United States Patent (19) 11 4,229,393

Wesche et al. 45 Oct. 21, 1980

54 METHOD OF PRODUCING SAND-LME 56) References Cited
BRCKS WITH A LOW BULK DENSTY U.S. PATENT DOCUMENTS
(76) Inventors: Karlhans Wesche, Lohmiihlenstrasse 3,226,242 12/1965 Huettemann ......................... 106/120
5a; Peter H. Schubert, Königshigel 3,438,853 4/1969 Haines et al. ........................ 264/333
34; Horst W. Glitza, Westend 15, all 3,764,357 10/1973 Bowles et al. ....................... 264/333
ofAachen, Fed. Rep. of Germany, Primary Examiner-John A. Parrish
5100
Attorney, Agent, or Firm-Finnegan, Henderson,
21 Appl. No.: 935,758 Farabow, Garrett & Dunner
22 Filed: Aug. 22, 1978 57 ABSTRACT
Related U.S. Application Data A method for producing sand-lime bricks of low bulk
density and having a green strength of at least 1 kp/cm
63 Continuation of Ser. No. 692,747, Jun. 4, 1976, aban in which at least 1% by weight of cement is added to a
doned. mixture of sand, lime and water and the mixture is then
(51) Int, Cl’.............................................. C04B 35/14 compacted in molds by vibration or under a pressure of
(52) U.S. C. ...................................... 264/42; 106/120; less than 150 kp/cm2 to form bricks which are subse
264/82; 264/333 quently cured.
58 Field of Search ..................... 264/63, 333, 82, 42;
106/120 15 Claims, No Drawings
 4,229,393
1. 2
destroyed by the low compacting pressures which are
METHOD OF PRODUCING SAND-LME BRICKS possible in this case.
WITH A LOW BULK DENSITY It is further provided that air-entraining or foam
forming agents be added to the mixture. In this way
This is a continuation of application Ser. No. 692,747, with the low compaction pressures the brick bulk den
filed June 4, 1976, now abandoned. sity can be further reduced.
The invention relates to a method of producing sand Through the use of cement as a binder it is possible, in
lime bricks with a low bulk density and a green brick accordance with a further proposal of the invention, to
strength of 21 kp/cm2 wherein a mixture of sand, lime produce bricks of single-sized aggregates having a parti
and water is produced and then compressed in moulds 10 cle size of less than 0.25 mm. These single-sized aggre
of a compactor to form green bricks which are subse gates or sand-like grains lead to a reduction in brick
quently cured in an autoclave. bulk density and therefore to an improvement in heat
In the wake of continuous cost increases in the energy insulating properties while maintaining the strength
supply field, efforts are at present being intensified to required in the brick.
wards improving the heat insulation properties of build 15 The invention further proposes that the bricks be
ing bricks by reducing the bulk density thereof. Funda provided with a porosity of 225%. This porosity can
mental ways of achieving this include increasing the be produced in all brick sizes in use to improve heat
number of voids in the brick, the use of lightweight insulating properties without the strength of the bricks
aggregates and the production of artificial air voids. falling below the required value.
The reduction of brick bulk density as a prerequisite for 20 In accordance with the invention it has been found to
improving heat insulation properties creates consider be advantageous if 10% by weight of CaO, 5% by
able difficulty on account of the reduced green strength weight of water in addition to the water for slaking,
associated therewith, particularly in the case of sand 81% by weight of sand having a particle size between 0
lime bricks, since with the green strength of the brick and 2 mm and 4% by weight of quick-setting cement are
having been reduced the stresses resulting from the 25 mixed together and the mixture is compacted at a pres
previously used transporting or conveying operations sure of 10 kp/cm2 after being left to stand for 30 mi
cannot be absorbed without intolerable damage being nutes. This low pressure, which is only a fraction of the
done to the bricks. According to the previously known pressure normally required in the production of sand
method of producing sand-lime bricks of low bulk den lime bricks which is of the order of approximately 150
sity, to achieve sufficient green brick strength necessi
30 kp/cm2, is also advantageous in view of the stresses to
tates a high degree of minimum compaction which which the necessary compactor is subjected.
counteracts a low bulk density in the brick. In accordance with a further proposal of the inven
The problem for the present invention is to achieve, tion the mixture, after addition of the cement, is vi
brated or acted upon by tamping rods.
with a method of the initially described type, a lower 35 In this manner the brick bulk density may be further
bulk density without substantially impairing green brick reduced to improve heat insulating properties. More
strength so that bricks produced in accordance with the over, only a relatively low expenditure on apparatus is
method can be conveyed by the previously known de necessary with this method of procedure.
vices. It is to be understood that by the use of the term Finally the invention proposes that the compacting of
"brick' in the specification and claims applicants mean the mixture be effected by vibration alone acting on the
a sand-lime building block of any shape and size. moulds. This leads to the compactor being particularly
This problem in a method of the type mentioned at simple in design.
the beginning of the specification is solved in accor In accordance with a first embodiment a mixture
dance with the invention by adding at least 1% by comprising 10 parts by weight of CaO, 5 parts by
weight of cement to the mixture prior to introduction 45 weight of water in addition to the necessary water for
into the compactor, and then compressing the mixture slaking and 81 parts by weight of sand is produced in a
in a compactor at pressures of less than 150 kp/cm2. mixer. Sand having a particle size S2 mm is used in this
Prior to the compacting operation the cement, which case. 4 parts by weight of quick-setting cement are
acts as a binder and is added to the mixture consisting added to this mixture. The mixture thus obtained, i.e.
essentially of sand, lime and water, causes strength 50 10% by weight of CaO
forming reactions to come into play which give the 5% by weight of water (in addition to the necessary
unfinished brick the desired strength even when little water for slaking)
compacting occurs in the compactor. 81% by weight of sand
The invention provides that, after addition of the 4% by weight of quick-setting cement,
cement, the mixture be also retained in a mixer or an 55 is conveyed to an intermediate silo where it is left for
intermediate silo for approximately one hour to initiate approximately 30 minutes. Strength-forming or harden
strength-forming reactions and subsequently conveyed ing reactions in the cement are initiated in this silo.
to the compactor. The mixture is then conveyed into moulds in a com
The invention further provides that the cement to be pactor. Here a pressure of approximately 10 kp/cm2 is
used be a quick-setting cement so that the time the mix exerted on the mixture, this pressure being equal to
ture is maintained in front of the compactor can be kept about 1/15th of the pressure hitherto used for compact
relatively short. ing in the production of sand-lime bricks.
The invention further proposes that lightweight ag The bricks thus produced are removed from the com
gregates be added either fully or partially to the mixture pactor in the conventional manner and transferred to an
in place of the sand. Through their own low bulk den 65 autoclave. After leaving the compactor the brick have a
sity these lightweight aggregates are instrumental in green strength of approximately 1.6 kp/cm2. In this
reducing the bulk s of the brick. In contrast to connection the bulk density of the brick material prior
conventional sand-lime brick production, they are not to hardening is approximately 1.7 kg/dm.
 4,229,393
3 4.
As a result of a brick green strength of approximately (a) preparing a mixture of sand, line, water and ce
1.6 kp/cm2 which is achieved despite a relatively small ment, said mixture consisting essentially of sand,
degree of compaction, the bricks obtained in this man lime and water and also including a relatively small
ner can be easily conveyed by the devices hitherto used amount of cement as a binder, said cement being
in sand-lime brick production. present in relatively small amount in relation to the
In accordance with a second embodiment a mixture total amount of said sand, lime and water, said
comprising 7 parts by weight of CaO, 7 parts by weight cement being present in an amount in excess of 1%
of water in addition to the necessary water for slaking by weight to provide said mixture with a green
and 80 parts by weight of sand are produced in a mixer. strength of at least 1 kg/cm2 subsequent to compac
Sand having a particle size of up to 2 mm is used in this O tion of said mixture; m
case. 6 parts by weight of quick-setting cement are (b) compacting said mixture in a mold at a pressure of
added to this mixture. Then 30 l of a foam-forming less than 150 kg/cm2 to form green brick;
agent are added to 100 kg of the thus obtained mixture (c) removing said green brick from said mold;
of: (d) transporting said green brick to an autoclave; and
7% by weight of CaO 5 (e) curing said green brick in the autoclave to form
7% by weight of water (in addition to the necessary said building brick.
water of slaking) 2. The method of claim 1, in which the compacting
80% by weight of sand step is carried out by means of vibrating said mixture
6% by weight of quick-setting cement. within said mold.
The mixture thus obtained is conveyed to an interme 20 3. The method of claim 1, in which the mixture is left
diate silo where it is left for approximately 30 minutes. to stand for up to one hour following addition of the
Strength- or hardness-forming reactions, in the cement cement to initiate strength-forming reactions before the
are initiated in this silo. mixture is compacted.
The mixture is then conveyed into moulds in a vibrat 4. The method of claim 1, in which the cement is a
ing machine where it is compacted. The machine has a 25 quick-setting cement.
vibration frequency of 150 Hz with an amplitude of 2 5. The method of claim 4, in which the quick-setting
mm. The vibration time is 20 seconds. In this compact cement is added to the mixture in an amount ranging
ing operation there is no load concentrated on the mix from at least about 1% to about 6% by weight of ce
ture in the moulds. ment based on the weight of the mixture.
The bricks thus produced are removed from the com 6. The method of claim 1, in which the sand is at least
pactor in the conventional manner and transferred to an partially replaced by light-weight aggregates.
autoclave. After leaving the compactor the bricks have 7. The method of claim 1, in which foam-forming
agreen strength of approximately 1.2 kp/cm2 and, prior agents are added to the mixture prior to compaction.
to hardening, a bulk density of 1.4 kg/dn. The green 8. The method of claim 1, in which the sand has a
strength thus obtained is still sufficient to enable the 35 particle size of less than 0.25 mm.
bricks to be conveyed by the devices hitherto used in 9. The method of claim 1, in which the bricks have a
sand-lime brick production. porosity of at least 25%.
The mixture can alternatively be compacted by 10. The method of claim 1, in which the mixture
means of tamping rods instead of by the vibration ma comprises 10% by weight CaO, 5% by weight of water
chine used in this embodiment. in addition to the necessary water for slaking, 81% by
All the previously described embodiments can be weight of sand with a particle size of up to 2 mm and
simply modified by replacing the sand portion entirely 4% by weight of quick-setting cement and in which the
or partially with lightweight aggregates. mixture is left to stand for about hour and then com
At the same time or as an alternative, foam-forming pacted at a pressure of 10 kp/cm2.
agents can be added to the mixture prior to compaction. 45 11. The method of claim 1, in which stabilizers are
Moreover, simultaneously with each individual or all added to the mixture to prevent decomposition.
the previously described measures for reducing bulk 12. In a method for producing a sand-lime building
density or as an alternative thereto, single-size aggre brick by molding a mixture consisting essentially of
gates having a particle size of less than 0.25 mm can sand, lime, and water in a mold under pressure to form
either partially or fully replace the normal sand portion. 50 green brick, removing the green brick from the mold
In any case the bulk density can additionally or alter and curing the green brick in an autoclave to produce
natively be reduced by arranging voids in the brick to said building brick, the improvements of: lowering the
produce a porosity of 25% or more. bulk density of the building brick by incorporating in
Particularly in a case where the mixture is compacted said mixture a relatively small amount of cement as a
by means of a vibrating machine, it can be advanta 55 binder, said amount being small in relation to the total
geous, in accordance with a further embodiment of the amount of said sand, lime and water, and compacting
method of the invention, to add to the mixture aggre said mixture at a pressure less than 150 kg/cm2 to form
gates having a water-saving and/or liquefying effect, as the green brick, said cement being present in said mix
are already known in concrete manufacture. ture in an amount sufficient to produce a green brick
In all the described embodiments methyl cellulose, having a strength of at least 1 kg/cm2.
for example, or any known stabilizer producing a simi 13. The method of claim 12, in which said compact
lar effect can be added to the mixture in order to coun ing step is carried out by vibrating said mixture within
teract and decomposition or disintegration of the mix said mold.
ture components in this manner and, if required, to 14. The method of claim 12, in which the cement is a
obtain a certain bonding effect. 65 quick-setting cement.
We claim: 15. The method of claim 12, in which the bricks have
1. A method for producing a sand-lime building brick a porosity of at leastax 25%.
of low bulk density comprising the steps of: