Pre-filled Mortar Packages for Single-Person Masonry Construction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional dry-stacked stone walls are prone to shifting and structural integrity issues due to weather and stressors, requiring labor-intensive reinforcement methods that often necessitate multiple people for effective mortar application.
Innovation Solution
Mortar packages with a porous outer surface and embedded adhesive, activated by liquid, are used between masonry elements to provide stabilization and bonding, allowing for single-person construction and improved structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional mortar reinforcement methods are used, then structural integrity is improved, but labor requirements increase to two or more people
Solution Approach 1:
The mortar system is segmented into pre-packaged individual units, each containing mortar and adhesive components in separate compartments. This allows a single worker to handle and apply individual packages without needing assistance for mixing or positioning, while still achieving proper mortar reinforcement between stones.
Solution Approach 2:
The mortar and adhesive are pre-prepared and packaged in ready-to-use units before reaching the construction site. The adhesive is pre-applied to the package exterior, and the mortar is pre-measured and contained, eliminating the need for on-site mixing and preparation that would require multiple workers.
2Ease of operation
If dry-stacking method is used, then labor intensity is reduced, but structural stability deteriorates due to stone shifting
Solution Approach 1:
The mortar package acts as an intermediary element placed between stones during dry-stacking. It provides the necessary adhesive bonding and structural reinforcement without requiring the worker to perform complex mortar application techniques, thus maintaining low labor intensity while improving stability.
Solution Approach 2:
The mortar package is designed to be self-contained and self-applying. The adhesive on the package exterior automatically bonds to surrounding stones when activated by moisture, and the mortar interior provides structural support without requiring additional manipulation or application steps by the worker.
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 use of mortar packages enhances the structural stability and resistance to weather damage of stone walls, enabling single-person construction and reducing the need for extensive labor and multiple workers.
Implementation Method 1
the adhesive and the mortar mixture are preferably both activated by a liquid (e.g. water)
Implementation Method 2
Incorporated into or on the porous outer surface is an adhesive
Data Source
AI summary
Pre-filled mortar packages are positioned between masonry construction elements (such as stones, blocks or bricks) when forming a wall (such as a dry-stack stone wall). Each mortar package includes an outer covering with a porous outer surface, a mortar mixture covered by the outer covering, and (optionally) an adhesive incorporated onto or in the porous outer surface. Both the adhesive and the mortar mixture are activated by a liquid, such as water. The mortar packages may be pre-wetted and placed on masonry construction elements when stacking the masonry construction elements. Alternatively, the mortar packages may be dry when placed on masonry construction elements, and activated by applying water or by wetting from rain water. Mortar packages are more convenient and efficient than adhesives or mortar alone, and create walls and other structures with increased strength and improved aesthetics.