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WO1996011309A1 - Procede de stabilisation de la terre pour la construction de structures et de murs en terre - Google Patents

Procede de stabilisation de la terre pour la construction de structures et de murs en terre Download PDF

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Publication number
WO1996011309A1
WO1996011309A1 PCT/US1995/013534 US9513534W WO9611309A1 WO 1996011309 A1 WO1996011309 A1 WO 1996011309A1 US 9513534 W US9513534 W US 9513534W WO 9611309 A1 WO9611309 A1 WO 9611309A1
Authority
WO
WIPO (PCT)
Prior art keywords
soil
approximately
binding agent
comprised
earth
Prior art date
Application number
PCT/US1995/013534
Other languages
English (en)
Inventor
David C. Easton
Original Assignee
Easton David C
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Easton David C filed Critical Easton David C
Priority to AU40055/95A priority Critical patent/AU4005595A/en
Publication of WO1996011309A1 publication Critical patent/WO1996011309A1/fr

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/84—Walls made by casting, pouring, or tamping in situ
    • E04B2/842—Walls made by casting, pouring, or tamping in situ by projecting or otherwise applying hardenable masses to the exterior of a form leaf

Definitions

  • This invention provides a novel method of building stabilized earthen walls for housing and other structures which is more efficient, less costly, and results in a wall of equal or superior strength, longevity and aesthetics as achieved in traditional methods.
  • the present invention is based upon the discovery that direct pneumatic force, such as that provided by gunite equipment, rather than manual or pneumatically-assisted tamping, can successfully be used to impact soil and create an earthen wall so strong that it exceeds the seismic standards of the most severe earthquake regions in the United States, such as California Zones 3 and 4.
  • direct pneumatic pressure to impact the soil dispenses with much of the labor previously required to manually tamp the soil and enables structures of stabilized earth to be built more efficiently and on a production scale.
  • Walls of stabilized earth can be monolithic, load bearing structures which are earthquake safe, fire proof, termite proof, and water resistant. They can serve as structural walls, including building and retaining walls, or in boundary fences, fireplaces, fountains and ponds.
  • the walls can be used as primary structural material or in combination with conventional materials, such as wood, metal and plaster.
  • the buildings formed by these walls are energy efficient, quiet, and long-enduring.
  • the strength and durability of stabilized earth walls are related to the selection and use of appropriate soils, precise control of the component ratios, thorough mixing, and the use of proper forming and reinforcing methods. By using apparatus of the gunite industry to regulate the mixing and moisture content of the soil/cement materials, the present invention assures consistent, high-quality results.
  • the walls built according to this invention will normally have a stucco-like texture on the exterior and a smooth finish on the interior (resulting from the use of a smooth form) which can be finished with traditional materials such as plaster, paint, or tile, if desired. Since these walls are inherently waterproof, they do not require painting or other exterior finishes. These walls can be built in a variety of natural earth tones, yielding surfaces of striking color and texture, which require much less maintenance, and are far more durable than conventional walls.
  • Rammed earth building is an ancient technique wherein moist earth is repeatedly pounded into structural walls, layer by layer in an enclosed form, using heavy tampers on hand-held poles. It is a slow, tedious and arduous process. The process forces the soil particles into tight molecular and mechanical configurations, strengthening the wall by recreating or reconstituting the rock-like characteristics once possessed by the bound components of the soil aggregate. After the form is filled, the formwork is stripped away, leaving a wall having properties similar to sedimentary rock.
  • Thick earthen walls when shaded from the direct rays of the sun, will stay cool throughout the day, and spaces enclosed by these walls will be in thermal equilibrium with the mass. Protected from direct exposure to the sun, the walls will absorb heat slowly enough that the interior spaces will not increase in temperature until well after the sun has set.
  • Properly designed buildings incorporating stabilized earth walls can maintain indoor air temperatures between 60-80°F during summer months without air conditioning in climates where outside air temperatures exceed 90°F.
  • the objects of this invention are to stabilize earth compositions by directly pneumatically impacting them into earthen walls and structures which are durable, energy-efficient and structurally superior. These walls can be erected more quickly, more efficiently and with less expenditures of time and labor than traditional rammed earth methods.
  • the invention is carried out by preparing a composition of well chosen clay-containing earth, mixing the earth with a small amount of binding and stabilizing agent such as portland cement, feeding the mixture to a conveying apparatus such as gunite equipment, applying a carefully regulated pneumatic pressure of at least 65 psi under normal conditions to the mixture held in the gunite gun chamber, hydrating the mixture to approximately 18% by weight, and directing the hydrated mixture, at high pressure and at an approximate 45 degree downward angle, from a distance of 2 to 3 feet, against a sufficiently sturdy form or backboard for the walls or structure to be formed.
  • a conveying apparatus such as gunite equipment
  • the soil composition of the partially formed wall is repeatedly and directly impacted by the projected soil composition. This process creates a build-up of the soil composition against and away from the form, forming the walls to the height and depth determined by the gunite operator. As the wall builds, the earth particles comprising the wall, as well as the particles as they are being shot, are compacted into a tight configuration. The resulting wall approaches the strength and physical properties of sedimentary rock.
  • gunite is used in this disclosure to refer genericaliy to the specialized equipment which was designed and has heretofore been used to apply a thin cementitious coating to an object.
  • compressed air is pumped into gunite equipment where it pneumatically powers the equipment and also passes into a gun chamber in which a very fine and uniform 1:4-1:6 mixture of portland cement and clean sand is also being fed.
  • the air in the chamber is maintained at a substantially constant pressure sufficient to convey the cement mixture onto the object to be coated, generally around 45 psi.
  • the compressed air and pneumatically powered apparatus conveys the mixture from the gun chamber into an attached conduit, usually a hose or a flexible pipe, at the end of which is a water source, and beyond that a nozzle for directing the hydrated cement mixture to the object to be coated.
  • the conventional gunite cement mixture is hydrated to about 4% moisture, resulting in a relatively wet mixture, as it passes through the hose, after which it emerges from the nozzle under moderate pressure sufficient to convey it to the object to be coated and to lightly compact it.
  • the hydrated material is then directed horizontally toward an object or surface to be coated.
  • the material upon curing, hardens into a high strength cementitious layer which is resistant to weathering, heat, abrasion, and many forms of chemical attack.
  • a common application of gunite is in the building of in- ground pools.
  • the method of the present invention primarily utilizes earth, a readily available, low-cost material to build the walls.
  • Suitable earth for the practice of this invention may be found at the site itself, eliminating the cost of hauling earth to the site.
  • Use of soil from the site also enhances the aesthetic integration of the walls with the building site. If the building site soil is not suitable, the earth can be obtained from places such as rock quarries, where earth suitable for use in this invention is considered waste which burdens the quarry owner with removal and disposal costs.
  • a binder such as portland cement or a pozzolanic material may be
  • portland cement need only be added in small proportions in order to stabilize the composition.
  • a pozzolanic material such as fly ash, reduces dependence on portland cement with its
  • Structural wails built in accordance with this invention are preferably between 8 to 24 inches thick.
  • An eight-inch thick wall built according to this invention provides thermal mass and can be structural.
  • the earthen walls of this invention are built using single-sided vertical forms rather than the two-sided vertical formwork needed to build concrete and conventional rammed earth walls. Besides requiring less wood overall, the single-sided formwork of the present invention can be removed from the earthen wall and later integrated into the building as roof sheathing or the like, or reused as formwork for another building project. This decreases the cost of the project and conserves natural resources.
  • unreinforced stabilized earth walls can attain a compressive strength of 800 psi and greater, building code regulations in earthquake-prone sections of the United States, for example, in California, require steel reinforcement in walls.
  • an engineered system of steel reinforcement can be readily incorporated into the walls.
  • workers When using conventional rammed earth techniques, workers must tamp the soil compositions between the two sides of the formwork, commonly 18-24 inches apart. In order to build the initial bottom portions of the wall, the workers must stand inside the forms while tamping. The presence of a network of steel reinforcing bars, as well as utility boxes and conduits, severely handicap the worker's ability to construct the wall.
  • An earthen wall built in accordance with this invention is preferably erected on a reinforced concrete perimeter foundation.
  • the reinforcement consists of horizontal steel bars run in a continuous line embedded in the perimeter of the foundation with vertical reinforcing steel dowels, extending vertically out of the foundation line, set at regular intervals.
  • Suitable foundation techniques to support the walls built in accordance with the invention are, e.g., a typical spread footing and stem wall, a concrete slab with thickened edge, a grade beam poured directly into a trench, or a gunite foundation.
  • the formwork for the earthen walls is put in place.
  • the formwork is built by constructing a frame of vertical and horizontal wooden studs and facing the frame with 3/4 inch plywood.
  • the inside building line is chalked on top of the foundation grade beam, already in place. Stud plates are set into the top of the grade beam so that the plywood of the formwork, when placed against the outside of a plate, will meet the chalk line from inside its perimeter.
  • the first sheet of plywood is set on edge with its long dimension on the grade beam in line with the comer and up against a stud plate.
  • the first vertical stud is attached to the plywood. If the walls are shot from outside the building, the formwork assembly should be screwed together from the inside for disassembly once the walls are built.
  • a second sheet of plywood is set on edge on the grade beam so that it butts against the first sheet and creates the first corner.
  • a second vertical stud is set at this corner joint and screwed through into the second sheet of plywood.
  • the corner can be reinforced by screwing the two vertical studs together.
  • one vertical stud is set every 16 inches along the plywood, with a screw through the studs into the plywood.
  • the corner should be stiffened with a brace and every third or fourth vertical braced with kickers staked to the ground.
  • the edge of the third sheet of plywood is butted against the end of the second sheet, creating a plywood seam.
  • a vertical stud is placed over the seam and the sheet is braced. Placement of the plywood continues in this manner until the second corner is reached.
  • the plywood is cut if necessary to align with the inside building line.
  • one row of studs is set around the inside perimeter at a height of about three feet for alignment and stiffening.
  • the vertical studs are then checked for plumbness and the braces adjusted as necessary.
  • the second course of plywood is then stacked on the first, making sure that the sheets fit together as tightly as possible.
  • the seams are staggered from the first course.
  • the dimension of the top and final course of plywood is adjusted to the predetermined height of the wall. If necessary, the top of the
  • forms can extend above the top of the finished wall and a chamfer strip can be nailed to the forms to indicate where the wall ends.
  • a final horizontal stud is set at the top of the forms and braced back.
  • the inside building line should be straight and true.
  • VDBs volume displacement boxes
  • VDBs are preferably constructed of a double thickness of plywood, the sides supported by 2x4 vertical struts and splayed for removal from the wall. Once the VDB is assembled, it is set in place against the formwork and screwed into the strut from the inside of the building.
  • the wall as bond beam steel.
  • Anchor bolts for sill plates at the top of the wall or for ledgers that support intermediate floors are put in place before the earth is shot.
  • the anchor bolts can be simply attached through holes drilled in the formwork at the correct location.
  • the bolts are tied off to the bond beam steel.
  • Plumbing lines are wrapped and either butted against the inside face of the formwork or extended through holes drilled in the forms.
  • Electrical boxes are secured to the formwork with either screws or tie wire, and joined together with conduit.
  • Screed wires are stretched from corner to corner as a point of reference to indicate the outside building line.
  • the wires are run horizontally and spaced about 30 inches apart. They are attached to vertical 4x4 wood posts accurately set at each of the building comers. The inside corner of the 4x4 post should align with the outside corner of the building.
  • the base of the post is anchored at the ground either with stakes or with steel dowels drilled into the grade beam and into the
  • the posts should be braced away from the wall with studs and stakes.
  • a brace at the top is added to secure the posts to tops of the wall forms.
  • a suitable earth composition is one which contains clean and well-graded aggregate, preferably with the maximum size of the particles not exceeding 3/8 inch in diameter, fines comprising no more than 30% and preferably between 10-20%, and the clay content not exceeding 20% of the aggregate. Since too much clay content in the soil mixture can result in unacceptable cracking and separating upon drying of the material, a sample should be subjected to two tests by a geotechnical laboratory to determine soil suitability. First, a sieve analysis, in which a measured amount of soil is shaken through a series of screens of decreasing size, should be performed. The "fines" or smallest particles, silt and clay, those which pass a 200 mesh screen, should not substantially exceed 30% of the soil.
  • Atterburg Limits Test which measures the plasticity of the soil sample, an indication of the proportion of clay content in the fines. Acceptably low plasticity measurements will indicate a decreased possibility of shrinkage cracking. If earth found at the building site does not meet these standards, it can be altered by adding the elements which are missing. Alternatively, earth can be obtained from other sites, such as rock quarries where inexpensive but suitable "quarry fines,” “quarry waste,” “reject sand,” or “dirty sand” are often available.
  • an additional binding agent in a ratio of about 1:15 in the soil composition can be added to further stabilize the earth.
  • Preferred binders are pozzolanic materials such as fly ash, portland cement Type I or II complying with A.S.T.M. standard specification C 150-67, or additional clay.
  • the mixing ratio can also be expressed as 1.5 sacks of cement per cubic yard of earth. The binder is mixed by machine into the dry earth for uniform distribution.
  • Samples of the earth/binder mixture should be compacted into 3" x 6" cylindrical molds, allowed to cure, and tested by a certified laboratory in accordance with A.S.T.M. Standard 39.
  • Minimum 28 day compressive strength should be at least 600 psi.
  • Typical compressive strenths in walls built according to this invention are in the range of 1000 to 1500 psi.
  • the earth/binder mixture is then fed into a standard gunite apparatus such as the Lova sold in the United States by Reed Manufacturing or the Hydrostatic Rotary Gun available from Blastcrete Equipment Co.
  • a flow of compressed air is supplied to the apparatus and the air pressure in the gun chamber holding the earth mixture is maintained preferably at the highest pressure the apparatus can attain, preferably no less than 65 psi when the application site or form is at a distance of no more than approximately 100 feet from, and at a height of no more than approximately 10 feet above, the gun.
  • the pressure should be increased from 65 psi by at least approximately 5 psi per additional 50 feet of distance from the gun to the form.
  • That distance generally determined by the length of a flexible pipe leading from the gun, is preferably no greater than about 50 feet, as the soil composition must be hydrated and applied at a height of 12 feet or more above the gun. Also, because the soil composition used in this invention generally creates more friction in transit than conventional gunite cement, yet must be applied with greater impact, the distance between the gun and the application site should be minimized. Preferably, the means for conducting the soil composition to its application site should not exceed 150 feet.
  • the mixture is hydrated with clean water at the nozzle. Moisture content is continuously monitored and maintained at between approximately 10-20% by weight of dry mass. Proper hydration is achieved when the rebound, which is the shot material that does not adhere to and rebounds from the wall, is between approximately 5 and 0% of the propelled mass.
  • the water content of a conventional gunite concrete mix is generally less than that of the mixture used in this invention, the absorptive clay in the earth in the latter mixture causes it to appear drier than standard clean sand gunite.
  • soil mixture of this invention should be hydrated to appear drier than conventional gunite cement, although a greater amount of water in relation to mix is actually being used.
  • the emerging hydrated mixture is directed against the formwork at a downward angle of approximately 45° and at a distance of about 2 to 3 feet from the form to maximize the force of the impact.
  • the shooting is begun at one comer of the building and moves laterally along the foundation, building the earth out to the full thickness of the wall (typically 18 to 24 inches) in maximum lifts of 30 inches, completely embedding the reinforcement, if any.
  • the material should emerge from the nozzle in a steady, uninterrupted flow. Using the screed wires as a guide, the excess earth is trimmed to a flat and true building line.
  • the second one can begin and the process repeated until the desired height of the wall is reached.
  • Loose material from waste and rebound should be blown off the top of a course before placing the fresh material.
  • the shot earth wall will have obtained enough strength to support itself, without the aid of the formwork, within 24 hours.
  • the forms are removed carefully from the walls to avoid marring the inside surfaces. The wires which had been holding the electrical boxes and rebar to the formwork, and the screws which had been holding the VDBs in place, are cut.
  • Any voids in the earthen structure should be filled with a moist earthen mixture handpacked into the void and trowelled off.
  • the interior smooth surface may be coated with a polymer sealing compound, although this is generally unnecessary.
  • Conventional window frames, doorframes and roofs are used with the earthen walls of this invention to create comfortable, energy-efficient and aesthetically pleasing living, working or storage spaces.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)

Abstract

L'invention concerne un procédé de construction de structures et de murs en terre, consistant à préparer une composition d'un agrégat de terre et d'argile judicieusement choisi, à mélanger de préférence la terre avec une faible quantité d'agent de stabilisation ou de liaison, à envoyer le mélange dans un appareil de transfert tel qu'une installation de projection de gunite, à appliquer une pression pneumatique élevée dans le mélange se trouvant dans une chambre de gunite, à hydrater le mélange et à le projeter contre une plaque de support ou un coffrage robuste avec une force suffisante pour créer un impact et entraîner la liaison de l'agrégat dans la structure.
PCT/US1995/013534 1994-10-07 1995-10-05 Procede de stabilisation de la terre pour la construction de structures et de murs en terre WO1996011309A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU40055/95A AU4005595A (en) 1994-10-07 1995-10-05 Method of stabilizing earth for building earthen walls and structures

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US31992694A 1994-10-07 1994-10-07
US08/319,926 1994-10-07

Publications (1)

Publication Number Publication Date
WO1996011309A1 true WO1996011309A1 (fr) 1996-04-18

Family

ID=23244181

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US1995/013534 WO1996011309A1 (fr) 1994-10-07 1995-10-05 Procede de stabilisation de la terre pour la construction de structures et de murs en terre

Country Status (4)

Country Link
AU (1) AU4005595A (fr)
IL (1) IL115527A0 (fr)
WO (1) WO1996011309A1 (fr)
ZA (1) ZA958455B (fr)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2002050384A1 (fr) * 2000-12-20 2002-06-27 Dharma Properties Taos, Inc. Composition, structure et procede de construction
FR3016376A1 (fr) * 2014-01-16 2015-07-17 Cematerre Nouveau perfectionnement a un procede de fabrication d'au moins un mur vertical a base de terre
US9157211B2 (en) 2013-10-28 2015-10-13 Oldcastle Precast, Inc. Cantilevered wing wall
US10584471B2 (en) 2017-06-15 2020-03-10 James Bradford Boulton Integrated retaining wall and fluid collection system
WO2021180931A1 (fr) 2020-03-12 2021-09-16 Saint-Gobain Weber France Fabrication d'un mur par projection par voie seche d'une composition comprenant de la terre crue

Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2270229A (en) * 1941-04-03 1942-01-20 Neff Wallace Building construction
US2806277A (en) * 1950-05-10 1957-09-17 Hand Wall-forming process
US3578732A (en) * 1968-10-21 1971-05-11 Graham C Lount Method of forming building walls
US3643910A (en) * 1968-03-07 1972-02-22 Heifetz H Inflatable forms
US4292783A (en) * 1979-05-21 1981-10-06 Mulvihill Dan R Insulated building structure and method for making same
US4365455A (en) * 1977-05-23 1982-12-28 Braine William G Method of building construction
US4565661A (en) * 1980-12-29 1986-01-21 Michienzi Giacomo F Method of molding a shelter structure
US4678157A (en) * 1984-08-30 1987-07-07 Robert Fondiller Apparatus for the construction of a low cost structure
US5161341A (en) * 1986-05-07 1992-11-10 Pierre Gilles Method for building walls with muddled clay, or stabilized earth, projecting machine adapted to its implementation, and wall thus obtained

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2270229A (en) * 1941-04-03 1942-01-20 Neff Wallace Building construction
US2806277A (en) * 1950-05-10 1957-09-17 Hand Wall-forming process
US3643910A (en) * 1968-03-07 1972-02-22 Heifetz H Inflatable forms
US3578732A (en) * 1968-10-21 1971-05-11 Graham C Lount Method of forming building walls
US4365455A (en) * 1977-05-23 1982-12-28 Braine William G Method of building construction
US4292783A (en) * 1979-05-21 1981-10-06 Mulvihill Dan R Insulated building structure and method for making same
US4565661A (en) * 1980-12-29 1986-01-21 Michienzi Giacomo F Method of molding a shelter structure
US4678157A (en) * 1984-08-30 1987-07-07 Robert Fondiller Apparatus for the construction of a low cost structure
US5161341A (en) * 1986-05-07 1992-11-10 Pierre Gilles Method for building walls with muddled clay, or stabilized earth, projecting machine adapted to its implementation, and wall thus obtained

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
PISE'HANDBOOK, "A Manual for the Professional Application of Earthbuilding Techniques", March 1992. *

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2002050384A1 (fr) * 2000-12-20 2002-06-27 Dharma Properties Taos, Inc. Composition, structure et procede de construction
US6718722B2 (en) 2000-12-20 2004-04-13 Dharma Properties Taos, Inc. Construction composition, structure, and method
US9157211B2 (en) 2013-10-28 2015-10-13 Oldcastle Precast, Inc. Cantilevered wing wall
US9469963B2 (en) 2013-10-28 2016-10-18 Oldcastle Precast, Inc. Cantilevered wing wall
FR3016376A1 (fr) * 2014-01-16 2015-07-17 Cematerre Nouveau perfectionnement a un procede de fabrication d'au moins un mur vertical a base de terre
EP2896604A1 (fr) * 2014-01-16 2015-07-22 Cematerre Nouveau perfectionnement à un procédé de fabrication d'au moins un mur vertical à base de terre
US10584471B2 (en) 2017-06-15 2020-03-10 James Bradford Boulton Integrated retaining wall and fluid collection system
WO2021180931A1 (fr) 2020-03-12 2021-09-16 Saint-Gobain Weber France Fabrication d'un mur par projection par voie seche d'une composition comprenant de la terre crue
FR3108115A1 (fr) * 2020-03-12 2021-09-17 Saint-Gobain Weber France Fabrication d’un mur par projection par voie sèche d’une composition comprenant de la terre crue
CN115210194A (zh) * 2020-03-12 2022-10-18 圣戈班韦伯法国公司 通过干式喷射包含生土的组合物制造墙壁

Also Published As

Publication number Publication date
IL115527A0 (en) 1996-01-19
ZA958455B (en) 1997-04-07
AU4005595A (en) 1996-05-02

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