MULTI-LAYER CONCRETE BLOCK FOR A SURFACE COVERING LAID IN BOND AND SURFACE COVERING

Information

  • Patent Application
  • 20250207410
  • Publication Number
    20250207410
  • Date Filed
    October 29, 2024
    12 months ago
  • Date Published
    June 26, 2025
    4 months ago
Abstract
A concrete block is described in the form of a surface covering element. The concrete block is made of at least one multi-layer concrete block body. The multi-layer concrete block body has a concrete block layer arranged on the concrete block top side, at least one second concrete block layer adjoining the first concrete block layer and a third concrete block layer adjoining the second concrete block layer. The third concrete block layer forms the concrete block underside. The second concrete block layer is a non-fines porous core layer. The first concrete block layer has a first porosity, the second concrete block layer has a second porosity, and the third concrete block layer has a third porosity, wherein a mean pore size of the pores in the third concrete block layer is smaller than the mean pore size of the pores in the second concrete block layer.
Description
BACKGROUND OF THE INVENTION

The invention relates to a multi-layer concrete block for a surface covering laid in bond as well as to a surface covering made of such multi-layer concrete blocks.


Particularly in urban areas, large regions of the surface are designed as walkable or drivable traffic areas, such as roads, paths, squares or car parks, and are covered with a surface covering. The surface coverings are often produced by laying individual blocks, in particular molded concrete blocks, in bond. For example, such surface coverings are produced by paving, wherein paving stones or corresponding molded concrete blocks are laid in bond on a bedding layer of the substrate. As a rule, joints remain between neighboring concrete blocks or molded blocks, in particular concrete paving stones, and are filled with suitable, usually sand-like or grit-like joint materials. Such surface coverings in the form of paving are sufficiently known.


It is also known here to use multi-layer concrete blocks or concrete paving stones to create such a surface covering. These multi-layer concrete blocks usually comprise at least one core layer and one face layer, wherein the core layer is usually made of a core concrete and forms a core of the concrete block, and wherein the face layer is usually made of a face concrete and forms the top side of the concrete block that can be walked or driven on, namely its visible surface.


It is also known here that the multi-layer concrete blocks of the aforementioned type, due to their structure and the nature of the individual layers, in particular also due to the nature of the concrete used to produce the individual layers, are designed in such a way that they have a certain or desired water penetrability or water permeability and/or also a certain or desired water storage capacity.


German Patent No. DE 102012100616 B4, for example, discloses a surface covering made of two-layer moulded blocks which have a water-absorbing, water-permeable layer below a substantially water-impermeable layer on the surface, so that incident rainwater can drain downwards both via the joints and via the water-permeable layer of the moulded blocks, i.e. via a seepage path through the concrete blocks themselves.


It is also known that rainwater can also be stored where applicable, thereby counteracting a so-called urban “heat island effect” through increased water evaporation, as evaporative cooling is generated during the evaporation of water. Such concrete blocks, which also have a multi-layer structure, are known, for example, from European Patent No. 3,889,351 A1 or German patent No. DE 102020108785 A1 and in particular, they have three layers.


However, a disadvantage of the concrete block known from European Patent No. 3,889,351 A1 is that the water impermeability of the lower, third layer can lead to the formation of waterlogging and thus to supersaturation of the middle, second layer, which delays the onset of the evaporation effect or only makes it possible to a limited extent, so that the evaporation properties are limited. The formation of waterlogging in the concrete block can also lead to damage to the concrete block in the event of a freeze/thaw cycle.


As global warming continues, the demand for surface coverings with an effective evaporation effect to positively influence the urban climate is increasing. There is therefore a continuing need for improved concrete blocks.


SUMMARY OF THE INVENTION

An object of the present invention is therefore to provide a concrete block which overcomes the disadvantages of the prior blocks and which has reliably and permanently improved evaporation properties.


The present invention provides a concrete block, in particular in the form of a surface covering element which can be laid in bond, for creating a surface covering. The concrete block comprises at least one multi-layer concrete block body with at least one concrete block underside and a concrete block top side opposite thereto. The multi-layer concrete block body comprises at least one first concrete block layer arranged on the top side of the concrete block, at least one second concrete block layer adjoining the first concrete block layer and furthermore a third concrete block layer adjoining the second concrete block layer. The third concrete block layer forms the concrete block underside, which is intended for laying on a bedding layer of a substrate. The second concrete block layer, which is arranged between the first and third concrete block layers, is a non-fines porous core layer. The first concrete block layer has a first porosity and comprises pores with a first pore size distribution. The second concrete block layer has a second porosity and comprises pores with a second pore size distribution and the third concrete block layer has a third porosity and comprises pores with a third pore size distribution. A mean pore size of the pores in the third concrete block layer is smaller than the mean pore size of the pores in the second concrete block layer.


The pores existing in the individual concrete block layers can also be understood in the present case as the totality of pores of the respective layers or as the sum or total number of pores existing in the respective concrete block layers. The pores of a respective concrete block layer thus represent in their entirety a cavity or a cavity volume within the concrete block layer, namely within the total volume of the concrete block layer. The “porosity” in the present sense is to be understood as the ratio of the cavity volume to the total volume of the respective concrete block layers.


A value for the porosity can, for example, also be determined or specified indirectly via a so-called pore number, which is in relation to the porosity, wherein the pore number is defined as the ratio of the cavity volume to the solid volume within a respective concrete block layer.


In the present case, the term “pore size distribution” refers in particular to the distribution of the pores in the respective concrete block layers in relation to their size, namely the pore size. The pore size, which in the present case can also be understood as pore volume, correlates with the dimensions of the pores, such as length, width and height, and can be determined or specified, for example, via a diameter of the pores, i.e. via a pore diameter. Since the individual pores in the concrete block layers are geometrically irregular in shape, the pore diameter can also be understood as a pore diagonal in the present sense.


For example, the porosity of the concrete block layers and the pore size of the pores in the concrete block layers can be determined by so-called thin section microscopic examinations known to a person skilled in the art. For the purposes of the present invention, the pore size or the pore volume can therefore also be specified as the pore area, which can be determined in particular by means of thin section microscopy. Such a pore area determined according to thin section microscopic evaluations correlates with the pore volume or pore size and can therefore serve as an indication of the pore size.


In accordance with the invention, a non-fines porous concrete block layer is understood to be a concrete block layer produced from a non-fines porous concrete material. In principle, such a non-fines porous concrete or core concrete comprises defined cavities between the aggregates, which is defined, for example, in DIN 18507. In contrast to DIN 18507, namely in contrast to the water permeability defined in section 4.3 and the compressive strength defined in section 4.4, the porous concrete used here in an advantageous embodiment of the invention has a water permeability of less than 1×10−5 m/s or an average water permeability kf of less than 1.5×10−4 m/s and/or a compressive strength of at least 50 N/mm2.


The many pores present in a particular concrete block layer are different from each other and have different pore sizes, i.e. smaller and larger pores occur side by side, wherein the pores are distributed over a specific or predetermined size range or over a size spectrum, i.e. the pores are present in a predetermined “pore size distribution”. Each concrete block layer contains pores up to a maximum pore size, which can be determined using thin section microscopy, for example. In the pore size distribution considered here, for example, all pores are taken into account that have a size from a selected or fixed or predetermined minimum size, namely a minimum pore size, up to the maximum pore size.


In the present understanding, the “mean pore size of the pores” is the average value or the averaged value of the pore size of all pores within the relevant size range, namely from the minimum to the maximum pore size.


The present concrete block, which can also be referred to synonymously as a paving block or concrete paving block, is thus composed of at least three layers. The concrete block, in particular concrete paving block, is advantageously manufactured as a one-piece or one-part molded body or concrete block body, i.e. all three concrete block layers are produced in one production process in the form of a complete block, for example in a paving block machine, i.e. in a production process using a paving block machine.


In the present concrete block, particular advantages result from the layer structure of the nature according to the invention, in particular with the porosity of the layers, since these interact particularly advantageously due to their composition in order to keep the second concrete block layer arranged between the first and third concrete block layer, i.e. the middle, porous concrete block layer, moist in the state of use of the concrete block, namely in a state laid in a surface covering, but at the same time to prevent waterlogging in order to reliably ensure an effective evaporation effect.


In particular, the concrete block layers interact to ensure that the second concrete block layer, which is formed as a non-fines porous core layer, absorbs and stores water due to its porosity and permeability. On the one hand, the water can be absorbed in the form of rainwater, wherein it can, for example, penetrate into the central second concrete block layer via the first concrete block layer and/or via the lateral surfaces or side flanks, namely via the concrete block sides, and can be “held” there.


The “storage” of the water in the second concrete block layer can also be understood in the present case as an inhibition of the gravity-induced passage of water through the concrete block, wherein the water is “held back” in particular by means of a reduced water permeability of the lower third concrete block layer, and thus a “leakage” or “dry running” of the second concrete block layer is counteracted. In other words, due to its lower water permeability, the third concrete block layer in turn ensures that the water contained in the water-absorbing and water-storing second concrete block layer does not run off unhindered downwards into the bedding layer but is retained in the second concrete block layer.


In the present concrete block, the composition and design of the concrete block layers according to the invention simultaneously ensure that water can also be “sucked in” from the substrate via capillary action of the lower, third concrete block layer and in this way can be absorbed through the lower, third concrete block layer into the middle, second concrete block layer.


The capillary effect of the lower, third concrete block layer resting on the bedding layer of the substrate in the state of use can also be referred to in the present case as the suction effect or suction force, wherein the reliable, safe and effective capillary effect or suction effect or suction force is caused in particular by the porosities of the concrete block layers, which are provided in accordance with the invention and are advantageously matched or adjusted to one another.


In other words, in the present case it can also be spoken of a capillary system, in particular in the third concrete block layer, through which, for example, the middle, second concrete block layer can be supplied with water from the substrate in the absence of rainwater in order to reliably and in particular sufficiently and continuously enable and maintain or ensure the evaporation reactions. The capillary effect of the lower, third concrete block layer in particular, namely its ability to transport water upwards against the force of gravity, can also be referred to as capillarity.


Depending on the design of the first concrete block layer, rainwater can be absorbed into the second concrete block layer both via the first concrete block layer and via the side flanks of the concrete block. It is also conceivable that the absorption of rainwater takes place mainly or substantially, or possibly exclusively, via the side flanks of the concrete block. When rainwater is absorbed via the side flanks or concrete block sides, the water penetrates from the joints or from the joint space, i.e. from the joints formed between the individual concrete blocks and filled with joint material, into the non-fines porous core layer or diffuses into the non-fines porous core layer, preferably into its inner areas.


Preferably, the mean pore size of the pores in the third concrete block layer is at most 0.3 times to 0.6 times, in particular at most 0.4 times to 0.5 times, the mean pore size of the pores in the second concrete block layer. The value of the average pore size of the pores in the third concrete block layer is thus so much smaller that it is preferably between 30% and 60% of the value of the average pore size of the pores in the second concrete block layer, in particular preferably between 40% and 50% of the value of the average pore size of the pores in the second concrete block layer. A ratio of the mean pore sizes of the pores in the second and third concrete block layer established in this way results in a particularly efficient capillary effect as well as stable moistening and particularly durable, long-lasting retention of the moisture in the non-fines porous second concrete block layer and consequently in the evaporation effect.


Furthermore, the mean pore size of the pores in the first concrete block layer is preferably smaller than the mean pore size of the pores in the second and third concrete block layers. In these preferred variants, all three concrete block layers are matched to each other in terms of their pore size distribution in order to maintain a particularly effective evaporation reaction in the concrete block reliably and, in particular, largely independent of rainfall.


Particularly preferably, the mean pore size of the pores in the first concrete block layer is at most 0.1 to 0.3 times, and in particular at most 0.2 times, the mean pore size of the pores in the second concrete block layer.


According to a particularly preferred variant, the mean pore size of the pores in the third concrete block layer corresponds to at least 3 to 4 times the mean pore size of the pores in the first concrete block layer.


If the mean pore size is again specified as a pore area determined by means of thin section microscopy and corresponding evaluations, the mean pore area or pore size can preferably be around 30,000 μm2 for the pores of the first concrete block layer, for example, around 262,000 μm2 for the pores of the second concrete block layer and around 108,000 μm2 for the pores of the third concrete block layer.


A “proportion of the pore area” determined by means of thin section microscopic examinations and evaluations—namely the determined pore area in relation to the examined area of the concrete block layer—correlates directly with the porosity, which is defined as the ratio of the pore or cavity volume to the total volume. The “proportion of pore area” can therefore be understood here as an expression of porosity.


For example, the proportion of the pore area in the first concrete block layer of the present concrete block can be 5.3%, in the second concrete block layer around 7.8% and in the third concrete block layer around 4.8%. As a result, the respective porosity of the first and third concrete block layer are in a similar range, i.e. close to each other, but the pores exist in completely different pore size distributions and the respective mean pore sizes differ significantly from each other.


Preferably, each of the concrete block layers has a number of pores that exceed a minimum pore size, wherein the number of pores with at least the minimum pore size in the second and third concrete block layers is the same or substantially the same or differs from each other by at most 10%. Furthermore, the number of pores with the minimum pore size in the first concrete block layer is preferably higher than in the second and third concrete block layer, in particular 5 to 6 times higher.


Pores with at least the minimum pore size are, for example, pores of which the pore diameter or pore diagonal is at least around 5 μm to 10 μm and/or of which the pore area (determined by thin section microscopy, for example) is greater than 100 μm2.


Preferably, each of the concrete block layers comprises pores with a maximum pore size in the totality of their respective pores, wherein the maximum pore size of the pores of the first concrete block layer is smaller than the maximum pore size of the pores of the second and third concrete block layers. Alternatively, or additively, the maximum pore size of the pores of the third concrete block layer is smaller than the maximum pore size of the pores of the second concrete block layer.


According to a particularly preferred variant of the present concrete block, the second concrete block layer arranged between the first and third concrete block layers is made of a non-fines porous core concrete and the concrete block is designed in particular to absorb and store water in the second concrete block layer. The non-fines porous second concrete block layer thus forms a water-storing layer that can absorb water, wherein the water is held or stored in the second water-storing layer, in particular by means of the interaction of all three concrete block layers.


The first concrete block layer is preferably designed as a face concrete layer and is, in particular, a concrete block layer made of structure-dense concrete, namely a structure-dense concrete block layer. Advantageously, the first concrete block layer is made from an earth-moist concrete, preferably from an earth-moist concrete with green strength.


It is understood that aggregates can be used in the concrete to produce the first concrete block layer, which forms the visible side, i.e. the surface that can be driven or walked on, when the concrete block is laid, in order to be able to vary and adapt the visual impression and/or the tactile properties of the first concrete block layer.


The third concrete block layer, which is preferably also a structure-dense concrete block layer, advantageously has a capillary suction effect for drawing water from the concrete block underside through the third concrete block layer into the second concrete block layer. Due to the suction effect, the “water supply” of the second concrete block layer can be significantly improved even in dry periods, for example when there is no precipitation, by “sucking” moisture or water from the bedding layer or from the substrate and transporting it by capillary action into the concrete block, in particular into the second concrete block layer. The third concrete block layer therefore has the advantage of capillarity and can therefore transport water upwards against the force of gravity.


Preferably, the third concrete block layer has a lower water permeability compared to the second concrete block layer and is designed in particular in such a way that a gravity-induced water flow through the third concrete block layer is reduced in volume, in particular throttled. As a result, the storage effect when storing water in the second concrete block layer can be further improved or increased, whereby an effective and reliable evaporation effect of the concrete block is also maintained over longer or prolonged periods of time.


The porosity or pore content of the individual concrete block layers can be adjusted during the production of the concrete block by selecting the appropriate concretes or concrete materials for the production of the individual concrete block layers and realised in the specified, coordinated manner. Preferably, the porosity or pore content is adjusted by selecting the appropriate aggregate and/or concrete aggregate material. In particular, this can be achieved by using aggregates and/or concrete aggregate material with predetermined, specific grading curves or particle-size distribution curves, for example also with a grading curve deviating from a so-called “continuous grading curve”, in particular with so-called precipitated aggregates.


A “continuous grading curve” is a grading curve, or particle-size distribution curve, which rises with a constant gradient, i.e. the different grain fractions are each contained in equal proportions.


For example, the second concrete block layer with its second porosity can advantageously be produced from a concrete material with a gap grading aggregate, in particular with a selected gap grading aggregate that has a coarse fraction that is higher than that of a continuous grading curve, wherein individual grain groups can also be deliberately omitted or reduced during the construction of the grading curve. For example, the aggregate for the second concrete block layer can be selected in such a way that the coarse fraction is increased compared to a continuous grading curve, the medium range is reduced or almost completely absent and there is only enough aggregate in the fine range (up to 2.0 mm) to create just enough glue to bind the coarse aggregate firmly and permanently so that the specified strength is achieved.


The third concrete block layer, in turn, can preferably be made from a concrete material with a reduced powder grain content, in particular with a reduced powder grain content of the aggregate grading curve compared to a continuous grading curve, which specifically improves the absorbent properties of the third concrete block layer. All materials in the concrete with a maximum grain size of 0.125 mm are categorized as powder. Accordingly, the powder content is made up of the cement and the grain content of up to 0.125 mm contained in the aggregate as well as any concrete additives. It is particularly preferable for the aggregate grading curve of the concrete material used to produce the third concrete block layer to have an aggregate content reduced by around 60% compared to a continuous grading curve.


The concrete block has been described above as a three-layer concrete block with exactly three concrete block layers. However, it is understood that additional layers can also be provided between the first and third concrete block layers, as long as the relative arrangement of the first, second and third concrete block layers described, including their composition and properties, is maintained, thereby maintaining their interaction or interplay with regard to water absorption and storage and with regard to capillary transport.


The present invention also relates to a surface covering comprising a plurality of multi-layer concrete blocks laid in bond on a bedding layer of a substrate, as described above. In the surface covering, joints are formed between neighboring concrete blocks which are filled with a substantially grit- and/or sand-like joint material and form an infiltration path for draining rainwater from a surface of the surface covering. Furthermore, the surface covering is designed and equipped to absorb and store water in order to provide water for evaporation via the surface of the surface covering.


The present invention also relates to a method for producing a concrete block as described above. In the method, after providing a formwork, concrete is introduced into the formwork in a first step to produce the third concrete block layer. In a second step for the production of the second concrete block layer, additional porous core concrete is then introduced into the formwork and in a third step for the production of the first concrete block layer, a facing concrete is introduced into the formwork. The concrete material is then compacted and cured.


The formwork is removed once the concrete has cured. Optionally or alternatively, the formwork can also be removed before curing or after partial curing.





BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be explained in greater detail below with reference to exemplary embodiments in conjunction with the drawings, in which:



FIG. 1 shows a highly simplified and roughly schematic a perspective view of an embodiment of a concrete block according to the invention;



FIG. 2 shows a rough schematic section through the concrete block of FIG. 1;



FIG. 3 shows, in a highly simplified sectional view, a schematic section through a surface covering portion produced using concrete blocks according to FIGS. 1 and 2;



FIG. 4 shows a schematic, enlarged and highly simplified section through the surface-covering portion according to FIG. 3 to explain the water absorption and evaporation by means of the present concrete blocks; and



FIG. 5a-c each show, in the form of a bar chart, a respective pore size distribution of the pores of the concrete block layers.





DETAILED DESCRIPTION OF THE INVENTION

Identical reference signs are used in the figures for like or equivalently acting elements of the invention. Furthermore, for the sake of clarity, only reference signs that are necessary for the description of the respective figure are shown in the individual figures.



FIG. 1 shows by way of example in a highly simplified schematic drawing a perspective view of an embodiment of the concrete block 1 according to the invention and FIG. 2 shows a schematic section along a plane of section running parallel to a centre vertical axis MHA and parallel to a longitudinal axis LA of the concrete block 1.


The concrete block 1 is preferably designed in the form of a surface element that can be laid in bond with others to create a surface covering 10 (see FIG. 3). In the present case, a concrete block 1, which can also be referred to synonymously as a concrete slab or paving block, is understood to mean substantially structurally identical elements that can be used in a known manner to create a surface covering 10, in particular a concrete block paving that can be driven on. For example, the concrete block 1 may be a concrete paving block. Depending on the chosen laying pattern, the concrete blocks 1 are laid in bond, for example interlocked with one another, and flush with the surface of one another, so that a preferably level surface covering 10 is created.


The concrete block 1 comprises at least one multi-layer concrete block body 2 with at least one flat concrete block underside 2.1 and a substantially flat concrete block top side 2.2 opposite thereto, which preferably forms the surface that can be walked or driven on, or also traffic surface. The specific configuration of the lateral surface portions of the concrete block 1 is not relevant to the invention, i.e. the specific cross-sectional shape of the concrete block 1 can be chosen almost at will without departing from the concept of the invention.


In the present exemplary embodiment, the concrete block 1 is cuboid in shape and has two pairs of two concrete block sides 2.3, 2.4, each with the same surface area and opposite each other. The concrete block underside 2.1 and the concrete block top side 2.2 run perpendicular or approximately perpendicular to the center vertical axis MHA of the concrete block body 2 or concrete block 1. The pair of concrete block sides 2.4 extends substantially perpendicular to the longitudinal axis LA and the concrete block sides 2.3 extend substantially parallel to the longitudinal axis LA.


The multi-layer concrete block body 2 shown comprises at least one first concrete block layer 2a designed as a face concrete layer and forming the concrete block top side 2.2, at least one second concrete block layer 2b adjoining the first concrete block layer 2a in the direction of the center vertical axis MHA and a third concrete block layer 2c adjoining the second concrete block layer 2b in the direction of the center vertical axis MHA, which forms the concrete block underside 2.1 and is intended for laying on a bedding layer 3 of a substrate. In the example shown, the first and second concrete block layers 2a, 2b and the second and third concrete block layers 2b, 2c are directly adjacent to each other.


The second concrete block layer 2b, arranged between the first and third concrete block layers 2a, 2c, is a porous core layer that is designed to absorb and store water.


The concrete block 1 has a total height H, which preferably corresponds to the sum of the layer thicknesses Da, Db, Dc of the first to third concrete block layers 2a, 2b, 2c. In the present exemplary embodiment, the first concrete block layer 2a has a first layer thickness Da, the second concrete block layer 2b has a second layer thickness Db and the third concrete block layer 2c has a third layer thickness Dc. For example, the third layer thickness Dc of the third concrete block layer 2c is between 2 mm and 10 mm, preferably between 2 mm and 5 mm. In relation to the total height H of the concrete block 1, the third layer thickness Dc is thus between 1% and 10% of the total height H of the concrete block body 2, preferably between 1% and 5% of the total height H.


To optimize the absorption and storage of water, the second layer thickness Db of the second concrete block layer 2b is between 60% and 90% of the total height H of the concrete block body 2, preferably between 70% and 85% of the total height H of the concrete block body 2.


In the exemplary embodiment shown, the concrete block 1 has so-called spacers or spacer lugs 4, which ensure uniform joints 5 (see FIGS. 3 and 4) of approximately uniform width when laying the concrete block 1 in combination and ensure a minimum width of the joints 5.


Each of the three concrete block layers 2a, 2b, 2c substantially represents a porous solid layer and has a predetermined porosity P1, P2, P3. The first concrete block layer 2a, which has a first porosity P1, comprises pores with a first pore size distribution q1 (not shown in FIGS. 1 and 2; see FIGS. 5a to 5c), the second concrete block layer 2b, which has a second porosity P2, comprises pores with a second pore size distribution q2, and the third concrete block layer 2c, which has a third porosity P3, comprises pores with a third pore size distribution q3.


The porosities P1, P2, P3 and the pore size distributions q1, q2, q3 of the individual concrete block layers 2a, 2b, 2c of the present concrete block 1 are matched or adjusted to each other in such a way that the water permeability and the water absorption and water storage of the concrete block 1 as well as the capillary water transport are optimised with regard to a reliable, sustained or constant and effective evaporation effect, and at the same time waterlogging is avoided.


In FIGS. 5a to 5c, the pore size distributions q1, q2, q3 of the concrete block layers 2a, 2b, 2c are shown as examples and each in the form of a bar chart. In FIGS. 5a to 5c, the number n of pores is shown on the ordinate (y-axis) and the abscissa (x-axis) shows the pore size A, which in the examples shown is given as the pore area A, which was determined by means of thin section microscopic evaluations (as described in greater detail below as Example 1).


The exemplary graphs 5a to 5c show a logarithmic representation, wherein the abscissa is to be understood as a logarithmic scale. FIGS. 5a to 5c thus substantially show the number of occurring pores (or frequency of occurrence of pores) as a function of their size.


As can be seen from the representation of FIGS. 5a to 5c, all three pore size distributions q1, q2, q3 of the concrete block layers 2a, 2b, 2c described by way of example are different from one another, i.e. the size distribution of the pores in the concrete block layers 2a, 2b, 2c is different.


In the first concrete block layer 2a (see FIG. 5a), the pore size distribution q1 substantially shows a pore maximum, i.e. pores with a pore size of around 10,000 μm2 occur most frequently. In the second concrete block layer 2b (see FIG. 5b), the pore size distribution q2 substantially shows two pore maxima, i.e. pores with a pore size of around 1,000 μm2 and around 100,000 μm2 occur most frequently, wherein the two pore maxima are approximately the same size. In the third concrete block layer 2c (see FIG. 5c), the pore size distribution q3 substantially shows two pore maxima, i.e. pores with a pore size of around 1,000 μm2 and around 100,000 μm2 occur most frequently, wherein, however, the first pore maximum (at 1,000 μm2) is significantly larger than the second pore maximum (at 100,000 μm2).


A respective average or mean pore size of the pores present in the individual concrete block layers 2a, 2b, 2c can be determined, for example, from the corresponding respective pore size distributions q1, q2, q3. In the example described, the respective mean pore sizes in all three concrete block layers 2a, 2b, 2c are different from each other.


The mean pore size of the pores in the third concrete block layer 2c is smaller here than the mean pore size of the pores in the second concrete block layer 2b. Similarly, the mean pore size of the pores in the first concrete block layer 2a is smaller than the mean pore size of the pores in the second concrete block layer 2b and at the same time smaller than the mean pore size of the pores in the third concrete block layer 2c.


In the following, an example, namely “Example 1”, is used to describe how the porosities P1, P2, P3 and the pore size distributions q1, q2, q3, for example, can be evaluated and determined.


Furthermore, using a “Table 1” explained below, corresponding properties with regard to the porosities P1, P2, P3 of the first, second and third concrete block layers 2a, 2b, 2c are then summarized in tabular form for an exemplary embodiment of the present concrete block 1, wherein the data have been obtained via thin section microscopic evaluations (as described in Example 1).


Example 1: Thin Section Microscopic Examination and Determination of the Pore Proportions of the Samples

Thin section microscopic examinations are generally known to a person skilled in the art and were carried out in the present case in a known manner, wherein details of the examinations are described in greater detail below.


For the thin section microscopic examination, a sample of each concrete block layer 2a, 2b, 2c was prepared in the form of a polished thin section with a section thickness of approximately 25 μm and a format of approximately 20 mm×40 mm. For preparation, the samples were embedded in epoxy resin with a fluorescent dye (“epodye”). This fills most of the pores and makes them visible under the microscope due to the coloring of the epoxy resin.


The subsequent microscopic examinations were carried out according to Example 1 using a digital microscope unit (Keyence VHX-7000) with corresponding objectives for a 20× to 500× magnification. Microscopy was performed with linearly polarized light and subsequent false colour imaging. Images were captured using a high-resolution 4K camera (Keyence VHX-7100).


A quantitative determination of the pores present in the samples of the respective concrete block layers 2a, 2b, 2c was carried out according to Example 1 as a determination of the total pore area in the respective thin section sample, i.e. as a quantitative determination of the respective total pore area proportions.


This determination was carried out using evaluation software with predetermined settings. All pores with a pore area A greater than 100 μm2 were selected and recorded using color identification of the colored epoxy resin. According to the evaluation settings, pores in aggregates were removed manually and pores with incompletely colored filling were added manually. The number n of recorded pores (each with a pore area A greater than 100 μm2) thus results from the evaluation in accordance with the specified evaluation settings.









TABLE 1







tabular summary of exemplary examination results


Table 1: tabular summary of exemplary examination results









Concrete block layer











2a
2b
2c














Number n of pores
1922
305
323


detected


Total area of the pores
57,098,052
80,041,579
34,929,925


[μm2]


Proportion of the pore
5.30
7.79
4.79


area [%]


Maximum pore size
685,464
5,867,605
2,664,421


[μm2]


Mean pore size [μm2]
29,707
262,431
108,142









As Table 1 clearly shows, the non-fines porous second concrete block layer 2b has the largest pores (with the largest maximum pore area) as well as the largest total pore area and the largest mean pore size.


In the example shown, the number n of pores in the first concrete block layer is significantly higher than the respective number n of pores in the second and third concrete block layers 2b, 2c. Although the proportion of the pore area in the first and third concrete block layer 2a, 2c is comparable or almost the same, significantly more pores are formed in the first concrete block layer 2a than in the third concrete block layer 2c, wherein the pores of the third concrete block layer 2c have a significantly enlarged mean pore size than the pores of the first concrete block layer 2a.


Due to these porosities P1, P2, P3 of the first, second and third concrete block layers 2a, 2b, 2c with the described pore size distributions q1, q2, q3 as shown by way of example in FIGS. 5a to 5c and in Table 1 for a preferred variant of the concrete block 1, the capillary system is set up in the concrete block 1, in particular in the third concrete block layer 2c, with a suction force in order to suck water or transport it via capillary action from the bedding layer of the substrate against gravity into the concrete block 1, namely into the second concrete block layer 2b, where the water can then be “held” or stored due to the porosity in order to be available for efficient evaporation.


The third concrete block layer 2c has a lower water permeability compared to the second concrete block layer 2b, which is significantly reduced in particular with regard to the gravity-induced water flow. In the present context, a water-permeable layer with low water permeability is understood to be a concrete block layer through which water can be transported or channeled, but with a time delay and/or with a mitigated or reduced, in particular significantly mitigated or reduced, flow rate compared to the second, water-permeable concrete block layer 2b.


With reference to FIGS. 3 and 4, the water transport in a surface covering 10 made of several concrete blocks 1 is illustrated once again. The surface covering 10 comprises a plurality of multi-layer concrete blocks 1 laid in combination on a bedding layer 3 of a substrate. Joints 5 are formed between adjacent concrete blocks 1 of the surface covering 10 and are filled with a joint material 6 and form an infiltration path for draining rainwater from the surface of the surface covering 10 facing away from the bedding layer 3. The bedding layer 3 is a conventional bedding layer, which substantially consists of a material mixture with a grain size of 0.1 mm to 5 mm.


The third concrete block layer 2c of the concrete blocks 1 has a capillary suction effect for drawing water from the underside of the concrete block 2.1 through the third concrete block layer 2c into the second concrete block layer 2b, namely in a first direction R1. Via this suction effect or capillary effect, water from the bedding layer 3 can be supplied to the second concrete block layer 2b in the surface covering 10 via the third concrete block layer 2c. As a result, the water-storing second concrete block layer 2b can always be kept moist or wet in order to promote evaporation V. The third concrete block layer 2c therefore has an “irrigation effect” for the second concrete block layer 2b.


The “irrigation effect” is particularly advantageous if, due to the capillary suction force of the third concrete block layer 2c, the first direction R1 running from the concrete block underside 2.1 towards the second concrete block layer 2b is greater than the second direction R2 running from the second concrete block layer 2b towards the concrete block underside 2.1.


The infiltration and absorption path for precipitation water, as indicated by the black simple arrows in FIG. 4, substantially reflects the condition in the event that water is present “in excess” due to incident rain. The rainwater hitting the surface of the surface covering 10 on the first concrete block layer 2a of the concrete blocks 1 preferably seeps through the joints 5 into the joint material 6. Depending on the design of the first concrete block layer 2a, the rainwater can also be let through and channeled by it. Irrespective of this, at least a sufficient proportion of the percolating precipitation water moving in the direction of the bedding layer 3 passes from the joint material 6 into the porous second concrete block layer 2b, which is designed to absorb and store water particularly effectively due to its porosity and permeability. The porous second concrete block layer 2b absorbs the water here like a sponge, for example. Due to the reduced water permeability of the third concrete block layer 2c, the passage of water in the second direction R2, namely through the third concrete block layer 2c into the bedding layer 3 or the substrate, is delayed or reduced or inhibited and possibly even completely prevented. This delayed, possibly almost blocked water transport in the second direction R2 is indicated by dashed arrows in FIG. 4, as is the optional water transport through the first concrete block layer 2a.


Due to the special design and nature of the porosities P1, P2, P3 of the individual concrete block layers 2a, 2b, 2c and in particular due to their special interaction, the water that has penetrated into the second concrete block layer 2b can be effectively retained or stored there.


In FIG. 4, the capillary water transport through the third concrete block layer 2c into the second concrete block layer 2b, i.e. the capillary water transport, namely the suction effect of the third concrete block layer 2c, is indicated by the double arrows in the first direction R1. This suction effect can ensure the “water supply” of the second concrete block layer 2b even in the absence of precipitation. The precipitation water absorbed and stored in the second concrete block layer 2b as well as the water “replenished” from the subsoil or the bedding layer 3 via the suction effect of the third concrete block layer 2c is available for evaporation V, which is maintained constantly and, in particular, effectively in this way.


LIST OF REFERENCE SIGNS






    • 1 concrete block


    • 2 concrete block body


    • 2
      a first concrete block layer


    • 2
      b second concrete block layer


    • 2
      c third concrete block layer


    • 2.1 concrete block underside


    • 2.2 concrete block top side


    • 2.3, 2.4 concrete block sides


    • 3 bedding layer


    • 4 spacer lugs


    • 5 joints


    • 6 joint material


    • 10 surface covering

    • A pore size, pore area

    • As layer thickness of the first concrete block layer

    • Db layer thickness of the second concrete block layer

    • Dc layer thickness of the third concrete block layer

    • H total height of the concrete block

    • LA longitudinal axis

    • MHA center vertical axis

    • n number of pores

    • P1, P2, P3 first, second, third porosity

    • q1, q2, q3 first, second, third pore size distribution

    • R1, R2 first and second direction of water permeability

    • V evaporation




Claims
  • 1. A concrete block in a form of a surface covering element which can be laid in bond for producing a surface covering, comprising at least a multi-layer concrete block body with at least one concrete block underside and a concrete block top side opposite thereto, wherein the multi-layer concrete block body comprises at least one first concrete block layer arranged on the concrete block top side, at least one second concrete block layer adjoining the first concrete block layer and, a third concrete block layer adjoining the second concrete block layer, wherein the third concrete block layer forms the at least one concrete block underside, which is for laying on a bedding layer of a substrate, and wherein the second concrete block layer arranged between the first concrete block layer and the third concrete block layer is a non-fines porous core layer, wherein the first concrete block layer has a first porosity and comprises pores with a first pore size distribution, and the second concrete block layer has a second porosity and comprises pores with a second pore size distribution, and in that the third concrete block layer has a third porosity and comprises pores with a third pore size distribution, wherein a mean pore size of pores in the third concrete block layer is smaller than a mean pore size of pores in the second concrete block layer.
  • 2. The concrete block according to claim 1, wherein the mean pore size of the pores in the third concrete block layer corresponds to at most 0.3 times to 0.6 times of the mean pore size of the pores in the second concrete block layer.
  • 3. The concrete block according to claim 1, wherein the mean pore size of the pores in the first concrete block layer is smaller than the mean pore size of the pores in the second concrete block layer and the third concrete block layer.
  • 4. The concrete block according to claim 1, wherein the mean pore size of the pores in the first concrete block layer (2a) corresponds to at most 0.1 times to 0.3 times of the mean pore size of the pores in the second concrete block layer.
  • 5. The concrete block according to claim 1, wherein the mean pore size of the pores in the third concrete block layer corresponds to at least 3 to 4 times the mean pore size of the pores in the first concrete block layer.
  • 6. The concrete block according to claim 1, wherein the first concrete block layer, the second concrete block layer and the third concrete block layer comprises in each case a number of pores which exceed a minimum pore size, wherein the number of pores with at least the minimum pore size in the second concrete block layer and the third concrete block layer is the same, or substantially the same, or differs from one another by at most 10%.
  • 7. The concrete block according to claim 6, wherein the number of pores with the minimum pore size in the first concrete block layer is higher than in the second concrete block layer and the third concrete block layer.
  • 8. The concrete block according to claim 1, wherein the first concrete block layer, the second concrete block layer and the third concrete block layer in a totality of their respective pores in each case comprises pores with a maximum pore size, wherein the maximum pore size of the pores of the first concrete block layer is smaller than the maximum pore size of the pores of the second concrete block layer and the third concrete block layer, and/or in that the maximum pore size of the pores of the third concrete block layer is smaller than the maximum pore size of the pores of the second concrete block layer.
  • 9. The concrete block according to claim 1, wherein the second concrete block layer arranged between the first concrete block layer and the third concrete block layer is produced from a non-fines porous core concrete and the concrete block is designed to absorb and store water in the second concrete block layer.
  • 10. The concrete block according to claim 1, wherein the first concrete block layer, formed as a face concrete layer, is a dense-structure concrete block layer which is produced from an earth-moist concrete.
  • 11. The concrete block according to claim 1, wherein the third concrete block layer comprises a capillary suction effect for sucking water from the concrete block underside through the third concrete block layer into the second concrete block layer.
  • 12. The concrete block according to claim 1, wherein the third concrete block layer comprises a lower water permeability than the second concrete block layer and is designed in such a way that a gravity-induced water flow through the third concrete block layer is reduced in volume, in particular throttled.
  • 13. The concrete block according to claim 1, wherein the non-fines porous core layer comprises a water permeability of less than 1×10−5 m/s or a water permeability on average of less than 1.5×10−4 m/s and/or a compressive strength of at least 50 N/mm2.
  • 14. A surface covering comprising a plurality of multi-layer concrete blocks laid in bond on a bedding layer of a substrate according to any one of claim 1, wherein joints are formed between adjacent concrete blocks of the surface covering, and wherein the joints are filled with a substantially grit join material and/or sand joint material and form a seepage path for draining rainwater from a surface of the surface covering, and wherein the surface covering is equipped to absorb and store water in order to provide water for evaporation via the surface of the surface covering.
  • 15. A method for producing a concrete block according to claim 1 comprising the steps of: providing a formwork:introducing a concrete into the formwork in a first step to produce the third concrete block layer:producing, in a second step, the second concrete block layer, wherein additionally non-fines porous core concrete is introduced into the formwork, andproducing, in a third step, the first concrete block layer, wherein a face concrete is introduced into the formwork, and wherein the concrete material introduced is subsequently compacted and cured.
Priority Claims (1)
Number Date Country Kind
102023136057.4 Dec 2023 DE national