The invention relates to the field of construction. More specifically, it relates to a method for making a building from prefabricated and interlocking elementary bricks, made from a material comprising plant fibers (hemp, straw, flax, etc.) agglomerated using a binder (in particular dirt, non-hydraulic or hydraulic lime).
The use of plant fibers to construct buildings, and more specifically to produce walls and partitions, has been known for some time. Examples include laterite mud, made up of a matrix of clay (or more generally dirt) and agglomerated plant fibers (in particular straw).
Hemp fibers have also been used in construction. One traditional technique consists of preparing a concrete (commonly, although wrongly, called hemp “concrete”) in situ from a plant aggregate (hemp chaff) and a binder (non-hydraulic or hydraulic lime), and filling a wooden framework wall using such a concrete.
Hemp concrete may also be used to produce concrete slabs, insulating coats, or insulation per se, which is for example poured into the rakes of a roof before placing a cover.
A number of recipes and applications exist for hemp concrete. The Association Construire en Chanvre specifically defined hemp concrete and formulated professional rules for building with hemp concrete. These rules were published in a volume entitled Construire en Chanvre (ISBN 978-2-915162-92-9). For an exhaustive list of works, articles and publications relative to hemp-based construction, see the bibliography published on the Association's website: http://www.construction-chanvre.asso.fr/.
While the ordinary techniques, today offered by several companies (including the company BCB, which offers hemp concrete under the Tradical registered trademark), may be deemed satisfactory in terms of mechanical, acoustic and thermal performance (greater than or equal to that of ordinary quarry stone constructions), they are nevertheless flawed by a high degree of technicality and difficult implementation, which limit their use to building professionals.
Techniques have been proposed to resolve these drawbacks and democratize the use of hemp in construction. One of these techniques, described in French patent application FR 2 871 487 in the name of the company Développement Construction Ecologique (see also the American equivalent US 2008/272270), consists of making a wall from prefabricated blocks that are assembled in situ. These blocks are provided with vertical shafts in which wooden posts are inserted to form a framework. The shafts are then sealed in the blocks using a filler, such as a binder of the lime milk type.
It is true that the use of prefabricated blocks makes it possible to save on the on-site preparation of the hemp concrete. However, the savings are marginal, since the insertion, then sealing of many posts in the shafts of the blocks are lengthy and tedious operations, which also require the in situ preparation of a large quantity of binder.
Due to the aforementioned drawbacks of the known techniques, including the most recent, the share of hemp concrete in construction is progressing little if at all, traditional quarry stone construction continuing to represent the vast majority of the market.
The invention aims to improve the use of plant fibers (in particular hemp) in construction, by proposing an implementation that is both simple and fast, capable of equaling or even surpassing the ordinary construction techniques (in particular terra cotta bricks or cement concrete quarry stone).
To that end, the invention first proposes a method for constructing a building using prefabricated bricks made from a material (such as hemp concrete) comprising plant fibers agglomerated using a binder, provided with grooves and tongues allowing the dry-joint connection thereof.
According to one embodiment, this method comprises the combined placement of solid base bricks, provided with a groove and a tongue that can be joined together, and honeycomb stiffening bricks, provided with a groove and a tongue, that can be joined together as well as a cell with the passage of a reinforcing post.
The following operations may be provided:
Each post for example comprises a metal framework embedded in (cement) concrete.
It is also possible to provide an operation for placing, at a post and above the stiffening brick, a half-stiffening brick, provided with a tongue to allow it to be joint-connected on the stiffening brick and a cell for the passage of the post, and having a length equal to half the length of the stiffening brick.
The following operations may also be provided:
Likewise, the following operations may be provided:
The invention secondly proposes, for the implementation of the aforementioned method, a hemp concrete brick, provided with a tongue designed to be joint-connected in a groove, said tongue having a protrusion whereof the ratio to an effective height or effective width of the brick is comprised between 1/10 and 1/4, preferably approximately 1/5.
According to one embodiment, the tongue also has a width whereof the ratio to an effective width of the brick is comprised between 1/4 and 1/2, preferably approximately equal to 1/3.
Other aims of advantages of the invention will appear in light of the following description, done in reference to the appended drawings, in which:
The proportions by volume of the preferred composition are as follows: hemp chaff 73%; non-hydraulic lime 8%; quick-setting cement 4%; water 15%, i.e., for 100 l (10 kg) of hemp chaff, approximately 11 l of non-hydraulic lime, 5.5 l of quick setting cement and 20 l of water.
After mixing and stirring of the composition, each type of brick is made by pressurized molding (the pressure is done by compaction of the still-wet composition). Once folded, each brick is stripped, then undergoes air drying for several weeks, or may be placed in a drying oven for accelerated drying.
A first type of brick 1 is illustrated in
The base brick 1 comprises:
The tongues 5, 7 have a (protruding) height 13 of 50 mm and a width 14 of 100 mm. The grooves 9, 10 have a depth 13 of 50 mm and a width 14 of 100 mm.
A second type of brick 15 is illustrated in
The stiffener 15 comprises a cell 16 with a square section pierced over the entire height thereof, the sides of which measure 150 mm and are spaced apart from the side 17 and rear 18 surfaces of the stiffener 15 by 75 mm.
The stiffener 15 comprises:
The lower tongue 19 has a protruding height 13 of 50 mm and a width 14 of 100 mm; the grooves 21, 23 have a depth 13 of 50 mm and a width 14 of 100 mm.
A third type of brick 25 is illustrated in
The tongues 27, 31 have a protruding height 13 of 50 mm and a width 14 of 100 mm.
A fourth type of brick 32 is illustrated in
The linking brick 32 comprises:
The tongues 39, 43 have a protruding height 13 of 50 mm and a width 14 of 100 mm.
The four types of prefabricated elementary bricks that have just been described make it possible to produce any masonry construction, and in particular to build walls and partitions.
To that end, the bricks 1, 15, 25, 32 may be combined with each other. They are in fact designed to fit together both horizontally and vertically. Thus:
As will be seen below, these fittings may be done as dry-joint connections (i.e. without jointing mortar), without harming the stability of the construction one wishes to make, owing to the size ratios between the sides (height and width) of the grooves and tongues, and the effective size ratios of the bricks.
In this way, the ratio between the width 14 of the tongues 5, 7, 19, 27, 31, 39, 43 (equal to that of the grooves 9, 10, 21, 23, 44) and the effective width 3 of the bricks 1, 15, 25, 32 is preferably comprised between 1/4 and 1/2. A ratio of approximately 1/3, which corresponds to the quoted values provided above, is a good compromise between good shearing strength of the tongues 5, 7, 19, 27, 31, 39, 43, which guarantees good strengths of the walls with respect to forces in the orthogonal direction (in particular wind and bearing forces) on the one hand, and a sufficient bearing surface of the bricks 1, 15, 25, 32 on one another, on either side of the tongues 5, 7, 19, 27, 31, 39, 43, guaranteeing good stability of the walls, on the other hand.
Furthermore, the ratio between the height of the tongues 5, 7, 19, 27, 31, 39, 43 (equal to the depth of the grooves 9, 10, 21, 23, 44) and the effective height (or the effective width, equal to the effective height) of the bricks 1, 15, 25, 32 is preferably comprised between 1/10 and 1/4. A ratio of approximately 1/6, which corresponds to the quoted values provided above, is a good compromise between a certain ease of assembly on the one hand, and the need to maximize the contact surfaces between the bricks 1, 15, 25, 32 (i.e. the friction therebetween), so as to stiffen the structure, on the other hand.
The wall 45 is built on a base 48 (forming a compression slab) made from water-repellent cement mortar, which is poured on a concrete foundation 49 situated below ground level as defined by a finished (i.e. tamped) outside terrain 50. As shown in
In anticipation of the production of the opening 46 on the one hand, and to consolidate the wall 45 on the other hand, two metal frameworks 52 with a square section are vertically implanted in the base 48 for the subsequent production of reinforcing posts 53, while being spaced apart by a predefined value corresponding to three brick lengths (i.e. 1800 mm), this measurement being done on the central axis of the frameworks 52. The frameworks 52 are preferably pre-positioned during pouring of the base 48, so as to be embedded therein, but it is also possible to consider making the base 48 first, then later drilling housings as a function of the desired positioning of the frameworks 52, in the scenario where that positioning is not known when the base 48 is poured.
The wall 45 is then erected through the successive stacking of rows of bricks fitted into each other both horizontally and vertically.
The base bricks 1 are all oriented in the same direction (their rear surface 12 here turned toward the back in
This first row is placed dry, without mortar joints, by simple fitting of the bricks 1, 15 into the base 48. Given the identical quoted values (for the height and width) of the groove 51 of the base 48 and the tongues 5, 7, 19 of the bricks 1, 15, there is no functional play between the groove 51 and the tongues 5, 7, 19. This lack of play does not, however, prevent the fitting, due to the relative elasticity of the material of the bricks 1, 15 (unlike cement concrete, for example, which is extremely rigid).
Before placing the second row of bricks, the following two operations are carried out:
The second row of bricks can then be placed. As shown in
Once the second row of bricks is placed, the same filling in and cutting out operations are carried out in the stiffeners 15 of the second row as those done in the stiffeners 15 of the first row, so as to allow the placement of the third row. The third row is then placed, the base bricks 1 and the stiffeners 15 being oriented in the same direction as those of the first row (and therefore opposite those of the second). As before, the fitting is simple, with no mortar joints.
The cells 16 of the stiffeners 15 can then be filled in using a cement concrete, thereby embedding the frameworks 52 and forming reinforced posts 53 that vertically stiffen the wall 45 and form a reveal for the window 46.
The third row delimiting a support for the window 46, no fourth row bricks are placed between the frameworks 52. However, to horizontally stiffen the frame of the window, the following operations are carried out:
In order to allow the stiffeners 15 of the subsequent row to be fitted, as before, cutouts 55 are made in the upper surfaces 24 of each stiffener 15. The bricks of the following row are then placed (the fourth, in the illustrated example). As shown in
As shown on the right in
Once the reveal for the window 46 has reached the desired height (which in this case corresponds to four rows of bricks, or a height of 1200 mm), an additional row of linking bricks 32 is placed that will participate in producing a lintel for the window 46.
As shown in
In order to allow the passage of the vertical frameworks 52, the bottom 38 of the linking bricks 32 placed overhanging the reveal for the window 46 are also cut out with an opening 60 with a square section, said opening 60 being filled in using a cement concrete to complete the vertical reinforcing post 53 of the wall 45 (and the window 46).
As illustrated in
Furthermore, in order to allow the placement of the slab 47 resting on that last row of bricks 32, side walls 37 are cut out (in this case by complete leveling) on an inner side of the linking bricks 32. As shown in
As also shown in
The subsequent fastening of jambs (doors, windows) is done directly in the posts, supports, reveals and lintels of the openings. To access them, one need only form mortises in the bricks to allow the passage of fastening tongues of the jambs.
As previously described, the corner wall 63 rests on a base 48 provided with a groove 51 hollowed on an upper surface, and poured over a foundation (not shown) situated below the ground level of the finished terrain. The wall 63 is made up of two wall faces 64, 65 (which are arbitrarily called left face 64 and right face 65, in reference to the orientation chosen for
The first row of bricks comprises a first stiffener 15 fitted on the base in the corner of the wall 63, with the metal corner framework 52 slipped into the cell 16 of the stiffener 15. This first stiffener 15 may be oriented differently along either of the wall faces 64, 65. In the drawing of
The first row of bricks also comprises several (two in the case at hand) base bricks 1, fitted on the base 48 in each face. In the left face 64, where the corner stiffener 15 extends, the base bricks 1 are oriented toward the corner, the front tongue 7 of the base brick 1 adjacent to the corner stiffener 15 fitting into the front groove 21 thereof. As illustrated, a half-stiffener 25 is fitted on the base 48 at the framework 52 of the left face 64, which is slipped in its cell 16. The half-stiffener 25 is oriented toward the corner, such that its front tongue 27 fits into the rear groove 11 of the adjacent base bricks 1.
In the right face 65, the (two) base bricks 1 are oriented opposite the corner, the rear surface 12 of the base brick 1 adjacent to the corner stiffener 15 being pressed flat against a side surface 17 thereof. As also illustrated, a stiffener 15 is fitted on the base 48 at the framework 52 of the right face 65, which is slipped into its cell 16. The stiffener 15 is oriented toward the corner, such that the front tongue 7 of the adjacent base brick 1 fits into the front groove 21 of the stiffener 15.
As in the example described in reference to
Once the first row is placed, the following two preparatory operations are carried out in anticipation of the placement of the second row:
It is then possible to place the bricks of the second row, as illustrated in
Likewise, the base bricks 1 of the left face 64 of the second row are oriented opposite the corner, and a stiffener 15 is placed at the framework 52 of the left face 64, such that the front tongue 7 of the adjacent base brick 1 fits into the front groove 21 of the stiffener 15. No mortar joint is used between the bricks. As shown in
One can see that, irrespective of the configuration of the construction to be built, the use of the hemp bricks described above allows an easy and rapid construction, in particular owing to the absence of jointing, which allows considerable savings in terms of time and material. As an example, the construction of a traditional building with a ground surface area of 150 m2, which requires approximately 1000 bricks (in all), of the various described types, may be completed (excluding light work) in one week with one single person on the worksite, i.e. time savings of more than 50% relative to the known methods, or ordinary quarry stone-based masonry, or hemp-based masonry set on a wooden frame, or hemp concrete block-based masonry jointed and placed on a wooden frame.
By using a reinforced concrete frame to produce the posts (which may also serve as a rigid frame for the openings) and slabs, the erection, from the hemp bricks described above, of a multi-floor construction does not suffer any restrictions, whereas the professional rules regarding hemp concrete constructions made traditionally on a wooden frame limit the height of the structures to two floors (ground floor with one upper four).
The combination of solid base bricks and cellular stiffener bricks for the erection of the walls limits the number of reinforcing posts and avoids the use of a frame requiring the intervention of a specialized carpenter, while the quantity of cement concrete is nevertheless limited and the environmental qualities of the construction are preserved. However, it is fully possible to consider replacing the reinforced concrete posts with wooden pillars or non-reinforced lime concrete, just as it is possible to consider replacing the support and lintel reinforcements of the openings made from reinforced concrete with wooden beams or non-reinforced lime concrete.
Number | Date | Country | Kind |
---|---|---|---|
1002585 | Jun 2010 | FR | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
---|---|---|---|---|
PCT/FR11/51415 | 6/20/2011 | WO | 00 | 5/1/2013 |