Lightweight Interior Sidewall and Method for Fabricating the Same

Abstract

A lightweight interior sidewall and a method for fabricating the same are provided. The lightweight interior sidewall is formed by a plurality of adjacent slabs. A method for fabricating the slabs includes forming a concrete block made of cement, fine sand, bamboo-shaped short fibers and a lightweight aggregate material, cutting the block to form multiple slabs, and grinding a central region of two sides of each slab to form a longitudinal groove therein. The method for fabricating the lightweight interior sidewall includes disposing multiple slabs adjacent to each other, securing each slab between a reverse U-shaped clamp on the ceiling and a support element on the floor, and filling a cement mortar into the longitudinal grooves to bind the slabs together. The lightweight and robust sidewall can be thereby formed in an efficient manner.

1 . A lightweight interior sidewall formed by a plurality of adjacent slabs, each slab comprising 20% to 60% of cement, 30% to 70% of fine sand, 2% to 20% of bamboo-like shaped short fibers, and 30% to 50% of a lightweight aggregate grain material, wherein each slab has a thickness between 5 to 15 centimeters, and a longitudinal groove is defined in a central region of two sides of each slab and is adapted to be filled with a binder substance during construction. 
     
     
         2 . The lightweight interior sidewall as claimed in  claim 1 , wherein each slab has a length between 1.8 and 5.0 meters, and a width between 0.4 and 1.0 meters. 
     
     
         3 . The lightweight interior sidewall as claimed in  claim 1 , wherein a chamfer is formed on edges of the two sides of each slab. 
     
     
         4 . The lightweight interior sidewall as claimed in  claim 1 , wherein each slab comprises a plurality of glass fibers having a length between 0.5 and 2 centimeters. 
     
     
         5 . The lightweight interior sidewall as claimed in  claim 1 , wherein the lightweight aggregate grain material comprises high clay-containing foamed ceramic grains, and the ratio of the lightweight aggregate grain material is greater than 0.3. 
     
     
         6 . The lightweight interior sidewall as claimed in  claim 1 , wherein each of the two sides of the slab have at least one injection hole perpendicular to the longitudinal groove. 
     
     
         7 . A method for fabricating a slab used in lightweight sidewalls, comprising:
 (1) forming a composite mixture by mixing and agitating together 20% to 60% of cement, 30% to 70% of fine sand, 30% to 50% of a lightweight aggregate grain material, 2% to 20% of bamboo-shaped short fibers and water;   (2) pouring the composite mixture into a generally-rectangular mold, and drying the mixture to form a concrete block of at least 40 centimeters in thickness;   (3) cutting the concrete block by using a cutting apparatus having a set of parallel cutting blades spaced from each other by at least 5 centimeters to form a plurality of slabs having a thickness of at least 5 centimeters, and grinding a central region of two sides of the slab to form a longitudinal groove therein.   
     
     
         8 . The method as claimed in  claim 7 , wherein step (1) further comprises incorporating glass fibers having a length of at least 0.1 centimeters and/or a foaming agent and/or a water-reducing agent, and step (3) further comprises grinding edges of the two sides of the slab to form a chamfer thereon. 
     
     
         9 . A method for fabricating an interior sidewall, comprising:
 (1) providing lightweight slabs having at least the same thickness and length, wherein each slab has a longitudinal groove defined in a central region of two sides thereof;   (2) fixing an elongated clamp of a reverse U-shape on a ceiling at a location for receiving the placement of the sidewall, wherein the clamp has an opening oriented downward and retains a flexible element therein;   (3) vertically erecting the slabs adjacent to each other on a floor, and engaging an upper edge of each slab into the elongated clamp;   (4) locking a bottom edge of each of slab with a support element used for adjusting the height of each slab;   (5) fixing a baseboard at a lower portion of a front surface and a rear surface of each slab, wherein the baseboard is tightly adhered on the floor; and   (6) forming an injection hole at an upper region of an interface between the two slabs for injecting a viscous binder substance that fills up each of the longitudinal grooves and a gap between the bottom edge of each slab and the floor.   
     
     
         10 . The method as claimed in  claim 9 , wherein step (1) comprises using a mixture including cement, sand and a lightweight aggregate to form a concrete block, and cutting and grinding the concrete block to form each slab, step (2) comprises using a rubber mat as the flexible element, step (4) comprises using a screw as the support element, and step (6) comprises using a cement mortar as the binder substance.