WO2009006647A2 - Building elements and a method of manufacture of preformed building products - Google Patents
Building elements and a method of manufacture of preformed building products Download PDFInfo
- Publication number
- WO2009006647A2 WO2009006647A2 PCT/ZA2008/000056 ZA2008000056W WO2009006647A2 WO 2009006647 A2 WO2009006647 A2 WO 2009006647A2 ZA 2008000056 W ZA2008000056 W ZA 2008000056W WO 2009006647 A2 WO2009006647 A2 WO 2009006647A2
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- composite building
- adhesive
- building material
- composite
- building
- 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.)
- Ceased
Links
Classifications
-
- 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
- C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
- C04B26/02—Macromolecular compounds
-
- 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
- C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
- C04B26/02—Macromolecular compounds
- C04B26/10—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
- C04B26/18—Polyesters; Polycarbonates
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
- E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
-
- 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
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
- C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/50—Reuse, recycling or recovery technologies
- Y02W30/91—Use of waste materials as fillers for mortars or concrete
Definitions
- This invention relates to building elements and a method of manufacture of preformed building products and in particular wall board.
- Pre-formed or pre-moulded building products are well-known and are popular particularly for use in low cost housing initiatives.
- a composite building material comprises an inorganic filler material, organic material of fine particulate size, an adhesive or binder and a catalyst to expedite the curing process, the materials being mixed and poured into a mould into which one or more sheets of fibreglass sheeting have been laid to produce a moulded product which may be cut to size if required.
- a method of manufacture of a building element includes the steps of mixing an inorganic filler material, a particulate organic material and an adhesive or binder in the presence of a catalyst, then pouring the slurry thus formed into a mould containing one or more sheets of fiberglass and allowing the mixture to cure.
- the inorganic filler material comprises one or more of expanded perlite powder, foamed plastic, magnesia, ash, chloridised magnesium, gypsum or calcium carbonate.
- the inorganic filler preferably comprises 45% of the material by weight.
- the organic material may comprise wood sawdust, crop powder or nutshell powder and comprises approximately 5 to 15% of the material by weight.
- the adhesive preferably comprises a polyester adhesive while a polyester resin may be employed to provide a waterproof and /or fireproof finish.
- the binder or adhesive comprises approximately 10 % by weight of the material.
- the catalyst makes up approximately 40% of the material by weight.
- the material may be produced in sheets and cut to size.
- the material may be produced in panel form with a tongue and groove design for ease of construction and for the insertion of a steel profile for reinforcement and fixing.
- Curing preferably takes place in curing room where temperature is maintained at approximately 60 degrees Celsius and humidity is high, for a period of seven days.
- the material may then be air-dried in the sunshine.
- There surface may be painted with a resin lacquer to give a protective and decorative finish.
- the filler material may comprise between 5 and 15% by weight of recycled plastic, 30 to 40% of perlite powder, 10 to 20% ash, and between 5 and 15% calcium carbonate, which are mixed with an adhesive.
- This product has it ideal application as a middle-layer building element.
- the filler material comprises between 70 and 85 % of chloridised magnesium, between 13 and 18 % magnesia, and between 2 and 17% of a modifier, which are mixed with an adhesive. This material may be used as a surface tile.
- the filler material may comprise 25 to 35% magnesia, which is mixed with sawdust (15 to 25%) and between 10 and 25% of a modifier, all mixed together with an adhesive.
- This material may be used as a building block or brick type of product.
- the material may be molded to form tiles, wall boards, blocks, bricks, doors or even furniture or the like.
- foamed concrete or a mixture of foamed concrete and expanded polystyrene may be located between two wall board-like sheets of the material of the invention to form a type of pre-cast wall.
- each board element includes at the ends thereof a protruding formation in the form of a right-angled ridge.
- a pair of boards is arranged with the ridges orientated inwardly toward the interior of the panel to be formed.
- the panels formed interengage and include along one vertical end, a channel formation extending into the body of the panel for receiving and engaging a corresponding protruding formation on the opposite end of an adjacent panel in a tongue and groove relationship.
- the channel formation preferably engages a vertical steel or the like metal profile affixed to the floor by means of a mounting element.
- the profile may comprise a channel section in which the arms of the channel include perpendicular flanges dimensioned to cover at least the filler portion of the panel. Panels are located between a framework of the spaced apart steel profiles which are themselves secured in conventional footings.
- a panel 10 comprises a pair of moulded boards 12 each having right-angled ridges 14 at their ends.
- the boards comprise a composite of an inorganic filler material, organic material of fine particulate size, an adhesive or binder and a catalyst to expedite the curing process, all of which are mixed and moulded together with fiberglass sheeting as described above.
- a pair of boards 12 are integrally moulded with a filler portion 16 comprising foamed concrete and expanded polystyrene to form the panel 10.
- One end 18 of the panel has a tongue formation 20 for engaging the opposite end 22 of an adjacent panel, which is formed with a groove or channel.
- the grooves and tongues preferably engage steel profiles 24 which are anchored in convention footings and provide a framework between which the panels are located.
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Structural Engineering (AREA)
- Architecture (AREA)
- Materials Engineering (AREA)
- Organic Chemistry (AREA)
- Civil Engineering (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Finishing Walls (AREA)
- Laminated Bodies (AREA)
Abstract
The invention relates to a novel composite for forming pre-fabricated building elements, as well as a method of using the composite to mould new building elements. The composite comprises a combination of organic and inorganic material mixed with a binder and a catalyst. The volumes in which each element of the formulation is added depends on which specific element is being formed - the formulation may for instance differ between a building block and a pre-cast wall or a floor tile. The mould used to in the method to manufacture building elements comprising the novel composition contains one or more sheets of fiberglass in a specific shape.
Description
BUILDING ELEMENTS AND A METHOD OF MANUFACTURE OF PREFORMED
BUILDING PRODUCTS
TECHNICAL FIELD OF THE INVENTION
This invention relates to building elements and a method of manufacture of preformed building products and in particular wall board.
BACKGROUND ART
Pre-formed or pre-moulded building products are well-known and are popular particularly for use in low cost housing initiatives.
Light steel structure becoming more prevalent for the building of structures. Typically, a steel framework is set into conventional concrete foundations and cladding is added for external walls and dry wall being used for internal walling.
It is an object of this invention to provide a new composite building material and a building element comprised thereof which is lightweight, easily produced, waterproof and fireproof, as well as a method of manufacture thereof.
DISCLOSURE OF THE INVENTION
According to the invention a composite building material comprises an inorganic filler material, organic material of fine particulate size, an adhesive or binder and a catalyst to expedite the curing process, the materials being mixed and poured into a mould into which one or more sheets of fibreglass sheeting have been laid to produce a moulded product which may be cut to size if required.
According to a second aspect of the invention, a method of manufacture of a building element includes the steps of mixing an inorganic filler material, a particulate
organic material and an adhesive or binder in the presence of a catalyst, then pouring the slurry thus formed into a mould containing one or more sheets of fiberglass and allowing the mixture to cure.
In the preferred form of the invention, the inorganic filler material comprises one or more of expanded perlite powder, foamed plastic, magnesia, ash, chloridised magnesium, gypsum or calcium carbonate. The inorganic filler preferably comprises 45% of the material by weight.
The organic material may comprise wood sawdust, crop powder or nutshell powder and comprises approximately 5 to 15% of the material by weight.
The adhesive preferably comprises a polyester adhesive while a polyester resin may be employed to provide a waterproof and /or fireproof finish. The binder or adhesive comprises approximately 10 % by weight of the material.
The catalyst makes up approximately 40% of the material by weight.
The material may be produced in sheets and cut to size.
The material may be produced in panel form with a tongue and groove design for ease of construction and for the insertion of a steel profile for reinforcement and fixing.
Curing preferably takes place in curing room where temperature is maintained at approximately 60 degrees Celsius and humidity is high, for a period of seven days. The material may then be air-dried in the sunshine. There surface may be painted with a resin lacquer to give a protective and decorative finish.
The mixture may be varied to produce building products having different applications. For example, in one form, the filler material may comprise between 5 and 15% by weight of recycled plastic, 30 to 40% of perlite powder, 10 to 20% ash, and between 5 and 15% calcium carbonate, which are mixed with an adhesive. This product has it ideal application as a middle-layer building element.
In an alternate form, the filler material comprises between 70 and 85 % of chloridised magnesium, between 13 and 18 % magnesia, and between 2 and 17% of a modifier, which are mixed with an adhesive. This material may be used as a surface tile.
In a further alternate form, the filler material may comprise 25 to 35% magnesia, which is mixed with sawdust (15 to 25%) and between 10 and 25% of a modifier, all mixed together with an adhesive. This material may be used as a building block or brick type of product.
The material may be molded to form tiles, wall boards, blocks, bricks, doors or even furniture or the like.
In one form of the invention, foamed concrete or a mixture of foamed concrete and expanded polystyrene (EPS) may be located between two wall board-like sheets of the material of the invention to form a type of pre-cast wall.
In the preferred form of the invention, each board element includes at the ends thereof a protruding formation in the form of a right-angled ridge. When used to form a moulded panel, a pair of boards is arranged with the ridges orientated inwardly toward the interior of the panel to be formed.
The panels formed interengage and include along one vertical end, a channel formation extending into the body of the panel for receiving and engaging a corresponding protruding formation on the opposite end of an adjacent panel in a tongue and groove relationship.
The channel formation preferably engages a vertical steel or the like metal profile affixed to the floor by means of a mounting element. The profile may comprise a channel section in which the arms of the channel include perpendicular flanges dimensioned to cover at least the filler portion of the panel. Panels are located between a framework of the spaced apart steel profiles which are themselves secured in conventional footings.
BRIEF DESCRIPTION OF THE DRAWING
The preferred embodiment of a panel of the invention is described below with reference to the accompanying drawing, Figure 1 which is a section through a panel.
BEST MODE FOR CARRYING OUT THE INVENTION
In the drawing, a panel 10 comprises a pair of moulded boards 12 each having right-angled ridges 14 at their ends. The boards comprise a composite of an inorganic filler material, organic material of fine particulate size, an adhesive or binder and a catalyst to expedite the curing process, all of which are mixed and moulded together with fiberglass sheeting as described above.
A pair of boards 12 are integrally moulded with a filler portion 16 comprising foamed concrete and expanded polystyrene to form the panel 10. One end 18 of the panel has a tongue formation 20 for engaging the opposite end 22 of an adjacent panel, which is formed with a groove or channel. The grooves and tongues preferably engage steel profiles 24 which are anchored in convention footings and provide a framework between which the panels are located.
Claims
1. A composite building material characterized in that it comprises an inorganic filler material, organic material of fine particulate size, an adhesive or binder and a catalyst to expedite a curing process, the materials being mixed and poured into a mould into which one or more sheets of fiberglass sheeting have been laid to produce a molded product which may be cut to size if required.
2. A method of manufacture of a building element characterized in that it includes the steps of mixing an inorganic filler material, a particulate organic material and an adhesive or binder in the presence of a catalyst, then pouring the slurry thus formed into a mould containing one or more sheets of fiberglass and allowing the mixture to cure.
3. A composite building material as claimed in claim 1 characterized in that the inorganic filler material comprises one or more of expanded perlite powder, foamed plastic, magnesia, ash, chloridised magnesium, gypsum or calcium carbonate.
4. A composite building material as claimed in claim 3 characterized in that the inorganic filler comprises 45% of the material by weight.
5. A composite building material as claimed in any of claims 3 or 4 characterized in that the organic material comprises wood sawdust, crop powder or nutshell powder and comprises 5 to 15% of the material by weight.
6. A composite building material as claimed in any of claims 3 to 5 characterized in that the adhesive comprises a polyester adhesive while a polyester resin is employed to provide a waterproof and fireproof finish.
7. A composite building material as claimed in claim 6 characterized in that the binder or adhesive comprises 10 % by weight of the material.
8. A composite building material as claimed in any of claims 3 to 7 characterized in that the catalyst makes up 40% of the material by weight.
9. A composite building material as claimed in any of the above claims characterized in that the material is produced in sheets and cut to size.
10. A composite building material as claimed in any of the above claims characterized in that the material is produced in panel form with a tongue and groove design for ease of construction and for the insertion of a steel profile for reinforcement and fixing.
11. A composite building material as claimed in any of the above claims characterized in that the curing takes place in curing room where temperature is maintained at 60 degrees Celsius and humidity is high, for a period of seven days after which the material is air-dried in the sunshine and painted with a resin lacquer.
12. A composite building material as claimed in any of the above claims characterized in that the mixture varies to produce building products having different applications.
13. A composite building material as claimed in claim 12 characterized in that the filler material comprises between 5 and 15% by weight of recycled plastic, 30 to 40% of perlite powder, 10 to 20% ash, and between 5 and 15% calcium carbonate, which are mixed with an adhesive for application as a middle-layer building element.
14. A composite building material as claimed in claim 12 characterized in that the filler material comprises between 70 and 85 % of chloridised magnesium, between 13 and 18 % magnesia, and between 2 and 17% of a modifier, which are mixed with an adhesive to be used as a surface tile.
15. A composite building material as claimed in claim 12 characterized in that the filler material comprises 25 to 35% magnesia, which is mixed with 15 to 25% sawdust and between 10 and 25% of a modifier, all mixed together with an adhesive to be used as a building block or brick type of product.
16. A composite building material as claimed in any of the above claims characterized in that the material can be molded to form tiles, wall boards, blocks, bricks, doors, furniture or the like.
17. A building element formed according to claims 10 and 16 characterized in that it comprises foamed concrete or a mixture of foamed concrete and expanded polystyrene (EPS) located between two wall board-like sheets of the material of the composite building material to form a pre-cast wall panel.
18. A building element as claimed in claim 17 characterized in that each board element includes at the ends thereof a protruding formation in the form of a right-angled ridge.
19. A building element as claimed in any of claims 17 to 18 characterized in that a pair of boards is arranged with the ridges orientated inwardly toward the interior of the panel to be formed.
20. A building element as claimed in any of claims 17 to 19 characterized in that the panels formed interengage and include along one vertical end, a channel formation extending into the body of the panel for receiving and engaging a corresponding protruding formation on the opposite end of an adjacent panel in a tongue and groove relationship.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| ZA200705346 | 2007-07-05 | ||
| ZA2007/05346 | 2007-07-05 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| WO2009006647A2 true WO2009006647A2 (en) | 2009-01-08 |
| WO2009006647A3 WO2009006647A3 (en) | 2009-03-19 |
Family
ID=40070929
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/ZA2008/000056 Ceased WO2009006647A2 (en) | 2007-07-05 | 2008-07-03 | Building elements and a method of manufacture of preformed building products |
Country Status (1)
| Country | Link |
|---|---|
| WO (1) | WO2009006647A2 (en) |
Cited By (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2471343A (en) * | 2009-06-25 | 2010-12-29 | Perry Day | Gypsum and polymer building profile and a method of using waste gypsum to make a profile |
| RU2500644C2 (en) * | 2012-03-23 | 2013-12-10 | Федеральное государственное бюджетное образовательное учреждение высшего профессионального образования "Казанский государственный архитектурно-строительный университет" КГАСУ | Composition for producing self-supporting heat insulating material and method for production thereof |
| CN104234301A (en) * | 2014-10-15 | 2014-12-24 | 杨海波 | Thermal insulating composite board |
| CN104594552A (en) * | 2015-02-09 | 2015-05-06 | 山东凝华建筑科技有限公司 | Composite foamed gypsum core embedded interior partition wall board and manufacturing method thereof |
| CN105986629A (en) * | 2015-01-30 | 2016-10-05 | 中铁建工集团有限公司 | Light wallboard installation method |
| US10012637B2 (en) | 2013-02-05 | 2018-07-03 | Genia Technologies, Inc. | Nanopore arrays |
| RU186882U1 (en) * | 2018-09-25 | 2019-02-07 | Общество с ограниченной ответственностью "Русский Декор" | DECORATIVE WALL PANEL |
| CN109868911A (en) * | 2019-02-23 | 2019-06-11 | 浙江华锦建筑装饰设计有限公司 | Structure is built in a kind of interim room in quick detachable building site |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN105986635B (en) * | 2016-01-05 | 2020-10-09 | 钟祥鼎茂科技有限公司 | Production process of novel foamed cement purification plate |
| CN105863154A (en) * | 2016-05-31 | 2016-08-17 | 重庆思贝肯节能技术开发有限公司 | Superposed type lightweight wall plate and connection structure thereof |
Family Cites Families (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB1555521A (en) * | 1975-08-07 | 1979-11-14 | Crouzet P A | Composition for use as a concrete substitute |
| FR2400089A1 (en) * | 1977-08-11 | 1979-03-09 | Khoury Fernand | Composite concrete panel with intermediate layer of rigid foam - for insulation and accommodation of thermal expansion |
| JPS62260745A (en) * | 1985-11-19 | 1987-11-13 | チエン チヨン リン | Manufacture of hydraulic material, concrete material and concrete |
| CN100353015C (en) * | 2003-01-28 | 2007-12-05 | 郑志伟 | Composite sandwich wall panel |
-
2008
- 2008-07-03 WO PCT/ZA2008/000056 patent/WO2009006647A2/en not_active Ceased
Cited By (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2471343A (en) * | 2009-06-25 | 2010-12-29 | Perry Day | Gypsum and polymer building profile and a method of using waste gypsum to make a profile |
| RU2500644C2 (en) * | 2012-03-23 | 2013-12-10 | Федеральное государственное бюджетное образовательное учреждение высшего профессионального образования "Казанский государственный архитектурно-строительный университет" КГАСУ | Composition for producing self-supporting heat insulating material and method for production thereof |
| US10012637B2 (en) | 2013-02-05 | 2018-07-03 | Genia Technologies, Inc. | Nanopore arrays |
| CN104234301A (en) * | 2014-10-15 | 2014-12-24 | 杨海波 | Thermal insulating composite board |
| CN105986629A (en) * | 2015-01-30 | 2016-10-05 | 中铁建工集团有限公司 | Light wallboard installation method |
| CN104594552A (en) * | 2015-02-09 | 2015-05-06 | 山东凝华建筑科技有限公司 | Composite foamed gypsum core embedded interior partition wall board and manufacturing method thereof |
| RU186882U1 (en) * | 2018-09-25 | 2019-02-07 | Общество с ограниченной ответственностью "Русский Декор" | DECORATIVE WALL PANEL |
| CN109868911A (en) * | 2019-02-23 | 2019-06-11 | 浙江华锦建筑装饰设计有限公司 | Structure is built in a kind of interim room in quick detachable building site |
Also Published As
| Publication number | Publication date |
|---|---|
| WO2009006647A3 (en) | 2009-03-19 |
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