RU2828722C2 - Method of producing building blocks - Google Patents

Abstract

FIELD: building materials.

SUBSTANCE: invention is related to a method for production of building blocks. The method uses: a) the first material, which is a moistened compressible mass containing a hydraulic binder and a fine-grain porous filler, b) the second material, which is a coarse-grain concrete made by encapsulating a coarse-grain porous filler with a liquid solution of a hydraulic binder, in which the hydraulic binder does not completely fill the space between the particles of said filler, and the method includes the following steps: 1) the first material is fed into the vibropress mould and vibrocompression is carried out using a semi-dry method, producing a workpiece with a side surface of the compacted first material and an internal cavity open at the top and bottom, 2) the workpiece obtained in step 1 is allowed to gain strength, after which 3) the second material is fed into the internal cavity of the workpiece and compacted by vibration and pressing, then 4) the upper layer of the second material is compacted by means of a plate vibrator press, 5) the workpiece obtained in step 3 is allowed to gain strength.

EFFECT: invention provides a method for manufacturing solid building blocks, which does not require a large number of moulds, and the core of the block is made of large-pore concrete, reinforced by pressing.

26 cl, 24 dwg, 3 tbl

Description

AREA OF TECHNOLOGY

The present invention relates to the field of production of building materials.

LEVEL OF TECHNOLOGY

It is well known that some of the shortcomings of traditionally used building materials can be eliminated by combining different materials in one product.

In particular, building blocks made of large-pore concrete have excellent thermal insulation properties, are lightweight, but at the same time have a rough, unattractive outer surface, crumble, allow air, steam, moisture to pass through, and do not hold anchor connections.

This disadvantage can be eliminated, for example, by forming on the surface of building blocks made of large-pore concrete, an additional layer of high-density material that would be free of the aforementioned disadvantages, for example, concrete with a small filler particle size.

There are known building blocks in which at least the front wall is made of a different material (than the core) (RU Patents for Inventions Nos. 2478040, 2465415, 2060332, 2742921, Russian patent for utility model No. 91690, GB 526787 A, DE 19917653 A1 and Russian application for invention No. 2003126451 A).

The disadvantage of the known blocks is the complex manufacturing technology (for example, in 2060332 it is necessary to use a metal mesh separator), or the fact that the layer of dense material protects only one or two sides of the block.

The closest method is described in the Russian Federation application for invention No. 2003126451. The known method for producing multilayer wall stone includes the following stages:

permanent formwork is formed by installing a closed outer form, the sides of which are made with vertical slots, on a pallet or on another flat surface,

a similar internal insert is placed symmetrically inside it, the sides of which are provided with vertical slots corresponding to the slots of the form,

fix the form and insert relative to each other with vertical elements installed in the slots,

fill the space between the form and the insert with construction sand concrete,

it is monolithized by vibration pressing or vibration casting,

remove the form, insert and vertical elements,

cells are formed inside the resulting permanent formwork by laying dividing interconnected partitions, the free ends of which are fixed in the cracks of the sides of the permanent formwork obtained from the vertical elements,

the cells are filled with either cellular concrete or concrete on lightweight fillers in the form of polystyrene, expanded clay, sawdust, ash, they are aged, dried, the dividing partitions are removed and

They receive finished multilayer wall stones, which are sent for stacking.

Based on the description of the known method, it can be assumed that the block blanks are kept in collapsible forms to gain strength. This is indicated, for example, by the mention of three separate elements from which the primary formwork is assembled, which is typical for the assembly of forms for vibration casting, in which fixing elements (inserts) are used.

The use of vertical fixing elements on four sides is also typical for thin-walled formwork used by the vibration casting method and is due to the need to maintain the geometry of the forms at the moment of accepting the load from the supplied mixture, and vice versa, when using the vibration pressing method on well-known examples of vibration pressing equipment, vertical elements are usually used only on two opposite sides of the form and have a different task, namely, constant fixation of the inner part of the form (insert) and also, due to the significant loads perceived from the vibration pressing process, have a conical shape and a size significantly thicker than necessary for a dividing partition, which makes the formed slots of such a shape unsuitable for the implementation of technical solutions specified in the patent in question.

The description of the known method does not mention that the material of the walls of the permanent formwork (mixture) is compressed by a press, but it is indicated that the height of the formwork used is equal to the height of the product, which is only possible when using the vibration casting method, since when using the vibration pressing method on well-known types of equipment, the shrinkage of the mixture in the form reaches 10% or more.

The description of the known method states that during vibration pressing the form is removed after the initial crystallization of the mixture, which implies the use of a separate molding form for each product, which is again typical for vibration casting technologies, since during vibration pressing one matrix is used with thick, strong walls made of load-resistant steels, and the product comes out of the formwork within a few seconds after molding without preliminary strength gain.

However, in this case, to produce blocks on an industrial scale, a large number of forms will be required (equal to the number of blocks produced per shift).

In addition, the known method for manufacturing the outer perimeter of the block uses construction sand concrete, which has low heat-insulating characteristics, due to which the closed outer perimeter of the permanent formwork will create cold bridges, and blocks made of such material will not be heat-efficient. It is proposed to combat this by complicating the design and technology of its manufacture by introducing additional layers of lightweight concrete.

The core of permanent formwork in the known method is filled with concrete on light fillers, without any additional processing in the form of, for example, vibration or smoothing of the mixture, which is possible only if the mixture is very mobile and has a plasticity of P5 and higher (which is typical for concretes with filling of the intergranular space). This excludes the use of large-porous sand-free concretes made of porous filler encapsulated with liquid cement mortar for filling the core of the block, since the latter has plasticity, as a rule, on average P2 and requires additional physical action for uniform placement in the form.

It can be stated that the known method can most likely be implemented only when using vibration casting into a mold for all layers of permanent formwork and filling the core. At the same time, this technology provides for two cycles of assembly and disassembly of the formwork: first, the mold-forming equipment for permanent formwork, then the assembly and disassembly of the internal partitions, which makes the process labor-intensive. In addition, the use of rigid welded formwork from three elements for permanent formwork will significantly complicate its removal from the finished product and will make it very difficult to clean the remains of the solution and lubricate the internal walls in contact with concrete with release agents due to the small distance between the walls of the formwork forming the product.

SUMMARY OF THE INVENTION

The objective of the invention is to create a method for producing building blocks that have high thermal insulation properties due to the high content of porous filler in the main thickness (core) of the block and at the same time have high resistance to negative environmental factors and decorativeness of external surfaces, which is unattainable for solid blocks made of large-porous material.

The technical result provided by the proposed method is that the set task is solved while not requiring a large number of forms to produce building blocks, and the core can be made from large-pore concrete reinforced by pressing.

To achieve the specified technical result, during the production of concrete blocks at the first stage (on the block wall molding line) in a matrix on standard well-known equipment for semi-dry vibration pressing (vibration press), permanent formwork is made, consisting of a closed perimeter formed by block walls made of a mixture that includes a porous filler of a round or gravelly shape of small fractions.

Next, the workpiece on the process pallet is sent to dry to gain strength.

After gaining sufficient strength, the workpiece is sent to the second stage of processing on the block core molding line to fill the permanent formwork with large-porous sand-free concrete containing a porous filler of a round or gravelly shape using the liquid cement mortar encapsulation method.

In this case, after the technological pallet with the permanent formwork (outer walls of the product) that has gained the required strength is fed into the technological cutout area of the work table, the work table is lowered and the walls of the permanent formwork are fixed in the working position using clamps, which perform, among other things, the function of accepting lateral loads from vibration pressing when filling with large-pore concrete and ensure the integrity of the walls of the permanent formwork is maintained.

Next, using a measuring box, large-porous sand-free concrete containing a porous filler made by the method of encapsulation with liquid cement mortar is fed, while the use of the encapsulation method makes the mixture more mobile, which in turn requires lower compressive loads, reduces lateral loads on the walls of the permanent formwork and improves ease of placement in the form, and also with the method of encapsulating the filler with liquid cement mortar, the enveloping cement layer on the granules of the porous filler is thin enough, due to which the thermal efficiency of the block is preserved. Next, the mixture is vibrated using a pin vibrator, which is necessary for a more uniform distribution of the mixture of large-porous concrete inside the permanent formwork, after which the measuring box is returned to its original position.

In case of using a filler with an unstable granulometric composition, regardless of the accuracy of the mixture dosing, it is almost impossible to achieve an exact location of the filler surface flush with the upper ends of the permanent formwork after vibration. In this regard, two technology options are possible: either use a filler with a given granulometric composition (for example, one narrow fraction or a mixture of several narrow fractions with a given size) and stable properties, or feed slightly less mixture into the formwork than is necessary to fill it flush with the upper ends of the formwork, and after vibration fill the remaining space between the level of porous concrete and the upper ends of the formwork with plastic concrete, which is not subject to shrinkage.

In the first version of the technology, when large-pore concrete with a controlled granulometric composition of the filler is used, the formwork can be filled with a precisely specified amount of concrete with the expectation that after vibration and compression with a plate vibrator press, the surface plane of the large-pore concrete will be flush with the upper ends of the formwork.

In the second version of the technology, after vibration, the mixture is leveled in a plane and additionally compressed using a plate press-vibrator for large-pore concrete to a position below the level of the upper edge of the permanent formwork to the depth of laying the top layer of concrete with fine-grained porous filler.

Next, using a measuring box for concrete made of fine-grained porous filler, the mixture is fed into permanent formwork, not completely filled with large-pore concrete, and the measuring box is returned to its original position, then using a plate press - vibrator, the mixture of fine-grained porous filler is leveled in a plane and compressed in height to the upper edge of the permanent formwork, becoming flush with it, or a smoother is used for leveling in a plane, for example, in the form of a vibrating beam, after which the clamps are moved away from the walls of the block, releasing it, the working table is raised to the desired height and the process pallet with the product is sent to dry.

The use of a layer of concrete with fine-grained porous filler allows avoiding the occurrence of differences in height, caused by the fact that in practice the granulometric composition of large fractions of the main porous fillers such as, for example, expanded clay, differs from batch to batch, and along with this, the depth (percentage) of shrinkage of the mixture of large-grained concrete changes.

After gaining strength in drying, the block is ready for use.

DETAILED DISCLOSURE OF THE ESSENCE OF THE INVENTION

The task that the invention is aimed at solving is to reduce the cost of producing blocks of large-porous sand-free concrete containing porous filler using a mixed technology of encapsulating the filler with liquid cement mortar and semi-dry vibration pressing with improved technical and economic indicators of such production.

The task at hand is solved due to the fact that the proposed method of producing building blocks uses:

(a) a first material which is a moistened pressing mass containing a hydraulic binder and a fine-grained porous filler,

(b) the second material is a large-pore concrete produced by encapsulating a large-grained porous filler with a liquid solution of a hydraulic binder, in which the hydraulic binder does not completely fill the space between the particles of said filler.

The proposed method includes the following stages:

(1) said first material is fed into the mold of the vibration press and vibration pressing is carried out using a semi-dry method, with the production of a workpiece having a side surface made of compacted first material and an internal cavity open at the top and bottom,

(2) allow the workpiece obtained in stage 1 to gain strength, after which

(3) said second material is fed into the inner cavity of said blank and compacted by vibration and pressing, then

(4) compacting the top layer of said second material by means of a plate vibrating press,

(5) allow the workpiece obtained in stage 3 to gain strength.

Thus, the method combines two technological methods based on opposite principles of operation: vibration pressing using a semi-dry method and encapsulation of the filler with liquid cement mortar.

During vibration pressing, the mixture is made rigid, semi-dry and compressed under high pressure, simultaneously vibrating, while the particles are compacted, “intertwined” and create mutual adhesion to such a state that they can maintain the static shape of the product when the original matrix is removed immediately, while air is removed from the formed part as much as possible (the remaining air pores are usually from 3 to 7%).

When encapsulating the filler with liquid cement mortar, the mixture is more plastic and, with minor vibration efforts, takes the form into which it is fed, does not independently hold the shape given to it, and removal of the molding matrix is possible only after a certain gain in strength of the product. In this case, the formed part contains from 25% to 40% of air pores between the filler granules.

After step 4, the surface of the said second material may be flush with the upper ends of the walls of the said blank. Alternatively, after step 4, a free space may arise between the upper ends of the walls of the said blank and the surface of the said second material, which is filled with a third material containing a porous filler of small fractions and a hydraulic binder, and the upper layer of the said third material is compacted by means of a plate vibrator press in such a way that the surface of the said third material is flush with the upper ends of the walls of the said blank. Compaction of the upper layer of the said third layer may be carried out by means of a vibrating screed so that the surface of the said third material is flush with the upper ends of the walls of the said blank.

In one embodiment of the above-described method, the above-mentioned layer, located flush with the upper ends of the walls of the said workpiece, can be provided with at least one thermal break.

In another embodiment of the above-described method, vibration in step (3) is carried out by means of a vibrator equipped with pins designed with the possibility of immersion into the thickness of the above-mentioned second material when vibration is carried out.

In another embodiment of the above-described method, vibration and pressing at step (3) are carried out by means of an apparatus equipped with a clamp with movable walls designed with the possibility of being applied to the above-mentioned side walls of the workpiece obtained at step (2) in such a way that when vibration and pressing at step (3) are carried out, the movable walls of the said clamp prevent the destruction of the side walls of the workpiece.

In one embodiment of the above-described method, the above-mentioned porous filler in the above-mentioned first and/or second and/or third materials is selected from the group comprising glassy porous filler, expanded clay, perlite, vermiculite and shungite.

In another embodiment of the above-described method, the above-mentioned hydraulic binder in the above-mentioned first and/or second and/or third materials is Portland cement.

In another embodiment of the above-described method, the above-mentioned first and/or second and/or third materials are practically free of sand. Reducing the proportion or eliminating sand from the composition of the materials allows for a decrease in their density and thermal conductivity.

In one embodiment of the above-described method, the above-mentioned first and/or second and/or third materials additionally contain functional additives selected from the group consisting of a plasticizer, a setting accelerator, and an air-entraining additive.

In another embodiment of the above-described method, the above-mentioned first and/or second and/or third materials additionally contain fly ash.

In another embodiment of the above-described method, the above-mentioned first and/or third materials have a mass moisture content of 6-8 wt%.

In one embodiment of the above-described method, the D60 of the filler particles in the above-mentioned first and/or third material is less than 2 mm. By "D60" is meant that at least 60% of the particles have a size (determined using a sieve with an appropriate mesh size) corresponding to the specified value/range.

In another embodiment of the above-described method, the above-mentioned first and/or third materials additionally contain a fibrous alkali-resistant filler selected from the group consisting of staple glass fiber and staple basalt fiber.

In another embodiment of the above-described method, the above-mentioned first and/or third material has the following composition, wt.%:

porous filler of round or gravelly fraction 0-7 mm bulk density from 300 to 700 kg/ ^m3 from 30 to 60, construction sand fraction 0-3 mm from 1 to 15, Portland cement grade M400-M500 from 20 to 50, functional additives from 0.1 to 5, water rest

In one embodiment of the above-described method, the D60 of the filler particles in the above-mentioned second material is more than 7-25 mm.

In another embodiment of the above-described method, the volume fraction of filler and voids not filled with binder in the above-mentioned second material is greater than 50%.

In another embodiment of the above-described method, the volume fraction of air pores in the above-mentioned second material is greater than 15%.

In one embodiment of the above-described method, the above-mentioned second material has the following composition (per 1 ^m3 ):

porous filler of round or gravelly fraction 7-25 mm with bulk density from 180 to 550 kg/ ^m3 1 ^m3 , Portland cement grade M400-M500 from 110 to 180 kg, functional additives from 0.1 to 15 kg, water from 80 to 170 l

In another embodiment of the above-described method, said third material has the following composition (wt.%):

porous filler of round or gravelly fraction 0-7 mm bulk density from 300 to 700 kg/ ^m3 from 30 to 70, Portland cement grade M400-M500 from 20 to 50, functional additives from 0.1 to 5, water rest

In yet another aspect, the present invention relates to a building block obtained by the above-described method.

In one embodiment of the above-described block, its walls are provided with projections and grooves of a matching shape.

In another embodiment of the above-described block, at least one of its walls has a vertical ribbed surface for applying plaster or adhesive solutions.

In another embodiment of the above-described block, its vertical walls form a complex figure of five or more walls.

In one embodiment of the above-described block, its walls are provided with technological grooves and/or openings for using other technological elements.

The invention, having been described generally, will be illustrated below with the aid of the accompanying figures by way of example of some preferred embodiments.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

Fig. 1 - Variants of blocks produced using mixed technology.

Fig. 2 - General view of line 1 for forming the outer walls of block 1.

Fig. 3 - Types of block walls (permanent formwork) 1.

Fig. 4 - External view of the core forming line of block 2.

Fig. 5 - Arrangement of mechanisms, top view.

Fig. 6 - Arrangement of mechanisms, bottom view.

Fig. 7 - Flow chart of block production using mixed technology.

Fig. 8 - Initial position of the desktop.

Fig. 9 - Work table in the position of fixed formwork.

Fig. 10 - Initial position of measuring box 17.

Fig. 11 - Feeding large-pore concrete into the molding zone in permanent formwork.

Fig. 12 - Vibration of large-pore concrete with a pin vibrator.

Fig. 13 - Vibration of large-pore concrete in permanent formwork using a plate vibrator press.

Fig. 14 - Section of the vibration unit of layer 2 made of large-pore concrete.

Fig. 15 - Difference in height of a layer of large-pore concrete with unstable granulometric composition when applying the same press pressure.

Fig. 16 - Initial position of measuring box 22.

Fig. 17 - Feeding concrete with porous filler from small fractions into the molding zone in permanent formwork.

Fig. 18 - Measuring box with a breaker for a concrete layer with a filler made of small fractions for forming a layer with a thermal break.

Fig. 19 - Vibration of the top layer of concrete with a filler of small fractions in permanent formwork using a plate vibrator press.

Fig. 20 - Section of a vibration unit made of concrete with fine-grained filler.

Fig. 21 - Completion of the block production cycle on line 2 for forming the block core.

Fig. 22 - Products made of sand-free large-pore concrete containing large fractions of filler.

Fig. 23 - Molds for the production of products from sand-free large-pore concrete containing large fractions of filler.

Fig. 24 - Mold for production using the semi-dry vibration pressing method.

IMPLEMENTATION OF THE INVENTION

The proposed method is intended for the production of a building block having side (vertical) walls 1 made of concrete containing a porous filler of small fractions, forming a single contour, a core 2 made of sand-free concrete containing a porous filler of large fractions, and a cover 3 made of concrete containing a porous filler of small fractions, made flush with the upper edge of the walls of permanent formwork in the form of a leveling layer on top of the core (Fig. 1).

In the proposed method according to the invention, two main stages can be distinguished: the production of permanent formwork and the formation of the core of the block inside the permanent formwork.

The mass for forming permanent formwork (i.e. the outer walls of the block) is prepared as follows:

First, to prepare a semi-dry mixture, the required amount of porous filler of fraction 0-7, construction sand of fraction 0-3, Portland cement grade M400 - M500 is measured out using a dosing complex and fed into a mixer, where the specified components are mixed in a dry state.

Next, measure out the water and functional additives and feed them into the mixer with the other previously prepared components, after which they are finally mixed until the required mixture consistency is obtained.

The resulting semi-dry mixture, in addition to the parameters achieved in the product, must correspond to the operating parameters of the equipment (vibration press) - workability, compression, maintaining the specified shape when leaving the matrix and until strength is gained.

After feeding to the vibropress, the mixture is vibrated and compressed in the press form, forming a stable form of permanent formwork (the outer shell of the block) on the technological pallet. After this, the resulting blank is sent to dry for initial strength gain.

After drying, the permanent formwork is sent to the block core filling line. Then, for the production of large-pore concrete by the method of encapsulation with liquid cement mortar, the required amount of cement, water, additives is measured out and fed into the mixer and mixed. The resulting mixture must have a liquid phase to enable subsequent enveloping of the filler granules with a thin layer. Then, large-fraction porous filler is fed into the mixer and mixed. During the mixing process, the filler particles are envelopped (encapsulated) with a thin layer of cement milk. In this case, for mixing, it is preferable to use either special mechanisms "capsulators" or forced-action mixers with horizontal shafts, since in this case, when the finished concrete is dispensed by the mixer blades, the excess liquid fraction of the mixture (cement milk) flows to the bottom of the mixer. The large-pore concrete obtained in this way is fed into the permanent formwork, which is fixed along the perimeter with clamps on the process pallet. After feeding the large-pore concrete, the pin vibrator is lowered into this mixture and vibrated, thereby evenly distributing it throughout the internal volume of the permanent formwork. Then the distributed mixture is compressed, simultaneously vibrating by means of a plate vibrator to a level below the upper edge of the permanent formwork wall. At the same time, the mixture for the upper layer of the block is prepared, for which the required amount of porous filler of fraction 0-7, Portland cement grade M400 - M500 is measured out and fed into the mixer. After that, the specified components are mixed in a dry state. Then, water and functional additives are measured out and fed into the mixer with the previously prepared other components, after which the final mixing takes place until the required consistency of the mixture is obtained. The resulting semi-dry mixture, in addition to the parameters achieved in the product, including must comply with the operating parameters of the equipment (vibration press) - workability, compression, maintaining the specified shape after molding and until strength is gained. After feeding into the permanent formwork over a layer of large-pore concrete, the mixture is vibrated in the matrix and compressed to a level flush with the upper edge of the permanent formwork. After which the resulting product is sent to dry. After reaching the design strength, the product is ready for use.

For the production of blocks, one can use, for example, mixtures whose composition is given in Tables 1-3.

The first stage is carried out in a matrix on the line for forming the outer walls of the block (see Fig. 2 and 3), which, in essence, includes the known equipment for semi-dry vibration pressing:

1. conveyor for technological pallets 4,

2. supporting frame 5,

3. unit for feeding the mixture into the matrix 6,

4. a press form 7 consisting of a punch and a matrix,

5. hydraulic press 8,

6. vibration table 9.

The second stage is carried out on the block core forming line (see Fig. 4-6), which includes:

1. a supporting frame 11, designed to accommodate a set of mechanisms necessary for the entire production cycle of the product,

2. feeding conveyor 12, designed for feeding process pallets 10 with permanent formwork 1 after preliminary strength gain,

3. work table 13 with vertical stroke, for horizontal movement of the measuring box with concrete

4. bunker 19 of ready-mixed large-porous sand-free concrete with large porous filler,

5. measuring box 17,

6. pin vibrator 20 for large-porous concrete with large porous filler with a fixing mechanism on a hydraulic press and a cleaning mechanism,

7. plate press vibrator 21 for large-porous concrete with large porous filler with a fixing mechanism on a hydraulic press and a cleaning mechanism,

8. measuring box 22 for concrete made of porous filler of small fractions, fed from the feed bin 23 of ready-mix concrete of small fractions,

9. Plate vibrator 24 for concrete made of fine-grained porous filler with cleaning mechanism and locking mechanism

10. on a hydraulic press 25.

The working table 13 is provided with clamps 14 for permanent formwork in the lower part. These clamps are intended for pressing and fixing permanent formwork. The clamps are provided with a drive 15 (mechanical, hydraulic or pneumatic), made with the possibility of adjusting the pressure force. The clamps have one or more cutouts 16 in the horizontal plane of the table in the form of the (internal) perimeter of the permanent formwork in accordance with the amount of permanent formwork placed on the process pallet.

The measuring box 17 is equipped with a shutter with a vibrator 18 for feeding large-pore sand-free concrete, produced using the technology of encapsulation with liquid cement mortar, fed into the measuring box 17 from the hopper 19.

As shown in Fig. 7, the method according to the invention is carried out as follows.

1. On the line for forming the walls of a concrete block containing a porous filler of small fractions, permanent formwork is prepared using the semi-dry vibration pressing method,

2. Dry the permanent formwork to gain preliminary strength.

3. After preliminary strength gain, the permanent formwork is fed from the drying to the core molding line.

4. Move the work table to the working position.

5. Fix the permanent formwork in the working position using clamps on the work table.

6. Prepare large-porous sand-free concrete with large porous filler using the liquid cement mortar encapsulation method.

7. Large-pore sand-free concrete is fed into permanent formwork using a measuring box.

8. Vibrate large-pore sand-free concrete in permanent formwork using a pin vibrator.

9. Move the mechanisms of the measuring box for large-pore concrete and the pin vibrator away from the molding area.

10. Vibrate and simultaneously press large-pore concrete using a plate vibrator.

11. concrete containing fine-grained porous filler is fed into the molding zone using a measuring box for fine-grained concrete, the measuring box for fine-grained concrete is removed from the molding zone, vibrated while simultaneously pressing a layer of concrete made of fine-grained porous filler, and the work table is returned to its original position.

12. The finished product is sent for drying to achieve the design strength.

13. Pack finished products.

The working cycle on the block core forming line begins with the moment of raising the working table 13 to the height required for the passage of the process pallet above the conveyor 12, then the process pallet 10 with the permanent formwork 1 is fed into the filling zone of the subsequent layers 2 and 3 of the block (see Fig. 8). After feeding the process pallet, the working table 13 is lowered, whereby the cutout 16 is above the permanent formwork 1, completely repeating its internal perimeter, whereby the upper plane of the working table, having a special projection, is raised above the upper edge of the permanent formwork to the height required for the preliminary formation of layer 3 before its vibration pressing.

Then, using the drive 15, the clamps 14 grasp and fix the permanent formwork in the working position (see Fig. 9), while the pressure of the clamps on the permanent formwork should be adjusted to select the required load, at which, on the one hand, pressure is formed, which performs, among other things, the function of accepting lateral loads from vibration pressing of the internal filling made of large-pore concrete and, as a consequence, maintaining the integrity of the walls of the permanent formwork at this moment, on the other hand, the pressure should not be excessive and lead to the destruction of the walls of the permanent formwork at the moment of fixation.

After completing the technological operations associated with filling the formwork with concrete layers 2 and 3, the work table is raised to its original position, the technological pallet with the finished block is sent to dry to gain the design strength, and a new pallet with unfilled permanent formwork is fed in its place.

From the feed bin 19 (see Fig. 10) the large-porous sand-free concrete, made by the method of encapsulation with liquid cement mortar, is fed into the measuring box 17, after which it is moved to the molding zone. The material is a mass of particles of porous filler, between the particles of which there are air layers. The said material is very mobile, which in turn requires lower compressive loads, reduces lateral loads on the walls of the permanent formwork and improves ease of placement in the mold. In addition, with the method of encapsulation with liquid cement mortar, the enveloping cement layer on the granules of the porous filler is sufficiently thin, due to which the thermal efficiency of the block is preserved. In the molding zone, the valve with the vibrator 18 is opened and the mixture enters the permanent formwork (see Fig. 11). After vibration, the valve with the vibrator is closed and the measuring box is returned to its original position.

After feeding large-pore concrete into the permanent formwork and opening the gate, the pin vibrator 20 with the locking mechanism on the hydraulic press is moved, fixed on the hydraulic press 25, lowered into the concrete and begins to vibrate, simultaneously immersing it into the permanent formwork (see Fig. 12).

The use of a pin vibrator is due to the fact that large-porous concrete is poorly distributed in the horizontal direction and it must be "pushed" into corners and hard-to-reach places, evenly distributed, and the resulting voids must be compressed at the time of unloading from the measuring box. After the concrete is evenly distributed throughout the internal volume of the permanent formwork, the pin vibrator returns to its original position and is cleaned.

After vibration, the shutter with vibrator 18 is closed and the measuring box 17 is returned to its original position.

Next, the plate press-vibrator for large-pore concrete 21 with a locking mechanism on the hydraulic press 25 is moved to the molding zone and finally compresses with simultaneous vibration the layer 2 of large-pore concrete, giving it a horizontal upper surface below the level of the upper edge of the walls of the permanent formwork for the subsequent placement of layer 3 of fine-fraction concrete (see Fig. 13, Fig. 14).

After this, the plate vibrator press 21 returns to its original position.

Since in practice the granulometric composition of the porous filler of large fractions differs from batch to batch, and along with this the depth (percentage) of shrinkage of the mass of large-pore concrete changes, the use of a layer of small-fraction concrete should also level out these differences in height (Fig. 15), for which purpose the measuring box 22 is filled from the bin for feeding the finished mixture with concrete and small fractions of expanded clay 23, after which the mixture is fed into the permanent formwork not completely filled with large-pore concrete (see Fig. 17).

The measuring box 22 can form not only a continuous filling in the plane of the upper part of the block but also a separate filling in the form of strips of material separated by gaps (for example, for a thermal break device in the upper layer) for which the measuring box can be made of two sections between which a layer interruption is formed. In this case, to make a discontinuous layer, triangular-shaped inserts are installed as shown in Fig. 18, and upon completion of this operation, the measuring box 22 is returned to its original position (see Fig. 16).

Next, using a hydraulic press 25 equipped with a plate vibrator press 24 for fine-fraction concrete with a cleaning system, layer 3 of fine-fraction porous filler is vibrated and compressed to the upper edge of the wall of permanent formwork 1 flush with the permanent formwork (see Fig. 19, Fig. 20).

After this, the clamps 14, fixing the product, are moved away from the walls of the permanent formwork and the work table 13 is raised up to a height sufficient for horizontal movement of the process pallet with the product along the conveyor.

Next, the next process pallet with unfilled permanent formwork enters the processing zone and the cycle repeats (see Fig. 21).

The pallet with the freshly made block is sent to dry to gain the design strength.

After gaining strength, the block is ready for packaging and shipping to consumers.

When producing products using semi-dry vibration pressing technology, the pressed mass is strongly compacted. The latter, in addition to cement, contains sand, which is necessary to maintain the shape of the product when the matrix is removed. Such products have a high density, their thermal efficiency is low.

When producing blocks using mixed technology, in which they are first made using the semi-dry vibration pressing method from fine-fraction concrete, a permanent formwork is made (the outer perimeter of the block walls), after which large-pore concrete is fed into it (from 75% to 90% of the total volume of the product) and a leveling layer of fine-fraction concrete, the resulting product is capable of satisfying modern requirements for thermal efficiency. The closest to these products in terms of technical characteristics are blocks made of sand-free large-pore concrete made using a molding formwork using the vibration casting method (see Fig. 22).

Comparison of identical production capacities of 50,000 cubic meters/year using different technologies shows that the production of products (blocks) from large-porous sand-free concrete using vibration casting technology requires 11,000 molds made of special steels with a service life of no more than 4 years, which require constant assembly-disassembly, repair, cleaning and lubrication during operation (usually manually), as well as a room with an area of 2,500-3,000 square meters (see Fig. 23).

When producing using mixed technology over a 4-year period, only 16 matrices (for four blocks) and a room from 900 to 1200 sq. m. are required (Fig. 24).

Claims (37)

1. A method of producing building blocks that uses: a) the first material, which is a moistened pressing mass containing a hydraulic binder and a fine-grained porous filler, b) the second material is a large-pore concrete produced by encapsulating a large-grained porous filler with a liquid solution of a hydraulic binder, in which the hydraulic binder does not completely fill the space between the particles of the said filler, including the following stages: 1) the said first material is fed into the mold of the vibration press and vibration pressing is carried out using a semi-dry method, with the production of a workpiece having a side surface made of compacted first material and an internal cavity open at the top and bottom, 2) allow the workpiece obtained in stage 1 to gain strength, after which 3) the said second material is fed into the internal cavity of the said workpiece and compacted by vibration and pressing, then 4) compact the top layer of the said second material using a plate vibrating press, 5) allow the workpiece obtained in stage 3 to gain strength. 2. The method according to claim 1, wherein after step 4 the surface of the above-mentioned second material is located flush with the upper ends of the walls of the said workpiece. 3. The method according to claim 1, wherein after step 4 between the upper ends of the walls of the above-mentioned blank and the surface of the above-mentioned second material there is a free space, which is filled with a third material containing a porous filler of small fractions and a hydraulic binder and the upper layer of the above-mentioned third material is compacted by means of a plate vibrating press in such a way that the surface of the above-mentioned third material is located flush with the upper ends of the walls of the above-mentioned blank. 4. The method according to claim 1, wherein after step 4 between the upper ends of the walls of the above-mentioned blank and the surface of the above-mentioned second material there is a free space, which is filled with a third material containing a porous filler of small fractions and a hydraulic binder and the upper layer of the above-mentioned third material is compacted by means of a vibrating screed so that the surface of the above-mentioned third material is flush with the upper ends of the walls of the above-mentioned blank. 5. The method according to any one of claims 3 or 4, wherein the above-mentioned layer, located flush with the upper ends of the walls of the said workpiece, is provided with at least one thermal break. 6. The method according to claim 1, wherein the vibration in step 3 is carried out by means of a vibrator equipped with pins designed with the possibility of being immersed into the thickness of the above-mentioned second material when the vibration is carried out. 7. The method according to claim 1, wherein vibration and pressing at step 3 are carried out by means of an apparatus equipped with a clamp with movable walls designed with the possibility of being applied to the above-mentioned side walls of the workpiece obtained at step 2 in such a way that when vibration and pressing at step 3 are carried out, the movable walls of said clamp prevent the destruction of the side walls of the workpiece. 8. The method according to any one of claims 1, 3 or 4, wherein the above-mentioned porous filler in the above-mentioned first and/or second and/or third materials is selected from the group comprising glassy porous filler, expanded clay, perlite, vermiculite and shungite. 9. The method according to any one of claims 1, 3 or 4, wherein said hydraulic binder in said first and/or second and/or third materials is Portland cement. 10. The method according to any one of claims 1, 3 or 4, wherein the above-mentioned first and/or second and/or third materials are substantially free of sand. 11. The method according to any one of claims 1, 3 or 4, wherein the above-mentioned first and/or second and/or third materials additionally contain functional additives selected from the group consisting of a plasticizer, a setting accelerator and an air-entraining additive. 12. The method according to any one of claims 1, 3 or 4, wherein the above-mentioned first and/or second and/or third materials additionally contain fly ash. 13. The method according to any one of claims 1, 3 or 4, wherein the above-mentioned first and/or third materials have a mass moisture content of 6-8 mass%. 14. The method according to any one of claims 1, 3 or 4, wherein the D60 of the filler particles in the above-mentioned first and/or third material is less than 2 mm. 15. The method according to any one of claims 1, 3 or 4, wherein the above-mentioned first and/or third materials additionally contain a fibrous alkali-resistant filler selected from the group consisting of staple glass fiber and staple basalt fiber. 16. The method according to any one of claims 1, 3 or 4, wherein the above-mentioned first and/or third material has the following composition, mass %: porous filler of round or gravelly shape, fraction 0-7 mm, bulk density from 300 to 700 kg/ ^m3 from 30 to 60, construction sand fraction 0-3 mm from 1 to 15, Portland cement grade M400-M500 from 20 to 50, functional additives from 0.1 to 5, water rest. 17. The method according to claim 1, wherein the D60 of the filler particles in the above-mentioned second material is more than 7-25 mm. 18. The method according to claim 1, wherein the volume fraction of filler and voids not filled with binder in the above-mentioned second material is greater than 50%. 19. The method according to claim 1, wherein the volume fraction of air pores in the above-mentioned second material is greater than 15%. 20. The method according to claim 1, wherein the above-mentioned second material has the following composition (per 1 ^m3 ): porous filler of round or gravelly shape, fraction 7-25 mm, bulk density from 180 to 550 kg/ ^m3 1 ^m3 , Portland cement grade M400-M500 from 110 to 180 kg, functional additives from 0.1 to 15 kg, water from 80 to 170 l. 21. The method according to any one of claims 3 or 4, wherein said third material has the following composition (wt.%): porous filler of round or gravelly shape, fraction 0-7 mm, bulk density from 300 to 700 kg/ ^m3 from 30 to 70, Portland cement grade M400-M500 from 20 to 50, functional additives from 0.1 to 5, water rest. 22. A building block, characterized in that it is obtained by the method according to any of paragraphs 1-21. 23. The block according to item 22, characterized in that its walls are provided with projections and grooves of a matching shape. 24. The block according to item 22, characterized in that at least one of its walls has a vertical ribbed surface for applying plaster or adhesive solutions. 25. A block according to item 22, characterized in that its vertical walls form a complex figure of five or more walls. 26. The block according to item 22, characterized in that its walls are provided with technological grooves and/or openings for the use of other technological elements.