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Title:
A CONSTRUCTION STRUCTURE AND METHOD OF MAKING THEREOF.
Document Type and Number:
WIPO Patent Application WO/2016/055974
Kind Code:
A4
Abstract:
The present invention relates to a construction structure comprising a combination / arrangement of at least two units of elements (350 & 351) selected from compacted intermeshing blocks that are soil based, ash based or a combination, modularly reinforced load bearing unit for floor and/or slab, peggable contoured roofing element, reinforcement substance/s. The components of the structure are modular and could be built onsite. The process of making compacted intermeshing blocks is green with a substantially lower embodied energy obviating heating in kiln. The compacted intermeshing blocks comprise of regular compacted intermeshing block, half size regular compacted intermeshing bock, compacted intermeshing block with a longitudinal cavity, half size compacted intermeshing block with a longitudinal cavity. The configurations using compacted intermeshing blocks and intermittent reinforcement reduces use of mortar, enables use of locally available material such as soil as well as disposable waste material such as fly ash to build a construction structure.

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Inventors:
NAIK PRAFUL (IN)
STHAPIT GYANENDRA RATNA (NP)
JABADE SIDDHARTH (IN)
AMATYA SUDIKSHA (NP)
ACHARYA KIRAN (NP)
JAENGJIT PREECHA (TH)
JAENGJIT CHALARD (TH)
Application Number:
PCT/IB2015/057728
Publication Date:
July 21, 2016
Filing Date:
October 09, 2015
Export Citation:
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Assignee:
WORSAK KANOK NUKULCHAI (TH)
NAIK PRAFUL (IN)
International Classes:
E04B2/32
Attorney, Agent or Firm:
MAJUMDAR, Subhatosh et al. (5 Harish Mukherjee Road, West Bengal, Kolkata 5, IN)
Download PDF:
Claims:
1

AMENDED CLAIMS

received by the International Bureau on 17 May 2016 (17.05.2016)

1 . A construction structure comprising

a combination of regular, half-length regular, U-shaped, half-length U-shaped compacted intermeshing blocks comprising a top surface (54), bottom surface (55) and side surfaces (52 and 53);

intermittent horizontal reinforcement, intermittent vertical reinforcement, configured to traverse through the intermeshed layers of blocks;

modularly reinforced load bearing unit for floor and/or slab comprising two load bearing elements (350 and 351 ) that are connected with pans (352) that are contoured in convex shape, steel mesh;

peggable contoured roofing element used in sloping roof;

wherein

a grain size distribution of raw materials, stabilizing agent/s; mechanical stabilization; controlled chemical stabilization imparts properties to the compacted intermeshing block for use as a structural element.

2. A construction structure as claimed in claim 1 wherein the structure comprises of an arrangement of at least two units of elements selected from the compacted intermeshing block, modularly reinforced load bearing unit for floor and/or slab, peggable contoured roofing element, reinforcement substance/s.

3. A construction structure as claimed in claim 1 wherein the structure comprises of

a roof comprising either a sloping roof or flat roof or a combination;

window/s, door/s;

optional staircase comprising prefabricated stairs, concrete stringer and tread that are interlocked with each other, steel reinforcement, welded wire mesh and blaster; a foundation comprising optional piles stone, ash based compacted intermeshing blocks, optional concrete;

plinth comprising at least two layers of Damp Proof Course, compacted intermeshing blocks with horizontal reinforcement; 2

walls comprising a combination of regular, half-length regular, U-shaped, half-length U shaped compacted intermeshing block configurations assembled with horizontal and vertical reinforcement.

A construction structure as claimed in claim 1 wherein regular compacted intermeshing block further comprises

respective grooves (50, 51 ) at each of the surfaces (52 and 53), the said grooves extends from the top surface (54) to the bottom surface(55) of the block; the said grooves are substantially rectangular shape, and wherein

said top surface (54), bottom surface (55), side surfaces (52 and 53) coinciding with the width (W) of the block,

the top surface (54) comprises a raised substantially circular portions (56 and 57); the raised portions are provided with a cavity (58 and 59) respectively throughout from the top surface (54) to the bottom surface (55); a rectangular cavity (60) is disposed between the said two raised portions,

the bottom surface (55) of the block comprises substantially circular portion that has circular depression below the surface (55) towards the direction of surface (54) wherein the said depression is dimensioned to removably receive the raised portions (56 and 57) of the other block thus enabling intermeshing; the said cavities (58 and 59) extend through the said circular depressions from the said top surface 54 throughout the compacted block.

A construction structure as claimed in claims 1 -2 wherein compacted intermeshing blocks include regular compacted intermeshing blocks, half-length regular compacted intermeshing block wherein regular ash based compacted intermeshing block comprises of

a top surface (54), bottom surface (55), side surfaces (52 and 53) coinciding with the width (W) of the block,

respective grooves (50, 51 ) at each of the surfaces (52 and 53), the said grooves extends from the top surface (54)to the bottom surface(55) of the block; the said grooves are substantially rectangular shape, 3

the top surface (54) comprises a raised substantially circular portions (56 and 57); the raised portions are provided with a cavity (58 and 59) respectively throughout from the top surface (54) to the bottom surface (55); a rectangular cavity (60) is disposed between the said two raised portions,

the bottom face (55) of the block comprises substantially circular portion that has circular depression below the surface (55) towards the direction of surface (54) wherein the said depression is dimensioned to removably receive the raised portions (56 and 57) of the other block thus enabling intermeshing; the said cavities (58 and 59) extend through the said circular depressions from the said top surface 54 throughout the compacted block;

half-length regular compacted intermeshing block with length half that of the regular ash based compacted intermeshing block;

U-shaped compacted intermeshing block with longitudinal cavity comprising

a substantially rectangular longitudinal cavity (60) that extends along the length of the, the substantially flat horizontal surface (63) of the said cavity (60) is provided with preferably circular cavities (65 and 66) throughout,

bottom portion with depressed regions that are intermeshed with the raised portions (56 and 58) of the adjoining regular block below;

U-shaped half-length compact intermeshing block with length half that of the U-shaped ash based compacted intermeshing block.

A construction structure as claimed in claim 1 wherein construction configuration of masonry such as wall structure comprises

a regular compacted intermeshing blocks (70), U shaped compacted intermeshing blocks provided with a longitudinal cavity (71 ), horizontal reinforcement substance (72) in the form of a preferably cylindrical rod/bar, vertical reinforcement substance (73) in the form of a preferably cylindrical rod /bar, half-length regular ash based compacted intermeshing block (80), half-length U shaped ash based compacted intermeshing blocks the said wall structure is constructed in steps of: 4

installing vertical reinforcement bars (73) installed / fixed on a base / support of the foundation with a defined interval, the said vertical reinforcement bars (73) is used at the end of the wall;

laying of first layer of the said regular ash based compacted intermeshing blocks wherein the said vertical reinforcement bars (73) pass through the said cavity (58 or 59) wherein the said blocks are laid perfectly horizontal, and in a straight line, or at right angles at corners. In one of the embodiments the said cavities 58 / 59 are filled with cement grout;

the said vertical bars (73) is a single long bar extending from foundation up to the height of the wall, optionally said bar (73) is formed in pieces;

the vertical reinforcement bar 73 is used at the corners of the walls, at the wall intersection;

laying second level of the said regular ash based compacted blocks (70) in a manner that the depressed portions at the bottom of the said block is intermeshed with the raised portion (56 or 57)of the first layer of the blocks, intermeshing of the top block (74) is in a manner that the each of the raised portion of the two adjacent blocks (75 and 76) from the first layer is intermeshed with corresponding depressions wherein mortar is not used between the two blocks and the blocks are self-aligned due to intermeshing;

laying the said compacted intermeshing block (71 ) with a longitudinal cavity over the regular block and passing through the said horizontal reinforcement bar (72)wherein the use of the said block type 71 with the longitudinal cavity using horizontal reinforcement and concrete mortar under and above the windows and doors eliminates the need of beams and lintels in the construction walls.

A construction structure as claimed in claim wherein the method of making the regular, half-length, U shaped, half-length U shaped compacted intermeshing block comprise steps of: soil testing using drop, bottle and box test;

preparation of composition of the raw material with appropriate proportions of soil, stabilizing agent, additive, liquid agent such as water depending on the type 5

of locally available soil; appropriately grading each of the raw material of the composition to arrive at appropriate grain sizes;

mixing the said prepared composition to get a homogenous mixer and particle distribution to prepare the mix;

compacting the said mix using a compacting device;

air drying the compacted blocks;

wet curing the said compacted blocks wherein the combination of gradation of grain size, mechanical stabilization by controlled compaction, controlled chemical stabilization between stabilizing agent and soil minerals imparts compressive strength to the blocks.

8. A construction structure comprising

a combination of regular, half-length regular, U-shaped, half-length U shaped soil based compacted intermeshing blocks;

intermittent horizontal reinforcement, intermittent vertical reinforcement, configured to traverse through the intermeshed layers of blocks;

modularly reinforced load bearing unit for floor and/or slab comprising two load bearing elements (350 and 351 ) that are connected with pans (352) that are contoured in convex shape, steel mesh; ;

peggable contoured roofing element used in sloping roof;

wherein

a grain size distribution of raw materials, stabilizing agent/s; mechanical stabilization; controlled chemical stabilization imparts desired properties to the compacted intermeshing block to be used as a structural element.

9. A construction structure as claimed in claims 1 -8 wherein the raw material of the compacted intermeshing blocks comprises of soil, stabilizing agent/s comprising hydraulic or non-hydraulic binders;

soil is selected from black cotton soil, laterite soil;

stabilizing agent/s is/ are selected from cement, lime, blast furnace slag, pozzolana; natural stabilizing agents are selected from straw, plant fibres, plant juices (sap, latexes, oils), wood ashes (cinders), animal excrete (mainly cow dung, horse urine), other animal products (blood, hair, glues, termite hills, processed plant extracts, such as 6

sap from trees; plant juices include banana leaves precipitated with lime improves erosion resistance and slows water absorption, latex of certain trees (eg. euphorbia, hevea) or concentrated sisal juice in the form of organic glue, Vegetable oils and fats, Coconut, cotton and linseed oils, castor oil;

10. A construction structure as claimed in claims 1 , 3, 6, 7, 9 wherein raw material for the compacted intermeshing block comprises of laterite soil, lime, sand, cement , water, clay wherein

the clay and silt is maximum 66% in the sand, the grain size of the sand is in the range of 2 mm to 5.5 mm;

wherein the composition of the raw material by volume is 1 part of cement, 1 part of lime, 3 parts of sand and 5 parts of soil.

1 1 . A construction structure comprising

a combination of regular, half-length regular, U-shaped, half-length U shaped ash based compacted intermeshing blocks;

intermittent horizontal reinforcement, intermittent vertical reinforcement, configured to traverse through the intermeshed layers of blocks;

modularly reinforced load bearing unit for floor and/or slab comprising two load bearing elements (350 and 351 ) that are connected with pans (352) that are contoured in convex shape, steel mesh;

peggable contoured roofing element used in sloping roof;

wherein

a grain size distribution of raw materials, stabilizing agent/s; mechanical stabilization; controlled chemical stabilization imparts desired properties to the compacted intermeshing block to be used as a structural element.

12. A construction structure as claimed in claim 1 1 wherein the raw material for the compacted intermeshing blocks comprises a lime composition and pozzolanas that include volcanic ash, power station fly ash, burnt clays, ash from some burnt plant materials, silicious earths such as diatomite;

combination of fly ash and lime; burnt clay and fly ash; fly ash, sand and lime; fly ash and cement; fly ash, cement and lime; fly ash and hydration augmenting additive; .fly ash, sand, lime and hydration augmenting additive; fly ash, crushed stone and lime; fly ash, crushed stone and cement. 7

13. A construction structure as claimed in claim 1 wherein sloping roof comprising

peggable contoured roofing element (400) is composed of cement sand, stone-dust, water, iron oxide colour, galvanised metal wire and flat roof; batten, purlin;

the peggable contoured roofing element comprises of one or plurality of protruding provisions (401 and 402) that are press-fitted in the corresponding receiving provision

(403 and 404) of roofing support (405);

a wire is used to fix / attach the said roofing element with the support wherein the said roofing element is provided with openings to provide passage for wire;

wherein the peggable contoured roofing element is supported on a truss frame (32) that comprises a combination of horizontal and vertical elongated elements joined together with the support from other shorter elements wherein the said combination of the elongated elements provides a mounting surface for the said roofing tiles (31 ) that are provided with projections to removably press-fit the said projections in corresponding receiving provision on the elements of the truss elongated elements;

the truss frame (32) is supported on walls.

14. A construction structure as claimed in claim 1 wherein flat roof comprises of

a slab (34) comprising plurality of modularly reinforced load bearing unit (35) wherein each of such unit comprises two load bearing elements (350 and 351 ) preferably of rectangular cross section made up of concrete that are connected with pans (352) that are contoured in convex shape, steel mesh, DPC-plastic, bitumen, cast in-situ concrete and floor finish assembly (353) that is mounted / laid on the said assembly (35).

15. A construction structure as claimed in claim 1 wherein the plinth (37) comprises multilayer of Damp Proof Course (DPC), intermeshing blocks with longitudinal cavity with horizontal reinforcement bars;

foundation (38) is selected from trip, isolated and pile, stone, brick, intermeshing block, concrete which most suits the soil type

16. A construction structure as claimed in claim 1 comprising toilet system comprising of a sanitary ring, steel reinforcement, toilet pot; a multi-baffle anaerobic septic system for sanitation with plurality of baffles used for sanitation treatment to substantially reduce hydraulic retention time.

17. A construction structure as claimed in claims 1 -16 wherein pattern of disposition of the type of regular compacted intermeshing block, half-length regular compacted 8

intermeshing bock, U shaped compacted intermeshing block with a longitudinal cavity, half-length U shaped compacted intermeshing block with a longitudinal cavity along with the intermittent vertical and horizontal reinforcement substances in the form of a bar renders the wall desired load bearing strength eliminating the use of mortar in between the two blocks, eliminating need of lintels and beams, eliminating the need of a skilled labour to align the blocks, eliminating need of external plaster as the surface finish of the said ash based compacted intermeshing blocks is not powdery and irregular.

18. A construction structure comprising

a combination of soil based regular, half-length regular, U-shaped, half-length U shaped compacted intermeshing blocks;

a combination of ash based regular, half-length regular, U-shaped, half-length U shaped compacted intermeshing blocks;

intermittent horizontal reinforcement, intermittent vertical reinforcement, configured to traverse through the intermeshed layers of blocks;

modularly reinforced load bearing unit for floor and/or slab comprising two load bearing elements (350 and 351 ) that are connected with pans (352) that are contoured in convex shape, steel mesh; :

peggable contoured roofing element used in sloping roof;

wherein

a grain size distribution of raw materials, stabilizing agent/s; mechanical stabilization; controlled chemical stabilization imparts desired properties to the compacted intermeshing block to be used as a structural element.

19 A construction structure as claimed in claim 1 wherein the compacted intermeshing block comprises of the raised portions (56 and 57) of polygonal shape, corresponding depressions on bottom face (55) of polygonal shape.

20. A construction structure as claimed in claim 1 wherein the constituents of the compacted intermeshing blocks are selected from treated bagasse fibres wherein the bagasse fibres are boiled in water to remove sugar content; straw and dried grass; fibre along with cement and soil; treated pineapple leaf fibre wherein the pineapple leaf fibre 9

is soaked and softened, followed by scraping to extract the cellulose fibres; saline water, treated effluent from industry, wastewater, non-potable water; binders that include tars and bitumens, sodium silicate which is produced from the heat activated reaction between silica and sodium hydroxide, casein which is a milk whey, oils and fats, molasses, plant-based materials such as gum arabic, resins, sap, latexes, juices from trees; organic binders such as epoxy resin, acrylic emulsion;

antifungal, antimicrobial, pest resistant agents, fragrance providing agents as per desired end use;

natural and/or artificial colour pigments.