WO2025114522A1 - Composite loam material, use thereof, additive, and method for producing a loam building material - Google Patents

Abstract

The invention describes a composite loam material having a loam content of at least 35 wt.% and an additive having a glutine glue content and/or a gelling agent content and an acid content.

Description

Composite clay material, its use, an additive and a process for producing a clay building material

The invention relates to a composite clay material, its use, an additive and a process for producing a clay building material.

Clay bricks are well known for their construction purposes. A clay brick is a block of clay formed by hand or with formwork and then air-dried, used in clay construction. Sand is mixed with rich clay and sometimes with fibrous materials such as straw or animal dung from herbivores such as camels, cattle, and horses. Plant fibers reduce weight, improve thermal insulation, and provide tensile strength, thus reducing cracking during drying. In heavy rain, the clay brick softens again. Clay walls must be protected from constant moisture and driving rain. Firing turns a clay brick into a brick, clay tile, or clinker.

Clay is used to make air bricks (green bricks), usually mixed with sand, plant fibers, or other fillers. Too much sand reduces the load-bearing capacity of the bricks, while too much clay causes them to crack. The addition of dry or soaked straw must also be carefully measured. The carefully kneaded, viscous clay mixture is traditionally pressed into rectangular wooden molds, but nowadays it is also often used in metal molds. Once the mass has solidified, the mold frame is removed. Bricks with a high clay content are usually stored in the shade to dry, as rapid evaporation can cause cracks. However, the green bricks can also be exposed to direct sunlight to dry.

To efficiently produce clay bricks with improved load-bearing capacity, mechanical presses can be used. The machine-pressed bricks are referred to as compressed earth blocks (CEB). Bricks to which cement or other binding agents are added for stabilization are referred to as compressed stabilized earth blocks (CSEB) or stabilized earth blocks (SEB). Clay bricks can usually be fully recycled. Mortar and plaster residue from clay can usually be easily removed. Whole and half bricks can be rebuilt. Broken bricks are soaked in water and processed into mortar, plaster, or new clay bricks.

DE 202 21 176.2 discloses a ceiling and wall element with a cooling or heating pipe system integrated into the element for wall and/or ceiling heating according to the radiant heat system. The ceiling and wall element is designed as a statically self-supporting structural element. This structural element is prefabricated. Depending on the position of the installed pipes, a main cooling and main heating side of the structural element can be defined.

DE 102016 101 934 A1 relates to a thermally conductive plaster with a clay base, which has an additive comprising mineral and/or metallic and/or ceramic particles to increase the thermal conductivity.

DE 202009 006 566 U1 relates to a joint filling agent which contains a clay-loam mixture soaked in water as a binding agent and is packaged ready for use in a workable consistency.

DE 197 36 526 A1 relates to a building material mixture made of unfired loam and/or clay with an admixture of plant fibres made of mechanically processed bast fibres, whereby the building material is free of synthetic and/or non-biodegradable additives.

EP 1 172 344 A2 relates to a factory-made dry mortar based on clay powder, aggregates and other conventional additives, which contains 20 to 60 wt.% of setting gypsum.

The disadvantage is that the known clay is designed for the production of clay bricks for building purposes, but no other applications for available and the areas of application and strength of the materials are inadequate.

The object of the invention is therefore to provide a composite clay material and a clay building material which has improved mechanical properties and is easier to process.

Disclosure of the invention

The invention is solved by the subject matter of the independent claims. Advantageous embodiments and further developments are disclosed in the subclaims, the description, and the figures.

The composite material, with a clay content of at least 35 percent by weight and an additive containing a gluten glue content and/or a gelling agent content as well as an acid content, has the advantage that the clay building material made from the composite clay material is easier to process and, in addition, exhibits improved tensile strength, compressive strength, gravitational tensile strength, adhesive strength, shear strength, and abrasion resistance compared to natural clays. Furthermore, the flowability and thus the workability of the composite material are improved. The acid used lowers the processing temperature and reduces susceptibility to mold growth. An acid in a low concentration has a comparatively high water content and can be used for processing without additional water.

In one embodiment, the additive contains at least one organic acid and/or inorganic acid, wherein the organic acid is, in particular, acetic acid, formic acid, lactic acid, tartaric acid, malic acid, or citric acid, while the inorganic acid used is, in particular, hydrochloric acid, sulfuric acid, or nitric acid. Preferably, only organic acids are used, as they are ecologically beneficial and biodegradable.

The additive may also contain water if the viscosity is to be increased, whereby the viscosity depends on the respective further processing purpose. In particular, in a design in which the additive is in dry or powder form and is added to the clay or base clay in dry form is added, the addition of water is not only useful but necessary in order to be able to adjust the desired processing properties of the composite material for the production of building materials, for example stones, load-bearing components and the like.

In a further development, the additive contains sodium carbonate and/or sodium bicarbonate as pore-forming agents, which allows the porosity of the composite clay material to be adjusted. The porosity of the composite clay material also determines the porosity of the finished product or clay building material after drying.

In an advantageous embodiment, the additive has a concentration of between 3% and 75% by weight of glutin glue and/or gelling agent, with glutin glue providing greater strength, water resistance, and flowability compared to plant-based gelling agents. The acid content is between 0.1% and 97% by weight, the water content is between 0% and 97% by weight, and the sodium carbonate and/or sodium bicarbonate content is between 0% and 40% by weight, with the sum of the components of the additive equaling 100% by weight.

If further additives or components are added to the admixture, for example to improve flowability or to change colour and/or mechanical properties, this is not excluded; the other additional components of the admixture are then deducted from the total weight and are not included in the percentage distribution.

In one embodiment, the gelling agent consists of alginic acid, sodium alginate, potassium alginate, ammonium alginate, calcium alginate, agar-agar, carrageenan, locust bean gum, guar gum, tragacanth, xanthan gum, taracrane flour, gellan, pectin, cellulose powder, gelatin and/or modified starch.

To change the mechanical properties, plant fibres, in particular wood fibres, straw, hemp fibres, jute, sisal and/or flax can be added to the composite clay material. Other plant fibres, for example bamboo, can also be added to improve the stability and the contribute to the mechanical properties of the product made from the composite clay material.

In particular, the composite clay material is provided as a processable mixture, for example, it is present together with the glutin glue and/or the gelling agent and the acid in a dry form, so that only water and, if necessary, heat have to be added to adjust the viscosity.

The composite clay material described above is used in particular for the production of a clay building material, whereby water and heat are added to the composite clay material until the mixture reaches the desired viscosity, in particular a viscosity greater than 100 mPas, i.e., a viscosity that allows spraying, spreading, extrusion, pressing, or primary shaping. The mixture of composite clay material and water, and optionally heat, is formed into the desired shape and then dried to produce a finished clay building product, for example, clay bricks, clay panels, clay cardboard panels, lintels, ring beams, and the like.

The mixture is preferably formed into the desired shape using a molding or extrusion process, or by applying the mixture in multiple layers and allowing it to dry. Applying the mixture in multiple layers and allowing it to dry creates a laminate structure within the clay building product and allows for precise adjustment of both the final dimensions and mechanical properties.

To improve the mechanical properties of the clay building products, plant fibers and/or fabrics are added to the mixture in a further development and dried together with the composite clay material.

The additive for producing a composite clay material, which is added to a base clay, comprises 3 wt.% - 75 wt.% glutin glue and/or gelling agent, 0.1 wt.% to 97 wt.% organic and/or inorganic acid, 0 wt.% to 97 wt.% water and 0 wt.% to 40 wt.% sodium carbonate and/or sodium bicarbonate, together making up 100 wt.%. If additional materials are added to the base clay, these are excluded from the weight balance.

In one embodiment, the water content of the additive is reduced so that it is in powder form. Alternatively, the additive is provided in a liquid form that can either be added directly to the base clay or adjusted to the appropriate viscosity by adding water and, if necessary, heat.

For the preparation of the basic mixture of the additive, a ready-to-use glutin glue (liquid), a gelatin (liquid), a glutin glue granulate powder (dry) or gelatin in dry form can be used.

By adding water and, depending on the glutin glue or gelatin used, possibly heat, a liquid form is achieved. If granules/powder are used, they can either be soaked in the measured amount of water (pre-soaking) or added directly to the clay. Pre-soaking reduces the energy required for liquefaction, improves workability, and ensures even distribution throughout the clay building material.

Water can be added either as pure drinking water, distilled water, river water, pond water, sea water or as a water mixture.

The mixture—gluten glue granules or gelatin and water—is then heated in a water bath to the required melting temperature until the granules and gelatin liquefy. The mixture is then stirred to evenly blend the two ingredients.

By adding one or more acids, the processing temperature and susceptibility to mold are reduced.

The added acid dissolves the cell membranes of the gelatin and thus ensures a rapid reaction during heating and thus the Reduction of the processing temperature. At the same time, the very acidic pH value, depending on the amount and concentration of the added acid, reduces or prevents mold growth.

Organic acids such as acetic acid, formic acid, lactic acid, tartaric acid, malic acid, and others can be used, or inorganic acids such as hydrochloric acid, sulfuric acid, nitric acid, and others. The acid should be added after the heating process, as it evaporates at higher temperatures.

The ingredients and processes mentioned above result in the so-called base mixture for the admixture, which can be used in different concentrations depending on the application. If, for example, acetic acid is used in the admixture, a vinegar-lime reaction can occur with the lime naturally occurring in the clay. The CO2 gas produced from the reaction increases the void volume. This volume is maintained by the stabilizing effect of the admixture, which prevents the gas from escaping.

If the void volume needs to be increased even further, a more intense reaction can be generated by adding sodium carbonate or sodium bicarbonate. These reactions also produce CO2, which increases the void volume in the clay building material.

The sodium carbonate/sodium bicarbonate powder is added to the dry or earth-moist clay building material/natural clay. The reaction is activated by adding the additive consisting of glutin glue, water, and acetic acid. The ratio of vinegar to sodium carbonate/sodium bicarbonate must be adjusted to the clay, as no residue of the sodium carbonate/sodium bicarbonate should remain in the building material.

The ingredients and processes mentioned in the previous paragraphs result in the air entraining agent, which can be used in different concentrations depending on the application. By increasing the acid content and water temperature in the base mix, the clay building material is temporarily fluidized. The lower viscosity of the glutin paste used ensures better gliding of the clay components (clay, silt, and sand). This reduces the consistency band, the distance between the clay's flow limit and its rolling limit, as needed, without additional water, allowing for longer workability. After the drying process, the remaining glutin paste ensures the aforementioned strength increases again. The plasticizer can be used to produce clay mortars, clay leveling compounds, and clay thin-bed mortars, for example.

For the base mixture, the air entraining agent and the liquefier, the water components evaporate during the drying process and only the organic components remain.

The base mix, air-entraining agent, and plasticizer have a wide range of applications and varying effects. This wide range and the varying effects result from the various naturally occurring and industrially produced clay mixtures, the different additives such as fibers, fabrics, and different aggregates, the processing methods (e.g., molding, extrusion, etc.), and other factors. The admixtures should be adapted for each application to achieve the optimal mixing ratio. For this purpose, the base mix, air-entraining agent, and plasticizer can be produced in different concentrations as required.

The concentrations of the additive for the composite clay material can be found in the spectra

Glutin glue/gelatin gelling agent 3 - 75 wt.%

Acid 0.1 - 97 wt.%

Water 0 - 97 wt.%

Soda/soda 0 - 40 wt.%.

The concentration information for the additive refers to the

Weight percentage of gluten glue or gelling agent. A 17% concentration means that 17% by weight of glutin glue and/or gelling agent are contained in the additive.

For example, 1 kg of additive requires 170 g of bone glue, 30 g of vinegar essence at a 25% concentration, and 800 g of water. For a 37% concentration, 370 g of bone glue, 67 g of vinegar essence at a 25% concentration, and 563 g of water are used.

One application involves adding 1% by weight of the additive to a base clay, i.e. 1 kg of additive to 999 kg of clay.

When using the 17% admixture at a 1 wt.% concentration, 1 kg of admixture is used per 1000 kg of composite clay material, resulting in an initial 0.17 wt.% glutin glue, specifically bone glue, in the composite clay material. The volatile components and water, respectively, disappear during drying.

In such an application, an increase in the flexural tensile strength or load increase of 50% was measured at 0.17 wt.% glutin glue in the composite clay material when the composite clay material was processed using the compression molding process.

With a 15 wt% share of glutin glue, e.g. bone glue, in the composite material, which was processed using a hand-mixing process, an increase in flexural tensile strength or a load increase of 5000% compared to a clay without additives was observed.

In one application, 60 kg of water, 40 kg of bone glue, and 7 kg of 25% vinegar essence were added to 300 kg of clay and mixed manually to produce load-bearing components. This resulted in a bone glue concentration of 9.83 wt.% in the composite clay material, while the additive had a concentration of 37.38%.

The processing of the base mixture, the air entraining agents and the plasticizer can be introduced into the earth building material or natural clay by atomization or direct addition. Depending on the type of production of the clay building materials, the amount of additives added can vary for the same clay building material.

Using the example of a commercially available clay slab with a 1 wt.% addition of the base mixture (17% solution) of the additive, the following values were achieved:

- Compression molding process with a pressure of 40 N/mm ² Load increase from 1.5 N/mm ² to 2.28 N/mm ²

- Extrusion process with a pressing pressure of 13 N/mm ² Load increase from 1.5 N/mm ² to 1.71 N/mm ²

Application examples

Example 01 : Clay mortar

The developed admixture was added as a base mix to a commercially available clay mortar without added fibers. The addition resulted in increased flexural strength of 15 N/ ^mm² , compressive strength of 20 N/ ^mm² , and bond strength of 2.4 N/ ^mm² . The expected strengths depend on the amount of admixture added, the concentration of the admixture, the type of clay particles, the grain size distribution, the amount of mixing water, the type of reinforcement added (e.g., natural fibers, wood cross-sections, geotextiles), the processing method, and the desired parameters. Even higher strengths can be achieved with optimized grain sizes and mixtures.

Example 02: Surface protection of clay plasters, clay bricks, clay paint, etc.

The developed admixture was added to a sprayer as a base mixture, e.g., at a concentration of 17%. The sprayable admixture is applied to the surface of the selected clay component to be protected. Depending on the surface condition and the desired level of protection, one or more layers may be required. Sorption is reduced slightly to significantly depending on the application.

Using a commercially available clay slab as an example, water penetration was increased from 3 min to 25 h with two layers of the additive.

Using a commercially available solid clay brick as an example, the dissolution in the immersion test with one layer was increased from 11 min to 45 min. Using a commercially available clay paint as an example, cleaning with a damp cloth and a 2% direct application of the additive was possible without any material removal. Less than 0.1 g of abrasion was generated in the standard test. When a commercially available dry clay plaster was sprayed with the above-mentioned additive, the surface exhibited very high abrasion resistance. Less than 0.1 g of abrasion was generated in the standard test.

Example 03: Clay panels

Commercially available clay (cardboard) boards currently have a flexural tensile strength of around 1.5 N/mm ² . With the addition of, for example, the 17% solution of the base mixture with a 1% addition to the clay mixture, the flexural tensile strength of the clay (cardboard) board can be increased to 2.28 N/mm ² in the compression molding process.

Example 04: Clay leveling compound

For a clay without added fiber, the plasticizer, at a concentration of 37%, was added at a temperature of 40 °C (mixing water and admixture) to the clay mortar prepared according to the manufacturer's instructions. The slump increased from 175 mm beyond the edge of the measuring device.

Example 05: Clay insulationZ-clay porous bricks

For a clay without added fibers, the air-entraining agent was added at a concentration of 25% at a rate of 15%. The bulk density was reduced from 1600 kg/ ^m³ to 610 kg/ ^m³ , while retaining a compressive strength of 5 N/ ^mm² .

Example 06: Load-bearing clay componentsZ-hybrid components

For the production of a load-bearing earth component, a high concentration of gluten is used in the admixture. The final product should exhibit high strength and reduce reversibility. The use of reinforcement (e.g., bamboo tube fibers, etc.), combined with the high adhesive strength of the composite clay, i.e., grain-posite clay material, can produce strength values exceeding 20 N/ ^mm² .

Example: clay lintel in layered construction without reinforcement A clay was mixed with 20% of a 37% solution of the additive and processed into a slab. After drying, the slab was cut lengthwise into strips, for example, 11.5 cm wide. These strips were bonded together in a layered system using the same clay mixed with 20% of a 37% solution of the additive until the lintel dimensions were reached. In the test, flexural tensile forces of 13 N/ ^mm² and compressive forces of 18.6 N/ ^mm² were achieved for a lintel measuring 1250 x 115 x 71 mm.

Example: hybrid clay lintel in layered construction

A clay was mixed with 20% of a 37% solution of the additive and processed into a board. After drying, the board was cut lengthwise into strips, for example, 11.5 cm wide. These strips were then bonded together in a layered system with the same clay mixed with 20% of a 37% solution of the additive, with inserted plywood panels until the lintel dimension was reached. In the test, bending tensile forces of 21 N/ ^mm² and compressive forces of 24 N/ ^mm² were achieved.

Example 07: Sealing

For example, a clay is mixed with 30% of a 37% solution of the additive. The resulting composite clay is applied to a sand-lime brickwork in the ground using a trowel, e.g., a thickness of 5 mm. After the composite clay has dried, it is preserved with a previously tamped layer of clay/loam, e.g., 10 cm thick, and the remaining excavated pit is left to decay. When the composite clay comes into contact with groundwater, it forms a gel-like layer on the surface and prevents water penetration.

In one test, the 5 mm thick waterproofing membrane was tested for one week with groundwater directly at the surface. Only the first 3 mm of the composite clay was stimulated to swell. The underlying KS masonry was completely shielded from groundwater during this time.

Example 08: Thin-walled clay moldings

Example: Clay sound insulation element with natural fiber reinforcement

For example, a clay is mixed with 30% of a 37% solution of the additive. The resulting composite clay is evenly mixed with 5% by volume of hemp wool as fiber reinforcement. The finished mixture is then vibrated into the desired shape. In the test, a hemisphere with a mounting frame was produced with Dimensions L x W x H = 500 x 500 x 150 cm and a material thickness of 7 mm. The compressive strength was 22 N/mm ² .

Example 09: Injection clay mortar

For anchoring in clay building materials, e.g., for bonding masonry anchors, clay is mixed with, for example, 25% of a 40% solution of an admixture with slightly swelling properties. The resulting injection clay mortar can be injected into a conically positioned drill hole, and the masonry anchor is bonded into it. In the test, a commercially available rammed earth wall failed under a tensile load of 55 N/ ^mm² . The injection was undamaged.

Example 10: Clay in furniture production

Example: Clay chair

For example, a clay is mixed with 30% of a 45% solution of the additive. The resulting composite clay is evenly mixed with 5% by volume of hemp wool as fiber reinforcement. Before the finished composite clay mass is poured into the mold, threaded metal attachments are inserted as attachment points for the chair legs. The finished mixture is then vibrated into the desired combined seat and backrest shape.

Example 11 : Clay 3D printing

To use the composite clay in 3D printing, the ready-to-use clay is transported to the nozzle of the 3D printer. Only at the nozzle is the additive, e.g., a 30% solution of a 45% solution, injected into the clay under high pressure. As the temperature drops, the clay applied from the printer's nozzle gains a high initial strength, allowing subsequent layers to be applied directly without causing the material to sag. Because the surface of the composite clay is not yet completely dry, a monolithic bond is created between the individual layers.

Example 12: Clay bricks

Clay bricks currently on the market have a compressive strength of brick class 6. With the addition of, for example, the 17% solution of the base mixture, with 1% addition to the clay mixture, the compressive strength of the clay bricks can be increased to 10 N/mm ² in The strength can be increased by molding. The grain size of the clay contributes significantly to the degree of strength increase.

The invention thus made it possible to achieve significant, maximum possible load increases:

- Compressive strength up to 20 N/mm ² and thus 2.6 times that of commercially available clay with 7.5 N/mm ²

- Flexural strength up to 15 N/mm ² , 50 times that of commercially available clay with 0.31 N/mm ²

- Adhesive strength up to 2.4 N/mm ² , 24 times that of commercially available clay with 0.1 N/mm ²

- Abrasion resistance: Abrasion less than 0.01 g and thus 70 times lower than commercially available clay with 0.7 g

- Water resistance varies depending on the size of the component, e.g. 4 x 4 x 16 cm, duration 6 h, regular 5 min

- Porosity 300 kg/m ³ and thus 7 times lower than commercially available clay with 2000 kg/m ³ .

Furthermore, a composite clay material, its use, a method for producing a clay building material, and an additive for producing the composite clay material are disclosed. The clay can be strengthened with an additive. The resulting clay building material includes, in particular, clay masonry mortar, clay plaster mortar, clay filler, clay reinforcement compound, clay adhesive, clay screed, clay paint, rammed earth, clay bricks, clay (cardboard) panels, load-bearing components such as lintels, ring beams, and possibly others. The clay building material made from such a composite clay material is suitable for the installation of underfloor heating and, in one embodiment, comprises a clay mortar for an underfloor heating installation system in a clay screed.

The installation system uses clay mortar, which bonds the various elements together. The clay mortar contains additives that can be varied in quantity and composition, allowing the admixture to be adapted to different base clays and be used flexibly. The additives form the admixture that can modify the properties of the clay building materials made from the composite clay material. Depending on the quantity, concentration, and mixing ratio of the individual ingredients, parameters such as tensile/compressive/flexural/shear strength, abrasion resistance, and/or water resistance of the finished building material or product can be increased. The flowability, adhesive strength, and other properties such as porosity of earth building materials and natural clays can be increased many times over. The properties of the composite clay material and the earth building material are influenced, and the admixture can even induce foaming. The additives used are biodegradable and sustainable. Stabilizing and foaming additives can be added to the clay mortar.

The additive can be added directly or by spraying to a clay material - an industrially produced clay - or a naturally occurring clay, or applied to clay surfaces.

To stabilize, increase the flowability, or foam clay building materials, the additives bone glue granules, vinegar essence (25%), and water are used. The bone glue granules are either soaked in the measured water and allowed to swell for 24 hours, or processed without pre-swelling. The mixture of bone glue and water is heated in a water bath between 50 and 60°C and stirred continuously until the bone glue granules have liquefied and mixed with the water. The vinegar essence is then added while stirring. The vinegar essence dissolves the cell membrane in the bone glue, making it workable at room temperature. When the additive is added to a clay building material, the clay absorbs the additive due to its high cohesive strength and bonds with it. Crystal-like compounds form, increasing the overall stability. The small addition of vinegar essence allows minimal swelling of the clay mixture, but the addition of vinegar essence is necessary to prevent mold growth during the drying process.

The basic mixture contains 300g clay mortar, 40g bone glue granules, 60g tap water and 7g vinegar essence (25%).

The determined strengths are:

Bending tensile strength = 10 N/mm ² , compressive strength = 20 N/mm ² The 40 g of bone glue from the original recipe can alternatively be substituted for other glutin glues or pure gelatin. Glutin glues are impure (e.g., bone glue, hide glue, rabbit glue, fish glue) and still contain residual substances (e.g., meat scraps, animal fur, solvents from manufacturing). Purified glutin glue is gelatin (pure) and therefore virtually odorless. Depending on the purity of the glue/gelatin used, the properties may vary when used with clay products. This may result in increased mold growth, reduced strength, a lower processing temperature, or more difficult processing.

To increase resistance and bond strength, clay mortars and clay fillers containing the additives can be used. Any base mortar or clay filler from a clay manufacturer is used in conjunction with the developed additive. The increase in strength and bond strength can be controlled by the amount of additive. The properties will vary depending on the manufacturer's base mortar due to natural mixing ratios and must be determined before each distribution.

To increase flowability, clay mortar, clay leveling compound, and/or clay leveling compound can be used. For example, any base mortar or clay filler from a clay manufacturer with an additive (increased water content) can be used. The increase in flowability can be controlled by the amount of water. Shrinkage cracks are possible depending on the clay content of the base material. The properties will vary depending on the manufacturer's base material due to natural mixing ratios and must be determined before each sale.

To achieve clay insulation, the amount of vinegar essence can be increased and the amount of water added reduced, thus creating the effect of foaming the clay. Adding baking soda to the clay base material as needed can intensify the foaming process. This can create larger air pores. The baking soda is mixed into the clay building material and then added shortly before processing. Depending on the amount of vinegar essence and the Soda reduces the load-bearing capacity and density of the clay. Foam-like structures form. This mixture can be molded into insulation panels. These can be used as floor or wall insulation.

One embodiment may include, in particular, 1200g of clay mortar, 120g of bone glue granules, 70g of tap water, 130g of vinegar essence (25%), and 12g of baking soda. The strength values may be, for example, 5.5 N/ ^mm² for the flexural tensile strength and 12 N/ ^mm² for the compressive strength.

To increase resistance and bond strength, for lintels and ring beams with additional reinforcement (e.g., bamboo rods), as well as for clay blocks, any base mortar from a clay manufacturer is used in combination with the developed additive. The load-bearing component is created from individual thin layers. For production, an approximately 10 mm thick slab is produced from the specified mixture and in the desired length/width. After the drying process, the individual slabs are mortared together using the same material until the desired component dimensions are achieved. The increase in strength and bond strength can be controlled by the amount of additive. The properties will vary depending on the manufacturer's base material due to naturally occurring mixing ratios and must be determined before each distribution.

To increase the resistance and resulting load transfer of clay building boards or clay plasterboards with load transfer, any base mortar, clay filler, any clay building board mix, or rammed earth from a clay manufacturer is used in combination with the developed additive and inserted reinforcement (e.g., jute fabric) or paper glued to the outer surfaces, as with plasterboard. The increase in strength and adhesive force can be controlled by the amount of additive. To prevent the high-strength material from chipping when screwing or nailing, the clay content in the original clay building material must be increased. This results in a fracture pattern similar to that of plasterboard. The properties will vary depending on the manufacturer's base material due to naturally occurring mixing ratios and must be determined before each sale. If the additive is to be used later for storage/transport, it is filled into suitable containers after the described manufacturing process at the required temperature of 50°C - 60°C and sealed. Cooling creates a vacuum in the container, which preserves the additive. Depending on the desired processing temperature, the additive may need to be briefly heated in a water bath.

To create clay underfloor heating, i.e. underfloor heating in clay screed, a clay mortar with the additive and prefabricated clay modules, in particular rammed earth modules, are used. To create the (rammed) clay modules, 7.5 kg of 0/8 rammed earth is used, which is mixed with the water content specified by the manufacturer and placed in a steel mold with the internal dimensions W x H x H = 300 x 400 x 100 mm. The rammed earth mixture is processed without the additive. The rammed earth mixture is pressed in the steel mold using a suitable press with 13.33 N/ ^mm² , the formwork is removed and then dried on a suitable base. To prevent the module from cupping, the support surface must be kept as small as possible during drying. The pressed modules have dimensions of L x W x H = 400 x 300 x 27 mm. The dried modules can be stacked and stored on a Euro pallet.

The installation of the underfloor heating begins with the clay leveling compound. This is applied to the subfloor depending on the structure (floating, composite), and the first layer of clay modules is laid on the clay leveling compound. Installation is carried out using T-joints. The joints are sealed with clay mortar with additives during installation. Additional clay modules are then cut to the pipe spacing (e.g., 95 x 400 mm). The cut clay modules form the second layer, in which the heating pipe is laid. The surface of the clay modules in the first layer is brushed with a little water shortly before applying the clay mortar with additives to create a bond between the clay mortar with additives and the clay modules. The cut clay modules are then laid in the clay mortar with additives at the pipe spacing, and the installation joint for the heating pipe is limited with spacers (e.g., heating pipe remnants). The excess mortar with additives is removed from the installation joint so that the heating pipe can be installed in accordance with the standards after it has dried. Once the second layer has been laid, a drying time of 1 - 2 days must be observed, depending on the room climate. After the drying time, the heating pipe (e.g. PE-RT, PE-XE, PE-XC, aluminum composite pipe) is inserted into a newly applied bed of clay mortar with additive in the installation joint and then covered with the clay mortar with additive. Immediately afterwards, just before the clay mortar with additive is applied, the surfaces of the clay modules are brushed with a little water to create a bond between the clay mortar with additive and the clay modules. The third layer of clay modules is laid in the subsequently applied clay mortar with additive. Installation is carried out using T-joints. The joints are glued with the clay mortar with additive during installation. Excess mortar on the surface is removed. This upper layer must again dry for 24 hours. The created floor surface is then leveled with a clay filler using the additive required for the surface quality. The surface of the installed clay modules must be brushed with water again before the leveling compound is applied. After the leveling compound has dried, approximately after 24 hours, the surface can be treated or designed as desired. The surface is to remain visible, it must be protected against moisture. This can be done with carnauba wax. If, for example, laminate or parquet flooring is chosen, the impact sound insulation and the floor covering can be laid directly onto the untreated surface of the clay leveling compound.

The thickness of the clay underfloor heating system can be selected in 30 mm increments depending on the design (floating, composite) and the desired installation height. The minimum is two layers (60 mm), a heating pipe layer and a heat distribution layer. The maximum is limited by the structural conditions. The flexural tensile strength can be 3.32 N/mm² and the compressive strength 3.31 N/ ^mm² .

The clay building material according to the invention has the advantage that, through the use of additives, an additive is formed that can positively modify the properties of clay building materials, particularly for the installation of underfloor heating systems. Depending on the amount of the individual ingredients, parameters such as tensile/compressive/flexural/shear strength, flowability, affect the adhesive strength and cause foaming. The additives used are biodegradable and sustainable,

Reuse/Recycling/Disposal

The clay material to be recycled with additives (e.g., clay mortar with additives) is crushed and soaked in water. Warm water accelerates the soaking process. A calculated amount of vinegar essence must be added to the water to prevent mold growth, as the vinegar essence degrades during the initial processing. The softened material can then be reincorporated into the manufacturing process. Depending on the purity of the recycled material, almost the original strength can be achieved again. However, this must be re-determined before use.

If a clay building material made from or with a composite clay material is to be disposed of, it can be returned to nature. Environmental influences such as precipitation and naturally occurring microorganisms and molds convert the additive, in the case of purely organic additives, into plant-available nitrogen.

Further advantages and advantageous embodiments of the invention can be found in the following description of the figures, the drawings and the claims.

An exemplary embodiment of the inventive solution is explained in more detail below with reference to the attached schematic drawings. It shows:

Fig. 1 shows a three-layer clay underfloor heating system in longitudinal section, Fig. 2 shows a two-layer clay underfloor heating system in longitudinal section, Fig. 3 shows a clay module layer in a plan view, Fig. 4 shows the clay module layer for the two- or three-layer clay underfloor heating system in a plan view

Fig. 5 shows the clay module layer with a heating pipe in plan view and Fig. 6 shows the clay module layer with a filled surface in plan view. Fig. 1 illustrates the use of a clay building material 100 for a clay underfloor heating system 10, in this embodiment a 3-layer clay underfloor heating system 12. To stabilize, increase the flowability, or foam the clay building material 100, an additive comprising bone glue granules, vinegar essence (25%), and water is added. The 3-layer clay underfloor heating system 12 has a floating structure. Three layers of a clay module 14 are formed. To create the clay underfloor heating system 10, i.e., an underfloor heating system in a clay screed, a clay mortar 18 with an additive and prefabricated clay modules 14 are used. Additives can include, in particular, bone glue granules, vinegar essence (25%), and water. For the construction of the clay modules 14, 7.5 kg of 0/8 rammed earth are used in this example, which is mixed with the water content specified by the manufacturer and placed in a steel mold with the internal dimensions WXLXH = 300 x 400 x 100 mm.

The rammed earth mixture is processed without the additive. The rammed earth mixture is pressed into a steel mold using a suitable press at 13.33 N/ ^mm² , removed from the formwork, and then dried on a suitable support. To prevent the module from warping, the support surface must be kept as small as possible during drying. The pressed clay modules (14) have dimensions of L x W x H = 400 x 300 x 27 mm. The dried clay modules (14) can be stacked and stored on a Euro pallet.

The surface is formed from a clay filler 16 containing an additive. Between two clay modules 14, a clay mortar 18 with an additive is formed. A heating pipe 20 is arranged in this clay mortar 18. A clay module 14 rests on a clay leveling compound 22, also containing an additive. A bottom side facing towards a floor has a seal 24 and insulation 26. To achieve insulation 26 designed as clay insulation, the amount of additive, in particular vinegar essence, can be increased and the amount of water added can be reduced, thereby creating the effect of foaming the clay. If baking soda is added to the clay starting material as needed, the foaming process can be intensified. The baking soda is mixed into the clay building material 100 and then the additive is added shortly before processing. This way, depending on the amount of vinegar essence and baking soda, the The load-bearing capacity and density of the clay are reduced. Foam-like structures form. Using a mold, insulation panels for insulation 26 can be created from this mixture. These can be used as floor or wall insulation. The exemplary embodiment may include, in particular, 1200 g of clay mortar 18, 120 g of bone glue granules, 70 g of tap water, 130 g of vinegar essence (25%), and 12 g of baking soda. The strength values can be, for example, 5.5 N/ ^mm² for the flexural tensile strength and 12 N/ ^mm² for the compressive strength.

Fig. 2 shows the use of a clay building material 100 for a clay underfloor heating system 10, in this second embodiment of a 2-layer clay underfloor heating system 24. Two layers are formed from two clay modules 14. The clay mortar 18 with additive is arranged between these two layers. A heating pipe 20 is embedded in this clay mortar 18. An upper cover is formed from a clay filler 16 with additive. The clay leveling compound 22, comprising an additive, rests on a concrete ceiling 26.

Clay mortar 18 is used for an installation system, which bonds different elements together. Clay mortar 18 includes additives that can be used flexibly. The additives, for example, the base mix, which consists of 300 g of clay mortar, 40 g of bone glue granules, 60 g of tap water, and 7 g of vinegar essence (25%), form the admixture that can modify the properties of clay building materials. Depending on the amount of the individual ingredients, parameters such as tensile/compressive/flexural/shear strength, flowability, and adhesive strength can be influenced, and foaming can be created. The additives used are biodegradable and sustainable. Stabilizing and foaming additives can be added to Clay mortar 18. |

For the installation of the underfloor heating, as described above, we start with the clay leveling compound 22. This is applied to the subfloor depending on the structure (floating, as a composite), and the first layer of clay modules 14 is laid on the clay leveling compound 22. The installation is carried out with T-joints. The joints are glued with a clay mortar 18 with additive during installation. Then, additional clay modules 14 are cut to the pipe spacing (e.g., 95 x 400 mm). The cut clay modules 14 form the second layer, in which the heating pipe 30 is laid. Shortly before applying the clay mortar 18 with additive, the surface of the clay modules 14 of the first layer is brushed with a little water to create a bond between the clay mortar 18 with additive and the clay modules 14. The cut-to-size clay modules 14 are then laid in the clay mortar 18 with additive at a pipe spacing of 28 mm, and the installation joint for the heating pipe 30 is limited with spacers (e.g., heating pipe remnants). The excess clay mortar 18 with additive is removed from the installation joint to allow the heating pipe 30 to be installed in accordance with standards after drying. Once the second layer has been laid, a drying time of 1 to 2 days must be observed, depending on the room climate. After the drying time, the heating pipe 30 (e.g., PERT, PE-XE, PE-XC, aluminum composite pipe) is inserted into a newly applied bed of clay mortar with additive in the installation joint and then bridged with clay mortar 18 with additive. Immediately afterwards, shortly before applying the clay mortar 18 with additive, the surfaces of the clay modules 14 are brushed with a little water to create a bond between the clay mortar 18 with additive and the clay modules 14. The third layer of clay modules 14 is laid in the subsequently applied clay mortar 18 with additive. Installation is carried out using T-joints. The joints are glued with the clay mortar 18 with additive during installation. Excess clay mortar 18 on the surface is removed. This upper layer must again dry for 24 hours. The created floor surface is then filled with a clay filler 16 with the additive required for the surface quality. The surface of the installed clay modules 14 must be brushed with water again before the filler of the clay filler 16 is applied. After the filler has dried, approximately after 24 hours, the surface can be treated or designed as desired. If the surface is to remain visible, it must be protected against moisture. This can be done with carnauba wax. If, for example, a laminate or parquet floor is chosen, the impact sound insulation and the floor covering can be laid directly on the untreated surface of the clay filler 16.

Fig. 3 shows a layer of a clay module 14. This layer is formed in a floating structure in a clay leveling compound 22. Shown is a laying pattern for this floating layer of the clay module 14. To increase the resistance and adhesive strength, clay mortar 18 and clay filler 16, containing the additives, are used. Any A base mortar or clay filler 16 from a clay manufacturer is used in conjunction with the developed additive. The increase in strength and adhesive strength can be controlled by the amount of additive. The properties will vary depending on the manufacturer's base mortar due to natural mixing ratios and must be determined before each distribution.

To increase flowability, clay mortar 18, a clay leveling compound, and/or a clay leveling compound can be used. For example, any base mortar or clay filler 18 from a clay manufacturer with the additive (increased water content) is used. The increase in flowability can be controlled by the amount of water. Shrinkage cracks are possible depending on the clay content of the base material. The properties will vary depending on the manufacturer's base material due to natural mixing ratios and must be determined before each distribution.

Fig. 4 shows a layer of a clay module 14 cut into a clay leveling compound 22 in a composite structure. The clay module 14 can also be arranged in a clay mortar 18, wherein the clay mortar 18 contains an additive. The clay leveling compound 22 is dried for approximately 24 hours. Spacings 28 are provided for heating pipes 30.

Fig. 5 shows the installation of a 30 mm heating pipe. The thickness of the clay underfloor heating system can be selected in 30 mm increments depending on the structure (floating, composite) and the desired installation height. The minimum is two layers (60 mm): a heating pipe-carrying layer and a heat distribution layer. The maximum is limited by the structural conditions. The flexural tensile strength can be 3.32 N/ ^mm² , and the compressive strength 3.31 N/ ^mm² .

Fig. 6 shows a clay module 14 in a clay mortar 18 with an additive, which is to be dried for 24 hours. The surface is then filled with a clay filler 16 with an additive.

The invention also relates to 1. a clay building material (100) with a clay mortar (18), with which different elements can be bonded together, for a laying system of an underfloor heating system in a clay screed, characterized characterized in that the clay building material (100) comprises additives which can be used flexibly and are formed from an additive mixture, whereby the properties of the clay building materials (100) can be changed and, depending on the variance of the individual ingredients of the additives, the parameters tensile, compressive, flexural, shear strength and flowability and an adhesive force can be influenced.

It also relates to 2. a clay building material (100) according to point 1 ., characterized in that the clay building material (100) comprises clay masonry mortar, clay plaster mortar, clay filler, clay reinforcing compound, clay adhesive, rammed earth, clay bricks, clay panels, clay cardboard panels, lintels and ring beams.

It also relates to 3. a clay building material (100) according to point 1 or 2, characterized in that an additional mixture of bone glue granules, 25% by weight of vinegar essence and water is formed for stabilizing, increasing the flowability or foaming the clay building materials (100).

It also relates to 4. a clay building material (100) according to one of the preceding points 1 to 3, characterized in that the additive mixture comprises 300 g of clay mortar, 40 g of bone glue granules, 60 g of tap water and 7 g of 25% vinegar essence.

It also relates to 5. a clay building material (100) according to one of the preceding points 1 to 4, characterized in that for the production of insulating devices, soda is added to the clay building material (100) and mixed therein together with the additive mixture, so that the process of foaming of the clay building material (100) is intensified.

It also relates to 6. a clay building material (100) according to point 5, characterized in that the clay building material (100) comprises, in order to achieve larger air pores, 1200 g of clay mortar, 120 g of bone glue granulate, 70 g of tap water and 130 g of 25% vinegar essence, as well as 12 g of baking soda, and the strengths for the flexural tensile strength are 5.5 N/mm ² and for the compressive strength 12 N/mm ² . It also relates to 7. a clay building material (100) according to one of points 1 to 6, characterized in that the heating pipe is made of PE-RT, PE-XE, PE-XC, or an aluminum composite.

It also relates 8. to a method for producing a clay building material (100) with underfloor heating in a clay screed according to one of points 1 to 7, with the following steps: a. producing prefabricated clay modules (14) by b. mixing a 0/8 rammed earth and mixing with water c. pouring into a mold d. pressing in the mold e. drying f. applying a clay leveling compound (22) to a substrate g. laying out a first layer of clay modules (14) on a clay leveling compound (22) h. producing a clay mortar (18) comprising an additive, and i. bonding joints with the clay mortar (18) j. producing a bond between the clay modules (14) and the clay mortar (18) with the additives by applying water to a surface of the first layer k. cutting further clay modules (14) to a pipe spacing l. Forming a second layer with the cut clay modules (14) m. Drying n. Inserting a heating pipe into a newly laid bed of clay mortar (18) with additive into a laying joint o. Covering with the clay mortar with additive.

It also relates to 9. A method according to point 8, characterized in that after step o) an application of at least one further layer takes place after a drying phase of the surface of the second layer and after a subsequent brushing of the surface of the clay modules (14) with water and the application of a further clay mortar (18) with an additive. It also relates to 10. a method according to point 8. and/or 9., characterized in that as a further method step a floor surface created thereby is filled with a clay filler (16) with an additive depending on the surface quality requirements, wherein the surface of the laid clay modules (14) is brushed again with water before the filler of the clay filler (16) is applied and after the filler has dried, the surface is treated or designed.

It also relates to 11. a method according to point 10, characterized in that the surface is protected against moisture by the application of a carnauba wax, whereby the surface remains visible.

It also relates to 12. a method according to point 10, characterized in that during the subsequent application of a floor covering in the formation of a laminate or parquet floor, an impact sound insulation and the floor covering are laid directly on the untreated surface of the clay filler compound of the clay filler (16).

It also relates 13. to a method according to one of points 8 to 12, characterized in that 7.5 kg of 0/8 rammed earth are used to produce the clay modules (14), which rammed earth is mixed with a suitable water content and placed in a mold designed as a steel mold with the internal dimensions WXLXH = 300 x 400 x 100 mm, the rammed earth mixture being processed without any additives and the rammed earth mixture being pressed in the steel mold with a suitable press at 13.33 N/mm ² , stripped of the formwork and then dried on a suitable base, and in order to avoid the clay module (14) cupping, the contact surface of the clay module (14) is kept as small as possible during drying, the pressed clay modules (14) having a dimension LXBXH = 400 x 300 x 27 mm.

It also relates to 14. a method according to one of points 8 to 13, characterized in that the joints of method step i) are formed as T-joints and the T-joints are glued with the clay mortar (18) with additive during laying and excess clay mortar (18) is subsequently removed from the surface. It also relates to 15. a method according to one of points 8 to 14, characterized in that the clay levelling compound (22) is formed either in a floating manner or as a composite and is applied to a respective substrate.

All features presented in the description, the following claims and the drawings can be essential to the invention both individually and in any combination with one another.

List of reference symbols

10 - Clay underfloor heating

12 - 3-layer clay underfloor heating

14 - Clay module

16 - Clay filler

18 - Clay mortar

20 - Heating pipe

22 - Clay leveling compound

24 - 2-layer clay underfloor heating

26 - Concrete ceiling

28 - Distance heating pipe

30 - Heating pipe

100 - Clay building material

Claims

Claims 1. Composite clay material with a clay content of at least 35% by weight and an additive containing a glutinous glue content and/or a gelling agent content and an acid content. 2. Composite clay material according to claim 1, characterized in that the additive contains at least one organic acid and/or inorganic acid. 3. Composite clay material according to claim 2, characterized in that the organic acid is acetic acid, formic acid, lactic acid, tartaric acid, malic acid or citric acid and the inorganic acid is hydrochloric acid, sulfuric acid or nitric acid. 4. Composite clay material according to one of the preceding claims, characterized in that the additive contains water. 5. Composite clay material according to one of the preceding claims, characterized in that the additive contains sodium carbonate and/or sodium bicarbonate as pore former. 6. Composite clay material according to claim 2, 3 and 5, characterized in that the concentration in the additive contains 3 wt.% - 75 wt.% glutin glue and/or gelling agent, 0.1 wt.% to 97 wt.% organic and/or inorganic acid, 0 wt.% to 97 wt.% water and 0 wt.% to 40 wt.% sodium carbonate and/or sodium bicarbonate, together making up 100 wt.%. 7. Composite clay material according to one of the preceding claims, characterized in that the gelling agent consists of alginic acid, sodium alginate, potassium alginate, ammonium alginate, calcium alginate, agar-agar, carrageenan, locust bean gum, Guar gum, tragacanth, xanthan gum, taracrane flour, gellan gum, pectin, cellulose powder, gelatin and/or modified starch. 8. Composite clay material according to one of the preceding claims, characterized in that it comprises plant fibers, in particular wood fibers, straw, hemp fibers, jute, sisal and/or flax. 9. Composite clay material according to one of the preceding claims, characterized in that it is provided as a processable mixture. 10. Use of the composite clay material according to one of the preceding claims for the production of a clay building material, in particular clay bricks, clay plaster, clay mortar, clay filler, clay reinforcing compounds, clay screed, clay paint, clay leveling compound, clay adhesive, clay panels, clay cardboard panels, lintels, ring beams or rammed earth. 11. A process for producing a clay building material with a composite clay material according to one of claims 1 to 9, characterized in that water and heat are added to the composite clay material until the mixture reaches a viscosity greater than 100 mPas and the mixture is brought into the desired shape and dried. 12. The method according to claim 11, characterized in that the mixture is brought into the desired shape by a molding process or extrusion process or by repeated layer-by-layer application and drying. 13. A method according to claim 11 or 12, characterized in that plant fibers and/or fabrics are introduced into the mixture. 14. Additive for producing a composite clay material according to one of claims 1 to 9, characterized in that the additive contains 3 wt.% - 75 wt.% glutin glue and/or gelling agent, 0.1 wt.% to 97 wt.% organic and/or inorganic acid, 0 wt.% to 97 wt.% water and 0 wt.% to 40 wt.% sodium carbonate and/or sodium bicarbonate, together making up 100 wt.%. 15. Additive according to claim 14, characterized in that the water content is low that it is in powder form.