Reusable Clay Plaster System with Layered Strength
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Solution Overview
Problem
Current plaster systems used in construction are not reusable, leading to waste and inefficiency in resource management, as they form a firm, inseparable bond with the substrate, hindering circular economy goals in the construction industry.
Innovation Solution
A plastering system comprising a base plaster made of clay with a dry or earth-moist composition and a top plaster with higher surface strength, allowing for separation and reuse, where the base plaster is applied in a thicker layer and the top plaster in a thinner layer, enabling the mixture to be reused after dismantling without loss of quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional plaster systems with permanently hardening binders (lime, cement, gypsum) are used, then the plaster achieves high strength and durability, but the plaster forms an inseparable bond with the substrate and cannot be reused
Solution Approach 1:
The invention changes the fundamental parameter of binder hardening from permanent chemical setting (hydraulic setting, silicification, polymerization) to reversible physical bonding through clay mineralogy. The clay binder maintains plasticity and reversibility by utilizing clay-water complexes that can be reactivated with water, allowing the plaster to be removed and reused while maintaining adequate strength through controlled drying and clay particle interlocking
Solution Approach 2:
The invention creates a composite material system combining clay binder with carefully selected aggregates (sand, gravel, crushed stone) and optional natural fibers. This composite structure provides mechanical strength through the aggregate framework while the clay matrix maintains reversibility. The composite nature allows the plaster to achieve construction-grade strength while preserving circular economy principles through reusable composition
2Reliability
If plaster forms a firm bond with the substrate to meet protection and surface requirements, then the plaster system achieves functional performance, but the substrate and plaster cannot be separated for reuse
Solution Approach 1:
The invention introduces dynamic reversibility to the plaster-substrate bond through clay's unique property of reactivating with water. The plaster transitions from a static, permanently bonded state to a dynamic system where the bond can be strengthened during application, maintained during service, and easily released when needed by applying water. This dynamic characteristic enables both reliable performance and ease of separation for reuse
Solution Approach 2:
The clay binder acts as an intermediary between the substrate and the plaster aggregate structure. It provides a bonding mechanism that is sufficiently strong for functional performance but inherently reversible through water reactivation. This intermediary clay layer enables the plaster system to achieve both reliability in service and ease of separation, as the clay-water interaction serves as a controllable bond breaker
3Manufacturing precision
If traditional plaster materials are used to achieve desired surface properties, then the aesthetic and functional surface requirements are met, but the materials cannot be returned to the material cycle without quality loss
Solution Approach 1:
The invention segments the plaster system into distinct functional layers: a base coat layer providing structural integrity and a top coat layer providing surface properties. Both layers use the same reusable clay-aggregate composite composition. This segmentation allows each layer to be optimized for its specific function while maintaining overall compositional stability for reuse, as both layers can be removed together and recombined without quality loss
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system allows for the circular use of plaster materials, improving resource management by enabling the separation and reuse of plaster components, enhancing ecological and energy efficiency while maintaining desired surface properties.
Implementation Method 1
The binder creates a bond between the individual grains themselves and the substrate to which the plaster is applied
Implementation Method 2
The binder bonds the grains to each other, and the plaster to the substrate
Implementation Method 3
Plaster only achieves its final properties when it hardens on the component... clay as a binder that hardens upon drying
Data Source
Figure 1~2
Figure 3
AI summary
The present invention relates to a plaster system comprising at least a base coat (5) with a first composition and a top coat (7) with a second composition for application over a surface to a wall (1) or ceiling, wherein at least the base coat (5) consists of a dry plaster preparation for mixing with mixing water, wherein the base coat (5) has a first composition and the top coat (7) has a second composition, wherein the base coat (5) is applied in a first layer thickness d1 and the top coat (7) in a second layer thickness d2, wherein the first layer thickness d1 is greater than the second layer thickness d2, and wherein the base coat (5) is a clay plaster with a first surface strength and the top coat (7) is a plaster with a second surface strength, wherein the second surface strength is higher than the first surface strength.wherein the first layer thickness d1 and the second layer thickness d2 and the first composition and the second composition are coordinated in such a way that a mixture of the base coat (5) and the top coat (7) can be reused as a dry plaster preparation for mixing as base coat (5) after removal and crushing.