Lightweight wall

Abstract

The invention discloses a lightweight wall which comprises concrete, and the concrete comprises cement, water, an auxiliary cementing material, mixed synthetic fibers, mixed sand, a composite high-efficiency water reducing agent and a foaming agent. Prefabricated wire tubes, sockets and / or other embedded components are pre-installed when needed, and the wall body is produced according to specifications preset by a user.

Description

Technical Field

[0001] This invention relates to the field of wall construction. More specifically, this invention relates to a high-strength lightweight concrete wall and provides a method for its installation. Background Technology

[0002] Enclosing walls and / or interior partitions are walls used to separate or divide the interior space of a building. They are typically non-load-bearing walls, meaning they do not bear the structural weight of the building and are used only to create separate areas or rooms. Enclosing walls and / or interior partitions can be temporary or permanent and are indispensable in the functional layout design of residential, commercial, and industrial buildings.

[0003] Enclosures and / or interior partitions can be made from a variety of materials. Existing enclosures and / or interior partitions present numerous problems in terms of materials, construction, and use. Many enclosures and / or interior partitions, especially those made of drywall or thin materials, offer poor sound insulation, leading to noise interference between rooms. Furthermore, installing electrical conduits, sockets, or other embedded components in traditional enclosures and / or interior partitions often requires cutting or sawing the wall, installing the components, and then reassembling them. This process is not only time-consuming and labor-intensive but can also compromise the integrity of the wall structure. In addition, non-load-bearing enclosures and / or interior partitions sometimes lack the necessary strength and durability, making them susceptible to damage from impacts or heavy fixtures. Some materials used for enclosures and / or interior partitions are prone to cracking or have uneven surfaces, making it difficult to achieve a smooth and aesthetically pleasing finish.

[0004] In damp or humid environments, especially for enclosures and / or interior partitions made of drywall materials, moisture can be absorbed, leading to mold growth and structural damage. Furthermore, some enclosures and / or interior partitions lack adequate insulation, which can affect energy efficiency and comfort within the building. Additionally, not all enclosures and / or interior partitions possess sufficient fire resistance, potentially posing serious safety hazards within the building. Therefore, existing enclosure and / or interior partition solutions may suffer from problems such as low mechanical properties, poor durability, difficulty in mounting furniture, poor thermal and sound insulation, and low cost-effectiveness due to material selection.

[0005] To address the aforementioned problems, people have experimented with using different materials to construct enclosure walls and / or interior partitions. Below are some relevant examples of existing technologies.

[0006] Chinese Patent Publication No. 105601323A discloses a foamed concrete composite lightweight partition wall panel, comprising a face foamed concrete panel and a core foamed concrete panel. The face foamed concrete panels are symmetrically arranged on both sides of the core foamed concrete panel. This prior art designs a composite lightweight partition wall panel by using foamed concrete layers of different densities and functions, using high-density and high-strength foamed concrete to replace the traditional calcium silicate face foam structure, and using relatively low-density and low-strength core foamed concrete to fill the middle part of the composite wall. This method can effectively reduce the use of calcium silicate boards, reduce the production cost of lightweight composite panels, and simplify the production process; the resulting foamed concrete composite lightweight partition wall panel has excellent properties such as waterproofing, heat insulation, fire resistance, sound insulation, and phase change energy storage, and has broad application prospects. However, foamed concrete, especially the low-density core, may not be as durable as traditional materials, especially in areas with high traffic volume, where it is prone to wear and tear. In addition, compared with traditional fire-resistant materials, foamed concrete may have lower resistance to extremely high temperatures, which may limit its use in environments with strict fire protection requirements. Sound insulation performance can also vary depending on the density and composition of the foamed concrete layer, making it difficult to achieve consistent sound insulation performance across different batches or installations.

[0007] Chinese Patent Publication No. 108395276A discloses a method for preparing high-strength, lightweight cast-in-place concrete partition walls using construction waste. This partition wall is constructed using a non-demolition, cast-in-place method, which improves construction efficiency and reduces construction costs. Furthermore, the partition wall exhibits high strength, waterproofing, earthquake resistance, and good overall integrity. However, using construction waste (construction debris) as a raw material may affect the quality and consistency of the concrete. Additionally, the concrete in this prior art has a low density, which may affect the structural integrity and load-bearing capacity of the partition wall. Moreover, low-density concrete tends to be more brittle and more prone to cracking, spalling, and other forms of damage during handling, transportation, and installation.

[0008] Chinese Patent Publication No. 104108912A discloses a lightweight, high-performance foamed concrete. This prior art also discloses a method for preparing foamed concrete. Foamed concrete has advantages such as low volumetric weight, high strength, low water absorption, and low shrinkage, while also possessing waterproof and crack-resistant properties. However, the various components added to this product, such as slag, fly ash, gypsum, fine aggregates, admixtures, and fibers, may increase the overall material cost. Its preparation method requires precise measurement and mixing of multiple components, which complicates the production process and requires specialized equipment and technology. Furthermore, due to the fluctuations in the properties of the constituent materials (especially slag and fly ash), it is difficult to guarantee the consistency of quality and performance between different batches of concrete.

[0009] US Patent Publication No. 10040725B2 discloses a foamed cementitious composition with a lower water-cement ratio than conventional compositions and using only a small amount of aggregate or no aggregate at all. The stable foamed cementitious mixture can be used to manufacture cement boards and other cement products. This foamed cementitious composition is prepared by adding a polyvinyl alcohol (PVOH) foaming stabilizer and a surfactant foaming agent to create foamed water or by introducing air into the cementitious slurry mixture. The foamed cementitious composition contains a small amount or preferably no perlite and lightweight aggregate. However, the use of advanced additives and specific mixing processes requires expertise, which may limit its use by general contractors familiar with conventional materials. Furthermore, the method involves a complex mixing process that requires precise measurement and control. This complexity can lead to increased production time and the need for specialized equipment and technical support. Additionally, although the insulation performance of foamed cement boards may be superior to that of conventional cement, in some applications, without an additional insulation layer, its insulation performance may still be insufficient to meet standard requirements.

[0010] Despite the progress made in some aspects of the existing technologies mentioned above, there remains a need for a comprehensive solution for enclosure walls and / or interior partitions, requiring a technology that can overcome the limitations of existing enclosure walls and / or interior partitions. Summary of the Invention

[0011] One object of the present invention is to provide a cost-effective, high-strength, and lightweight concrete wall that is easy to transport and install and has a very low likelihood of cracking and shrinkage.

[0012] Another objective of this invention is to provide a high-strength concrete wall that is flexible in design and can be precisely customized to meet user needs.

[0013] Another objective of this invention is to provide a concrete wall with better thermal insulation, sound insulation, waterproofing and fireproofing properties, with a minimum thickness of only 65mm, while meeting or exceeding international, national and regional specifications, standards or requirements.

[0014] Therefore, the above objectives can be achieved by following the technical solution of this invention. This invention relates to a lightweight wall comprising concrete, which includes cement, water, auxiliary cementitious materials, mixed synthetic fibers, mixed sand, a composite high-efficiency water-reducing agent, and a foaming agent; wherein the wall is manufactured according to user-predetermined specifications.

[0015] The lightweight concrete wall of this invention, with its thinness and durability, is ideally suited for prefabricated buildings, serving as enclosure walls and / or interior partitions. Applying this type of wall effectively reduces building weight, improves space utilization, facilitates factory prefabrication and rapid on-site installation, thereby significantly improving construction efficiency and shortening the construction period. Simultaneously, its excellent thermal insulation, sound insulation, and fire resistance properties contribute to improved building quality and occupant comfort, playing a positive role in promoting the industrialization of construction and the development of green buildings. Detailed Implementation

[0016] To aid in understanding the principles of the invention, reference will now be made to the embodiments described below. It should be understood that the invention includes any modifications and variations to the illustrated embodiments, and includes further applications that would normally occur to those skilled in the art without departing from the scope of the invention.

[0017] This invention discloses a lightweight wall comprising concrete, which includes cement, water, auxiliary cementitious materials, mixed synthetic fibers, mixed sand, composite high-efficiency water-reducing agent, and foaming agent; wherein the wall is produced according to user-predetermined specifications.

[0018] According to a preferred embodiment of the invention, the ratio of water to all cementing materials is 0.23.

[0019] According to a preferred embodiment of the present invention, the weight ratio of the concrete components is as follows: 1.0 part cement, 0.3 parts water, 0.3 parts auxiliary cementitious materials, 0.01 parts mixed synthetic fibers, 0.9 parts mixed sand, 0.03 parts composite high-efficiency water-reducing agent, and 0.009-0.01 parts foaming agent. Through this concrete combination, the present invention achieves higher strength. The compressive strength achieved by the present invention can reach 35 MPa, thereby enabling furniture to be installed on the wall. The high strength achieved by the present invention further supports the use of precast concrete blocks for the installation of door and window openings, thereby reducing deformation of door and window openings during the service life. Furthermore, the air-entraining properties of concrete contribute to improved thermal insulation, sound insulation, waterproofing, and fire resistance exceeding one hour. The sound insulation performance of the present invention is superior to similar proprietary products, with a sound insulation index exceeding 40 dB for a 65 mm thick wall.

[0020] According to a preferred embodiment of the present invention, the mixed synthetic fiber is polypropylene fiber.

[0021] According to a preferred embodiment of the invention, the wall thickness is between 65 mm and 120 mm. The wall can be customized to meet user needs, with a thickness-to-height ratio of 1:5. For example, the wall thickness is 65 mm and the height is 3250 mm. This ratio allows for maximum utilization of available floor space when replacing ordinary brick, aerated concrete (AAC), or lightweight concrete block walls. The invention provides design flexibility, with each wall meticulously crafted to match customer specifications. This ensures accuracy in dimensions and measurements, and precise pre-installation of embedded reinforcements, electrical conduits, sockets, or other service facilities. Therefore, users can specify their requirements within the available space.

[0022] Furthermore, although the lightweight wall design of this invention reduces the thickness to 65mm, the performance of this wall still surpasses and meets the requirements of all relevant international, national, and regional wall product specifications, such as enclosure walls and / or interior partition walls. Details are shown in Tables 1 and 2 below.

[0023] The wall performance of this invention was tested according to the national standard GB / T23451-2023 "Lightweight Partition Wall Panels for Buildings", JC / T2475-2018 "Foamed Concrete Wall Panels and Roof Panels", the Hong Kong Housing Department Specifications Database 2018 (HKHA SL-2018 (Second Batch)) and the British standard BS 5234-2:1992 (Specification for Strength and Stability Performance Requirements) . The 65mm thick lightweight concrete wall met all the standard requirements. Tables 1 and 2 show the performance test results of a 65mm thick wall according to the national standard GB / T23451-2023 "Lightweight Partition Panels for Buildings", JC / T 2475-2018 "Foamed Concrete Wall Panels and Roof Panels", "Hong Kong Housing Department Specification Library 2018 (HKHA SL-2018 [Batch 2])", and the British standard BS 5234-2:1992 (Strength and Robustness Performance Requirements Specification). The density of this invention is expressed in air-dried condition, not dry condition, while the density of prior art is expressed in dry density.

[0024] Table 1: Performance tested according to national standards

[0025]

[0026]

[0027]

[0028] Table 2: Performance tested according to Hong Kong and British standards

[0029]

[0030]

[0031]

[0032]

[0033]

[0034] According to a preferred embodiment of the present invention, the wall is produced by prefabrication. The wall of the present invention is prefabricated in a factory using customized molds.

[0035] According to a preferred embodiment of the present invention, the density of the wall is in the range of 1200 to 1800 kg / m³. 3 For example, walls with a thickness between 65mm and 120mm have a density ranging from 1200 to 1800 kg / m³. 3 The tolerance is 100 kg / m 3 .

[0036] This invention addresses the shortcomings of conventional drywall panels and aerated lightweight concrete (AAC) enclosures and / or interior partitions on the market. Although AAC is widely used in existing enclosure and / or interior partition products, its thickness and service life are often limited. In contrast, the foamed concrete used in this invention offers superior workability, excellent mechanical properties, better thermal insulation, improved sound insulation, lower shrinkage, and higher cost-effectiveness.

[0037] According to a preferred embodiment of the present invention, the wall further comprises hot-rolled ribbed steel bars. The hot-rolled ribbed steel bars (diameter φ6mm) serve as the reinforcing material in this invention, with a center-to-center spacing of 100mm for the steel mesh. Furthermore, the wall employs various joint types to enhance structural strength and improve overall stability. Tongue and groove joints ensure joint precision, with a maximum joint gap of 3mm, and the joints are filled with non-shrink cement mortar to achieve a seamless appearance. The joint width of the structural wall is ≤25mm, and the L-shaped joint width is ≤12mm. Bottom joints are allowed to be filled with a maximum thickness of 20mm of non-shrink cement mortar; top joints are ≤12mm thick and filled with non-shrink cement mortar. Moreover, compared to conventional masonry walls, the wall of the present invention exhibits extremely small shrinkage, thereby significantly improving the stability of the wall.

[0038] According to a preferred embodiment of the invention, the wall also includes embedded components that can integrate electrical conduits, sockets, etc., based on the user's predetermined needs. The embedded components (e.g., electrical conduits, sockets, and other building service facilities) can be integrated into the wall according to the user's requirements and follow the wiring layout approved by the building service engineer. The embedded electrical conduits are integrated into the wall according to the approved wiring layout, which conforms to, but is not limited to, BS 4607, "Specifications for Rigid Plastic Conduits for Electrical Installations". The lightweight nature of the invention helps simplify the installation process.

[0039] Furthermore, compared to traditional wall panels, this invention offers superior performance in terms of pouring, handling, installation, and cost-effectiveness. Concrete can be poured simultaneously through multiple pipes, significantly improving construction efficiency. After pouring, it can be directly molded using, for example, steel molds, completely eliminating the need for subsequent surface treatment. Through the simplified pouring process and the smooth finish of the steel molds, the wall of this invention becomes an economical and efficient alternative to traditional block walls, particularly suitable for the construction of multi-story buildings.

[0040] This invention also discloses an example of a wall installation method. The steps include: cleaning the area to be installed before the installation process begins; marking positioning lines on the floor and wall; and checking tolerance levels. If the tolerance levels exceed standard values, remedial work is required, such as repairing the wall with cement mortar and leveling the floor.

[0041] In addition, the installation method includes drilling holes in the concrete wall using an 8mm diameter electric drill, inserting plastic expansion plugs, nailing 100mm long concrete nails into the wall, and hammering a 100mm long concrete nail into each slot of the wall panel to attach it to the concrete wall during the initial installation of the wall panel.

[0042] The installation method also includes the following steps: securing at least two rubber pads to the top of the wall by driving a 45mm long nail into the wall or using tape; erecting the wall along the marked lines on the floor and wall; inserting and securing a wooden wedge under the bottom of the wall with a hammer; checking the verticality of the front and edges of the wall using a calibrated level; and, if necessary, fine-tuning by tightening the wooden wedges until the rubber pads are compressed.

[0043] Repeat the above steps to install the subsequent walls. After the non-shrink cement mortar has hardened, remove the wooden wedges. Finally, let the cement mortar stand for one day before installing the ceiling slab.

[0044] The above description of the present invention is not limited to the above embodiments. For those skilled in the art, various substitutions, modifications and alterations can be made without departing from the scope of the present invention.

Claims

1. A lightweight wall comprising concrete, the concrete comprising: cement; water; supplementary cementitious material; mixed synthetic fiber; mixed sand; composite superplasticizer; and foaming agent; wherein the wall is produced based on a user preset specification.

2. The lightweight wall according to claim 1, wherein the ratio of water to all cementitious materials is 0.

23.

3. The lightweight wall according to claim 1, wherein the weight ratio of the components of the concrete is: 1.0 parts cement, 0.3 parts water, 0.3 parts supplementary cementitious material, 0.01 parts mixed synthetic fiber, 0.9 parts mixed sand, 0.03 parts composite superplasticizer, and 0.009-0.01 parts foaming agent.

4. The lightweight wall according to claim 1, wherein the mixed synthetic fiber is polypropylene fiber.

5. The lightweight wall according to claim 1, wherein the thickness of the wall is 65-120 mm.

6. The lightweight wall according to claim 1, wherein the wall is produced by a precast method.

8. The lightweight wall according to claim 1, wherein the wall further comprises hot-rolled ribbed steel bars.

9. The lightweight wall according to claim 1, wherein the wall further comprises pre-embedded components, the pre-embedded components comprising pipes, sockets, and / or other embedded components. ​ ​ ​ ​ ​ ​ ​ 7. A lightweight wall according to claim 1, wherein the density of the wall is from 1200 to 1800 kg / m3 3 . ​ ​

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