AU2002210267A1 - Lightweight aggregate binder formulation - Google Patents
Lightweight aggregate binder formulationInfo
- Publication number
- AU2002210267A1 AU2002210267A1 AU2002210267A AU1026702A AU2002210267A1 AU 2002210267 A1 AU2002210267 A1 AU 2002210267A1 AU 2002210267 A AU2002210267 A AU 2002210267A AU 1026702 A AU1026702 A AU 1026702A AU 2002210267 A1 AU2002210267 A1 AU 2002210267A1
- Authority
- AU
- Australia
- Prior art keywords
- composition according
- thermally stable
- stable composition
- oxide
- aqueous phase
- Prior art date
- Legal status (The legal status 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 status listed.)
- Abandoned
Links
Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B20/00—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials
- C04B20/10—Coating or impregnating
- C04B20/1018—Coating or impregnating with organic materials
- C04B20/1029—Macromolecular compounds
- C04B20/1044—Bituminous materials
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B16/00—Use of organic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of organic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
- C04B16/04—Macromolecular compounds
- C04B16/08—Macromolecular compounds porous, e.g. expanded polystyrene beads or microballoons
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L95/00—Compositions of bituminous materials, e.g. asphalt, tar, pitch
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Organic Chemistry (AREA)
- Structural Engineering (AREA)
- Materials Engineering (AREA)
- Health & Medical Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Civil Engineering (AREA)
- Curing Cements, Concrete, And Artificial Stone (AREA)
- Compositions Of Macromolecular Compounds (AREA)
- Paints Or Removers (AREA)
- Emulsifying, Dispersing, Foam-Producing Or Wetting Agents (AREA)
Description
TITLE: "LIGHTWEIGHT AGGREGATE BINDER FORMULATION" TECHNICAL FIELD
The present invention relates to aggregate suitable for use in lightweight concrete, and to lightweight concrete including the aggregate. BACKGROUND ART
The preparation of low density concrete by the incorporation of lightweight aggregates such as vermiculite, cork, slag, asbestos, bagasses and the like in a hydraulic binder such as a cement/sand/water mixture is well known. Low density concrete having much improved properties may be prepared by the incorporation of lightweight aggregate, in particular, foam particles such as polystyrene, into the binder.
However, cementitious materials do not readily bond with these lightweight aggregates, which are generally highly hydrophobic. The hydrophobic character and low density of polystyrene beads produces a tendency to float to the surface of the concrete as it sets. To overcome this problem, various bonding agents have been used to facilitate the incorporation of polystyrene foam particles into lightweight aggregates. These agents include bituminous products, Goal tars and mixtures of pitch with epoxy resins or phenolic resins. The use of such bonding agents has proved problematic because coating of the polystyrene particles results in a tacky surface causing the particles to coalesce into a mass which is difficult to disperse in the cementitious matrix. Further, the
coatings generally retain a strong bituminous odour which remains unacceptably detectable in the end product. More importantly, the bonding strength between the foam particles and the other components in the cured cement has not been ideal, resulting in an inferior product. Applicant's earlier patent AU670754 (see also corresponding US patent
5,472,498) the contents of which are incorporated herein by reference) provided a major advance in the art. By treating polystyrene foam particles with a bonding agent consisting of an emulsion comprising a discontinuous bituminous phase, and a continuous aqueous phase and having ferric oxide suspended in the aqueous phase. The use of this emulsion avoided the problems of surface tackiness and aggregation, provided a lightweight aggregate which was uniformly dispersible in concrete, and strongly bonded therewith providing a lightweight concrete of substantially improved strength. The ferric metal ions kept the lightweight aggregate in suspension in the wet concrete, preventing the aggregate particles from floating to the top, and also led to a strong bond between the aggregate and the concrete in the cured mixture providing a lightweight concrete of improved strength.
Prior to application to the lightweight particles, it was usual for the emulsion described in AU670754 to be diluted with water in compliance with specified concentrations. Failure to adhere to the specified concentration range would lead to a deterioration in the performance of the final product. The previous coating agent typically required addition of around 1 part of the emulsion to 2 parts water prior to application. Attempts by users to extend the emulsion by adding more water, contrary to product specifications, could result in an inferior concrete product.
Any discussion of the prior art throughout the specification should in no way be considered as an admission that such prior art is widely known or forms part of common general knowledge in the field.
Further, the previous bonding agent did not always store well for extended periods of time in conditions of extreme temperature, exhibiting a tendency to settle. Extreme temperature fluctuations can cause stratification of the mixture.
Previous mixtures have also sometimes required the addition of a thickening agent to increase viscosity. These thickening agents are typically cellulose based and are thus vulnerable to bacterial attack. It is an object of the present invention to overcome or ameliorate one or more of the disadvantages of the prior art, or to provide a commercial alternative.
DESCRIPTION OF THE INVENTION
According to a first aspect, the invention provides a thermally stable composition for use in the manufacture of a lightweight aggregate including: a continuous bituminous phase; a discontinuous aqueous phase an anionic oxide suspended in the discontinuous aqueous phase, and at least one emulsifying agent.
Preferably, the anionic oxide is a naturally occurring metal oxide, for example red oxide, such as Cupric Oxide (CuO). It is highly preferred to use metal oxides having a needle like crystal structure. However, other naturally occurring oxides, for instance yellow oxide, may be used.
The discontinuous aqueous phase is preferably distilled, or deionized, water.
Grade 170 Bitumen is preferred as the continuous bituminous phase, although other crude oil or hydrocarbons or mixtures thereof may be used.
The emulsifying agent is preferably a clay emulsifier, such as the sodium
bentonites, hydrous aluminium silicose clays and montmorillonite families. A highly
preferred emulsifier is Volclay® premium gel, which is a 200 mesh bentonite. Other
gels having a similar structure, i.e. with an oleophilic tail and an oleophobic head have
also been found suitable for use in the present invention.
Preferably, the composition further includes one or more of a thickener, an
inhibitor, and a perfume. The selection of concentrated fragrance used does not appear
to be critical. In the present invention, the preferred fragrance is "Eternal". Similarly,
the biocidal concentrate used does not appear to be critical, but sodium ortho-
phenylphenol ("opp") is preferred.
According to a second aspect, the invention provides lightweight aggregate
particles coated with a composition according to the first aspect.
Although the coating composition can be applied to a wide range of light weight aggregate materials, it is preferred to apply the composition to polymer foam (including
recycled polymer foam) particles, and it is especially desirable to select polystyrene
foam particles as the lightweight aggregate to be coated.
According to a third aspect, the invention provides a building material formed
from a lightweight aggregate according to the second aspect in combination with a
cementitious material.
According to a fourth aspect, the present invention provides a method of forming
a composition according to the first aspect, including the steps of: optionally blending one or more of an air entrainment agent, a fragrance and a
biocide with water and shearing to form a soap; adding an emulsifier;
dispersing naturally occurring anionic oxide particles in the aqueous phase; and
dispersing the aqueous phase in a bituminous phase.
The present invention will now be described by way of example only with reference to the embodiments shown in the accompanying drawings and/or examples.
BRIEF DESCRIPTION OF THE DRAWINGS Fig 1 shows a flow chart of a preferred method of forming the coating composition of the present invention
BEST MODES FOR CARRYING OUTTHE INVENTION
EXAMPLE 1. BONDING AGENT
The preferred bonding agent of the present invention has the following composition (all values are wt %):
Compatible chemicals performing a similar function may be substituted for any of those exemplified in the above formulation, and the relative quantities adjusted accordingly in a manner which will be apparent to a skilled formulator based on the teachings hereof.
EXAMPLE 2 PREPARATION OF BONDING AGENT
The binder formulations of the present invention are best formed by an "in line" emulsification procedure according to the following steps:
1. Micro-aire 940, an air entrainment agent; "Eternal", the desired fragrance; and sodium ortΛophenylphenol, an antibacterial agent ("opp") are added to distilled water to form a soap. This soap is circulated for 25 minutes while the temperature is raised to
35°C.
2. Volclay® premium gel is then added to the soap at a slow rate, approximately 10
kg per minute. 3. Red oxide is then dispersed in the mixture at a rate of around 10 kg per minute
4. The mixture is sheared in a high shear mill while Gradel70 Bitumen at 195°C is
added at around 1500 kg per hour.
In the above method, the exact sequence of addition in the manufacture of the composition is critical for obtaining the water-in-oil emulsion structure and for providing the coating composition with its useful properties. However, those skilled in the art of emulsification will appreciate that the conditions will vary with equipment employed and formulation used and that other methods for producing the water-in-oil emulsion with a dispersed aqueous phase containing the oxide in suspension may be suitable. EXAMPLE 3 PHYSICAL STRUCTURE OF EMULSION The preferred physical structure of the natural anionic oxides preferred in the present invention may be classified as either "needle-like" or "spherical". "Needle-like" oxides hold more water, so when they are formed into a paste, this tends to be drier, and thus more viscous than that formed from the corresponding "spherical oxide". Needlelike oxides are highly preferred. However, the oxides may be either "needle-like" or "spherical".
The droplets in the emulsion of the present invention have been found to be
around 25 microns in diameter, which is considerably larger than the 5 micron diameter
droplets found in typical emulsions, and contain the oxide as a suspension within the
droplets.
EXAMPLE 4. STABILITY OF COMPOSITION
The emulsion has been tested for prolonged exposure to freezing. No noticeable
deterioration of the structure or qualities of the composition was observed.
EXAMPLE 5. PREPARING COATED AGGREGATE
The coating composition (1 part by weight) is mixed with water (8 parts by
weight). The formulation can then be used to coat polystyrene balls in a manner similar
to that described in AU670754. The coated balls are free flowing when dry and have a
pink appearance.
EXAMPLE 6. CONCRETE PREPARATION
The coated polystyrene balls form an aggregate which is mixed with cement, sand and water. Other types of conventional aggregate can be added if required.
The concrete produced using the present invention can be worked in the same way
as normal concrete. The exact quantities used will depend upon the required properties
of the concrete and the nature of the other materials used.
EXAMPLE 7. CONCRETE PRODUCED The concrete produced is compatible with the lightweight concrete described in
AU670754 in terms of physical performance. The weight and other physical properties
of the concrete produced in accordance with the present invention is similar to that described in AU670754. However, surprisingly, a compressive strength of around 30
MPa may be obtained using aggregate coated with bonding formulations of the present invention, which is unexpectedly 20% higher than that obtainable from the concrete of AU670754. Those skilled in the art will appreciate that lightweight concrete is designed for low load bearing applications.
Concrete weights as low as 250 kg/m3 can be obtained, but to achieve the maximum strength, 1200 - 1800 kg/m3 are used, which is about 50-75% the weight of conventional concrete. Concrete density may be controlled by varying the amount of polystyrene in the mixture.
The concrete also has the desirable insulation properties of the lightweight concrete in AU670754, namely a thermal insulation coefficient of 0.065w/m degree C, and R up to 1.9. The sound insulation properties are also as for the concrete in AU670754, with an STC rating of 40-55. Although the invention has been described with reference to a specific example, it will be appreciated by those skilled in the art that the compositions and methods of manufacture may be varied without departing from the inventive concept herein disclosed and that the invention may be embodied in many other forms.
Claims (22)
1. A thermally stable composition for use in the manufacture of a lightweight aggregate including: a continuous bituminous phase; a discontinuous aqueous phase; an anionic oxide suspended in the discontinuous aqueous phase; and at least one emulsifying agent.
2. A thermally stable composition according to daim 1 wherein the anionic oxide is a naturally occurring metal oxide.
3. A thermally stable composition according to claim 1 or claim 2 wherein the anionic oxide is a metal oxide having a needle-like crystal structure.
4. A themially stable composition according to any one of the preceding claims wherein the anionic oxide is red oxide (CuO) or yellow oxide.
5. A thermally stable composition according to any one of the preceding claims wherein the anionic oxide is present in an amount of 20 wt% of the composition.
6. A thermally stable composition according to any one of the preceding claims wherein the discontinuous aqueous phase is distilled and/or de-ionised water.
7. A thermally stable composition according to any one of the preceding claims wherein the discontinuous aqueous phase is water present in an amount of 40 wt% of the composition.
8. A thermally stable composition according to any one of the preceding claims wherein the continuous bituminous phase is grade 170 bitumen.
9. A thermally stable composition according to any one of the claims 1 to 7 wherein the continuous bituminous phase is selected from crude oil, hydrocarbons or mixtures thereof.
10. A thermally stable composition according to any one of the preceding claims wherein the continuous bituminous phase is present in an amount of 35 wt% of the composition.
11. A thermally stable composition according to any one of the preceding claims wherein the emulsifying agent is a clay emulsifier.
12. A thermally stable composition according to claim 8 wherein the clay emulsifier is selected from sodium bentonites, hydrous aluminium silicose clays, montmorillonite clays, and mixtures thereof.
13. A thermally stable composition according to claiml 1 or claim 12 wherein the clay emulsifier is a 200 mesh bentonite.
14. A thermally stable composition according to any one of the preceding claims wherein the emulsifying agent is present in an amount of 5 wt% of the composition.
15. A thermally stable composition according to any one of claims 1 to 10 wherein the emulsifying agent is a gel having an oleophilic tale and an oleophobic head.
16. A thermally stable composition according to any one of the preceding claims further including one or more of a thickener, a biocidal inhibitor, and a perfume.
17. A thermally stable composition according to claim 16 wherein the biocidal inhibitor is sodium ort/zo-phenylphenol.
18. Lightweight aggregate particles coated with a composition according to any one of claims 1 to 14.
19. Lightweight aggregate particles according to claim 18 formed from polymer foam.
20. Lightweight aggregate particles according to claim 18 or 19 formed from polystyrene foam particles.
21. A building material formed from a lightweight aggregate according to any one of claims 18 to 20 in combination with a cementitious material.
22. A method of forming a composition according to any one of claims 1 to 17 including the steps of optionally bending one or more of an air entrainment agent, a fragrance and a biocide with water and shearing to form a soap; adding an emulsifier; dispersing naturally occurring anionic oxide particles in the aqueous phase; and dispersing the aqueous phase in a bituminous phase.
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AUPR0992 | 2000-10-24 | ||
AUPR0992A AUPR099200A0 (en) | 2000-10-24 | 2000-10-24 | New formulation |
PCT/AU2001/001351 WO2002034688A1 (en) | 2000-10-24 | 2001-10-22 | Lightweight aggregate binder formulation |
Publications (1)
Publication Number | Publication Date |
---|---|
AU2002210267A1 true AU2002210267A1 (en) | 2002-05-06 |
Family
ID=3825039
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
AUPR0992A Abandoned AUPR099200A0 (en) | 2000-10-24 | 2000-10-24 | New formulation |
AU2002210267A Abandoned AU2002210267A1 (en) | 2000-10-24 | 2001-10-22 | Lightweight aggregate binder formulation |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
AUPR0992A Abandoned AUPR099200A0 (en) | 2000-10-24 | 2000-10-24 | New formulation |
Country Status (7)
Country | Link |
---|---|
US (1) | US20050235875A1 (en) |
EP (1) | EP1343733A1 (en) |
KR (1) | KR20030068139A (en) |
CN (1) | CN1471497A (en) |
AU (2) | AUPR099200A0 (en) |
CA (1) | CA2426239A1 (en) |
WO (1) | WO2002034688A1 (en) |
Families Citing this family (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US8652392B1 (en) * | 2007-10-22 | 2014-02-18 | Paulette Locke | Method of forming concrete |
KR101045266B1 (en) * | 2010-11-19 | 2011-06-29 | 주식회사 중앙기업사 | Structure of an ceiling opening for checking the pipe laying, wiring, etc |
CN103289104B (en) * | 2013-03-21 | 2015-01-21 | 镇江金阳道路材料科技发展有限公司 | A cationic asphalt emulsifier capable of emulsifying SBS modified asphalt and a preparation method thereof |
CN105368082B (en) * | 2015-12-04 | 2017-10-17 | 喜跃发国际环保新材料股份有限公司 | A kind of seamless industrial floor additive and its production technology and application method |
RU2616012C1 (en) * | 2016-03-15 | 2017-04-12 | Юлия Алексеевна Щепочкина | Method for producing aggregate for concrete |
Family Cites Families (13)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2996450A (en) * | 1957-04-23 | 1961-08-15 | Atlas Powder Co | Water-in-oil emulsion drilling fluid |
JPS5523793B2 (en) * | 1974-04-26 | 1980-06-25 | ||
JPS5179118A (en) * | 1974-12-30 | 1976-07-09 | Mitsubishi Petrochemical Co | Keiryokotsuzaino seizohoho |
JPS51116823A (en) * | 1975-04-05 | 1976-10-14 | Nichireki Chem Ind Co | Superrapid hardening mixture |
US4332620A (en) * | 1980-09-29 | 1982-06-01 | Quinn Robert L | Colored paving composition |
AT383823B (en) * | 1983-02-22 | 1987-08-25 | Asphalt Ges Richard Felsinger | METHOD FOR PRODUCING A FINE DISTRIBUTED THERMOPLASTIC PLASTIC-CONTAINING POWDER |
GB8615243D0 (en) * | 1986-06-23 | 1986-07-30 | Cox Preservation Ltd Peter | Plaster & plastering |
DE3716300A1 (en) * | 1987-05-15 | 1988-11-24 | Bayer Ag | NEW COLOR-PURE IRON OXIDE PIGMENTS, METHOD FOR THEIR PRODUCTION AND THEIR USE |
GB9013951D0 (en) * | 1990-06-22 | 1990-08-15 | British Petroleum Co Plc | The bitumen blends |
ZA925701B (en) * | 1991-08-08 | 1993-04-13 | Bst Holdings Pty Ltd | Lightweight concrete. |
JPH0597489A (en) * | 1991-10-11 | 1993-04-20 | Mitsui Toatsu Chem Inc | Ordinary temperature waterproofing material |
AU4490596A (en) * | 1995-01-03 | 1996-07-31 | Emile Jacques Muntzer | Method for coating carriers, emulsion used therein, resulting coated materials, and devices for producing and laying coated materials |
US5626658A (en) * | 1995-09-05 | 1997-05-06 | Mcardle; Blaise | Method of enhancing internal adhesion of cementitious compositions and compositions therefor |
-
2000
- 2000-10-24 AU AUPR0992A patent/AUPR099200A0/en not_active Abandoned
-
2001
- 2001-10-22 EP EP01978003A patent/EP1343733A1/en not_active Withdrawn
- 2001-10-22 CA CA002426239A patent/CA2426239A1/en not_active Abandoned
- 2001-10-22 WO PCT/AU2001/001351 patent/WO2002034688A1/en active Application Filing
- 2001-10-22 AU AU2002210267A patent/AU2002210267A1/en not_active Abandoned
- 2001-10-22 CN CNA018178634A patent/CN1471497A/en active Pending
- 2001-10-22 KR KR10-2003-7005675A patent/KR20030068139A/en not_active Application Discontinuation
- 2001-10-22 US US10/399,873 patent/US20050235875A1/en not_active Abandoned
Also Published As
Publication number | Publication date |
---|---|
EP1343733A1 (en) | 2003-09-17 |
US20050235875A1 (en) | 2005-10-27 |
KR20030068139A (en) | 2003-08-19 |
WO2002034688A1 (en) | 2002-05-02 |
CN1471497A (en) | 2004-01-28 |
AUPR099200A0 (en) | 2000-11-16 |
CA2426239A1 (en) | 2002-05-02 |
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Legal Events
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MK4 | Application lapsed section 142(2)(d) - no continuation fee paid for the application | ||
NA | Applications received for extensions of time, section 223 |
Free format text: AN APPLICATION TO EXTEND THE TIME FROM 22 OCT 2006 TO 22 MAY 2007 IN WHICH TO PAY A CONTINUATION FEE HAS BEEN FILED . |
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NB | Applications allowed - extensions of time section 223(2) |
Free format text: THE TIME IN WHICH TO PAY A CONTINUATION FEE HAS BEEN EXTENDED TO 22 MAY 2007. |
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MK5 | Application lapsed section 142(2)(e) - patent request and compl. specification not accepted | ||
NA | Applications received for extensions of time, section 223 |
Free format text: AN APPLICATION TO EXTEND THE TIME FROM 18 AUG 2007 TO 18 FEB 2008 IN WHICH TO GAIN ACCEPTANCE HAS BEEN FILED . |
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NB | Applications allowed - extensions of time section 223(2) |
Free format text: THE TIME IN WHICH TO GAIN ACCEPTANCE HAS BEEN EXTENDED TO 18 FEB 2008. |
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MK5 | Application lapsed section 142(2)(e) - patent request and compl. specification not accepted |