AU752467B2 - Improved lightweight prefabricated construction element - Google Patents
Improved lightweight prefabricated construction element Download PDFInfo
- Publication number
- AU752467B2 AU752467B2 AU14731/97A AU1473197A AU752467B2 AU 752467 B2 AU752467 B2 AU 752467B2 AU 14731/97 A AU14731/97 A AU 14731/97A AU 1473197 A AU1473197 A AU 1473197A AU 752467 B2 AU752467 B2 AU 752467B2
- Authority
- AU
- Australia
- Prior art keywords
- core
- facing sheets
- slurry
- mix
- constructional element
- 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.)
- Ceased
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
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
- C04B28/04—Portland cements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/50—Producing shaped prefabricated articles from the material specially adapted for producing articles of expanded material, e.g. cellular concrete
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B19/00—Machines or methods for applying the material to surfaces to form a permanent layer thereon
- B28B19/0092—Machines or methods for applying the material to surfaces to form a permanent layer thereon to webs, sheets or the like, e.g. of paper, cardboard
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
- E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
- E04C2/288—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material
-
- 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
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
- C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/50—Reuse, recycling or recovery technologies
- Y02W30/91—Use of waste materials as fillers for mortars or concrete
Description
IMPROVED LIGHT WEIGHT PRE-FABRICATED CONSTRUCTIONAL ELEMENT FIELD OF THE INVENTION The present invention relates to improved lightweight prefabricated constructional elements such as panels and to a method of manufacture thereof. Though reference is made herein to panels as the constructional elements, such a reference is only by way of example and not to be construed in a limited manner.
PRIOR ART Panel materials are known in the art with core of gypsum having paper facings.
These materials, though having reasonably good fire resistant property, have low e impact values and limited resistance to water.
It is also known in the art to have panels made of particle board and like materials. However, such panels have limited fire resistance properties.
It is possible to have a panel material with a core using cementicious materials' such as cement as binder with commonly used aggregates. However, such panels have a high density. To reduce density of the said composite core, use of lightweight material aggregates such as rice husk and or an expanded polymeric i'.e material is also known. Such aggregates though reduce the weight but limit the fire resistant properties and curing system.
-2- OBJECTIVE OF THIS INVENTION It is an object of this invention to propose lightweight prefabricated constructional elements such as panels that have high strength, water resistant, good sound and heat insulation properties and are cost effective.
It is a further object of the present invention to propose a process for producing lightweight prefabricated constructional elements with high bond strength between core and facing sheets in-situ with fire resistant, lightweight core material between two fire resistant facing sheets.
DESCRIPTION OF INVENTION According to this invention, there is provided an improved lightweight prefabricated constructional element comprising a composite core prepared from a mix having water 35 60% of the total weight of the solids of the core mix mixed with 100 parts of solids comprising 0,05 to 0.5% of an aerating agent such as aluminium powder, 0 to 20% of low density aggregate such as exfoliated vermiculite and/or perlite, 0 to 70% of a pozzolonic material such as pulverised fly ash, the remainder being portland cement, said composite core being with facing sheets on opposite sides thereof.
In the instant invention the objective of using aerating agent such as aluminium powder is not only to reduce the weight of constructional element as is done in known products which are in market but also to utilise the chemistry of generation of hydrogen gas when cementious material reacts with aluminium powder in the slurry of instant core material to increase tdie pressure in the confined space created by holding the facing sheets rigidly in a specially designed jig sealed on all sides (by removable extrusions) the pressure so generated in turn results in forceful entry of slurry of core material in fine pores of the facing sheets resulting in positive bonding between facing sheets and core material when slurry of core material sets and is cured.
In accordance with another embodiment, the constructional element comprises a panel having said core composite aerated between two facing sheets to obtain in-situ bonding resulting in improved lightweight sandwiched ppanels.
In accordance with yet another embodiment of this invention the constructional element comprises a panel having said core composite aerated between two facing sheets which have grooves/rough surface, on one side of facing sheets which come in contact with core mix to obtain much higher in-situ bonding between core and facing sheets due to higher surface area available for bonding as a result of grooves/rough surfaces provided in said facing sheets.
The presence of exfoliated vermiculite and/or perlite allows the composite core to be cured either by water or steam. The panels which are subjected to steam curing attain advantageous properties, such as very low shrinkage.
Anhydrous gypsum used is 0 to 15% of total weight of solids in core mix, which facilitates process and improves green strength for handling of precured panels. Lime used is 0 to 20% of total weight of solids in core mix.
Preferably in autoclaved product to balance the reaction with pozzolonic material depending on the chemical composition of the pozzolonic material used.
The construction element such as panels of the present invention are manufactured in-situ and have high bond strength between the surface of thle core and the facings.
The slurry of said composite core mix with the aerating agents is introduced between the facing sheets which are held rigidly in ajig, aerate, expand due to aeration, thereby generating pressures and effectively fill the pores of the facing sheets to facilitate stronger bonding between the facing sheets and core; the construction elements so manufactured is allowed to set and is subjected to curing. The construction element so prepared has good bond strength between core and facing sheets.
For applications demanding higher bond strength, the present invention ensures a much stronger bond and locking action between the core and facing sheets, each of the facing sheet on the inner side are provided with profile such as grooves or random recesses provided preferably during the process of manufacture of the facing sheets. The slurry of composite core mix with the aerating agents, when introduced in between the said facings held rigidly in the jig, aerate, expand and generate pressure hence effectively fill the grooves or recesses provided apart from the crevices and pores in the facing sheets; the construction element so manufactured are allowed to set and are subjected to curing such construction elements are, having much higher bond strength due to availability of more surface area and better locking between the profiled facings and core.
Moreover, the aerated composite forming the core of the panel of the invention has improved characteristics such as lightweight, fire and water resistance, having good heat insulation properties apart from being cost effective.
Reference is now made to the core composition comprising 0 to 70% of Pozzolonic material. The presence of fine silica in Pozzolona allows a reaction with free lime present in portland cement to produce calcium silicate and minimise leaching of free lime.
from the panel in due course. The amount of the pozzolonic material added to the core is dependent on the amount of free lime present in the core composition. Preferably, pulverised fly ash is added to the core as the pozzolonic material. A distinct advantage of employing pulverised fly ash as the pozzolonic material is that it is environmentally friendly apart from being cost effective, being a waste product of thermal stations and is available in abundance at negligible costs.
The core contains an aerating material such as aluminium powder.
Aluminium powder reacts with lime present in the core composition to liberate hydrogen gas which gets entrapped as air bubbles within the core.
Such a liberation of gas causes an expansion of the core making the core lighter and aids in better bonding and locking of core with the facings.
Besides aluminium powder, suitable grade of surfacants can be used.
Surfactants entrap air bubble in the core mix and make the product lighter.
In the embodiment the core further comprises 0 to 20% of a low density aggregate such as exfoliated vermiculite and/or perlite.
Moreover, aggregates such as exfoliated vermiculite/perlite are more compatible with said cementicious core materials and allow high pressure steam curing apart from conventional water/humid curing whereas known aggregates such as polymer beads are not compatible with said core material and cannot be subjected to high pressure steam curing.
(n the instance the process of the present invention comprises water of total weight of the solids of the core mix, mixed with 100 parts of solids comprising 0.05 to 0.5% of an aerating material such as aluminium powder, 0 to 20% of low density aggregate such as exfoliated vermiculite and/or perlite, 0 to 70% of pozzolonic material such as pulverised fly ash, the remainder being portland cement to form a core mix. Slurry of such a core mix is introduced between the facing and allowed to aerate and cure under atmospheric conditions.
The thickness of the core and the facings is not a controlling parameter. It depends upon the application of the panel and thus cannot be limited to any thickness or range of thickness. The facings are selected depending on application from particle boards, cement bonded particle boards and/or metallic sheets and the like, with or without grooves/rough profile on one side of facing which comes in contact with core.
The invention is now described hereunder with reference to a preferrec exemplary embodiment of the process for manufacture of the light weight prefabricated panel of the present invention which is an illustration and not limitative.
EXAMPLE 1 Pulverised fly ash having surface area of 3500 cm2/g 30%, portland cement 59.9% was first mixed along with water in an amount of 35% of total weight of solids of the batch mix.
To the mix thus obtained, 10% of exfoliated vermiculite was added as light weight aggregate material followed by the addition of the aerating agent, aluminium powder in an amount of 0.1% mixed with water in an amount of of total weight of solids of the batch mix. The slurry of core mix thus obtained for introduction there between the facings which is discussed hereunder: The pair of facings which is obtained of fibre cement sheets of 4 mm thickness are separated and supported by using conventional jigs and fixtures. The distance between the facing was kept 42 mm to achieve mm thickness panel. Thereafter,the core mix slurry was introduced between the facings and all sides sealed by removable extrusions and allowed to aerate and harden for a period of 24 hours.
After the core was hardened, the construction element were separated from the jigs and thereafter subjected to humid curing by conventional technique to obtain panel having the following characteristic features: Thickness of pannel Weight Fire resistance rating Surface spread of flame Water penetration Linear expansion Thermal conductivity Bond Strength 50 mm 41 kg/m2 1 hour BS 476 Parts 20-22, 1987 Class 1 BS 476 Part 7:1989 No evidence of water penetration BS 4315 Part II 1970 2 mm/meter 0.22 W/M K 2.1 kg/cm2 vii) viii) EXAMPLE
II
The construction elements were prepared exactly as per example No. but the fibre cement facing sheets used were having grooves on one side which comes in contact with the core mix. These grooves are formed during the process of manufacture of facing sheets.
Fibre cement facing sheets of 4 mm thickness with grooves on one side were kept separated and held in jigs and fixtures, the distance between facing sheets being 42 mm so to produce a panel of 50 mm thickness.
The composition of core mix and the methodology adopted in preparation of panel was same as in example No.I.
The physical properties obtained for 50 mm thick panel was as follows: Thickness of panel Weight Fire resistance rating Surface spread of flame Water penetration Linear expansion Thermal conductivity Bond Strength 41 kg/m2 1 hour BS 476 parts 20-22, 1987 Class 1 No evidence of water penetration BS 4315 Part II 1970 2 mm/meter 0.22 W/M K 3.00 kg/Cm2 vii) viii) Although the above example has been discussed with reference to fibre cement sheet as the facing material, other suitable facing materials can also be used such as gypsum boards, particle boards, cement bonded particle boards, meteallic sheets and the like with or without grooves/rough profiles on the side which comes in contact with the core mix.
Claims (15)
1. The improved light weight constructional element comprising composite core resulting from slurry of cement, pozzolonic or other filler material with aerating agent between two facing sheets manufactured by allowing expansion of the slurry by aerating in a purposefully limited, confined space in all directions so that the slurry of core material is pressurised while expanding and thus the pressurised slurry is forced to enter the fine pores of facing sheets ensuring positive bonding between facing sheets and the core when the slurry of core material sets and cured.
2. An improved light weight constructional element as claimed in claim 1 wherein limited and confined space for poured slurry of core material is created by facing sheets held rigidly in jigs with extrusions positioned on all sides to ensure positive sealing of slurry thus when poured slurry areates high pressure is developed and the said pressurised slurry enters the fine pores of the facing sheets resulting in positive bonding between facing sheets and resulting core material when slurry sets in and is cured.
3. A constructional element as claimed in claim 1-2 wherein said composite core is prepared from a mix having water 35-60% of total weight of the solids of 'the core mix, mixed with 100 parts of solids comprising 0.05 to 0.5% of an aerating agent, aluminium powder, upto of low density aggregate exfoliated vermiculite and/or perlite individually or in combination and optionally upto 70% of pozzolonic material pulverized fly ash, the remainder being portland cement.
4. A constructional element as claimed in claim 1 wherein said facing sheets are plain. A constructional element as claimed in claims I wherein said facing sheets have grooves/rough profiles on the inner surface thereof so as to increase the surface area and improve locking and bonding between the core and said facings.
6. A constructional element as claimed in claims 1 wherein said facing sheets are fibre cement sheets or .gypsum boards or particle boards or cement bonded particle boards and/or metallic sheets.
7. A constructional element as claimed in claims 1 to 6 having anhydrous gypsum present in an amount of 0-15% in said composite core mix.
8. A constructional element as claimed in claims 1 to 7 having lime present in an amount of 0-20% in said composite core mix.
9. A constructional element as claimed in claims 1 to 8 wherein said aerating agent is aluminium powder used singularly or in combination with surfactant's the known air entraining agents. constructional element as claimed in claims 1 and 9 wherein said pozzolonic material is pulverised fly ash. 1 I .A process for the manufacture of improved light weight constructional element comprising composite core of cement pozzolonic or other filler between facing sheets manufactured by a method which results in pressurising the slurry of core material hence facilitating the entry of pressurised slurry of core material into fine pores of facing sheets ensuring positive bonding between facing sheets and core material when cured, the said facing sheets being held rigidly in a jig where extrusions are positioned to ensure positive sealing of slurry of core material which areates resulting in development of high pressure in the slurry of core material. 2. A process for the manufacture of light weight prefabricated constructional element as claimed in claim 11 comprising the steps of preparing a core from a water based slurry having water 35-60% of the total weight of the solids of the core mix mixed with 100 parts of solids comprising 0.05 to 0,5% of an aerating agent such as aluminium powder, 0-20% of low density aggregate exfoliated vermiculite and/or perlite individually or in combination 0-70% of pozzolonic material pulverised fly ash, the remainder being portland cement, allowing said core mix to aerate and cure between facings on opposite sides of said core. -11-
13. A process as claimed in claim 11 to 12 where said composite is prepared from a mix having water 35-60% of the total weight of the solids of the core mix, mixed with 100 parts of solids comprising 0,05 to 0.5% of an aerating agent such as aluminium powder, upto 20% of low density aggregate such as exfoliated vermiculite and/or perlite individually or in combination and optionally upto 70% of a pozzolonic material such as pulverised fly ash, the remainder being portland cement, allowing said core mix to aerate and cure.
14. A process as claimed in claim 11 to 13 wherein said composite core mix is introduced in between said pair of facing sheets held rigidly in jigs, allowed to aerate and expand and thereby cause to generate pressures to effectively fill the pores of said facing sheets, facilitating locking between said facing sheets and core and then allowed to set and subject it to curing, said construction element so prepared have good bond strength between the core and facing sheets. A process as claimed in claim 11 to 14 wherein said composite core mix is introduced between said pair of facing sheets held rigidly in jigs and having grooves/rough profile which are preferably obtained during the process of manufacture on one side of the facing sheets which come in contact with said core mix, allowing said core mix to aerate expand and thereby cause to generate pressure to effectively fill the pores crevices/grooves of said facing sheets facilitating effective locking of said facing sheets with the core due to availability of higher surface area of contact between core and said facing sheets and then allowed to set and cure, such construction elements have higher bond strength between said core and facing sheets.
16. A process as claimed in claims 11 to 15 wherein said aerating agent is aluminium powder used singularly or in combination with any other known air entraining agent,such as surfactants.
17. A process as claimed in claims 12 to 16 wherein anhydrous gypsum is present in an amount of 0-15% in said core.
18. A process as claimed in claims 12-17 wherein lime is present in an amount of 0-20% in said core.
19. A process as claimed in claims 11-18 wherein pozzolonic material is pulverised fly ash. A process as claimed in any one of claims 11 to 19 wherein the step of curing comprises water/humid curing or high pressure steam.
21. A process as claimed in claim 11 wherein said facing sheets is selected, from fibre cement sheet, gypsum boards, particle boards, cement bonded particle boards and/or metallic sheets and the like. BUILDING TECHNOLOGIES AUSTRALIA PTY LIMITED and HYDERABAD INDUSTRIES LIMITED By their Patent Attorneys FISHER ADAMS KELLY ooooo i S S S oS S 5o
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
IN769DE1996 | 1996-04-26 | ||
IN768/CAI/96 | 1996-04-26 | ||
IN769/CAI/96 | 1996-04-26 | ||
IN768DE1996 | 1996-04-26 |
Publications (2)
Publication Number | Publication Date |
---|---|
AU1473197A AU1473197A (en) | 1997-11-13 |
AU752467B2 true AU752467B2 (en) | 2002-09-19 |
Family
ID=26324667
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
AU14731/97A Ceased AU752467B2 (en) | 1996-04-26 | 1997-02-17 | Improved lightweight prefabricated construction element |
Country Status (1)
Country | Link |
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AU (1) | AU752467B2 (en) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2006011690A1 (en) * | 2004-07-27 | 2006-02-02 | Regional Mining Limited | Exfoliation |
WO2008037001A1 (en) * | 2006-09-25 | 2008-04-03 | Building Technologies Australia Pty Ltd | Improvements in sandwich panels |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB2324105B (en) * | 1996-04-26 | 2001-09-19 | Hyderabad Ind Ltd | Lightweight prefabricated constructional element |
Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB2174084A (en) * | 1985-04-26 | 1986-10-29 | Slosson Bing Jong | Building material |
EP0208070A2 (en) * | 1985-07-11 | 1987-01-14 | Rheinisch-Westfälische Kalkwerke AG | Process for producing construction materials from combustion residues |
-
1997
- 1997-02-17 AU AU14731/97A patent/AU752467B2/en not_active Ceased
Patent Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB2174084A (en) * | 1985-04-26 | 1986-10-29 | Slosson Bing Jong | Building material |
EP0208070A2 (en) * | 1985-07-11 | 1987-01-14 | Rheinisch-Westfälische Kalkwerke AG | Process for producing construction materials from combustion residues |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2006011690A1 (en) * | 2004-07-27 | 2006-02-02 | Regional Mining Limited | Exfoliation |
WO2008037001A1 (en) * | 2006-09-25 | 2008-04-03 | Building Technologies Australia Pty Ltd | Improvements in sandwich panels |
Also Published As
Publication number | Publication date |
---|---|
AU1473197A (en) | 1997-11-13 |
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Free format text: FT=AN APPLICATION TO EXTEND THE TIME FROM 19990609 TO 20000509 IN WHICH TO REQUEST EXAMINATION HAS BEEN LODGED |
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NB | Applications allowed - extensions of time section 223(2) |
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TC | Change of applicant's name (sec. 104) |
Owner name: BUILDING TECHNOLOGIES AUSTRALIA PTY LIMITED, HYDER Free format text: FORMER NAME: B.T.A. PTY LTD, HYDERABAD INDUSTRIES LIMITED |
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FGA | Letters patent sealed or granted (standard patent) |