Block-Type Building Stone Used As A Construction Material For Walls

Abstract

The invention relates to a block-type component that is used as a construction material for walls, e.g., noise barriers and walls of buildings. The component comprises an exterior and an interior, in addition to a three-ply construction including the following layers: an external layer, which consists of stone or concrete and forms the exterior, a central layer of insulating mortar with a high degree of thermal insulation, comprising at least 70% by volume (in relation to the volume of the central layer) of reprocessed, granular polyurethane and cement as the binding agent, and an internal layer that preferably contains cement as the binding agent, the layer forming the interior.

1 . A block-type building stone as a building material for walls such as soundproof walls and building walls, the building stone comprising: 
 an outside face; and    an inside face; and    a three-layered structure, three-layered structure including an outer layer forming the outside face, a middle layer made from insulating mortar with high thermal performance that has at least 70 volume percent (related to the volume of the middle layer of recycled, granular polyurethane and cement as a binder, and an inner layer that forms the inside face and preferably comprises cement as the binder.    
   
   
       2 . The block-type building stone as set forth in  claim 1 , wherein the width of the middle layer is greater than the width of the outer layer and is eater than the width of the inner layer, preferably that the middle layer has a thickness that is at least twice, more specifically three times, the thickness of the outer layer, the inner layer or the outer layer and the inner layer.  
   
   
       3 . The block-type building stone as set forth in  claim 1 , wherein the outer layer is thinner than the inner layer.  
   
   
       4 . The block-type building stone as set forth in  claim 1 , wherein the concrete from which the outer layer is made is a standardized concrete such as CEM I 52.5, CEM I 42.5, or CEM I 32.5.  
   
   
       5 . The block-type building stone as set forth in  claim 1 , wherein the middle layer comprises 90-94 volume percent of recycled hard polyurethane that has been shredded to form a mixture of powder and granules having a grain size of less than 8 mm and 6-10 volume percent of cement, more specifically, 92 volume percent of recycled hard polyurethane and 8 volume percent of cement, each relative to the volume of the middle layer.  
   
   
       6 . The block-type building stone as set forth in  claim 1 , wherein the thickness of the outer layer ranges between 4 and 15 cm, more specifically between 8 and 12 cm.  
   
   
       7 . The block-type building stone as set forth in  claim 1 , wherein the middle layer, the inner layer or the middle layer and the inner layer have an open pore structure.  
   
   
       8 . The block-type building stone as set forth in  claim 1 , wherein the building stone comprises an upper face and a bottom face and at least one projection on the upper face, and the bottom face defines a recess that is at least as large as the at lease one projection on the upper face and conforms to the shape of the at least one projection.  
   
   
       9 . The block-type building stone as set forth in  claim 1 , wherein the building stone comprises a front and a rear end surface that are both level.  
   
   
       10 . The block-type building stone as set forth in  claim 1 , wherein the outside face, the inside face or the outside face and the inside face are level surfaces.  
   
   
       11 . The block-type building stone as set forth in  claim 1 , wherein the building stone is 0.4 to 2.5 m in length.  
   
   
       12 . The block-type building stone as set forth in  claim 1 , wherein a strip-shaped material, more specifically, a rubber-type material, is provided that is interposed between two superposed block-type building stones.  
   
   
       13 . The block-type building stone as set forth in  claim 1 , wherein the outer layer, the inner layer or the outer layer and the inner layer have no gaps.  
   
   
       14 . A method of manufacturing a block-type building stone as set forth in  claim 1  comprising the steps of: 
 introducing a bottom layer into a water permeable mould to form an outer layer or an inner layer;    mixing cement, polyurethane and water to produce a pourable mixture;    pouring the mixture onto the bottom layer already formed in the mould to produce a middle layer;    observing a waiting time wherein the cement does not yet harden and water flows out of the mould so that the layer thickness of the middle layer is reduced by at least 0.5% preferably by 2 to 5%; and    applying an upper layer to form the inner layer or the outer layer.    
   
   
       15 . The method as set forth in  claim 14 , wherein at least one of (i) the middle layer is applied onto the bottom layer while the bottom layer is still fresh, (ii) the upper layer is applied onto the middle layer while the middle layer is still fresh and (iii) the middle layer is applied onto the bottom layer while the bottom layer is still fresh and the upper later is applied onto the middle layer while the middle layer is still fresh.  
   
   
       16 . The method as set forth in  claim 15 , wherein the upper layer is applied by pressing parts such as bricks, or rubble stones, into the still fresh middle layer.  
   
   
       17 . The method as set forth in  claim 14 , wherein, using normal hardening cement, the waiting time is at least 30 minutes and at most 5 hours.