting portion 3b of the module A which penetrates in the lower recess portion 4a of the module A1 which is partially superimposed, while the upper recessed portion 3a of the module A receives the lower projecting portion 4b of the other module A2 which is partially superimposed on the module A.

Similarly module A is supported by two lower modules A3 and A4. It is the lower projecting part 4b of the module A which enters the upper recessed part 4a of the module A3 which supports it, while the lower recessed portion 4a of the module A receives the upper projecting portion 3b of the other A4 module that supports it.

FIG. 2 shows an angle module A 'intended to be an angle module in the assembly referenced M in FIG. 3.

This angle module A 'has all the characteristics of an intermediate module referenced A in FIG. 1 except that the angle module A' is traversed by a vertical recess 7 from its upper face 3 to its lower face A . Advantageously but not necessarily, the vertical recess 7 passes through the angle module A 'by entering through the projecting portion 3b of the upper face 3 and out through the recessed portion 4a of the lower face 4 of the corner module AT'. In Figure 2, the vertical recess 7 is shown circular. This is not necessarily the case, the recess being square or rectangular. The assembly M may comprise two walls M1, M2 forming an angle between them formed by the superposition of angle modules A ', A6, the angle module A' superimposed on another angle module A6 being arranged perpendicularly to said other angle module A6.

As can be seen in FIG. 3 while also referring to FIG. 2, the angle modules A 'are superimposed by being placed perpendicularly to one another for two angle modules A' that overlap each other. vertical recesses 7 of the angle modules A 'thus superimposed being aligned. The arrangement between projecting and recessed parts for superposed corner modules A 'remains the same as for that of the intermediate modules A. In FIG. 3, the module A6 serves as an angle module and supports an angle module A 'placed perpendicularly, the projecting part of the module A6 penetrating into the recessed part of the module A' and vice versa for a module placed below module A6 and supporting it.

The purpose of the recesses 7 of the angle modules A ', A6 aligned with each other is to receive a column contributing to the stability of the assembly M makes at least two walls M1 and M2 perpendicular to each other. other.

Advantageously, on the front face 1 or the rear face 2 of the module A or A ', it can be provided at least one groove, not referenced in the figures for the passage of a water pipe and / or sheathed electrical son.

For order of idea and without this being limiting, so that the module A or A 'is easily manipulated, it is substantially a rectangular parallelepiped, preferably square, with dimensions of 50 cm in height without counting that of the part protruding, 50 cm in length and 25 cm thick. The protruding parts 3b, 4b, therefore at the outermost height level to the module A or A 'and the recessed portions 3a, 4a are offset in height by 5 cm so a total height of the module A or A' of 55 cm. The diameter of the recess 7 of an angle module A 'may be 15 to 20 cm. Such a module can weigh about 25 Kg.

On the other hand, a module according to the present invention may have other dimensions. For example, the height of a module can be 40cm where 45cm with the projecting part, the other dimensions remaining unchanged. The weight of the module then goes to 22 Kg and the quantity per pallet goes from 24 to 30 pieces. As an indication and not limitation, such a module A is made from a mixture of crushed and expanded volcanic rocks, mainly expanded perlite. A plant, for example but not only deli-edged agricultural hemp, can also be added as well as a lime-based binder.

Optionally, it may be possible to add tile or brick waste. Finally additives are added to the mixture, adjuvants which are frequently setting accelerators and air drainers.

The module therefore comprises expanded perlite, advantageously more than 75% by weight of expanded perlite, preferably with a particle size of 0.40 / 0.60. It may also contain a plant material, for example deli hemp and various binders such as hydraulic lime, one or more cements, gypsum or calcium sulphate, a hydrophobe, water and a setting accelerator, of the type calcium nitrate. The module may also be based on powdery perlite, advantageously with a particle size of 0.02 / 0.05.

In a nonlimiting and purely illustrative manner, the composition of such a module may be by weight of:

Perlite: 76%

Cement: 9%

Take Accelerator: 0.2%

Liquid water repellent: 0.1%

Gypsum: 1.3%

Water: 13% a percentage of hemp that can be included in the composition.

Such a module is advantageously obtained by a molding process on wire mesh bases allowing the evacuation of excess water and vertical side cheeks interlocked between them by a conventional locking system. The cheeks retain the material that is poured in and, once the grip is done, the cheeks are removed and the module thus manufactured enters its drying cycle. Then, the module being dry it is proceeded if necessary pre-cut the different networks on the modules.

Such modules are intended for the manufacture of an assembly forming plates or walls that can be used in the building for new constructions or for renovation and insulation. This is valid for housing construction as for industry, for example in public works for the construction of a noise barrier. The resulting module and assembly compete with concrete-based agglomerates or agglomerates frequently used in construction.

Such a module according to the invention is non-flammable, hydrophobic, isophonic hydric and resistant to compression. An appreciable advantage of such a module is that it can be isothermal.

Such modules according to the invention can be transported on a pallet by layer of 4 pieces on 6 high which is 24 pieces, the pallet then supporting 600 kg. This makes them more advantageous and more portable than the agglos on the market. The assembly of such modules according to the invention does not require a change in the habits of masons and they are much more profitable and more isothermal compared to agglos present on the market. The invention is in no way limited to the described and illustrated embodiments which have been given by way of example only.

Claims (12)

1. Module (A, A ', A1 to A6) of concrete-based construction having front (1) and rear (2) faces separated by a thickness forming the upper (3) and lower (4) faces of said module ( A, A ', A1 to A6), the front (1) and rear (2) faces being interconnected by lateral edges (5, 6) intended to be substantially vertical, the upper (3) and lower (4) faces (4). ) being intended to be substantially horizontal in the mounted position of the module (A, A ', A1 to A6) in an assembly (M), characterized in that the module (A, A', A1 to A6) is of perlite concrete expanded and that the upper (3) and lower (4) faces have shapes (3a, 3b; 4a, 4b) at different levels of height. 2. Module (A, A ', A1 to A6) of construction according to the preceding claim, wherein the shapes (3a, 3b, 4a, 4b) at different levels of height are respectively protruding portions and recessed faces upper and lower parts, the projections (3b, 4b) having a cross section equal to the recesses (3a, 4a). 3. Module (A, A ', A1 to A6) of construction according to the preceding claim, wherein the projecting portions (3b) and recessed (3a) of the upper face (3) are arranged inverted with respect to the parts in protrusion (4b) or respectively recessed (4a) of the lower face (4). 4. Module (A, A ', A1 to A6) of construction according to the preceding claim, wherein the section of the projecting portions (3b, 4b) and recessed (3a, 4a) is square, the projecting parts (3b , 4b) and recessed (3a, 4a) occupying the whole of the upper face (3) or lower (4) associated. 5. Module (A, A ', A1 to A6) of construction according to any one of the preceding claims, which is a module (A', A6) intended to be an angle module in an assembly (M), the module (A ', A6) having a recess (7) passing from its upper face (3) to its lower face (4). 6. Module (A, A ', A1 to A6) according to any one of the preceding claims, which is substantially parallelepiped square with a height and a length of 50cm, a width of 25cm, the shapes (3b, 4b) at levels of the most external height to the module (A, A ', A1 to A6) exceeding 5cm of the module (A, A', A1 to A6). 7. Module according to any one of the preceding claims, which comprises at least 75% by weight of expanded perlite. 8. Module according to the preceding claim, which comprises 76% expanded perlite, 9% cement, a setting accelerator, a liquid water repellent, gypsum and 13% water. 9. Assembly of modules (A, A ', A1 to A6), characterized in that it comprises at least two modules (A, A', A1 to A6) according to any one of the preceding claims, the two modules ( A, A ', A1 to A6) being laterally adjacent or arranged one below the other. 10. Assembly of modules (A, A ', A1 to A6) according to the preceding claim, which comprises at least two series of superimposed modules (A, A1 to A4) with offset modules of the series superimposed over the other series. 11. Assembly (M) according to any one of the two preceding claims, wherein the assembly (M) comprises two walls (M1, M2) forming an angle between them formed by the superposition of angle modules (A ', A6), the angle module (A ') superimposed on another corner module (A6) being arranged perpendicularly to said other corner module (A6). 12. Assembly according to the preceding claim, wherein, when the module (A ', A6) intended to be an angle module in the assembly (M) has a recess (7) passing through its upper face (3). at its lower face (4), the recesses (7) of the superposed angle modules (A ', A6) are aligned and receive a vertical post.