The present invention relates to a method for building a wall out of lime and hemp, prefabricated blocks made of hemp and lime for the use of the method and a device for molding such prefabricated blocks.
There are known ways of using mortar or concrete elements made of hemp or lime in construction work. For building walls, hemp-based mortar is traditionally shuttered in a wooden bearing frame. The hemp mortar is prepared on site, then poured and rammed down between two forms positioned around uprights of the wooden frame. This procedure proves to be particularly painstaking and costly because it especially necessitates the handling of corrosive material such as lime, the use of heavy means such as a mixer and forms, a very lengthy drying time of about one month and special expertise, especially in carpentry and masonry.
It has also been proposed to manufacture solid hemp bricks joined together to form a non-load-bearing wall around a wooden bearing structure. Such an implementation makes it possible to overcome at least one of the above-mentioned problems related to shuttering. However, the mounting of the non-load-bearing brick walls about preliminarily installed uprights of the wooden framework does not draw upon traditional techniques of masonry and calls for special expertise.
Consequently, despite their acknowledged properties in terms of thermal and hygrometric regulation, as well as their phonic qualities, hemp mortars are little used at present.
The aim of the present invention is to propose a method for the making of a wall out of hemp-and-lime-based mortar or concrete that is simple and quick to implement.
To this end, an object of the invention is a method for making a wall out of hemp and lime, characterized in that it comprises:
a) a step for assembling hemp-and-lime based prefabricated blocks provided with vertical channels in which the blocks are assembled in superimposed, horizontal rows so as to form vertical conduits with the vertical channels, the assembling of the blocks to one another being achieved by means of a binding material, preferably formed by fat lime,
b) a step for the insertion of posts, preferably made of wood, into the vertical conduits from the top, and
c) and a step for filling the vertical conduits with a filling material such as a milk-of-lime type binder to seal said posts into the blocks.
The term “vertical channel” is understood to mean a recess that opens into the upper face and lower face of the block, at a distance from the transversal faces as well as recess or depressions that open out into the upper face and the lower face of the block but are formed on the transversal faces. In this case, the vertical conduits for the insertion of the posts are formed especially by facing channels of two adjacent blocks of a same row.
Advantageously, the assembling step consists of the quincunxial stacking in superimposed rows of the prefabricated blocks provided with at least two vertical channels.
At each wall corner, door frame and/or partition wall junction, wider-sectioned conduits are formed out of specific blocks, into which there will be inserted several posts bound together or wider-sectioned posts.
In one embodiment, the first row is positioned on a sole plate, preferably made of wood, on which the posts take support. The method may include a step for fixing the posts to the sole plate, for example by means of connectors nailed to the sole plate and to the posts, to position the posts in the vertical conduits before the step for filling said conduits with said filling material. The method may furthermore include a step for fixing the posts by their upper ends to an upper purlin.
The present invention also proposes a prefabricated block made of hemp and lime for the implementation of the method, characterized in that it is made up of a parallelepiped-shaped single-piece body provided with vertical channels for the passage of posts. Each block preferably comprises at least one channel having a rectangular cross-section of at least 50×50 mm, preferably ranging from 50×50 mm to 200×200 mm.
According to one embodiment, the block comprises two vertical through-channels of substantially identical rectangular cross-section that open out on its upper and lower faces, placed symmetrically on either side of its transversal plane of symmetry and at a distance from its transversal sides, to form a solid wall block, the channels having cross-sections preferably ranging from 50×150 mm to 80×180 mm, preferably from 60×160 to 75×175 mm.
Another type of block may include two vertical through-channels of different rectangular cross-sections that open out on its upper and lower faces, at a distance from the transversal faces, one having a rectangular cross-section, preferably between 50×50 mm and 80×180 mm, preferably between 60×160 mm and 75×175 mm, and the other cross-section being bigger and square-shaped, preferably ranging from 80×80 mm to 200×200 mm, more preferably ranging from 150×150 to 180×180 mm, better still between 160×160 and 170×170 mm, to form a corner block whose widest-section channel is designed for the passage of particular stress-bearing posts such as corner posts, partition wall junction posts or window/door frame posts.
Advantageously, the block furthermore comprises secondary vertical channels for the passage of electrical sheaths and/or conduits.
The invention furthermore proposes a device for the molding of hemp-and-lime blocks as defined here above. The molding device of the invention is characterized in that it comprises a mold comprising a molding chamber formed by an upper wall surrounded by a side wall, said chamber being mounted so as to be vertically mobile on a chassis, and a counter-molding plate positioned on a support means and capable of closing the molding chamber; first shifting means to vertically shift the molding chamber between a top position in which the molding chamber is placed above the counter-molding plate for the stripping-off operation and a low position in which the counter-molding plate gets embedded in the molding chamber for the molding operation; tubes mounted so as to be vertically mobile on said chassis, capable of coming vertically into the chamber through apertures present in the upper wall of this chamber, elastically supported on the counter-molding plate in the low position of the molding chamber to form the vertical channels of the blocks; filling means to fill the chamber with hemp mortar in its low position; second shifting means to effect an additional relative vertical shift of the counter-molding plate with respect to the molding chamber in its low position to compress the mortar present in the molding chamber; and vibration means to make the mold vibrate, for example linearly, such as a vibrating table on which the chassis is mounted.
According to one particular feature, at least one of the tubes is hollow and is provided at its lower part with at least one aperture to enable the molding chamber to be filled with hemp and lime in its low position.
Advantageously, the device includes a conveyer capable of conveying counter-molding plates one by one to the support means facing the molding chamber and of removing them from said support means with the stripped-off blocks.
According to one embodiment, the second shifting means are capable of shifting the support means of the counter-molding plate.
Advantageously, the device has a screen mounted so as to be fixed on said chassis, said screen coming substantially against the upper wall of the chamber in its top position, preferably nested in a complementary counter-screen forming one piece with said upper wall and coming substantially to the level of the peripheral edge of the side wall of the molding chamber in its top position in order to facilitate the stripping of the blocks.
The invention will be understood more clearly and other details, features and advantages will appear more clearly in the course of the following detailed explanatory description of a presently preferred particular embodiment of the invention, made with reference to the appended schematic drawings, of which:
While the present invention is amendable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the present invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present invention.
Referring to
The two main channels 11, 12 have identical rectangular cross-sections and are positioned symmetrically on either side of the transversal plane of symmetry A1 of the block, at a distance from the transversal faces 16a and 16b, the big opposite walls of the channels being positioned in parallel to said plane A1.
The block 1 also has channels 13 called secondary channels for the passage of electrical sheaths and/or conduits. The secondary channels are, for example, circular in section and there are four of them. One pair of secondary channels is positioned about each main channel 11, 12, the secondary channels of each pair being positioned symmetrically on either side of the vertical axis of a main channel, for example aligned along the small walls of the main channels.
For example, the solid-wall blocks have a length, a width and a height respectively of 600, 300 and 300 mm. The main channels have a 70×170 mm section and are designed for the passage of posts having a 50×50 mm section.
In this embodiment, the upper face 14 and the lower face 15, as well as the transversal side faces 16a, 16b and longitudinal faces 17a, 17b are substantially flat. Positioning means of the type having raised zones and matching recessed zones may naturally be planned on the upper and lower faces and/or on the transversal faces to facilitate the alignment of the blocks from one row to the other and/or one and the same row.
Referring to
The technique of joining blocks to make walls, such as the bearing walls of a dwelling-type construction, is similar to that made with concrete blocks and bricks. Referring to
Once the blocks have been assembled, wooden posts 4 are slid in through the top up to the base of the construction in each of the conduits. A binder, such as milk of lime based on air-slaked lime and hydraulic lime is then poured into the conduits so as to seal the posts 4 in the blocks 1.
The specific blocks 2 can be used for the absorption of particular stresses by means of load-distribution posts having a bigger section, especially at each wall corner, partition and window/door frame. In the case of a wall corner, as illustrated in
The square-sectioned channels of the specific blocks may of course be replaced by channels used to obtain a continuous section conduit during the superimposition of the corner blocks at 90° to one another, such as circular-sectioned or polyhedron-sectioned channels.
A more detailed description shall now be given of the mounting of the carrier walls of a dwelling using solid-wall blocks. The walls according to the invention may rest on concrete ground beams. As illustrated in
The first row of blocks 1 is placed directly on the sole plate 82. Before the blocks of the first row are mounted, a transversal groove 18 is made on their lower face 15, vertical to the main channels 11, 12 and opening on its longitudinal faces to enable the nailing of the lower connectors 85a between the lower purlin and the posts 4 and verify that the support of the posts is clean when they are mounted. The sealing of the blocks of the first row to one another is done with fat lime or air-slaked lime in a paste, spread on the transversal side faces of the blocks by means of a spatula or a trowel. The spacing, of about 5 cm, between the ground beam and the lower faces of the blocks, is jointed with a mortar 86 insensitive to run-off water, such as a natural hydraulic lime mortar, in maintaining access to the grooves 18. To prevent any subsequent problems, the first row will be mounted so as to be strictly horizontal so that the channels receiving the framework posts easily correspond from rank to rank.
After the first row has been positioned, the blocks are mounted contiguously in superimposed rows, with heightwise cross-joints, a paste of air-slaked lime being spread on the transversal faces and lower faces of the blocks. Once the wall has been mounted to the desired height, for example to joist height, the last row of blocks is struck off if necessary to obtain the desired height.
The posts 4 are slid in by the top until they take support on the sole plate in the conduits formed by the vertically aligned channels, then traced and cut square in height. The posts are then withdrawn. At each end, along the small sides of the posts, lower connectors 85a, and upper connectors 85b (
Referring to
The use of these different blocks in the making of a wall with window is illustrated schematically in
A mode of making blocks according to the invention shall now be described.
The blocks are obtained by the molding of a hemp-and-lime based mortar. The mortar is formed for example out of a mixture of chevenotte, air-slaked lime and hydraulic lime and water,
Chevenotte, which is the internal part of the stem of the hemp plant, has a medium grain size, with a width of 1 to 5 mm and a length of 5 to 30 mm and is preferably fibre-free to prevent the appearance of pockets of water by draining during molding and disturbance of the lime carbonation process. Furthermore, the fines and dust, which tend to reduce the mechanical properties, will be preferably eliminated. The air-slaked quicklime (with a CaO content of over 90%) is advantageously slaked on the production site and used as a paste in order to ensure faster setting, smoothness greater than that of powdered slaked lime, a mixture of greater homogeneity and a percentage of water used that is lower by about 30 percent than that of a paste obtained from powdered slaked lime. Hydraulic lime can be used to create a structure with fast hydraulic setting giving the rough stripped-off block sufficient rigidity during its carbonation period.
Preferably, the mixture will furthermore include a pozzolanic reagent to make the mixture slightly hydraulic and obtain faster setting and greater resistance by pozzolanic reaction with air-slaked lime. The mixture may include additives such as, for example, moisturisers and plasticisers.
By way of an example, the following is the composition of a mixture for one m3 of the mortar:
1000 litres of chevenotte (115 to 130 kg)
fat lime (160 kg of quick lime+extinguishing water)
15 Kg of pozzolana
25 Kg of hydraulic lime
additives
water.
Air-slaked quicklime is slaked, for example, in a horizontal mixer with a continuous modulable flow. The mortar is obtained in a screw mixer. The mixture is fed continuously, for all the ingredients, and is modulated according to need.
The block-molding device comprises a mold formed by a molding chamber 201 comprising a substantially horizontal upper wall 201b, surrounded by a peripheral sidewall 201b, and a counter-molding plate 202 whose dimensions correspond to the internal dimensions of the molding chamber.
The molding chamber is mounted so as to be mobile in vertical translation on the uprights 203a of a carrier chassis 203 by means of side toes 201c, above a conveyor 204, for example using rollers, designed to carry the counter-molding plate 202, said carrier chassis being mounted on a vibrating table 205 capable of making the chassis vibrate linearly. The upper wall 201a comprises apertures for the passage of rectangular-sectioned hollow main tubes 206, and hollow or solid, circular-sectioned secondary tubes 207 designed respectively to form the main and secondary channels during the molding of the blocks. The tubes 206, 207 are mounted on a supporting plate 208 mounted so as to be vertically sliding on the uprights 203a. The main tubes have an upper end that is open for the feeding the system with mortar and a lower end closed by a bar 206a. The large faces of the main tubes have opposite apertures 206b at their lower part.
The device has a guide plate 209 mounted so as to be sliding on the uprights above the supporting plate 208 and provided with apertures for the passage of the main tubes and secondary tubes. The supporting plate is assembled to this guide plate by elastic means represented schematically under reference 210. The vertical shift of the molding chamber 201 and of the guide plate 209 is given by first shifting means (not shown), for example pneumatic jack type means. The screen 211 is mounted so as to be fixedly joined to the carrier chassis by means of arms 212 which also pass through apertures of the upper wall 201a. In the top position of the molding chamber illustrated in
Bars or push-rods 214 serving to support the counter-molding plates are positioned straight on the molding chamber, for example interposed between the rollers of the conveyor. Second shifting means 215, comprising a silentbloc element, are positioned beneath the conveyor to act on the push-rods in order to shift the counter-molding plates upwards, toward the molding chamber.
Advantageously, the dimensions of the mold and the number and arrangement of the tubes are designed to form a molding stab from which several blocks according to the invention will be cut out.
The molding operation is done as follows. A counter-molding plate 202 is conveyed by the conveyor to the push rods 214, vertically to the molding chamber in the high position. The guide plate 209 to which the tubes are connected elastically and the molding chamber 201 are then shifted by the shifting means to the low position, as illustrated in
The mixture of bulked mortar is then injected by the other ends of the main tubes, as shown schematically by the arrows 216, to fill the molding chamber closed by the counter-molding plate. The mortar coming from the mixer is, for example, stored in a buffer container which feeds a dosing screw for direct injection of a specified quantity of mortar into the chamber. To facilitate the flow of mortar through the apertures 206b, the bars 206a advantageously have an upper face with an inverted V shape.
After filling, to reduce the bulking and obtain a homogeneous block, the mortar is compressed through the upward shifting of the counter-molding plate using second shifting means 215 that act on the push-rods, and is made to vibrate by putting the vibration table on which the chassis is mounted into vibration. During the shift, the tubes shift upwards against the elastic means, sliding in a tightly sealed manner in the apertures of the upper wall.
For example, the injected mortar shows bulking of about 10%. Thus, for a desired height H of 30 cm for the blocks, the initial distance between the counter-molding plate and the upper wall of the chamber, prior to the pressurized vibrating operation designed to chase out the air bubbles, is in the range of 33 cm.
The mold is made to vibrate under pressure for a determined time of about 10 to 20 seconds, for example in the range of 15 seconds. Then the molding chamber is brought into the top position illustrated in
The slab carried by the counter-plate is then shifted through the conveyor and simultaneously a new counter-molding plate is brought right on to the molding chamber for a new molding operation.
The slabs are then stored on carbonation racks, and then when the carbonation is sufficient to enable cutting, for example after about 21 days, the blocks are cut out from the slabs by sawing or slicing using a guillotine.
The block-making method of the invention therefore has a step for filling a mold with a constant volume of a mixture of hemp mortar and lime, a step of vibration under pressure of the mixture contained in the mold and then a stripping-off step. The molding operation is done in one stroke, thus preventing stratification, and the strip-off operation is done immediately after the pressurized vibration step.
According to one alternative embodiment, the molding device has one or more separation plates mounted fixedly to the supporting plate 208 and capable of sliding vertically in slots of the upper wall of the molding chamber and resting against the counter-molding plate to separate the molding chamber into different compartments, each corresponding to the dimensions of a block. The use of such separating plates makes it possible to avoid a subsequent step of cutting out the blocks from molded slabs.
Although the invention has been described with reference to a particular embodiment, it is clear that this description is in no way restricted and that it includes all the equivalent techniques of the means described as well as their combinations if these should come within the scope of the invention.
Number | Date | Country | Kind |
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0406438 | Jun 2004 | FR | national |
This application claims priority to PCT Application No. PCT/FR2005/001458 filed Jun. 13, 2005, and French Application No. 0406438 filed Jun. 15, 2004, the disclosures of which are hereby incorporated by reference in their entireties.
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/FR05/01458 | 6/13/2005 | WO | 00 | 7/18/2008 |