In realizing the BMWi-sponsored project, new and demanding requirements to be placed on the construction material mix had to be taken into account. To satisfy this requirement, technical laboratory tests utilizing various types of lightweight aggregate were performed. Criteria to be met were dry density, green stability and compressive strength as well as recyclability. In addition to construction materials analyses, various compaction variants were investigated with forced harmonic stimulation, by means of numeric software, with simulation and testing on a test rig. The most significant findings gained from these preliminary investigations provided information on the compactability of the mix, its interactive adhesive properties and the demolding and/or coring of the finished multifunction block.
An essential instrument, and accordingly a crucial step on the way to the prototype, was the preparation of a complex functional pattern with which the automated process sequences were able to be tested. By completion of the project, in April of 2018, production of the initial small-scale series succeeded with this functional pattern. Presently, a machine concept with several form chambers is being prepared, to implement the principle in actual practice.
In summary, the Duplex Blockmaker offers the following advantages:
Space savings by elimination of intermediate storage areas
Reduction of the required production periphery down to one machine
Elimination of manual work for the installation of insulation materials
Hybrid and recyclable construction products (cradle-to-cradle), with supporting and insulating functions
Smooth and fast construction sequences by the great dimensional accuracy of the blocks
Elimination of insulation work on buildings
With respect to more efficient production, the new Duplex Blockmaker has earned good marks. From the standpoint of the manufacturer of dual-shell blocks, this technology – with its considerably shortened production times – meets the requirements for becoming a growth engine. Not least as seen in this context, the market relevance of function-integrating construction elements will significantly increase for construction of energy-saving buildings.