New Building Block Innovative Approach to Robotic Construction US Patent 9,194,125 PCT Application PCT/US15/49513 Sergei Romanenko, New Hampshire, USA Phone. 603 554-7250 sergei@usa.com
Executive Summary A new building block is presented with reinforcing triangle structure embedded into it. The block simplifies wall construction and provides consistent wall quality. The reinforcing structure allows a broader range of materials, not used before, and includes materials with higher insulation properties. These standardized blocks also reduce design and construction time, lower labor and construction cost, and enable robotic construction, thus further reducing the cost. Description The new building block is made of lightweight concrete with a steel triangle structure embedded into it. The embedded structure is load bearing, which allows a wider range of building materials for the block s body. With relaxed requirements on mechanical strength, the choice of the material can be prioritized on other highly desired properties, such as thermal insulation and vapor permeability. Newer wall construction protocols promoted by IBE 1, with the emphasis on healthy home, can be easily supported. The building block can provide enhanced mechanical stability to the constructed walls making it suitable for construction in seismically-active regions. The embedded triangle structures form a lattice embedded into the wall reducing the risk of catastrophic destruction during the earthquake. Figure 1. The wall construction involves a simple operation of aligning the block on top of others and bolting it to the threaded holes in the receiving plates of the blocks below (see figure 1). No mortar is needed, only sealing paste is placed between the blocks, which is known in the industry as dry cladding. The simplicity of the construction offers high quality and consistency without the need for skilled labor. The construction can be easily automated because only basic operations are used. A robotic system can include a crane with an arm, capable of carrying the block, and operating a screwdriver to fasten the block. This system can use a machine vision or positioning system to place the new block with needed precision. Such technologies already exist, they are well-developed and can be easily adapted to this type of construction. 1 IBE International Institute for Bau-biology and Ecology, Inc. (www.buildingbiology.net). NEW BUILDING BLOCK JANUARY 2016 1
The block has modifications such as corner blocks, blocks for doors and windows, and others. Similar to the toy set Lego, only a small set of block forms is needed to erect complex buildings. A relatively small set of block forms reduces the architectural design cost and complexity of corresponding software. Figure 2. The construction block is manufactured in a factory controlled environment allowing consistency and quality at a reduced cost. Combination of factors presented above multiplied by economies of scale, will bring construction cost down and facilitate a revolution in affordability and quality of house construction. The low-story buildings, such as individual houses, will benefit the most using this new technology. NEW BUILDING BLOCK JANUARY 2016 2
Proposed Construction Protocols Using New Block These two protocols look the most promising although more can be developed for specific purposes. These two proposed protocols use two types of block: single-layer/single material, and two-layer/two materials. See figure 3 showing cross sections of two walls assembled with these blocks. Figure 3. The first type is using cellular glass, a material with high insulation properties. Cellular glass is impermeable to water vapor, therefore no water condensation can happen inside the wall, and no mold can form inside the wall. The outer surface is glazed or covered with a coat of durable mineral paint. After a wall is assembled, the inner surface is covered by breathable stucco or dry wall plates. The hermetic seal between the blocks is placed left to the reinforcing structure and towards the outer surface (see figure 3). This placement keeps the reinforcing structure in the dry zone with relative humidity below 100%. The cellular glass is almost ideal building material: it is inert, durable, eco-friendly, excellent heat and noise insulator. To achieve R-40 insulation value, which is suitable for extremely cold climates, the thickness of the block is only 12 inches (30 cm). The low mechanical strength of cellular glass prevents it being used for load bearing walls. The reinforcement embedded into the block fixes this shortcoming and enables wide adoption of this material in construction. Other promising materials for single-layer block are: Autoclaved Aerated Concrete (AAC); Foam Concrete (Lightweight Cellular Concrete); Low-Density Wood Fiber-Cement; Renewable Plant Fiber-Cement, to mention a few. These materials are the most attractive choice in warm climates. Many of these materials have cell structure created by introducing air or gas in the form of small bubbles (usually 0.1 to 1.0 mm in diameter) during the mixing process and formation. Embedded air improves heat insulation and sound attenuation, although reducing mechanical strength. NEW BUILDING BLOCK JANUARY 2016 3
Therefore there materials have traditionally been used for no-load bearing walls, or required reinforcement by steel bars. The new construction block overcomes this limitation by using the embedded reinforcement. The second type has two layers sandwiched together. This protocol can be used where more mechanical strength and stability is required. The outer layer is made of cellular glass and the inner layer is made of lightweight concrete. The reinforcement is contained in the concrete partition of the block. For improved bonding between layers, a dovetail join is used (see the block top view). While the concrete layer is susceptible to vapor, the wall follows the outsulation principle with thermal insulation placed on the outer side of the wall. The concrete layer has relatively high heat conductivity, therefore the temperature drop in this layer will be small, exceeding dew point in the joint area with the cellular glass level. If the indoor surface is exposed to a spike of humidity, as in a bathroom while taking a shower, the water condensed inside the concrete level will dry out later, when humidity level gets back to normal. Therefore this wall complies with the breathable wall principle and avoids conditions for mold formation. Mission Statement The majority of individual houses in North America use wood-frame design developed over 50 years ago. While this type of construction was considered affordable at the time, it exposed numerous problems, now well-recognized by industry experts. One of the major problems is the inability of standard wood-frame walls to withdraw water when it gets inside. The relatively recent trend to seal the walls in order to achieve energy-efficient status led to increased use of vapor barriers, which exacerbated the problem of insufficient ventilation of wall internals. Therefore, once water gets inside the wall (an event which happens sooner or later with every house) this water becomes trapped long enough to develop several problems, from mold formation to degradation of thermal insulation. The mold presents a health threat. With reduced efficiency of the insulation, the conditions becomes more favorable to further water condensation accelerating degradation of wall properties. Therefore conventional wood-frame houses are prone to a sudden problems which are very expensive to fix. There are other shortcomings which makes wood-frame homes less desirable: they are dangerous to live in because of low fireproof standards; they require high maintenance cost for miscellaneous services (from rodent control to exterior maintenance); they are not sturdy enough to withstand high wind; their building materials outgas from volatile organic compounds; they have a presence of airborne particles from the fiberglass insulation; and they have an overall high ownership cost. All these factors have already started influencing the decision of a new generation of potential homeowners. They are more health-agnostic, eco-conscious, and don t want all the problems their parents had while owning the house. Therefore a new construction boom is brewing to address these changing needs of incoming generations. Our mission is to start the boom by offering technology which aligns house construction with the new requirements. The new construction block presented in this invention will further reduce the construction cost. The wall built with the new block doesn t use organic materials making the building health-friendly, durable, fireproof, and maintenance free. The improved insulation will reduce the energy bill and the ecological footprint of future houses. This is a technology for the 21 st century. NEW BUILDING BLOCK JANUARY 2016 4