# US 8,539,721 B2 · Lightweight building structure produced by using a mortar and a method for the production

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- Number: US 8,539,721 B2
- Document ID: US8539721B2
- Status: Granted
- Kind: B2
- Application number: 13/128,789
- Filed: 2009-11-10
- Published: 2011-09-15
- Granted: 2013-09-24
- Earliest claimed: 2008-11-19
- Applicants: Istvan Antal
- Inventors: Istvan Antal
- Web page: https://patentgrep.com/patent/US8539721B2

## CPC

- E04B 5/32: Floor structures wholly cast in situ with or without form units or reinforcements
- C04B 18/021: {agglomerated by a mineral binder, e.g. cement}
- C04B 18/027: {Lightweight materials}
- C04B 18/16: from building or ceramic industry
- C04B 28/02: containing hydraulic cements other than calcium sulfates
- C04B 40/0608: {Dry ready-made mixtures, e.g. mortars at which only water or a water solution has to be added before use}
- E04B 1/161: {with vertical and horizontal slabs, both being partially cast in situ}
- E04B 5/29: the prefabricated parts of the beams consisting wholly of metal (E04B5/28 takes precedence)
- E04B 7/02: with plane sloping surfaces, e.g. saddle roofs (E04B7/12 takes precedence)
- C04B 2111/00603: {Ceiling materials}
- C04B 2111/00698: {for cavity walls}
- C04B 2111/28: Fire resistance, i.e. materials resistant to accidental fires or high temperatures
- C04B 2111/346: {Materials exhibiting reduced plastic shrinkage cracking}
- C04B 2111/40: Porous or lightweight materials
- C04B 2111/52: Sound-insulating materials
- C04B 2111/60: Flooring materials
- E04B 2/8635: {with ties attached to the inner faces of the forms (E04B2/8611 and E04B2/8623 take precedence)}
- Y02W 30/91: Use of waste materials as fillers for mortars or concrete
- Y10T 428/249968: Of hydraulic-setting material
- E04B: GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS (border constructions of opening in walls, floors or ceilings E06B1/00; {electromagnetic shielding H05K9/0001})
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- Y02W: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

The invention concerns the field of a lightweight building structure produced by using a mortar containing foamed polystyrene and cement and a method for the production thereof. It includes at least one layer of prefabricated foam concrete panel affixed to a reinforcing frame structure wherein interspaces between elements of the reinforcing frame structure are at least partially filled with a mortar providing a first surface contacting the foam concrete panel. The mortar includes granules of 0.5-10 mm size produced by grinding a pressed foamed concrete that has been allowed to mature, 50-200 kg of unbound, anhydrous cement, and 150-300 liters of water added before application per one cubic meter of ground material, respectively.

## Claims

### Claim 1

A method for production of a lightweight building structure, comprising:
providing a frame structure having interspaces;
fixing a panel to the frame structure;
grinding a pressed foamed concrete that has been allowed to mature in order to produce granules of 0.5-10 mm size; and
filling at least partially said interspaces with a mortar having the foamed concrete granules of 0.5-10 mm size, 50-200 kg of unbound, anhydrous cement, and 150-300 liters of water added before application per 1 m3 of the ground foamed concrete, respectively;
wherein said panel is a hardened foam concrete panel.

### Claim 2 (depends on 1)

The method according to claim 1, wherein a permanent formwork is provided defining said interspaces by fixing a first and second layer of foam concrete panels to opposite sides of said frame structure.