CA1079312A - Materials containing silicon dioxide - Google Patents
Materials containing silicon dioxideInfo
- Publication number
- CA1079312A CA1079312A CA261,070A CA261070A CA1079312A CA 1079312 A CA1079312 A CA 1079312A CA 261070 A CA261070 A CA 261070A CA 1079312 A CA1079312 A CA 1079312A
- Authority
- CA
- Canada
- Prior art keywords
- weight
- refractory composition
- refractory
- composition according
- silicon dioxide
- 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.)
- Expired
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
- C04B18/00—Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
- C04B18/04—Waste materials; Refuse
- C04B18/14—Waste materials; Refuse from metallurgical processes
- C04B18/146—Silica fume
-
- 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
- C04B2111/00482—Coating or impregnation 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
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/20—Resistance against chemical, physical or biological attack
- C04B2111/28—Fire resistance, i.e. materials resistant to accidental fires or high temperatures
-
- 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
- C04B2111/52—Sound-insulating 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
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/90—Electrical properties
- C04B2111/92—Electrically insulating materials
-
- 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
Landscapes
- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Ceramic Engineering (AREA)
- Environmental & Geological Engineering (AREA)
- Civil Engineering (AREA)
- Materials Engineering (AREA)
- Structural Engineering (AREA)
- Organic Chemistry (AREA)
- Ceramic Products (AREA)
- Building Environments (AREA)
- Curing Cements, Concrete, And Artificial Stone (AREA)
- Paints Or Removers (AREA)
- Compositions Of Macromolecular Compounds (AREA)
- Pigments, Carbon Blacks, Or Wood Stains (AREA)
- Processing Of Solid Wastes (AREA)
- Inorganic Insulating Materials (AREA)
- Mold Materials And Core Materials (AREA)
- Laminated Bodies (AREA)
- Compositions Of Oxide Ceramics (AREA)
- Fireproofing Substances (AREA)
Abstract
Abstract of the Disclosure This invention relates to a refractory composition comprising from 7 to 20% by weight of hydraulic cement, and as a filler material, at from 20 to 50% by weight of predomi-nantly amorphous, dust-like silicon dioxide. The refractory composition itself may be used in the manufacture of a material required to have high fire and/or heat resistance or it may be used to improve the fire and/or heat resistance of an article, by being sprayed onto the article.
Description
3~L~
This invention is concerned with improvements in or relating to refractory compositions of the kind comprising a hydraulic cement and an aggregate.
In the manufacture of refractory compositions there is used as aggregate, or there is used in the refractory compo-sition, various materials in order to obtain or improve the heat-resistance, and particularly fire-resistance and/or resistance to ~emperature changes of the refractory compositions.
For the purpose of improving these properties it is customary to use, e.g. asbestos ~ibre, mineral wool, glass wool, pearlites, vermiculites, fragmented pumice stone, re~ractory clay, powdered refractory clay, slagsand, quart sand, sintered corundum, sintered dolomite, alumina, powdered dolomite, gypsum. However, these materials fulfill the above listed requirements only in part, or only imperfectly, or they raise problems in the produc-tion or processability of the materials. In addition, some of these materials are expensive or scarce, and others, such as asbestos, present considerable health risks which make their use undesirable.
According to this invention there is provided a refractory composition comprising an aggregate, from 7 to 20%
by weight of hydraulic cement, and as a filler material, from 20 to 50% by weight of~silicon dioxide, o which at least 82~
is amorphous, not more than 18~ being crystalline quartz, which ~ ~ .
25 ~ has a bulk weight within the range of 0.25 to 0.50 gram per millilitre, and of which at least 95% has a grain size below 50 microns.
1~$~2 The term "aygregate" is used herein to include mineral materials commonly mixed with cement in the manufacture of, for example, concrete, but does not include said silicon dioxide filler material.
The content of said silLcon dioxide is most advan-tageously between 20 and 30% by we:ight.
The refractory composit:ion itself may be utilised in the manufacture of a material requLred to have high fire and/or heat resistance, such as in the manufacture of refractory bricks, or refractory concrete. Alternatively, the refractory composi-tion may be utilised in improving the fire and/or heat resistance of an article, by being sprayed onto the articleO
Thus this invention also provides a method of improv-ing the fire and/or heat resistance of an article, the method comprising the step of applying to the article a coating of a refractory composition in accordance with this invention.
It has been found that not only does a refractory composition in accordance with this invention exhibit signifi-cantly improved fire and/or heat resistance, but additionally improves other physical properties when used in the manufacture of various articles. This allows the refractory composition in accordance with this invention to be used in the manufacture of a variety of articles, improving not only the fire and/or heat resistance of the article, but also improving other qualitiesj su¢h as the sound absorbancy thereof.
Thus, this invention also provides a refractory composition suitable for imparting fire, flame and heat resist-;~ ~ ance to matexial,, such as concrete or refractory bricks, , ? : - 3 -:
.
~ , , :., : ,:
3~
chipboard, concrete s]abs, ~ire-retarding panels, sound proofing panels, moulded plas-tics panels, corrosion resistant panels, refractory materials, heat insulating materials, electrical insulation materials, sound insulation materials, ~efractory moulding sand, emery paste, in which the refractory composition is incorporated in or applied to the material, the composition comprising an aggregate, from 7 to 20% by weight of a hydraulic cement, and, as a filler material, from 20 to 50% by weight of silicon dioxide, of which at least 82% is amorphous, not more than 18% being cristalline quartz, which has a bulk weight within the range of 0.25 to 0.50 gram per millilitre,.and of which at least 95~ has a grain size below 50 microns.
Conveniently, the filler material is obtained as a by-product produced in the electro-thermic production of ferro-silicon and/or silicon, such as an electro-thermic pxocess operating within a temperature of 1500 to 3000C. The basic constituent of this substance is a fine, dust-like x-ray am~rphous SiO2 (approximately 82 to 95%) some at least of which may have been produced by direct submilation from the vapour to the solid phase, with a small amount of crystalline quartz (approximately 5 to 18%). X-ray examination has shown that.with the exception of the comparatively small quartz content this : dust or powder may be classified as being x-ray amorphous. In ~ addition, the ~iller material may contain small amounts of .~ 25 oxides of.iron and/or calcium and magnesiuml and carbon.
The i.ncorporation of the silicon dioxide as a filler material in a refractory composition according to this invention not only contributes substantially to an improvement in the C
.- : . ~ - . - ~ ., :,, .' . .- , .:
, hea-t res.istance, particular'y fire resis~nce of -the refractor~
composition, but surpr:ising:Ly contribute~ c;ubstan-tially to an improvement in other physical properties, such as mechanical abrasion strength, resistance to temperature changes, thermal insulation, sound insulation, elect.rical insulation properties and improvements in the workability of masses, compositions or mixtures, in particular building mixtures~
In particular, a refractory composition according to this invention is well suited for u.se as or in a fire-inhibiting or fire-resistant material or mass, in particular a mixture or composition capable of being sprayed or tamped down for building purposes.
Fire-inhibiting refractory materials, which according to current custom and knowledge in the art consist of a mixture of cement and asbestos fibres~ are, for example, sprayed on steel girders to protect these against the action of fireO Whilst these convention refractory materials certainly ensure the - required fire protection, they are nevertheless very expensive.
Thus, by the use of this invention, a refractory composition having better fire protection may be obtained in a lçss expensive manner. Such a material has a high thermal insulation value which is, at least partly, due to the low density of the filler material, and over and above this it also has great resista~ce to mechanical abrasion.
It is possible to improve or to further improve certain other properties of the refractory composition by adding other materials, either by utilising such other materials as aggregate~ or by including such other materials in the composi~
tion in conjunction with the aggregate. For example, the .
.
.. . . . . .
", .........
. ..
.
~1~'7~
thermal insulation value thereof may be improved by the use of glass- or mineral- wool waste. Conveniently such materials are obtained from the by products or waste materials produced in the manufacture of insulation matting.
It is also possible to improve the adhesion properties and the strength/density ratiol by utilising, in the preparation of the refractory composition, wet1ing and/or flocculating agents and/or materials of a similar kind.
Where the filler material is in the form the dust-like products emitted in the electro-thermic manufacture o~ ferro-silicon, chemical and physical reactions with t~e other components of the refractory compositions are considerably . enhanced and shrinkage, with resulting crack formation under heat, is minimised, the filler material having the effect of . .
improving the thermal characteristics of the refractory composi-tion with increasing temperature exposure.
It is also possible to include further additives wi~h fire-inhibiting properties, such as calcium sulphate, advanta-geously in the form of waste products occurring in the desulphuri-zation of flue or smoke gases and containing predominantly or e~clusively CaSO~.
The refractory composition according to this invention ~ may be used in the preparation of a sprayable or a tampable : mass for use in the building industry generally, particularly in pre-stressed concrete buildings, for insulating and protecting ~ steel girders. ';uch material may also be used in, e.g. steel-: works, coke-ovens and foundries.
, : . f '~
~ J - 6 -3~
Example I
A refractory composition according to this invention was experimentally tested. For this purpose a sectional steel girder (profile HEB 220), 3.600 mm long with foot plates welded to top and bottom thereof was subj~ected to a load of 133 t~
after a protective layer had been applied to the girder of a fire-proofing refractory composition, comprising mineral wool, as aggregate, portland cement and the silicon dioxide filler material, according to the in~ention, in a layer which was 23 mm thick, and the qirder was then exposed, over a length of 3.100 mm, to ~emperatures rising from 8C to approximately 980C
in the course of 1.5 hours. The girder showed no reduction in its load bearing capacity. The protective layer shrank in the course of the testing time to an average thickness of 16 mm.
Comparative tests were carried out with commercially available conventional asbestos-bearing spray-materials. For achieving fire protection corresponding to class F 90, it was necessary to use 10 kg/m of the conventional refractory composi-tion containing asbestos, but only 7 kg~m2 were required with the same result of the refractory composition according to this invention. Specifically, the refractory composition in accord-ance with this inventin which was used contained by weight approximately 60% mineral wool, 20% cementl and 20% of the silicon dioxide filler material. The mixture was prepared with 25 kg dry substance for 15 1. of water, with 75 ml of Lensodel Registered Trade Uark), a tenside based on ethyleneoxide condensates, inc:Luded in the mixture. The layer thickness required to meet the demands of fire protection class F 90 for ~; ~ 7 , ~
a material containing by weight approximately 60~ mineral wool, 20% pearlite and 20% hydraulic cement was approximately 60 mm.
Using the refractory composition according to this invention and of the above specified composition only approximately 5 mm layer-thickness was nQeded, but because such thin layers cannot be very evenly applied it was found necessary in actual practice to apply a layer thickness of approximately 15 mm. The consti-tuents of the above mentioned refractory compo~ition may be varied within very wide limits depending on the mechanical and 1~ thermal demands and it is also possible to add further conven-tional materials to the mixture, such as, e.g. pearlites which have good heat insulation properties.
Another field of application of this invention is the manufacture of building panels. It is common practice to produce (for example) ceiling panels, partition walls, doors etc. from composition material panels, wherein the basic material may be a chipboard or hardboard material, sprayed with the fire-- proofing materials or mixtures. However, this type of production is rather expensive. The same also applies to panels or slabs made of concrete, gypsum or the like if these are to be fire-proofed.
However, by the use of this invention, h~at resistance and particularly fire resistance of such building panels is substantially improved if the above described re~ractory ~ composition is used in a basic mixture for building panels, particu1arly concrete slabs or panels and chipboard paneis, or subsequently s~prayed onto the article.
' r ~ ~ ~ 8 ~
~. ?
, . . . . . . . .. . . .. . . .
. - . . , , , .:
Advantageously such a panel may con~ist of a flarne-proof fabric of plastic or wire xeinforced with a sealing layer of paper or thin plastics ~oil, ~nd a layering on one or both sides thereof of the above mentioned refractory composition.
This provides a considerable simplification in the manufacture of building panels because, e.g. the wire mesh, which is reinforcingly sealed, may be drawn continuously off a roll to be subsequently rolled, sprayed or tamped on one or both sides thereof with the refractory composition. Again the precise ingredients of the refractory composition may be varied to suit mechanical and thermal demands.
It is also possible to construct a building panel, and especially a fire-yroof panel or mat in such a way that it comprises an inner core of compressed mineral and/or glass wool and an adhesive and protective layer of the refractory composi-tion according to this inven~ion, the aggregate comprising granulated or powdered stone.
Advantageously the refractory composition according to this invention may be used to provide protective coatings for refractory bricks~
- This invention is also suitable for making refractory compositions in the form of fire-proof concret~, which is particularly in demand for high-rise buildings. For achieving economical production without loss of strength in ~he concrete, the silicon dioxide filler material may be admixed with conven-tional ingredients of concrete. By an appropriate addition of the silicon dioxide filler material, it is possible to attain fire-protection safety factors of, for example Class F 90, _ g _ , :
. .: .. .~ .
: ~ .. : ~ : , . :
, Class F 120 or even Class F 240. The amount of silicon dioxide filler material in the concrete i~ preferably between 20 and 30% by weight. The concrete may c~lc;o contain further heat-resistant additives including mineral wool. In conventional concretes intended for exposure to very high temperatures, Portland cement is less suitable as hydraulic binding agent, and special binding agents which have so far been commonly employed for the manufacture of fire-proof concrete have been required.
However by the use of this invention it is not necessary to use special binding agents, and hydraulic cement may be retained as a binding agent. Experiments have shown that the concrete according to this invention may withstand a temperature of approximately 1200C for several hours~
The refractory composition in accordance with this invention may further he employed with great advanta~e in making refractory bricks and high temperature~ resistant linings for industrial furnaces and for the metallurgical industries.
Conventional tamping masses may be mixed with the silicon dioxide filler material in amounts up to approximatel~ 35% by weight and conventional spray masses up to approximately 50~ by weightO These masses show a low degree of potential shrinkage and a low starting point for sinter reaction, but a high degree of fire resistance, strong adhesion to their background~ high surface hardness and good elasticity. For example, a refractory composition comprising (b~ weight) 30 % refractory clay (grain -size 80% b~tween 0 and 0.5 mm), 30% sand (0 to 0.5 mm) 10 alumina flux cement and 30~ of the silicon dioxide filler material, to which 20~ ~y weight of water is added, is extremely suitable for spray application in repair work to the interior : . - . . , ...... . - ,:
. : " " :, . , ,: , - .
:: . :' . '. . : :, lining of coke oven~. In coke ovens, owing to the high tempera-ture gradient of approximately 800C in the vicinity of the door up to about 1,200~C in the middle of the firing chamber, it has hitherto been necessary to employ several differently constituted repair mixtures which were ad~pted to these different temperature zones. ~Iowever, the above speciied refractory composition may be successfully used in evexy region of the coke oven walls.
After the mixture has been sprayed on, it may provide a substan-tially completely fissure-free coating which adheres irmly to the wall and shows very good mechanical strength and durability.
A special ad~antage arises from the ~act that when the refractory material according to this invention is used as/or in refractory andhigh temperature resistant materials it is no longer ne'cessary to add alkaliesO Previously conventional refractory and high temperature resistant masses have required an addition of alkalies, i.e. sodium silicate, to ensure adequate adhesion of the mass to the refra~tory bricks. However, this means that one has to accept a lower mollification point and damags to the bricks.
Example II
A tamping mass for use in the repair of coke oven doors may by the use o~ this invention comprises by weight 15%
sand (0 - 0.5 mm), 50% chamotte B (0-~ mm), 15% alumina cement and 20% o~ the silicon dioxide fillar material. Such a tamping~-mass has a~temperature resistance of 1,100C.Example I~I
A tamping mass suitable for use in foundries comprises by weight 66% sand ~granulation 0 to 0.4 mm), 5% chamotte A, , ,. . . ~ . , . :
, , , , : .
: . . ~ : .. : : . . ...
~0~13~
7% Portland cement 450 and 22% of silicon dioxide filler material.
This tamping mass has temperature resistance up to 1,550C.
In all of the above mentioned cases, where control tests were carried out using extremely finely ground crystalline silicon dioxide, it was found impossible to obtain similarly good results to those achieved when using the refractory composi-tion of this inventioncomprising predominantly amorphous, dust-like silicon dioxide.
All percentages gi~en in the disclosure refer to percentages by weight.
No claim is made herein to compositions which include a substantial ~uantity of sodium silicate.
~' . .
. . .
~ .
~ . ~
.
:: : ' :
This invention is concerned with improvements in or relating to refractory compositions of the kind comprising a hydraulic cement and an aggregate.
In the manufacture of refractory compositions there is used as aggregate, or there is used in the refractory compo-sition, various materials in order to obtain or improve the heat-resistance, and particularly fire-resistance and/or resistance to ~emperature changes of the refractory compositions.
For the purpose of improving these properties it is customary to use, e.g. asbestos ~ibre, mineral wool, glass wool, pearlites, vermiculites, fragmented pumice stone, re~ractory clay, powdered refractory clay, slagsand, quart sand, sintered corundum, sintered dolomite, alumina, powdered dolomite, gypsum. However, these materials fulfill the above listed requirements only in part, or only imperfectly, or they raise problems in the produc-tion or processability of the materials. In addition, some of these materials are expensive or scarce, and others, such as asbestos, present considerable health risks which make their use undesirable.
According to this invention there is provided a refractory composition comprising an aggregate, from 7 to 20%
by weight of hydraulic cement, and as a filler material, from 20 to 50% by weight of~silicon dioxide, o which at least 82~
is amorphous, not more than 18~ being crystalline quartz, which ~ ~ .
25 ~ has a bulk weight within the range of 0.25 to 0.50 gram per millilitre, and of which at least 95% has a grain size below 50 microns.
1~$~2 The term "aygregate" is used herein to include mineral materials commonly mixed with cement in the manufacture of, for example, concrete, but does not include said silicon dioxide filler material.
The content of said silLcon dioxide is most advan-tageously between 20 and 30% by we:ight.
The refractory composit:ion itself may be utilised in the manufacture of a material requLred to have high fire and/or heat resistance, such as in the manufacture of refractory bricks, or refractory concrete. Alternatively, the refractory composi-tion may be utilised in improving the fire and/or heat resistance of an article, by being sprayed onto the articleO
Thus this invention also provides a method of improv-ing the fire and/or heat resistance of an article, the method comprising the step of applying to the article a coating of a refractory composition in accordance with this invention.
It has been found that not only does a refractory composition in accordance with this invention exhibit signifi-cantly improved fire and/or heat resistance, but additionally improves other physical properties when used in the manufacture of various articles. This allows the refractory composition in accordance with this invention to be used in the manufacture of a variety of articles, improving not only the fire and/or heat resistance of the article, but also improving other qualitiesj su¢h as the sound absorbancy thereof.
Thus, this invention also provides a refractory composition suitable for imparting fire, flame and heat resist-;~ ~ ance to matexial,, such as concrete or refractory bricks, , ? : - 3 -:
.
~ , , :., : ,:
3~
chipboard, concrete s]abs, ~ire-retarding panels, sound proofing panels, moulded plas-tics panels, corrosion resistant panels, refractory materials, heat insulating materials, electrical insulation materials, sound insulation materials, ~efractory moulding sand, emery paste, in which the refractory composition is incorporated in or applied to the material, the composition comprising an aggregate, from 7 to 20% by weight of a hydraulic cement, and, as a filler material, from 20 to 50% by weight of silicon dioxide, of which at least 82% is amorphous, not more than 18% being cristalline quartz, which has a bulk weight within the range of 0.25 to 0.50 gram per millilitre,.and of which at least 95~ has a grain size below 50 microns.
Conveniently, the filler material is obtained as a by-product produced in the electro-thermic production of ferro-silicon and/or silicon, such as an electro-thermic pxocess operating within a temperature of 1500 to 3000C. The basic constituent of this substance is a fine, dust-like x-ray am~rphous SiO2 (approximately 82 to 95%) some at least of which may have been produced by direct submilation from the vapour to the solid phase, with a small amount of crystalline quartz (approximately 5 to 18%). X-ray examination has shown that.with the exception of the comparatively small quartz content this : dust or powder may be classified as being x-ray amorphous. In ~ addition, the ~iller material may contain small amounts of .~ 25 oxides of.iron and/or calcium and magnesiuml and carbon.
The i.ncorporation of the silicon dioxide as a filler material in a refractory composition according to this invention not only contributes substantially to an improvement in the C
.- : . ~ - . - ~ ., :,, .' . .- , .:
, hea-t res.istance, particular'y fire resis~nce of -the refractor~
composition, but surpr:ising:Ly contribute~ c;ubstan-tially to an improvement in other physical properties, such as mechanical abrasion strength, resistance to temperature changes, thermal insulation, sound insulation, elect.rical insulation properties and improvements in the workability of masses, compositions or mixtures, in particular building mixtures~
In particular, a refractory composition according to this invention is well suited for u.se as or in a fire-inhibiting or fire-resistant material or mass, in particular a mixture or composition capable of being sprayed or tamped down for building purposes.
Fire-inhibiting refractory materials, which according to current custom and knowledge in the art consist of a mixture of cement and asbestos fibres~ are, for example, sprayed on steel girders to protect these against the action of fireO Whilst these convention refractory materials certainly ensure the - required fire protection, they are nevertheless very expensive.
Thus, by the use of this invention, a refractory composition having better fire protection may be obtained in a lçss expensive manner. Such a material has a high thermal insulation value which is, at least partly, due to the low density of the filler material, and over and above this it also has great resista~ce to mechanical abrasion.
It is possible to improve or to further improve certain other properties of the refractory composition by adding other materials, either by utilising such other materials as aggregate~ or by including such other materials in the composi~
tion in conjunction with the aggregate. For example, the .
.
.. . . . . .
", .........
. ..
.
~1~'7~
thermal insulation value thereof may be improved by the use of glass- or mineral- wool waste. Conveniently such materials are obtained from the by products or waste materials produced in the manufacture of insulation matting.
It is also possible to improve the adhesion properties and the strength/density ratiol by utilising, in the preparation of the refractory composition, wet1ing and/or flocculating agents and/or materials of a similar kind.
Where the filler material is in the form the dust-like products emitted in the electro-thermic manufacture o~ ferro-silicon, chemical and physical reactions with t~e other components of the refractory compositions are considerably . enhanced and shrinkage, with resulting crack formation under heat, is minimised, the filler material having the effect of . .
improving the thermal characteristics of the refractory composi-tion with increasing temperature exposure.
It is also possible to include further additives wi~h fire-inhibiting properties, such as calcium sulphate, advanta-geously in the form of waste products occurring in the desulphuri-zation of flue or smoke gases and containing predominantly or e~clusively CaSO~.
The refractory composition according to this invention ~ may be used in the preparation of a sprayable or a tampable : mass for use in the building industry generally, particularly in pre-stressed concrete buildings, for insulating and protecting ~ steel girders. ';uch material may also be used in, e.g. steel-: works, coke-ovens and foundries.
, : . f '~
~ J - 6 -3~
Example I
A refractory composition according to this invention was experimentally tested. For this purpose a sectional steel girder (profile HEB 220), 3.600 mm long with foot plates welded to top and bottom thereof was subj~ected to a load of 133 t~
after a protective layer had been applied to the girder of a fire-proofing refractory composition, comprising mineral wool, as aggregate, portland cement and the silicon dioxide filler material, according to the in~ention, in a layer which was 23 mm thick, and the qirder was then exposed, over a length of 3.100 mm, to ~emperatures rising from 8C to approximately 980C
in the course of 1.5 hours. The girder showed no reduction in its load bearing capacity. The protective layer shrank in the course of the testing time to an average thickness of 16 mm.
Comparative tests were carried out with commercially available conventional asbestos-bearing spray-materials. For achieving fire protection corresponding to class F 90, it was necessary to use 10 kg/m of the conventional refractory composi-tion containing asbestos, but only 7 kg~m2 were required with the same result of the refractory composition according to this invention. Specifically, the refractory composition in accord-ance with this inventin which was used contained by weight approximately 60% mineral wool, 20% cementl and 20% of the silicon dioxide filler material. The mixture was prepared with 25 kg dry substance for 15 1. of water, with 75 ml of Lensodel Registered Trade Uark), a tenside based on ethyleneoxide condensates, inc:Luded in the mixture. The layer thickness required to meet the demands of fire protection class F 90 for ~; ~ 7 , ~
a material containing by weight approximately 60~ mineral wool, 20% pearlite and 20% hydraulic cement was approximately 60 mm.
Using the refractory composition according to this invention and of the above specified composition only approximately 5 mm layer-thickness was nQeded, but because such thin layers cannot be very evenly applied it was found necessary in actual practice to apply a layer thickness of approximately 15 mm. The consti-tuents of the above mentioned refractory compo~ition may be varied within very wide limits depending on the mechanical and 1~ thermal demands and it is also possible to add further conven-tional materials to the mixture, such as, e.g. pearlites which have good heat insulation properties.
Another field of application of this invention is the manufacture of building panels. It is common practice to produce (for example) ceiling panels, partition walls, doors etc. from composition material panels, wherein the basic material may be a chipboard or hardboard material, sprayed with the fire-- proofing materials or mixtures. However, this type of production is rather expensive. The same also applies to panels or slabs made of concrete, gypsum or the like if these are to be fire-proofed.
However, by the use of this invention, h~at resistance and particularly fire resistance of such building panels is substantially improved if the above described re~ractory ~ composition is used in a basic mixture for building panels, particu1arly concrete slabs or panels and chipboard paneis, or subsequently s~prayed onto the article.
' r ~ ~ ~ 8 ~
~. ?
, . . . . . . . .. . . .. . . .
. - . . , , , .:
Advantageously such a panel may con~ist of a flarne-proof fabric of plastic or wire xeinforced with a sealing layer of paper or thin plastics ~oil, ~nd a layering on one or both sides thereof of the above mentioned refractory composition.
This provides a considerable simplification in the manufacture of building panels because, e.g. the wire mesh, which is reinforcingly sealed, may be drawn continuously off a roll to be subsequently rolled, sprayed or tamped on one or both sides thereof with the refractory composition. Again the precise ingredients of the refractory composition may be varied to suit mechanical and thermal demands.
It is also possible to construct a building panel, and especially a fire-yroof panel or mat in such a way that it comprises an inner core of compressed mineral and/or glass wool and an adhesive and protective layer of the refractory composi-tion according to this inven~ion, the aggregate comprising granulated or powdered stone.
Advantageously the refractory composition according to this invention may be used to provide protective coatings for refractory bricks~
- This invention is also suitable for making refractory compositions in the form of fire-proof concret~, which is particularly in demand for high-rise buildings. For achieving economical production without loss of strength in ~he concrete, the silicon dioxide filler material may be admixed with conven-tional ingredients of concrete. By an appropriate addition of the silicon dioxide filler material, it is possible to attain fire-protection safety factors of, for example Class F 90, _ g _ , :
. .: .. .~ .
: ~ .. : ~ : , . :
, Class F 120 or even Class F 240. The amount of silicon dioxide filler material in the concrete i~ preferably between 20 and 30% by weight. The concrete may c~lc;o contain further heat-resistant additives including mineral wool. In conventional concretes intended for exposure to very high temperatures, Portland cement is less suitable as hydraulic binding agent, and special binding agents which have so far been commonly employed for the manufacture of fire-proof concrete have been required.
However by the use of this invention it is not necessary to use special binding agents, and hydraulic cement may be retained as a binding agent. Experiments have shown that the concrete according to this invention may withstand a temperature of approximately 1200C for several hours~
The refractory composition in accordance with this invention may further he employed with great advanta~e in making refractory bricks and high temperature~ resistant linings for industrial furnaces and for the metallurgical industries.
Conventional tamping masses may be mixed with the silicon dioxide filler material in amounts up to approximatel~ 35% by weight and conventional spray masses up to approximately 50~ by weightO These masses show a low degree of potential shrinkage and a low starting point for sinter reaction, but a high degree of fire resistance, strong adhesion to their background~ high surface hardness and good elasticity. For example, a refractory composition comprising (b~ weight) 30 % refractory clay (grain -size 80% b~tween 0 and 0.5 mm), 30% sand (0 to 0.5 mm) 10 alumina flux cement and 30~ of the silicon dioxide filler material, to which 20~ ~y weight of water is added, is extremely suitable for spray application in repair work to the interior : . - . . , ...... . - ,:
. : " " :, . , ,: , - .
:: . :' . '. . : :, lining of coke oven~. In coke ovens, owing to the high tempera-ture gradient of approximately 800C in the vicinity of the door up to about 1,200~C in the middle of the firing chamber, it has hitherto been necessary to employ several differently constituted repair mixtures which were ad~pted to these different temperature zones. ~Iowever, the above speciied refractory composition may be successfully used in evexy region of the coke oven walls.
After the mixture has been sprayed on, it may provide a substan-tially completely fissure-free coating which adheres irmly to the wall and shows very good mechanical strength and durability.
A special ad~antage arises from the ~act that when the refractory material according to this invention is used as/or in refractory andhigh temperature resistant materials it is no longer ne'cessary to add alkaliesO Previously conventional refractory and high temperature resistant masses have required an addition of alkalies, i.e. sodium silicate, to ensure adequate adhesion of the mass to the refra~tory bricks. However, this means that one has to accept a lower mollification point and damags to the bricks.
Example II
A tamping mass for use in the repair of coke oven doors may by the use o~ this invention comprises by weight 15%
sand (0 - 0.5 mm), 50% chamotte B (0-~ mm), 15% alumina cement and 20% o~ the silicon dioxide fillar material. Such a tamping~-mass has a~temperature resistance of 1,100C.Example I~I
A tamping mass suitable for use in foundries comprises by weight 66% sand ~granulation 0 to 0.4 mm), 5% chamotte A, , ,. . . ~ . , . :
, , , , : .
: . . ~ : .. : : . . ...
~0~13~
7% Portland cement 450 and 22% of silicon dioxide filler material.
This tamping mass has temperature resistance up to 1,550C.
In all of the above mentioned cases, where control tests were carried out using extremely finely ground crystalline silicon dioxide, it was found impossible to obtain similarly good results to those achieved when using the refractory composi-tion of this inventioncomprising predominantly amorphous, dust-like silicon dioxide.
All percentages gi~en in the disclosure refer to percentages by weight.
No claim is made herein to compositions which include a substantial ~uantity of sodium silicate.
~' . .
. . .
~ .
~ . ~
.
:: : ' :
Claims (30)
1. A refractory composition comprising an aggregate, from 7% to 20% by weight of hydraulic cement, and as a filler material, from 20% to 50% by weight of silicon dioxide of which at least 82% is amorphous, not more than 18% is crystalline quartz, which has a bulk weight within the range 0.25 to 0.50 gram per millilitre, and of which at least 95% has a grain size below 50 microns.
2. A refractory composition according to Claim 1 comprising a wetting or flocculating agent.
3. A refractory composition according to Claim 1 comprising calcium sulphate.
A refractory composition according to Claim 1 comprising glass wool.
5. A refractory composition according to any one of claims 1, 2 and 3 comprising mineral wool.
6. A refractory composition according to any one of claims 1, 2 and 3 comprising fired and crushed clay.
7. A refractory composition according to any one of claims 1, 2 and 3 comprising pearlites.
8. A refractory composition according to one of claims 1, 2 and 3 comprising refractory clay.
9. A refractory composition according to claim 1 comprising between 20% and 30% by weight of said silicon dioxide.
10. A refractory composition according to claim 9 comprising between 10% and 20% by weight of hydraulic cement.
11. A refractory composition according to one of claims 9 and 10 comprising between 15% and 66% by weight of sand.
12. A refractory composition according to Claim 1, comprising approximately 15% by weight of sand, approximately 50% by weight of Chamotte B, approximately 15% by weight of hydraulic cement, and approximately 20% by weight of said silicon dioxide.
13. A refractory composition according to Claim 1, comprising approximately 66% by weight of sand, approximately 5% by weight of Chamotte A, approximately 7% by weight of hydraulic cement, and approximately 22% by weight of said silicon dioxide.
14. A refractory composition according to Claim 1, wherein the composition is capable of being sprayed.
15. A refractory composition according to Claim 1, wherein the composition is capable of being tamped.
16. A refractory composition according to claim 1 wherein not more than 95% by weight of said silicon dioxide is amorphous, and at least 5% by weight is crystalline quartz.
17. A method of improving the fire and/or heat resistance of an article, the method comprising the step of applying to the article a coating of a refractory composition according to Claim 1.
18. A method according to Claim 17 wherein the article is a refractory brick.
19. A method according to Claim 17 wherein the article is a wall of an industrial furnace.
20. A method according to Claim 17 wherein the article is a wall of metallurgical vessel.
21. A method according to Claim 17 where in the article is a steel girder.
22. A method according to any of of Claims 17,19 and 21 wherein the refractory composition is sprayed onto the article.
23. A method according to Claim 17 wherein the composition comprises between 10% and 20% by weight of hydraulic cement.
24. A method according to Claim 17 wherein the composition comprises between 20% and 30% by weight of said silicon dioxide.
25. A method according to Claim 17 in which water is added to the refractory composition in an amount of approximately 15 litres of water to 25 kilograms of the refractory composition, approximately 75 millilitres of a tenside being incorporated in the mixture.
26. A refractory composition suitable for imparting fire, flame and heat resistance to material, such as concrete or refractory bricks, chip board, concrete slabs, fire-retarding panels, sound proofing panels, moulded plastics panels, corrosion resistant panels, refractory materials, heat insulating materials, electrical insulation materials, sound insulation materials, refractory moulding sand, emery paste, in which the refractory composition is incorporated in or applied to the material,the composition comprising an aggregate, from 7% to 20% by weight of hydraulic cement, and as a filler material, from 20% to 50% by weight of silicon dioxide at which at least 82% is amorphous not more than 18% is crystalline quartz, which has a bulk weight within the range 0.25 to 0.50 gram per millilitre, and of which at least 95% has a grain size below 50 microns.
27. A refractory composition according to Claim 26 comprising between 20% and 30% by weight of said silicon dioxide.
28. A refractory composition according to Claim 26 comprising between 10% and 20% by weight of hydraulic cement.
29. A refractory composition according to Claim 26 comprising between 15% and 66% by weight of sand.
30. A refractory composition according to any one of Claims 26,27 and 28 wherein not more than 95% by weight of the said silicon dioxide is amorphous, and at least 5% by weight is crystalline quartz.
Applications Claiming Priority (5)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DE19752541822 DE2541822A1 (en) | 1975-09-19 | 1975-09-19 | Fireproof coatings for steel girders - using waste prods. from (ferro)silicon prodn. and mineral or glass fibre prodn. with an inorganic binder |
| DE19762604394 DE2604394A1 (en) | 1976-02-05 | 1976-02-05 | Heat-resistant plastics - prepd. by adding ferrosilicon and/or iron oxide or silica dust (NO 18.4.77) |
| DE19762608233 DE2608233A1 (en) | 1976-02-28 | 1976-02-28 | Refractory cement compsn. - contg. oxide by-prod. from electrothermal treatment of silicon (cpds.) (NO 18.4.77) |
| DE19762608232 DE2608232A1 (en) | 1976-02-28 | 1976-02-28 | Heat resistant lacquer - contg. oxide by-product from iron or ferrosilicon prodn., mixed with borax |
| DE19762634674 DE2634674A1 (en) | 1976-08-02 | 1976-08-02 | FILLER FOR IMPROVING THE MECHANICAL ABRASION AND / OR WAERMEBESTAENDIGKEIT, ESPECIALLY THE FIRE RESISTANCE AND / OR TEMPERATURWECHSELBESTAENDIGKEIT AND / OR THE INSULATION AND / OR SOUND INSULATION AND / OR THE ELECTRICAL ISOLATION AND / OR PROCESSABILITY OF MASSES, PARTICULARLY TREE ASSEN, AND / OR COATING AND THE LIKE |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1079312A true CA1079312A (en) | 1980-06-10 |
Family
ID=27510431
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA261,070A Expired CA1079312A (en) | 1975-09-19 | 1976-09-13 | Materials containing silicon dioxide |
Country Status (6)
| Country | Link |
|---|---|
| JP (1) | JPS5248577A (en) |
| CA (1) | CA1079312A (en) |
| FR (1) | FR2324593A1 (en) |
| GB (1) | GB1564611A (en) |
| IT (1) | IT1070803B (en) |
| NO (1) | NO763003L (en) |
Families Citing this family (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS5515927A (en) * | 1978-07-17 | 1980-02-04 | Tokyo Yogyo Kk | Nonshaped refractory |
| DK171879A (en) * | 1979-04-26 | 1980-10-27 | Rockwool Int | PROCEDURE FOR MANUFACTURING FIBER ARMED CEMENT PLATES |
| NO148995C (en) * | 1979-08-16 | 1986-06-12 | Elkem As | PROCEDURE FOR MANUFACTURING CEMENTS LURRY WITH LOW WEIGHT FOR USE BY CEMENTATION OF OIL AND GAS BURNS. |
| EP0078525A2 (en) * | 1981-10-30 | 1983-05-11 | Aktieselskabet Aalborg Portland-Cement-Fabrik | A method of improving characteristic of a body |
| JPS59106598U (en) * | 1983-01-07 | 1984-07-18 | 株式会社モリタ製作所 | Dental mercury wastewater treatment equipment |
| JPS62201944A (en) * | 1986-02-28 | 1987-09-05 | Nippon Mining Co Ltd | Filler for composite material and sound insulating composite material obtained by using same |
| JPH0222036A (en) * | 1989-05-24 | 1990-01-24 | Nippon Mining Co Ltd | Sound insulating molding |
| CN112159203B (en) * | 2020-09-07 | 2023-03-17 | 宜兴摩根热陶瓷有限公司 | Corrosion-resistant composite smoke-discharging brick |
-
1976
- 1976-09-01 NO NO763003A patent/NO763003L/en unknown
- 1976-09-06 GB GB36804/76A patent/GB1564611A/en not_active Expired
- 1976-09-13 CA CA261,070A patent/CA1079312A/en not_active Expired
- 1976-09-16 IT IT2724876A patent/IT1070803B/en active
- 1976-09-17 FR FR7628055A patent/FR2324593A1/en not_active Withdrawn
- 1976-09-20 JP JP11284676A patent/JPS5248577A/ja active Pending
Also Published As
| Publication number | Publication date |
|---|---|
| NO763003L (en) | 1977-03-22 |
| GB1564611A (en) | 1980-04-10 |
| IT1070803B (en) | 1985-04-02 |
| FR2324593A1 (en) | 1977-04-15 |
| JPS5248577A (en) | 1977-04-18 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| US4255195A (en) | Compositions containing silicon dioxide | |
| CA1079312A (en) | Materials containing silicon dioxide | |
| US3853571A (en) | Fire resistant composition containing gypsum and silicate-based material and processs for making same | |
| CN109971223B (en) | Environment-friendly fireproof coating prepared from solid waste in steel industry | |
| US2516892A (en) | Refractory concrete | |
| KR960001432B1 (en) | Refractories with insulation function | |
| RU2385851C1 (en) | Crude mixture for making fireproof coating | |
| RU2372314C1 (en) | Fireproof raw mix | |
| KR102204086B1 (en) | Fire-resistance coating materials composition using waste recycling materials, comprising fire-resistance materials and multi-foam materials and Panel for fire-resistance coating using the same | |
| KR870000737B1 (en) | Monolithic refractory composition | |
| EP1129151B1 (en) | Fire protection for buildings and other civil engineering constructions | |
| RU2348595C2 (en) | Method of fabrication of products from refractory mass (versions) | |
| JPH0632667A (en) | Refractory coating material with hydrogencarbonic acid compound | |
| KR900001727B1 (en) | Composition of heat - insulating material | |
| JP2000203951A (en) | Light weight heat-insulating castable composition | |
| KR100242593B1 (en) | Hard ceramic body | |
| RU2187525C1 (en) | Method of manufacturing heat-insulation and fire-protection coating | |
| JPS6154746B2 (en) | ||
| JPH06321599A (en) | Refractory coating material | |
| EP0313055B1 (en) | Improved composite material and method | |
| JPS6223024B2 (en) | ||
| US2014065A (en) | Insulating building and sound absorbing material | |
| Khlystov et al. | Ways to improve physical and thermal performance of refractory lining materials | |
| KR100492622B1 (en) | Compositions for Heat resistant and Fire resistant Construction Panel Material using Clay Minerals and its Manufacture | |
| KR920005400B1 (en) | Preparation method of fireproofing adiabatic material |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MKEX | Expiry |